Untitled

Users guide and and maintenance
manual
VOLVO
Generating set and
industrial engines
4-7 liter (EDC 4)
TAD 722GE
7745131 (06-2005) 33522067801_0_1

OPERATOR’S MANUAL
Generating set and industrial engines
4-7 liter (EDC 4)
Foreword
Volvo Penta industrial engines are relied upon throughout the world,
in both mobile and stationary applications, under some of the most
rigorous conditions imaginable. This is not by chance.
After more than 90 years of producing engines the name Volvo Penta
has come to symbolize reliability, technical ingenuity, first-class perfor-
mance and longevity. We believe that these characteristics are also
ultimately your requirements and expectations for new Volvo Penta
industrial engines.
To make certain that your expectations are matched, we ask that
you read carefully through the instruction book before starting
the engine.
Sincerely
AB VOLVO PENTA
Engine data
Engine designation ........................... Product number ....................................
Serial number .........................................................................................................
Clutch, type/nr. .......................................................................................................
Nearest Volvo Penta service location

Name .......................................................................... Telephone ....................
Address ...................................................................................................................
© 2005 AB VOLVO PENTA

Volvo reserves the right to make changes
Printed on environmentally friendly paper
Table of contents
Safety information ................................................. 2 Maintenance schedule ........................................ 18

Safety rules for operation and maintenance .......... 3 Maintenance schedule ........................................ 18
Introduction ........................................................... 6 Maintenance ........................................................ 20

Environmental responsibility ................................. 6 Engine, general ................................................... 20
Running in ............................................................. 6 Lubrication system .............................................. 22
Fuel and oils ......................................................... 6 Cooling system ................................................... 25
Maintenance and spare parts ................................ 6 Fuel system ........................................................ 30
Certified engines ................................................... 7 Electrical system ................................................ 32
Presentation .......................................................... 8 Laying up ............................................................. 36

Technical description ............................................ 8 Conservation ....................................................... 36
Identification numbers ......................................... 10 Removing conservation preparations ................... 36
EDC 4 ................................................................. 11
Fault tracing ........................................................ 37
Instruments ......................................................... 12 Symptoms and possible causes ......................... 37
Starting the engine .............................................. 13 Diagnostic function ............................................. 38

Before starting .................................................... 13 Diagnostic function ............................................. 38
Starting method EDC 4 ....................................... 13 Malfunction message .......................................... 38
Starting in extreme cold ...................................... 14 Fault tracing guide .............................................. 38
Never use start spray .......................................... 15 Effect on engine .................................................. 38
Starting with auxiliary batteries ........................... 15 Operation ............................................................ 39
Operation ............................................................. 16 Fault codes .......................................................... 40

Checking instruments ......................................... 16
Fault indication .................................................... 16 Technical data ..................................................... 46
Engine speed control .......................................... 16 General ............................................................... 46
Operation at low load .......................................... 16 Lubrication system .............................................. 49
Fuel system ........................................................ 50
Stopping the engine ........................................... 17 Cooling system ................................................... 51
Before stopping ................................................... 17 Electrical system ................................................ 51
Stop .................................................................... 17
After stopping ..................................................... 17
1
Safety information
Read this chapter very carefully. It has to do with your safety. This describes how safety information is presented
in the instruction book and on the product. It also gives you an introduction to the basic safety rules for using and
looking after the engine.
Check that you heave received the correct instruction book before you read on. If not, please contact your
Volvo Penta dealer.
Incorrect operation can lead to personal injury and damage to products or property. So read the
instruction book through very carefully before you start the engine or do any maintenance or ser-
vice work. If there is still something which is unclear or if you feel unsure about it, please contact
your Volvo Penta dealer for assistance.
This symbol is used in the instruction book and on the product, to call your attention to the
fact that this is safety information. Always read such information very carefully.
Safety texts in the instruction book have the following order of priority:
WARNING! Warns for the risk of personal injury, major damage to product or property, or
serious malfunctions if the instruction is ignored.
IMPORTANT! Is used to call attention to things which could cause damage or malfunctions
to product or property.
NOTE! Is used to call attention to important information, to facilitate work processes or operation.
This symbol is used on our products in some cases and refers to important information in
the instruction book. Make sure that warning and information symbols on the engine are clearly
visible and legible. Replace symbols which have been damaged or painted over.
2
Safety information
Safety rules for operation and maintenance
Daily checks Ignition lock

Make it a habit to give the engine and engine bay a vi- If the instrument panel does not have a key switch,
sual check before operating (before starting the en- the engine room must be lockable, to prevent unau-
gine) and after operation (when you have stopped thorized persons from starting the engine. Alternative-
the engine). This helps you to quickly discover ly, a lockable main switch can be used.
whether any leakage of fuel, coolant, oil or any other
abnormal event has happened, or is about to happen,.
Care and maintenance

Knowledge
Fuel filling
The instruction book contains instructions for doing
There is always a risk of fire and explosion during fuel
the most common service and maintenance tasks in a
filling. Smoking is not permissible, and the engine
safe and correct manner. Read them carefully before
should be stopped.
starting work.
Never over-fill the tank. Shut the tank cap securely.
Literature for more major tasks is available from your
Only use the fuel recommended in the instruction Volvo Penta dealer.
book. The wrong grade of fuel can cause malfunctions
Never do a job if you are not entirely sure about how
or stop the engine. In a diesel engine, it can also
to do it. Please contact your Volvo Penta dealer and
cause the injection pump to bind and the engine will
ask for assistance instead.
over-rev, entailing a strong risk of personal injury and
machinery damage.
Stop the engine.
Stop the engine before opening or removing the en-
Carbon monoxide poisoning gine hatch/hood. Care and maintenance work should
be done with the engine stopped unless otherwise
Only start the engine in a well- ventilated area. When specified.
operated in a confined space, exhaust fumes and
crankcase gases must be ventilated. Prevent the engine from being started by cutting the
current with the battery isolator, or remove the cable
from the battery positive pole before you start service
work. Fix a notice by the operator’s seat to say that
work is in progress.
Operation
Working with, or going close to a running engine is a
The engine must not be operated in environments
safety risk. Hair, fingers, loose clothes, or dropped
which contain explosive media since none of the elec-
tools can catch on rotating components and cause se-
trical and mechanical components are explosion
vere injury. Volvo Penta recommends that all service
proof.
work which requires the engine to be running should
Going close to a running engine is a safety risk. Hair, be done by a Volvo Penta authorized workshop.
fingers, loose clothes, or dropped tools can catch on
rotating components and cause severe injury.
When engines are supplied without touch guards, all
rotating components and hot surfaces must be pro-
tected after installation in their application, if neces-
sary for personal safety.
3
Safety information
Safety rules for operation and maintenance (contd.)
Lifting the engine Batteries

The existing lugs on the engine should be used for lift- Batteries contain and give off an explosive gas, espe-
ing. Always check that the lifting devices are in good cially when charged. This gas is very flammable and
condition and that they have the correct capacity for highly explosive.
the lift (engine weight together with auxiliaries, if fit-
Smoking, open flames or sparks must never occur in
ted). The engine should be lifted with an adjustable
or near to batteries or the battery locker.
lifting boom for safe handling. All chains or cables
should be parallel to each other and should be as Incorrect connection of a battery cable or start cable
square as possible to the top of the engine. Please can cause a spark which can be sufficient, in its turn,
note that auxiliary equipment installed on the engine to make the battery explode.
could change its centre of gravity. Special lifting de-
vices may then be needed to obtain the correct bal-
ance and safe handling. Never do any work on an en- Start spray
gine which just hangs from a lifting devise. Never use start spray or similar preparations to help in
starting an engine with air pre-heating (glow plugs /
starting heater). Explosions could occur in the inlet
Before starting manifold. Danger of personal injury.
Re-install all guards which have been removed during
service work, before re-starting the engine. Make sure
that there are no tools or other objects left behind on
the engine. Hot surfaces and fluids
Never start a turbocharged engine without the air filter A hot engine always offers the risk of burns. Be on
in place. The rotating compressor turbine in the turbo- your guard against hot surfaces: the exhaust mani-
charger can cause severe injury. There is also a risk fold, turbocharger, oil pan, charge air pipe, starting
that foreign bodies could be sucked in and cause ma- heater, hot coolant and hot lubricating oil in pipes,
chinery damage. hoses etc.
Fire and explosion Chemicals

Fuel and lubrication oil Most chemicals, such as glycol, rust preventer, con-
All fuel, most lubricants and many chemicals are servation oils, degreasers etc. are hazardous. Always
flammable. Always read and observe the advice on read and observe the advice on the packages.
the packages. Some chemicals, such as conservation oils, are flam-
Work on the fuel system must be done with the en- mable and also hazardous to breathe. Ensure good
gine cold. Fuel leakage and spills on hot surfaces or ventilation and use a protective mask for spraying. Al-
electrical components can cause fires. ways read and observe the advice on the packages.
Store oil and fuel soaked rags and other flammable Store chemicals and other hazardous material out of
material in a fire-proof manner. Oil soaked rags can the reach of children. Hand in surplus or used chemi-
self-ignite in certain circumstances. cals to a recycling station for destruction.
Never smoke when filling fuel, lubrication oil or close

to fuel filling stations or the engine bay.
Lubrication system
Non-original spare parts Hot oil can cause burns. Avoid skin contact with hot
oil. Make sure that the oil system is de-pressurized
Components in fuel systems and electrical systems before starting work. Never start or run the engine with
on Volvo Penta engines are designed and manufac- the oil filler cap removed, because of the risk of oil
tured to minimize the risk of explosions and fire, in ac- spillage.
cordance with applicable legal requirements.
The use of non-original spare parts can cause an ex-
plosion or fire.
4
Safety information
Cooling system Electric welding

Avoid opening the coolant filling cap when the engine Remove the positive and negative cables from the
is hot. Steam or hot coolant can spray out at the batteries. Then disconnect all cables connected to the
same time as the pressure built up is lost. alternator.
If the filler cap, coolant hose etc., still has to be Always connect the welder earth clamp to the compo-
opened or removed when the engine is hot, undo the nent to be welded, and as close as possible to the
filler cap slowly and carefully, to let the pressure out weld site. The clamp must never be connected to the
before removing the filler cap completely and starting engine or in such a way that current can pass through
work. Note that the coolant can still be hot and cause a bearing.
scalding.
When welding is completed: Always connect the al-
ternator cables before the battery cables are put
back.
Fuel system
Always protect your hands when searching for leaks.
Fluids which leak under pressure can force their way
into body tissue and cause severe injury. There is a
risk of blood poisoning (septicemia).
Always cover the alternator if it is located beneath the
fuel filters. Fuel spillage can damage the alternator.
Electrical system
Cut the current
Before any work is done on the electrical system, the
engine must be stopped and the current cut by switch-
ing off the main switch(es). External current supply for
engine heaters, battery chargers or other auxiliary
equipment connected to the engine must be discon-
nected.
Batteries
Batteries contain a highly corrosive electrolyte. Pro-
tect your eyes, skin and clothes during charging and
other handling of batteries. Always use protective gog-
gles and gloves.
If acid comes into contact with your skin, wash at
once with soap and a lot of water. If you get battery
acid in your eyes, flush at once with a lot of cold wa-
ter, and get medical assistance at once.
5
Introduction
This instruction book has been prepared to give you the greatest possible benefit from your Volvo Penta industrial
engine. It contains the information you need to be able to operate and maintain the engine safely and correctly.
Please read the instruction book carefully and learn to handle the engine, controls and other equipment in a safe
manner before you start the engine.
IMPORTANT! This instruction book describes the engine and equipment sold by Volvo Penta. Variations in
appearance and function of the controls and instruments may occur in certain variants. In these cases,
please refer to the instruction book for the relevant application.
Environmental responsibility Fuel and oils

All of us want to live in a clean, healthy environment, Only use the fuels and oils recommended in the in-
where we can breathe clean air, see healthy trees, struction book (please refer to the “Maintenance”
have clean water in lakes and seas, and be able to chapter under the fuel and lubrication system head-
enjoy the sunlight without fearing for our health. Unfor- ings). Other grades of fuel and oils can cause mal-
tunately, this is not self-evident these days, it is functions, increased fuel consumption and eventually
something all of us must work for. even shorten the life of the engine.
As an engine manufacturer, Volvo Penta has particu- Always change the oil, oil filter and fuel filter at the
lar responsibility and for this reason, environmental specified intervals.
care is a self-evident foundation of our product devel-
opment. Volvo Penta has a wide engine program
these days, where considerable progress has been
made in reducing exhaust fumes, fuel consumption, Maintenance and spare parts
engine noise etc.
Volvo Penta engines are designed for maximum reli-
We hope that you will be want to preserve these val- ability and long life. They are built to withstand a de-
ues. Always observe the advice in the instruction manding environment, but also to have the smallest
book about fuel grades, operation and maintenance, to possible environmental impact. Through regular ser-
avoid unnecessary environmental impact. Please con- vice and use of Volvo Penta original spare parts,
tact your Volvo Penta dealer if you notice any chang- these qualities are retained.
es such as increased fuel consumption or increased
exhaust smoke. Volvo Penta has a world-wide network of authorized
dealers. They are Volvo Penta product specialists,
Please remember to always hand in hazardous waste and have the accessories, original spares, test equip-
such as drained oil, coolant, old batteries etc. for de- ment and special tools needed for high quality service
struction at an approved recycling facility. and repair work.
If we all pull together, we can make a valuable contri- Always observe the maintenance intervals in the
bution to the environment together. instruction book, and remember to note the en-
gine/transmission identification number when you
order service and spare parts.
Running in
The engine must be “run in” during its first 10
hours, as follows:
Use the engine in normal operation. Full load should
only be applied for short periods. Never run the engine
for a long period of time at constant speed during this
period.
Higher oil consumption is normal during the first 100-
200 hours of operation. For this reason, check the oil
level more frequently than normally recommended.
When an opening clutch is installed, this should be
checked more carefully during the first days. Adjust-
ment may need to be done to compensate bedding in
of the friction plates.
6
Introduction
Certified engines • The engine must not be converted or modified,

except for the accessories and service kits which
If you own an emission certified engine, which is Volvo Penta has developed for the engine.
used in an area where exhaust emissions are regu-
lated by law, it is important to be aware of the fol- • No installation changes to the exhaust pipe and
engine air inlet ducts may be done.
lowing:
Certification means that an engine type has been • No seals may be broken by unauthorized
personnel.
checked and approved by the relevant authority. The
engine manufacturer guarantees that all engines made The general advice in the instruction book about ope-
of the same type are equivalent to the certified engi- ration, care and maintenance applies.
ne.
This makes special demands on the care and IMPORTANT! Delayed or inferior care/
maintenance you give your engine, as follows: maintenance, and the use of non-original spares,
mean that AB Volvo Penta can no longer be
• Maintenance and service intervals recommended
by Volvo Penta must be complied with.
responsible for guaranteeing that the engine
complies with the certified version.
• Only Volvo Penta original spares may be used.
Damage, injury and/or costs which arise from
• Service to injection pumps, pump settings and
injectors must always be done by an authorized
this will not be compensated by Volvo Penta.
Volvo Penta workshop.
Warranty
Your new Volvo Penta industrial engine is covered by a limited warranty, under the conditions and ins-
tructions compiled in the Warranty and Service book.
Please note that AB Volvo Penta’s liability is limited to the specification in the Warranty and Service
book. Read it carefully, as soon as possible after delivery. It includes important information about war-
ranty cards, service intervals, maintenance, which it is the responsibility of the owner to know, check
and carry out. If this is not done, AB Volvo Penta may fully or partly refuse to honor its warranty un-
dertakings.
Please contact your Volvo Penta dealer if you have not received a Warranty and Service book, or
a customer copy of the warranty card.
7
Presentation
TD420VE, TAD420VE, TD520GE, TAD520GE and TAD520VE are in-line, direct injected, 4-cylinder industrial die-
sel engines.
TAD620VE, TD720GE, TAD720GE, TAD720VE, TAD721GE, TAD721VE, TAD722GE and TAD722VE are in-line,
direct injected, 6-cylinder industrial diesel engines.
All engines are equipped with electronically controlled fuel management (EDC4), turbocharger, thermostatically
controlled cooling systems and electronic speed control. All TAD engines are also equipped with an intercooler.
Technical description Control unit
Engine and engine block – Microprocessor based fuel supply control unit
(EDC 4)
– The engine block and cylinder head are manufac-
tured of alloyed cast iron – Maximum ambient temperature 80° C
– Five bearing, induction hardened crankshaft – Automatic sensing of 24 V or 12 V.

(TD420VE, TAD420VE, TD520GE, TAD520GE, – Atmospheric pressure sensor for high altitude ap-
TAD520VE) plications (option)
Seven bearing, induction hardened crankshaft Fuel system
(TAD620VE, TD720GE, TAD720GE, TAD720VE,
TAD721GE, TAD721VE, TAD722GE, TAD722VE) – Belt driven feed pump - BOSCH injection pump,
one for each cylinder
– Replaceable wet cylinder liners (TD520GE,
TAD520GE, TAD520VE, TD720GE, TAD720GE, – HEINZMANN actuator
TAD720VE, TAD721GE, TAD721VE, TAD722GE, – EDC 4 (Electronic Diesel Control). Please refer to
TAD722VE) a separate description.
Replaceable dry cylinder liners (TAD620VE) Lubrication system
Liner-less (TD420VE, TAD420VE) – Water cooled oil cooler.
– Cast aluminum pistons with oil cooling – Crankshaft driven lube oil pump
– Three piston rings, with a “keystone” type top ring – Full flow filter with bypass
– Induction hardened overhead camshaft with valve Turbocharging system
lifters and push rods.
– Turbocharger
– Two valves per cylinder
Cooling system
– Replaceable valve seats and valve guides (does
not apply to TD420VE, TAD420VE, TAD620VE) – Radiator with expansion tank
– Air cooled intercooler (TAD)
Electrical system
– 24 V (standard), 12 V (option)
8
Presentation
TD420VE, TAD420VE, TAD620VE
TD520GE, TAD520GE, TAD520VE
TD720GE, TAD720GE
TAD720VE,TAD721GE, TAD721VE, TAD722GE, TAD722VE
9
Presentation
Identification numbers
Location of engine signs

The engines are supplied with two engine signs, of
which one is installed on the right side of the engine
block.
Engine plate
1. Engine model 9. Air temperature in °C (°F), in accordance with ISO

2. Engine specification number 3046
3. Engine series number (10 digits) 10. Altitude above mean sea level, in accordance
4. Engine power, peak, without fan with ISO 3046
5. Engine speed 11. EP code for injection pump (cylinder 1 on top)
6. Injection advance and type of camshaft 12. Piston class
7. Manufacturer’s identification code 13. Extra information
8. Indication of standard and/or specification
10
Presentation
EDC 4
EDC 4 (Electronic Diesel Control) and is an electronic system with CAN (Controller Area Network) or potentiome-
ter communication for diesel engine control. The system includes fuel management and diagnostic functions.
Summary Diagnostic function

The system includes sensors, control unit and an en- The task of the diagnostic function is to discover and
gine speed regulator. The sensors send input signals localize any malfunctions in the EDC 4 system, to
to the control unit, which controls the control rod for protect the engine and to ensure operation in the
the injection pumps in its turn, by means of an actua- event of serious malfunctions.
tor in the engine speed regulator.
If a malfunction is discovered, this is notified by the
Input signals diagnostic function, by warning lamps or via the CAN
network. By pressing the diagnostic switch, the opera-
The control unit receives input signals about engine
tor will receive a fault code as a guide for any fault-
operating conditions from the following components:
tracing. Fault codes can also be output via the CAN
– speed sensor, camshaft interface or with Volvo’s VODIA tool (including the
– coolant temperature sensor Penta EDC4 software) at an authorized Volvo Penta
workshop.
– charge pressure sensor
If there is a serious malfunction, the engine is shut
– oil pressure sensor down altogether. Yet again, fault codes can be output
– fuel temperature sensor via diagnostic connector, the CAN interface or with
Volvo’s VODIA tool (including the Penta EDC4 soft-
– coolant level sensor (the function is implemented ware) at an authorized Volvo Penta workshop.
in the control unit as standard, but no sensor is
supplied with the engine as a standard feature)
Output signals
The control unit controls the following components on
the basis of the input signals received:
– engine speed regulator (with position sensor for
the control rod and acutator)
– electric air pre-heating (option)
Information from the sensors provides exact informa-
tion about current operation conditions and allows the
processor to calculate the correct fuel volume, check
engine status etc.
11
Instruments
The engines are not supplied with instruments and

controls. The choice of instrument type and controls
is made by the customer.
The functions available are described below.
A. Engine speed potentiometer (throttle control)

B. CAN interface SAE J 1939
C. VODIA input
D. Droop contact
E. 1500 / 1800 rpm switch
F. Diagnostic button
G. Tachometer
H. Warning lamp, oil pressure
J. Diagnostic lamp
K. Warning lamp, high coolant temperature
L. Fuse 15 A
M. Main switch
N. Battery (24(12 V).
12
Starting the engine
Make it a habit to check the engine and engine room before starting. This will help you to discover quickly if any-
thing abnormal has happened, or is about to happen. Also check that instruments show normal values after start-
ing.
Before starting
• Check that the oil level is between the MAX and
MIN marks. Please refer to the “Maintenance, lu-
brication system” chapter:
• Open the fuel taps.
• Check that there is no leakage of oil, fuel or cool-

ant.
• Check the air filter pressure drop indicator. Please

refer to the “Maintenance, Engine, general” chap-
ter:
• Check the coolant level and that the radiator is not

blocked externally. Please refer to the “Mainte-
nance, cooling system” chapter:
WARNING! Do not open the expansion tank cap

when the engine is hot. Steam or hot fluid could
spray out.
• Turn the main current on.
IMPORTANT! Never disconnect the current with

the main switch(es) when the engine is running.
This will damage the alternator.
• Move the engine speed control to idle, and release

the opening clutch/gearbox if installed.
Starting method EDC 4

The engine speed lever must always be in neutral be-
fore starting. The EDC4 system ensures that the en-
gine always receives the correct amount of fuel - even
when the engine is cold!
Start the engine.
If the engine is equipped with a pre-heater, the pre-
heating time is adjusted to suit the engine tempera-
ture.
13
Starting the engine
Starting in extreme cold

Certain preparations must be made to facilitate engine
starting, and in some cases to make starting possible
at all.
Use a winter grade fuel (of a well-known make) which
has been approved for the relevant temperature. This
reduces the risk of wax deposits in the fuel system.
At extremely low temperatures, the use of a fuel heat-
er is recommended.
For fully acceptable lubrication, a synthetic engine oil
of recommended viscosity for the relevant tempera-
ture should be used. Please refer to the “Maintenance,
lubrication system” chapter: Synthetic lubricants are
able to manage a wider temperature range than miner-
al-based lubricants.
Pre-heat the coolant with a separately installed elec-
tric engine heater. In extreme cases, a diesel-burning
engine heater may be needed. Ask your Volvo Penta
dealer for advice.
IMPORTANT! Make sure that the cooling sys-

tem is filled with a glycol mixture. Please refer to
the “Maintenance, cooling system” chapter:
The batteries should be in good condition. Cold weath-

er reduced battery capacity. Increased battery capaci-
ty may be necessary.
14
Starting the engine
Never use start spray

WARNING! Never use start spray or similar prod-
ucts as a starting aid. Explosions could occur in
the inlet manifold. The consequence could be
personal injury.
Starting with auxiliary batteries

WARNING! Batteries (especially auxiliary batter-
ies) contain hydrogen which is highly explosive
in contact with air. A spark, which can be formed
if the auxiliary batteries are wrongly connected,
is enough to make a battery explode and cause
damage.
1. Check that the auxiliary batteries are connected

(series or parallel) so that the rated voltage corre-
sponds to the engine system voltage.
2. First connect the red (+) jumper cable to the auxil-
iary battery, then to the flat battery. Then connect
the black jumper cable (–) to the auxiliary battery,
and lastly to a place some distance from the flat
batteries, such as the negative cable by the main
switch or the negative cable connection on the
starter motor.
3. Start the engine.
WARNING! Do not move the connections when

you attempt to start the engine (risk of arcing),
and do not stand and lean over one of the batter-
ies.
4. Remove the jumper cables in the reverse order

from installation.
WARNING! The ordinary cables to the standard

batteries must not be loosened on any condition.
15
Operation
Correct operation technique is very important for both fuel economy and engine life. Always let the engine warm
up to normal operating temperature before operating at full power. Avoid sudden throttle openings and operation at
high engine speeds.
Checking instruments Engine speed control

Check all instruments directly after starting, and then Avoid sudden and violent throttle opening.
regularly during operation.
IMPORTANT! The lubrication oil level must be

checked every 8 hours on engines which oper- Operation at low load
ate continuously. Please refer to the “Mainte-
nance, lubrication system” chapter: Avoid long-term operation at idle or at low load, since
this can lead to increased oil consumption and even-
tually to oil leakage from the exhaust manifold, since
oil will seep past the turbocharger seals and accompa-
ny the induction air into the inlet manifold at low turbo
Fault indication boost pressure.
If the EDC4 system receives abnormal signals from One consequence of this is that carbon builds up on
the engine, the “Diagnostic lamp” will start to flash. By valves, piston crowns, exhaust ports and the exhaust
pressing the “Diagnostic button”, a fault code can be turbine.
received which can guide fault tracing (or a fault code
can be received via the CAN network). At low load, the combustion temperature is so low that
full combustion of the fuel can not be ensured, which
More information about fault codes and fault tracing is means that the lubrication oil can be diluted by diesel
found in the “Diagnostic function” chapter. fuel, and the exhaust manifold will eventually leak oil.
If the following points are done as a complement
to normal maintenance, there will be no risk of
malfunctions caused by operation at low load.
Effect on engine
The diagnostic function affects the engine in the fol-
lowing ways:
• Reduce operation at low load to a minimum. If the
engine is regularly test run without load once a
1. The diagnostic function has discovered a minor week, operation duration should be limited to 5
malfunction which does not damage the engine. minutes.
Reaction: The engine is not affected. The diag-
nostic lamp lights up. • Run the engine at full load for about 4 hours once
a year. This gives carbon deposits in the engine
2. The diagnostic function has discovered a serious and the exhaust pipe a chance to be burned away.
malfunction which will not immediately damage
the engine (e.g. high coolant temperature):
Reaction: The engine goes into “limp home”
mode. The diagnostic lamp lights up.
3. The diagnostic function has discovered a serious
malfunction which makes it impossible to control
the engine.
Reaction: The diagnostic lamp starts to flash. En-
gine is shut off.
16
Stopping the engine
During longer breaks in operation, the engine must be warmed up at least once every fortnight. This prevents cor-
rosion damage in the engine. If you expect the engine to be unused for two months or more, it must be laid up:
Please refer to the “Laying up” chapter.
IMPORTANT! If there is a risk of frost, the coolant in the cooling system must have sufficient frost protec-
tion. Please refer to the “Maintenance, cooling system” chapter: A poorly charged battery can freeze and
burst.
Before stopping
Allow the engine to run for a few minutes without load
before stopping it. This permits the temperature inside
the engine to even up, “after-boiling” is avoided, at the
same time as the turbocharger cools somewhat. This
contributes to long service life without malfunctions.
Stop
• Disengage the clutch (if possible).
• Depending on the equipment installed; press the

stop button and keep it depressed until the engine
has stopped, or turn the key to the stop position.
Release the key when the engine has stopped.
After stopping
• Check the engine and engine bay for leakage.
• Turn off the main switches before any long stop-

page.
• Carry out maintenance in accordance with the

schedule.
WARNING! Working with, or going close to a run-

ning engine is a safety risk. Watch out for rotat-
ing components and hot surfaces.
17
Maintenance schedule
General
It is important that the engine receives regular care & maintenance, to achieve maximum reliability and service
life. By following the service recommendations, engine performance is sustained and unnecessary environmental
impact is avoided.
MAINTENANCE SCHEDULE
WARNING! Before you start to do any maintenance work, read the “Maintenance”
chapter carefully. This contains instructions for doing work in a safe and correct man-
ner.
IMPORTANT! When both operation and calendar time are specified, do the
maintenance job at the interval which is reached first. Maintenance points marked
must be done by an authorized Volvo Penta workshop.
Daily, before first start

• Engine oil, level check 1) .............................................................................. page 23
• Coolant, level check .................................................................................... page 26
• Radiator, external checking and cleaning ..................................................... page 28
• Air filter indicator, inspection 1, 2, 3) ................................................................. page 20
•
1)
Leakage check, engine ............................................................................. not shown
In continuous operation, checks should be done every 8 hours.
2)
The air filter should be changed when the indicator remains in the red field after the engine has been stop-
ped.
3)
When operated in extremely dirty conditions, special air filters must be used.
After the first 100-200 hours

Valve clearance, check ............................................................................. not shown
Injectors, re-tighten 50Nm (36.88 lbf ft) ..................................................... not shown
Every 50 hours
• Battery, checking the electrolyte level ......................................................... page 32
•
1)
Release bearing, lubrication 1) ................................................................... not shown
Applies to a disconnection clutch with more than 15-20 clutch operations per day. Otherwise, every 400
hours.
Every 6 months
•
1)
Coolant filter, change 1) ............................................................................. not shown
The filter should not be changed when the coolant is changed, however.
18
Maintenance schedule
Every 50-600 hours or at least every 12 months

•
1)
Engine oil and oil filter, change 1) .............................................................. page 22-23
Oil change intervals vary, depending on oil grade and sulfur content of the fuel. page 26.
Every 500 hours

• Fuel tank (sludge trap), drain ..................................................................... not shown
• Drive belts, inspection/adjustment .............................................................. page 21
Every 1000 hours

• Air hoses, leakage check ............................................................................. page 20
• Fuel filter, changing ...................................................................................... page 29
Every 1500 hours

Valve clearance, inspection/adjustment .................................................... not shown
Every 2000 hours or every 12 months

• Air filter for air compressor, change .......................................................... not shown
•
1)
Air filter, clean (TAD engines) 1) ................................................................. not shown
When operated in extremely dirty conditions, it must be cleaned frequently.
Every 2400 hours

Turbocharger, check ................................................................................. not shown
Engine with equipment, general check ...................................................... not shown
Every 3000 hours

Injectors, check ........................................................................................ not shown
Every 5000 hours or at least every 24 months

• Coolant, change ...................................................................................... page 24-25
19
Maintenance
This chapter describes how the specified maintenance points should be done. Read them carefully before starting
work. The times when maintenance points need to be attended to are given in the previous chapter: Maintenance
schedule
WARNING! Read through the safety advice for care and maintenance work in the “Safety information” chap-
ter before starting work.
WARNING! Care and maintenance work should be done with the engine stopped unless otherwise specified.
Make it impossible to start the engine by removing the ignition key and cutting the system voltage with the
main switch. Working with, or going close to a running engine is a safety risk. Watch out for rotating compo-
nents and hot surfaces.
Engine, general
Air filter Check/change.

Change the air filters when the indicator remains in the
red field after the engine has been stopped. Reinstate
the pressure drop indicator after changing the filter, by
pressing in the button.
NOTE! The filters should not be touched until the indi-
cator shows the red field. Scrap the old filters. No
cleaning or re-use may be done.
IMPORTANT! In continuous operation, the filters

should be checked every 8 hours.
When operated in extremely dirty conditions,

such as coal mines, stone crushing mills etc.,
special filters are needed (not sold by Volvo Pen-
ta).
Air hoses. Leakage check.

Inspect the condition of the hoses, for cracks and oth-
er damage. Change as necessary. Test all hose
clamps for tightness.
20
Maintenance
Drive belts. Inspection/adjustment

Inspection and any adjustment should be done after
operation, when the belts are hot.
Loosen the screws (A) before tensioning the alternator
belts. It should be possible to press the belts down
about 10 mm (3/16 “) between the pulleys. Worn belts
which operate in pairs should be changed together.
On TD420VE, TAD420VE and TAD620VE, the fan
belts have an automatic belt tensioner and do not
need to be adjusted.
TD520GE, TAD520GE, TAD520VE, TAD620VE,
TD720GE, TAD720GE, TAD720VE, TAD721GE,
TAD721VE, TAD722GE and TAD722VE have me-
chanical belt tensioners.
Always check the condition of the drive belts. Change
as necessary.
21
Maintenance
Lubrication system
Oil change intervals can vary from 40 to 500 hours, depending on oil grade and sulfur content of the fuel. Note
that oil change intervals must never exceed a period of 12 months.
If you want longer oil change intervals than given in the table below, the condition of the oil must be checked by
the oil manufacturers through regular oil testing.
Sulfur content in fuel, by weight

Engine Oilgrade < 0,5 % 0,5 – 1,0 % > 1,0 %1)
Oil change interval, reached first in operation
T(A)D420-620VE VDS-3 500 h / 12 months 250 h / 12 months 125 h / 12 months
T(A)D520-721VE VDS-2
T(A)D520-720GE ACEA: E7, E5, E3
TAD721/722GE, open API: CI-4, CH-4, CG-4
crankcase ventilation
TAD721/722GE, closed ACEA: E4 500 h / 12 months 250 h / 12 months 125 h / 12 months

crankcase ventilation API: CI-4, CH-4
NOTE! Fully synthetic oil must be used
TAD722VE ACEA: E4
power<200kW 500 h / 12 months 250 h / 12 months 125 h / 12 months
power>200kW 250 h / 12 months 125 h / 12 months 60 h / 12 months
NOTE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the quality
requirements above.
NOTE! For 6 and 7-liter engines equipped with low profile type oil pans, the oil change interval must be halved.
1)
If the sulfur content is > 1.0% by weight, use oil with TBN > 15
2)
The engine oil must fullfil both requirements. For markets outside Europe, API: CG-4 and CH-4 can be used instead of
ACEA: E3.
VDS = Volvo Drain Specification

ACEA = Association des Constructeurs Européenne d’Automobiles
API = American Petroleum Institute
Global DHD = Global Diesel Heavy Duty
TBN = Total Base Number
22
Maintenance
Viscosity
Select the viscosity from the table below, for the ap-
propriate continuous ambient air temperature.
* Refers to synthetic or semi-synthetic oils.
Oil change volume

Please refer to the “Technical Data” chapter.
Oil level. Inspection

Make sure that the oil level is between the MAX and
MIN marks.
IMPORTANT! In continuous operation, the oil le-

vel should be checked every 8 hours.
WARNING! Working with, or going close to a run-

ning engine is a safety risk. Watch out for rota-
ting components and hot surfaces.
23
Maintenance
Oil and oil filters. Change

Always follow the recommended oil change interval
and always change the oil filter during oil changes. On
stationary engines, the bottom plug should not be
removed. Use an oil drain pump to suck the oil up.
1. Clean the oil filter holder thoroughly to avoid dirt
entry when the new filter(s) is/are installed.
2. Warm the engine up.
WARNING! Hot oil and hot surfaces can cau-
se burns.
3. Remove the bottom plug. Drain the oil.
4. Install the bottom plug with a new gasket.
5. Remove the filer (1). Check that the gasket has
not been left behind on the engine.
5. Fill the new filters with engine oil and wipe oil on
the gaskets. Screw the filters on by hand until the
gaskets just touch the mating surface. Then turn
the filter a further half turn. Not more!
6. Fill up with oil to the correct level. Do not fill over
the MAX level.
7. Start the engine and let it idle. Check that the oil
pressure is normal.
8. Stop the engine. Check that no oil leakage occurs
around the filters. Top up with oil as necessary.
Collect the old oil and old filters and hand them to
a re-cycling station for destruction.
24
Maintenance
Cooling system
The cooling system ensures that the engine operates at the correct temperature. It is a closed circuit system and
must always be filled with a mixture of at least 40 % concentrated coolant and 60 % water to protect against inter-
nal corrosion, cavitation and damage caused by freezing.
We recommend that you use “Volvo Penta Coolant, Ready Mixed”, alternatively “Volvo Penta Coolant” (con-
centrated) mixed with pure water according to spec, see “Coolant. Mixture”. Only coolant of this quality is suited
too and approved by Volvo Penta.
The coolant should contain ethylene glycol of a good quality with a suitable chemical consistency for an adequate
protection of the engine. Using anti-corrosion aditive exclusively is not permitted in Volvo Penta’s engines. Never
use water by itself as coolant.
IMPORTANT! Coolant, with a sutiable consistency, must be used all year round. This applies even if there
is never any risk for frost , to ensure that the engine has an adequate protection against corrosion.
Future warranty claims on the engine and additional equipment may be rejected if an unsuitable coolant has
been used or if the instructions concerning coolant mixing have not been followed.
NOTE: The anti-corrosive agents become less effective after a time, which means that the coolant must be re-
placed, see “Service schematic”. The cooling system should be flushed out at the same time as the coolant is re-
placed, see “Cooling system. Flushing”.
“Volvo Penta Coolant” is a concentrated coolant

that is to be mixed with water. It has been developed
to function optimally with Volvo Penta’s engines and
provides excellent protection against corrosion, cavi-
tation and frost damage.
“Volvo Penta Coolant, Ready Mixed” is a ready-

mixed coolant, 40% “Volvo Penta Coolant” and 60%
water. This concentration protects the engine against
corrosion, cavitation damage and freezing conditions
down to -28 °C (18°F).
25
Maintenance
Coolant. Mixture
WARNING! All glycol is hazardous and harmful
to the environment. Do not consume!
Glycol is flammable.
IMPORTANT! Ethylene glycol must not be

mixed with other types of glycol.
Mix:
40 % “Volvo Penta Coolant” (conc. coolant)
60 % water
This mixture protects the engine against internal cor-
rosion, cavitation and frost damage down to -28 °C
(18°F). (Using 60 % glycol lowers the freezing point to
-54 °C (65°F)). Never mix more than 60 % concentrate
(Volvo Penta Coolant) in the cooling liquid, this will
give reduced cooling effect and increase the risk of
overheating, and will give reduced freezing protection.
IMPORTANT! Coolant must be mixed with pure

water, use distilled - de-ionized water. The wa-
ter must fulfill the requirements specified by
Volvo Penta, see “Water quality”.
IMPORTANT! It is extremely important that the

correct concentration of coolant is added to the
system. Mix in a separate, clean vessel before
adding into the cooling system. Ensure that the
liquids mix properly.
Water quality
ASTM D4985:
Total solid particles ...................................... < 340 ppm
Total hardness: ............................................ < 9.5° dH
Chloride ......................................................... < 40 ppm
Sulfate ........................................................... < 100 ppm
pH value ........................................................ 5,5– 9
Silica (acc. ASTM D859) .............................. < 20 mg SiO2/l
Iron (acc. ASTM D1068) .............................. < 0.10 ppm
Manganese (acc. ASTM D858) ................... < 0.05 ppm
Conductivity (acc. ASTM D1125) ................ < 500 µS/cm
Organic content, CODMn (acc. ISO8467) .... < 15 mg KMnO4/l
26
Maintenance
Coolant. Checking and filling

WARNING! Do not open the filler cap when the
engine is warm, except in emergencies. Steam
or hot fluid could spray out.
Check the coolant level daily before starting. Top the

coolant up as necessary. The level should be about
50 mm (2”) below the sealing plane of the filler cap, or
between the MIN and MAX markings, if a separate ex-
pansion tank is installed.
IMPORTANT! Topping up should be done with

the same type of mixture as is already in the
cooling system.
Filling a completely empty system

Check that all drain points are closed.
The location of drain and vent taps is shown over-
leaf.
Filling should be done with the engine stationary. Fill
up slowly, to allow the air to flow out.
If a heating unit is connected to the engine cooling
system, the heat control valve should be opened and
the installation vented during filling.
Fill up with coolant to the correct level. Do not start
the engine until the system is vented and com-
pletely filled.
Start the engine and warm it up until the thermostats
are fully open (about 20 minutes). Open any venting
taps some while after starting, to allow shut-in air to
escape. Check the coolant level and top up as neces-
sary.
27
Maintenance
Coolant. Draining.
The engine must be stopped before draining, and
the filler cap unscrewed.
WARNING! Do not open the filler cap when the

engine is warm, except in emergencies. Steam
or hot fluid could spray out.
Open the drain taps and remove the drain plugs (posi-
tions are shown below). Unscrew and empty the cool-
ant filter if installed.
IMPORTANT! Deposits, which must be cleared

away, may be found inside the drain plugs/taps.
Check that all coolant really does drain out.
Drain/vent taps. Location
Drain plugs (P):

– under the radiator
– beside cyl. 3 or cyl. 5 (4 or 6-cylinder engines)
– under the oil cooler
Vent tap (1):

– On the coolant pump
28
Maintenance
Cooling system Flushing

Cooling performance is reduced by deposits in the ra-
diator and cooling galleries. The cooling system
should be flushed when the coolant is changed.
1. Drain the coolant, as in the description on the pre-
vious paragraph.
2. Insert a hose into the filler hole in the radiator, and
flush with fresh water until the water which runs out
is completely clear.
3. Close the drain taps and plugs. Fill up with fresh
coolant, as in the instructions in the chapter enti-
tled “Coolant. Checking and filling”.
Radiator (air cooled intercooler TAD).

External cleaning
Remove guards as necessary, to access the radiator.
Clean with water and a mild detergent. Use a soft
brush. Be careful not to damage the radiator matrix.
Re-install the components.
IMPORTANT! Do not use a high pressure power

washer.
29
Maintenance
Fuel system
Only use the grades of fuel recommended in the fuel specification below. Always observe the greatest cleanliness
during re-fueling and work on the fuel system.
All work on the injection system of the engine must be done by an authorized workshop. If the seal on the injec-
tion pump is broken by an unauthorized person, all warranties are void.
WARNING! Fire hazard. Work on the fuel system must be done with the engine cold. Fuel spills on hot sur-
faces or electrical components can cause fires. Store fuel-soaked rags in a fire-proof manner.
Fuel specification
The fuel must comply with national and international
standards for commercially supplied fuels, such as:
EN590 (with nationally adapted environmental and
cold requirements)
ASTM-D 975-No 1-D and 2-D.
JIS KK 2204
Sulfur content: Complying with legal requirements in
each country. If sulfur content exceeds 0.5% by
weight, the oil change intervals must be changed,
please refer to the “Lubrication system” heading.
Extremely low sulfur content fuel (urban diesel in
Sweden and city diesel in Finland) can cause a loss
of up to 5% of power and an increase in fuel con-
sumption of about 2–3 %.
30
Maintenance
Fuel filter. Change

Cleanliness! No dirt must be allowed to get into the
fuel system.
WARNING! Fuel filters must be changed when

the engine is cold, to avoid the risk of fire due to
spilled fuel on hot surfaces.
Remove the filters. Wipe a film of oil on the gaskets

of the new filters. Screw the filters on by hand until
the gaskets just touch the mating surface. Then tight-
en a further half turn, no more. Vent the fuel system.
Hand old filters in to an authorized waste process-
ing facility for destruction.
Start the engine and make sure that no leakage oc-
curs.
Fuel system. Venting

The fuel system must be vented after a filter change,
if the fuel tank has been run dry, after a long-term
stoppage etc.
Use the hand pump, if fitted, to vent the fuel system.
In other cases, vent the system by operating the
starter motor.
31
Maintenance
Electrical system
WARNING! Before any work is done on the electrical system, the engine must be stopped and the current
cut by switching off the main switch. Battery chargers or other auxiliary equipment installed on the engine
must be disconnected.
Fuses
No fuses or circuit breakers are supplied with the en-
gine. Customers have to install the electrical system
on the side of the vehicle themselves.
Fuses cut the current if the electrical system is over-
loaded.
If the engine can not be started, or if the instrument
stop working during operation, a fuse or circuit breaker
can have tripped. Check and replace fuses or re-set
circuit breakers.
IMPORTANT! Always investigate the reason for

the overload!
Main switch
The main switch must never be disconnected before
the engine has been stopped. If the circuit between
the alternator and the battery is disconnected when
the engine is running, the alternator can be damaged.
IMPORTANT! Never disconnect the current with

the main switch when the engine is running.
Electrical connections
Check that electrical connections are dry, free from
oxide and that they are securely tightened. Spray
these connections as necessary with water-repellent
spray (Volvo Penta universal oil).
32
Maintenance
Battery. Maintenance
WARNING! Fire and explosion hazard. Batteries
must never be exposed to open flames or
sparks.
WARNING! Never confuse the positive and neg-

ative poles on the batteries. Risk of arcing and
explosion.
WARNING! Battery electrolyte is highly corro-

sive. Always protect your eyes, skin and clothes
when handling batteries. Always use protective
goggles and gloves. If acid comes into contact
with your skin, wash at once with soap and a lot
of water. If you get battery acid in your eyes,
flush at once with a lot of water, and get medical
assistance at once.
Connection and disconnection

When you connect batteries, first connect the + cable
(red) to the + pole on the battery. Then connect the -
cable (black) to the - pole on the battery
When you disconnect batteries, connect the - cable
(black) first, then the + cable (red).
Cleaning
Keep the batteries dry and clean. Contamination and
oxide on the batteries and battery poles can cause
stray currents, voltage drop and discharge, especially
in wet weather. Clean oxidation from the battery poles
and terminals, using a copper brush. Tighten the ter-
minals securely and grease them with terminal grease
or Vaseline.
Filling
The electrolyte level should be 5-10 mm (0.2-0.4”)
above the cell plates in the battery. Top up with dis-
tilled water as necessary. After filling, the battery
should be charged for at least 30 minutes by running
the engine at fast idle. NOTE! Some maintenance-free
batteries have special instructions, which must be ob-
served.
33
Maintenance
Batteries, charging
WARNING! Explosion risk! Hydrogen is given off
when batteries are charged. This forms an explo-
sive mixture with air. A short circuit, open flame
or spark could cause a violent explosion. Venti-
late well.
WARNING! Battery electrolyte is highly corro-

sive. Protect your eyes, skin and clothes. Al-
ways use protective goggles and gloves. If acid
comes into contact with your skin, wash at once
with soap and a lot of water. If you get battery
acid in your eyes, flush at once with a lot of cold
water, and get medical assistance at once.
Charge batteries if they have become discharged. If

the engine is not used for a longer period of time, the
batteries should be fully charged, then possibly trickle
charged (please refer to the battery manufacturer’s
recommendations). Batteries are damaged by being
left discharged, and can also freeze and burst easier
in cold weather.
IMPORTANT! Observe the instruction manual for

the battery charger carefully. To avoid the risk of
electrochemical corrosion when an external
charger is connected, the battery cables should
be removed from the batteries before the charger
is connected.
During charging, unscrew the cell plugs but leave

them in the plug holes. Ventilate well, especially if the
batteries are charged in an enclosed space.
WARNING! Always switch off the charge current

before undoing the charging clamps. Never con-
fuse the positive (+) and negative (-) poles on the
batteries. This can cause serious arcing and can
cause an explosion.
Special instructions apply to so-called quick charg-

ing. Quick charging can shorten battery life, and
should therefore be avoided.
34
Maintenance
Component location
1. Speed sensor, camshaft

2. Speed regulator / Actuator
3. Coolant temperature sensor
4. Charge pressure sensor, 3 pin*
5. Charge pressure sensor, 4 pin*
6. Connection to control unit
7. Fuel temperature sensor
8. Oil pressure sensor
* Only one type of sensor is used.
35
Skötsel
Laying up
The engine must be laid up to prevent damage if it is not used for two months or more. It is important that this is
done in the correct manner, and nothing is forgotten. For this reason, we have compiled a check list of the most
important points.
Before laying up for a long period of time, an authorized Volvo Penta workshop should check over the engine and
other equipment. Have any faults and deficiencies attended to, so that the equipment is in order, ready for the
next start.
WARNING! Before you start to do any maintenance work, read the “Maintenance” chapter carefully. This
contains instructions for doing work in a safe and correct manner.
Conservation Removing conservation

preparations
● Change engine oil and oil filter.
● Check the oil level in the engine. Top up as neces-
● Change the fuel filter. Also change the primary fuel
sary. If special conservation oil has been put in,
filter, if fitted.
this must be changed together with the oil filter.
For the correct grade: Please refer to the “Mainte-
● Warm the engine up.
nance, lubrication system” chapter:
● Check that the coolant offers sufficient frost pro-
● Close/tighten drain taps/plugs.
tection. Top up as necessary.
● Check the drive belts.
IMPORTANT! Anti-corrosion mixture does not
offer any protection against frost. If there is
● Check the condition of all rubber hoses, and re-
any risk of frost, the system must be drained.
tighten the hose clamps.
● Drain any water and contamination from the fuel
● Check the coolant level and anti-freeze. Top up as
tank. Fill the fuel tank completely, to avoid con-
necessary.
densation.
● Connect the fully charged batteries.
● Clean the outside of the engine. Do not use a pow-
er washer. Touch up paint damage with Volvo Pen- ● Start the engine. Check that there is no leakage of
ta original paint. oil, fuel, coolant or exhaust gas, and that all con-
trols function normally.
● Disconnect the batteries. Clean and charge the
batteries. NOTE! A poorly charged battery can
freeze and burst.
● Spray the components of the electrical system

with water-repellent spray.
36
Fault tracing
A number of symptoms and possible causes of engine malfunctions are described in the table below. Always con-
tact your Volvo Penta dealer if any problems occur which you can not solve by yourself.
Symptoms and possible causes

The diagnosis button lamp flashes. Please refer to the “Diagnostic information” chapter.
Engine can not be stopped. 2, 4
Starter motor does not rotate 1, 2, 3, 4, 5, 6, 7, 24
Starter motor rotates slowly 1, 2
Starter motor rotates normally but engine does not start 8, 9, 10, 11
Engine starts but stops again 8, 9, 10, 11, 13
Engine does not reach correct operating speed at full throttle 9, 10, 11, 12, 13, 21, 25, 26
Engine runs roughly 10, 11, 27
High fuel consumption 12, 13, 15, 25
Black exhaust smoke 12, 13
Blue or white exhaust smoke 14, 15, 22
Too low lubrication oil pressure 16
Excessive coolant temperature 17, 18, 19, 20
Too low coolant temperature 20
No, or poor charge 2, 23
1. Flat batteries 10. Air in the fuel system 16. Too low oil level
2. Poor contact/open circuit in 11. Water/contamination in fuel 17. Coolant level too low
cables
12. Faulty injection pumps 18. Air in the coolant system
3. Main switch turned off
13. Insufficient air supply to engine: 19. Faulty circulation pump
4. Faulty ignition lock – blocked air filter
20. Defective thermostat
– air leakage between turbo-
5. Faulty main relay
charger and engine inlet pipe. 21. Blocked intercooler
6. Faulty starter motor relay – fouled compressor section in 22. Too high oil level
7. Faulty starter motor/solenoid turbocharger
– faulty turbocharger 23. Alternator drive belt slips
8. Lack of fuel: – poor engine bay ventilation 24. Water entry into engine
– fuel taps closed
– fuel tank empty/wrong tank 14. Excessive coolant temperature 25. High back pressure in exhaust
connected 15. Too low coolant temperature system
9. Blocked fuel filter/pre-filter 26. Break in “Pot+” cable to pedal
(because of contamination, or
27. Incorrectly set engine speed
paraffin fraction separation in
regulator / actuator
fuel at low temperature).
37
Diagnostic function
The diagnostic function monitors and checks that
the EDC 4 system functions normally.
Diagnostic function Effect on engine

The diagnostic function has the following tasks: The diagnostic function affects the engine in the fol-
• Discover and localize malfunctions. lowing ways:
• Notify that malfunctions have been discovered. 1. The diagnostic function has discovered a minor
malfunction which does not damage the engine.
• Give advice in fault finding.
Reaction: The engine is not affected. The diag-
• Protect the engine and ensure continued opera-
tion when serious malfunctions are discovered.
nostic lamp lights up.
2. The diagnostic function has discovered a serious

malfunction which makes it impossible to control
Malfunction message the engine.
If the diagnostic function discovers a malfunction in Reaction: The diagnostic lamp starts to flash. En-
the EDC 4 system, this is notified via the CAN bus gine is shut off.
or the diagnostic lamp lights up or starts to flash. At
the same time, the fault is stored in the control unit
memory. As soon as the fault has been attended to
and the ignition is turned off and on, the fault code
lamp goes out. Both rectified (passive) and un-recti-
fied (active) faults are stored in the control unit and
can be read by an authorized workshop.
Fault tracing guide

If the diagnostic button is depressed (for 1-3 sec-
onds) and then released, a fault code is flashed out
from the diagnostic lamp. The fault code is found in
the fault code list, with information about the reason,
reaction and measures to be taken. Please refer to
the “Fault codes” chapter.
38
Operation
During starting Reading fault codes
When the ignition is turned on, the diagnostic lamp Fault codes can either be read via:
lights up for two seconds, together with the warning - The VODIA tool (including the Penta EDC4 soft-
lamps for oil pressure and coolant. This is to check ware). Please refer to the “VODIA User’s Guide”
the lamp function. for advice on use.
If the diagnostic lamp flashes after the two seconds, - Diagnostic lamp
this indicates a serious fault and the engine can not
be started. One or more fault codes can then be - CAN
flashed out.
If the diagnostic lamp is lit, there are one or more less
serious faults. One or more fault codes can then be Diagnostic lamp
flashed out. If the diagnostic lamp is illuminated or flashes, a fault
code can be read by pressing the diagnostic button
(for 1-3 seconds) and then releasing it. The diagnostic
lamp goes out, and a fault code is then flashed out.
During operation The fault code consists of three groups of flashes,
separated by a pause of two seconds.
If the diagnostic lamp starts to flash during operation:
The first and third group consist of short flashes (0.4
1. Reduce engine speed to idling.
s). The second group consists of long flashes (0.8 s).
2. Press the diagnostic button (for 1-3 seconds).
A fault code is obtained by counting the number of
3. Release the diagnostic button and make a note of flashes in each group.
the diagnostic trouble code (DTC) that is flashed
Example: (2 short) pause (2 long) pause
out. Please refer to “Reading fault codes” below.
(1 short) = Fault code 2.2.1
4. Look up the fault code in the fault code list and
The fault code is stored and can be read as long as
take the necessary measures. Please refer to the
the fault remains. You can find information about
“Fault codes” chapter.
cause, reaction and actions in the fault code list.
If the diagnostic lamp starts to flash, the engine will Please refer to “Fault codes”.
be emergency stopped.
Read as follows:
IMPORTANT! In VE engines, there is a func-
1. Press the diagnostic button (for 1-3 seconds).
tion in the system which makes it possible to
start the engine again and run it for about 25 2. Release the diagnostic button and make a note of
seconds. This is so that the vehicle can be the fault that is flashed out.
moved from a railway level crossing etc.
3. Repeat items 1-2. A new fault code is flashed out
if more are stored. Repeat until the first fault code
is repeated.
NOTE! When the first fault code is repeated, all fault
codes have been read out.
When all faults have been rectified:
1. Turn the ignition on and off.
2. Press the diagnostic button (for 1-3 seconds) to
check whether any faults remain.
3. If there are no active faults, the diagnostic lamp
will give two short flashes, in other cases the re-
maining non-rectified faults will be flashed out
again.
39
Diagnostic function
Fault codes
Code 2.0.0 No faults PID 91, Code 2.2.1 Accelerator pedal sensor
There are no active faults. Reason: Faulty sensor, connector or cable.
Reaction: The engine goes into “limp home” mode.
Action:
PID 190, Code 2.1.1 Engine speed sensor,
camshaft • Check the sensor cable for breaks and short cir-
cuits.
Reason: Faulty sensor, connector, cables or incorrect
distance to cam wheel. High frequency interference. • Check sensor function. Change the sensor as
necessary.
Reaction: Engine is shut off.
Action:
• Check that the engine speed sensor is installed

with the correct distance to the camshaft.
• Check the cables for the engine speed sensor for

breaks and short circuits.
• Check the connector for poor contact.
• Check engine speed sensor function. Change the

sensor as necessary.
PID 190, Code 2.1.4 Overspeed

Reason: The engine speed is or has been higher than
the permissible limit.
Reaction: Fuel injection ceases and the fault code
lamp lights up until the engine speed falls below the
permissible limit again.
Action:
• Check the control rod for the injection pumps.
• Check the actuator, replace it if necessary.
• Check the cables for the actuator for breaks and

short circuits.
• Check the number of teeth on the camshaft

wheel.
• For VE engines, it may be necessary to check the

function of the “limp home” mode
40
Fault codes
PID 102, Code 2.2.3 Charge pressure sensor PID 174, Code 2.2.7 Fuel temperature sensor
Reason: Faulty sensor, connector or cable. Reason: Faulty sensor, connector or cable.
Reaction: A fault code is generated. Reaction: A fault code is generated.
Action: Action:
• Check the sensor cable for breaks and short cir- • Check the sensor cable for breaks and short cir-
cuits. cuits.
• Check sensor function. Change the sensor as • Check sensor function. Change the sensor as
necessary. necessary.
PID 100, Code 2.2.4 Oil pressure sensor PID 100, Code 2.3.1 Warning, oil pressure
Reason: Faulty sensor, connector or cable. Reason: Oil pressure below specified limit value (de-
pends on engine speed).
Reaction: A fault code is generated.
Reaction: A fault code is generated. The fault code
Action:
disappears when the oil pressure exceeds the recu-
• Check the sensor cable for breaks and short cir- peration value.
cuits. Action:
• Check sensor function. Change the sensor as Check the oil level and oil pump.
•
necessary.
• Check the sensor cable for breaks and short cir-
PID 110, Code 2.2.5 Temperature sensor, coolant cuits.
Reason: Faulty sensor, connector or cable. • Check sensor function. Change the sensor as
necessary.
Reaction: A fault code is generated.
• Check the limit value for oil pressure warning.
Action:
• Check the sensor cable for breaks and short cir- PID 110, Code 2.3.2 Warning, coolant temperature
cuits.
Reason: Excessive coolant temperature
• Check sensor function. Change the sensor as Reaction: A fault code is generated. The fault code
necessary. disappears when the coolant temperature falls below
the recuperation value.
Action:
• Check the coolant.

cuits.
• Check sensor function. Change the sensor as

necessary.
41
Fault codes
PID 111, Code 2.3.5 Warning, coolant level PID 174, Code 2.3.7 Warning, fuel temperature
Reason: Coolant level too low Reason: Excessive fuel temperature.
Reaction: A fault code is generated. Reaction: A fault code is generated. The fault code
disappears when the fuel temperature falls below the
Action:
recuperation value.
• Check the coolant level. Action:
• Check the sensor cable for breaks and short cir- Check the fuel.
cuits. •
• Check sensor function (if installed). cuits.
Change the sensor as necessary.
NOTE! The engine is supplied without a coolant level necessary.
sensor.
PID 100, Code 2.3.1 Emergency stop, oil pressure
PID 190, Code 2.3.6 Overspeed in limp home
mode Reason: Oil pressure below specified limit value.
Reason: When the limp home mode is activated and Reaction: Engine is emergency stopped.
the engine speed is or has been higher than the per- Action:
missible limit value.
• Check the oil level and oil pump.
Reaction: GE: Engine is shut off. A fault code is gen-
erated. • Check the sensor cable for breaks and short cir-
cuits.
VE: Fuel injection ceases when the control rod returns
to its home position and the fault code lamp lights up • Check sensor function. Change the sensor as
until the engine speed falls below the permissible limit necessary.
again.
• Check the limit value for engine shut-off due to oil
Action: pressure.
• Check the control rod for the injection pumps.
PID 110, Code 2.3.2 Emergency stop, coolant
• Check the actuator, replace it if necessary.
temperature
• Check the cables for the actuator for breaks and Reason: Excessive coolant temperature
short circuits.
Reaction: Engine is emergency stopped.
• Check the number of teeth on the camshaft
wheel. Action:
For VE engines, it may be necessary to check the • Check the coolant.

•
function of the “limp home” mode • Check the sensor cable for breaks and short cir-
cuits.

necessary.
• Check the limit value for engine shut-off due to

coolant pressure.
42
Fault codes
PID 111, Code 2.3.5 Emergency stop, coolant SID 23, Code 2.5.1 Control rod position sensor,
level difference
Reason: Low coolant level Reason: Injection pump/actuator has got stuck or is
not connected. Difference between control rod current
Reaction: The engine is emergency stopped and can
value and nominal value exceeds 10%.
not be re-started until the fault is rectified.
Action:
disappears when the difference between control rod
• Check coolant level. current value and nominal value falls below 10%.
Check the sensor cable for breaks and short cir- Action:
•
cuits. Check the control rod for the injection pumps.
•
• Check sensor function (if installed). Check the actuator, control rod and injection
•
Change the sensor as necessary. pumps. Change as necessary.
NOTE! The engine is supplied without a coolant level Check the cables for the actuator for breaks and
sensor. •
short circuits.
SID 24, Code 2.5.1 Control rod position sensor
Reason: Actuator not connected. Faulty value from SID 23, Code 2.5.2 Injection pump, auto
control rod position sensor in actuator. calibration
Reaction: Engine is emergency stopped. Actuator Reason: Automatic actuator equalization is not possi-
can not be controlled. ble. Faulty calibration.
Action: Reaction: The engine is emergency stopped and can
Check the actuator. Change as necessary. not be re-started until the fault is rectified. The regula-
• tor can not be activated.
• Check the cables for the actuator for breaks and Action:
short circuits.
• Check the actuator. Change as necessary.
• Check the actuator cables.
• Turn the ignition off and on, and check if the fault
SID 24, Code 2.5.1 Control rod position sensor, code remains.
reference
Reason: Actuator not connected. Faulty value from SID 231, Code 2.7.1 Communication fault, CAN
control rod position sensor in actuator. bus
Reaction: Engine is emergency stopped. Actuator Reason: CAN controller for CAN bus is faulty.
can not be controlled.
Reaction: --
Action:
Action:
• Check the actuator. Change as necessary.
• Check the cables.
• Check the cables for the actuator for breaks and
• Check the control unit.
short circuits.
43
Fault codes
SID 252, Code 2.8.1 Parameter programming PID 158, Code 2.8.2 Reference voltage 2
Reason: Memory fault Reason: Reference voltage for actuator exceeds per-
missible limit values.
not be re-started until the fault is rectified. Reaction: A fault code is generated. The fault code
disappears when the voltage returns to within the per-
Action:
missible limit values (5 V).
• Turn the ignition off and on, and check if the fault Action:
code remains.
• Check the voltage supplied.
SID 240, Code 2.8.1 Cyclical program test Turn the ignition off and on, and check if the fault
•
Reason: Memory fault code remains.
not be re-started until the fault is rectified.
PID 158, Code 2.8.2 Reference voltage 3
Action:
Reason: Reference voltage for actuator exceeds per-
• Turn the ignition off and on, and check if the fault missible limit values.
code remains.
PID 158, Code 2.9.1 Control unit, voltage supply missible limit values (5 V).
Reason: Voltage supplied to actuator exceeds per- Action:
disappears when the voltage returns to within the per- • Turn the ignition off and on, and check if the fault
missible limit values. code remains.
Action:
code remains.
PID 158, Code 2.8.2 Reference voltage 1

Reason: Reference voltage for actuator exceeds per-
missible limit values (5 V).
Action:
code remains.
44
PID 48, Code 2.9.2 Atmospheric pressure SID 240, Code 2.10.1 Stack overflow
Reason: Air pressure is outside permissible values. Reason: Internal calculation fault.
Reaction: A fault code is generated. The fault code Reaction: The engine is emergency stopped and can
disappears when the pressure returns to normal. Moni- not be re-started until the fault is rectified.
toring function for air pressure is activated.
Action:
Action:
• Turn the ignition off and on, and check if the fault code remains.
code remains.
SID 253, Code 2.10.1 Parameter fault

Reason: No data or incorrect data (fault only occurs
during parameter setting or reset).
Reaction: Engine can not be started.
Action:
• Check parameter settings.
code remains.
45
Felkoder
Technical data
General
Type designation .................................................... TD420VE TAD420VE TAD620VE
Direction of rotation (seen from flywheel) ............... Anti- clockwise Anti- clockwise Anti- clockwise
No. of cylinders ...................................................... 4 4 6
Cylinder bore mm (inch) ......................................... 101 (3.97”) 101 (3.97”) 98 (3.86”)
Stroke mm (inch) ................................................... 126 (4.96”) 126 (4.96”) 126 (4.96”)
Cylinder volume liter (inch 3 ) ................................... 4.04 (246.5) 4.04 (246.5) 5.7 (347.8)
No. of valves .......................................................... 8 8 12
Compression ratio:
EPA 1 ................................................................. 19:1 19:1 18.4:1
COM 2, EPA2 ..................................................... 19:1 19:1 18.4:1
Injection sequence ................................................. 1-3-4-2 1-3-4-2 1-5-3-6-2-4
Engine power kW (hp) ............................................ 75 (102)1) 103 (140)1) 155 (211)1)
Max torque Nm (lbf.ft) ............................................ 373 (275) 477 (352) 680 (501)
At engine speed rpm ........................................... 1800 1800 1800
Low idle rpm ........................................................... 800 800 800
Highest full load speed rpm .................................... 2000 – 2500 1) 2000 – 2500 1) 2000 – 2500 1)
Weight, dry (lb) ....................................................... 380 (838) 2) 380 (838) 2) 495 (1091) 2)
Type designation .................................................... TAD520VE

Direction of rotation (seen from flywheel) ............... Anti- clockwise
No. of cylinders ...................................................... 4
Cylinder bore mm (inch) ......................................... 108 (4.25”)
Stroke mm (inch) ................................................... 130 (5.12”)
Cylinder volume liter (inch 3 ) ................................... 4.76 (290)
No. of valves .......................................................... 8
Compression ratio:
EPA 1 ................................................................. 18.1:1
COM2, EPA2 ...................................................... 19:1
Injection sequence ................................................. 1-3-4-2
Engine power kW (hp) ............................................ 118 (160))
Torque Nm (lbf.ft) ................................................... 552 (407)
At engine speed rpm ........................................... 1800
Low idle rpm ........................................................... 800 – 950
Highest full load speed rpm .................................... 2000 – 2300 1)
Weight, dry (lb) ....................................................... 432 (952) 2)
1)
See engine plate for specifications.
2)
Weight according to DIN 70020-A
3)
Extra weight TAD520GE SAE 2 (1800 rpm) 36 kg (80 lb)
4)
Including clutch and frame
46
Technical data
Type designation .......................... TAD720VE TAD721VE TAD722VE

Direction of rotation, seen from flywheel: Anti- clockwise Anti- clockwise Anti- clockwise
No. of cylinders ............................ 6 6 6
Cylinder bore mm (inch) ............... 108 (4.25”) 108 (4.25”) 108 (4.25”)
Stroke mm (inch) ......................... 130 (5.12”) 130 (5.12”) 130 (5.12”)
Cylinder volume liter (inch 3 ) ......... 7.15 (436.3) 7.15 (436.3) 7.15 (436.3)
No. of valves ................................ 12 12 12
Compression ratio:
EPA1 ........................................ 18.4:1 18.4:1 —
COM2, EPA2 ............................ 19.0:1 19.0:1 19.0:1
Injection sequence ....................... 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4
Engine power kW (hp) .................. 174 (237)1) 195 (265)1) 200 (272)1)
Torque Nm (lbf.ft) ......................... 817 (603) 897 (661) 981 (724)
At engine speed rpm ................. 1800 1800 1800
Low idle rpm ................................. 800 – 950 800 – 950 800 – 950
Highest full load speed rpm .......... 2000 – 2300 1) 2000 – 2300 1) 2100 – 2300 1)
Weight, dry (lb) ............................. 572 (1261) 2) 572 (1261) 2) 680 (1496) 2
Type designation .......................... TD520GE TAD520GE TD720GE TAD720GE

Direction of rotation (seen from flywheel) Anti- clockwise Anti- clockwise Anti- clockwise Anti- clockwise
No. of cylinders ............................ 4 4 6 6
Cylinder bore mm (inch) ............... 108 (4.25”) 108 (4.25”) 108 (4.25”) 108 (4.25”)
Stroke mm (inch) ......................... 130 (5.12”) 130 (5.12”) 130 (5.12”) 130 (5.12”)
Cylinder volume liter (inch 3 ) ......... 4.76 (290) 4.76 (290) 7.15 (436.3) 7.15 (436.3)
No. of valves ................................ 8 8 12 12
Compression ratio:
EPA1 ........................................ 17.5:1 17.5:1 17.1:1 17.1:1
EPA2 ........................................ 17.5:1 17.5:1 17.1:1 17.1:1
Injection sequence ....................... 1-3-4-2 1-3-4-2 1-5-3-6-2-4 1-5-3-6-2-4
Engine power:
At 1500 rpm kW (hp) ................. 85 (116)1) 102 (139)1) 128 (174)1) 153 (208)1)
At 1800 rpm kW (hp) ................. 89 (121)1) 110 (150)1) 134 (182)1) 163 (222)1)
Torque Nm (lbf.ft) ......................... 541 (399) 649 (479) 815 (601) 974 (718)
At engine speed rpm ................. 1500 1500 1500 1500
Torque Nm (lbf.ft) ......................... 472 (348) 584 (430) 711 (524) 865 (638)
At engine speed rpm ................. 1800 1800 1800 1800
Low idle rpm ................................. 800 – 950 800 – 950 800 – 950 800 – 950
Highest full load speed rpm .......... 1500/1800 1) 1500/1800 1) 1500/1800 1) 1500/1800 1)
Weight, dry (lb) ............................. 550 (1213) 2) 575 (1268) 2,3) 750 (1653) 2) 760 (1674) 2)
Gross weight, dry (lb) ................... 580 (1279) 2) 606 (1336) 2,3) 790 (1742) 2) 804 (1773) 2)
1)
2)
3)
4)
47
Technical data
Type designation .......................... TAD721GE TAD722GE

Direction of rotation (seen from flywheel) Anti- clockwise Anti- clockwise Anti- clockwise Anti- clockwise
No. of cylinders ............................ 6 6
Cylinder bore mm (inch) ............... 108 (4.25”) 108 (4.25”)
Stroke mm (inch) ......................... 130 (5.12”) 130 (5.12”)
Cylinder volume liter (inch 3 ) ......... 7,15 (436) 7,15 (436)
No. of valves ................................ 12 12
Compression ratio:
EPA2 ........................................ 18,1:1 18,1:1
Injection sequence ....................... 1-5-3-6-2-4 1-5-3-6-2-4
Engine power
At 1500 rpm kW (hp) ................. 183 (249)1) 201 (273)1)
At 1800 rpm kW (hp) ................. 204 (277)1) 225 (306)1)
Torque Nm (lbf.ft)) ........................ 1165 (859) 1280 (944)
At engine speed rpm ................. 1500 1500
Torque Nm (lbf.ft) ......................... 1082 (798) 1193 (880)
At engine speed rpm ................. 1800 1800
Low idle rpm ................................. 800 – 950 800 – 950
Highest full load speed rpm .......... 1500/18001) 1500/18001)
Weight, dry (lb) ............................. 785 (1731)2) 785 (1731)2)
Gross weight, dry (lb) ................... 826 (1821)2) 826 (1821)2)
1)
2)
3)
4)
48
Technical data
Lubrication system
Oil
Change volume, including filter change,
TD420VE/TAD420VE: ............................................. 10 liter (2.64 US gal)
TD520GE/TAD520GE/TAD520VE: .......................... 13 liter (3.43 US gal)
TAD620VE: ............................................................. 16 liter (4.22 US gal)
TAD720VE/TAD721VE/TD720GE/TAD720GE: ....... 20 liter (5,28 US gal)
TAD721GE/TAD72GE: ........................................... 34 liter (8.97 US gal)
Oil pressure with engine oil at operating temperature (min 120°C)

At rated engine speed:
TD520GE/TAD520GE/TD720GE/TAD720GE/
TAD721GE/TAD722GE: .......................................... 400 kPa (58 psi)
TD420VE/TAD420VE/TAD620VE/TAD520VE/
TAD720VE/TAD721VE/TAD722VE: ........................ 450 kPa (65 psi)
Idle (800 rpm), min:

TD420VE/TAD420VE/TAD620VE/TAD520VE/
TAD720VE/TAD721GE/TAD721VE/TAD722GE/
TAD722VE: ............................................................. 80 kPa (11.6 psi)
TD520GE/TAD520GE//TD720GE/
TAD720GE: ............................................................ 150 kPa (22 psi)
Automatic stop at pressure less than:

TD420VE/TAD420VE/TAD620VE/
TAD520VE/TAD720VE/TAD721VE/TAD722VE: ..... 50kPa (7.2 psi)
TD520GE/TAD520GE/TD720GE/TAD720GE/
TD721GE/TAD722GE/: ........................................... 200kPa (29 psi)
Oil grade ................................................................ Please refer to the specification under “Maintenance.

Viscosity ................................................................ Please refer to the specification under “Maintenance.
Oil filter, full flow filter:

Quantity ................................................................. 1
(tighten ½ - ¾ turn after it just touches)
Lubrication oil pump

Type ...................................................................... Gear driven oil pump
49
Technical data
Fuel system
Injection sequence
TD420VE/TAD420VE/TD520GE/
TAD520GE/TAD520VE: .......................................... 1-3-4-2
TAD620VE/TD720GE/TAD720GE/
TAD720VE/TAD721GE/TAD721VE/TAD722GE
TAD722VE: ............................................................. 1-5-3-6-2-4
Feed pump
Supply pressure: ........................................................ 0.5 MPa (72.5 psi)
Supply pressure after fuel filter at
1500 rpm: Min ......................................................... 0.28 MPa (40.6 psi)
By-pass valve
Opening pressure ....................................................... 360–440 kPa (52.2–63.8 psi)
Fuel specification
The fuel must comply with national and international standards for commercially supplied fuels, such as:
EN 590 (with nationally adapted environmental and cold requirements)
ASTM D 975 No 1-D and 2-D.
JIS KK 2204
Sulfur content: Complying with legal requirements in each country.
Low density fuel (urban diesel in Sweden and city diesel in Finland) can cause a loss of up to 5% of power and an
increase in fuel consumption of about 2-3%.
50
Technical data
Cooling system
Type .......................................................................... Pressurized, sealed
Pressure cap, max. opening pressure:
TD520GE/TAD520GE/
TAD520VE/TAD720VE/TAD721GE
TAD721VE/TAD722GE/TAD722VE: ....................... 90 kPa (13 psi)1)
TD720GE/TAD720GE: ............................................ 60 kPa (8.7 psi)
1)
Refers to VE engines which are not equipped with a pressure valve at the factory.
Volume (engine)
TD420VE/TAD420VE: ............................................. 4,7 liter (1.24 US gal)
TD520GE/TAD520GE/TAD520VE: .......................... 7,2 liter (1.9 US gal)
TAD720VE/TD720GE/TAD720GE/
TAD721GE/TAD721VE/TAD722GE/TAD722VE: ..... 9,8 liter (2.59 US gal)
Volume (engine + radiator and hoses)
TD520GE: ............................................................... 17,5 liter (4.62 US gal)
TAD520GE: ............................................................ 19,7 liter (5.2 US gal)
TD720GE ................................................................ 22 liter (5.8 US gal)
TAD720GE ............................................................. 23,8 liter (6.3 US gal)
TAD721GE/TAD722GE ........................................... 27,3 liter (7.2 US gal)
Thermostat
Quantity and type ....................................................... 1 piston thermostat
Opening temperature
TD520GE/TAD520GE/
TD720GE/TAD720GE: ............................................ 83° C (181° F)
TAD520VE/TAD720VE/TAD 721GE/
TAD721VE/TAD722GE/TAD722VE: ....................... 87° C (189° F)
Fully open at
TD520GE/TAD520GE/
TD720GE/TAD720GE: ............................................ 95° C (203° F)
TAD520VE/TAD720VE/TAD721GE/
TAD721VE/TAD722GE/TAD722VE: ....................... 102° C (216° F)
Coolant filter
Quantity .................................................................. 1
Electrical system
System voltage .......................................................... 24 V (standard), 12 V (option)
51
Notes
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✂
Yes please,
I would like an operator’s manual in English at no charge.
Post or fax this coupon to: Publication number: 7745131
42200/615001/155099900192
Document & Distribution Center Name
Order Department
ARU 2, Dept. 64620
SE-405 08 Göteborg Address
Sweden
Fax: +46 31 545 772
Orders can also be placed
via the Internet:
http://www.volvopenta.com/
manual/coupon Country
Please note that this offer is valid for 12 months from the date of delivery
of the engine, after this it is subject to availability.
✂
Ja,
ich will kostenlos eine Betriebsanleitung in deutscher Sprache erhalten.
Schicken Sie den Coupon Publikationsnummer: 7745203
42200/615001/155099900192
per Post oder als Fax an: Name
Document & Distribution Center
Order Department
ARU 2, Dept. 64620 Anschrift
SE-405 08 Göteborg
Schweden
Fax: +46 31 545 772
Die Bestellung kann auch
über das Internet erfolgen:
http://www.volvopenta.com/ Land
manual/coupon
Bitte beachten Sie, dass das Angebot für die Dauer von 12 Monaten ab dem
Lieferdatum des Motors gilt, danach nur noch bis zum Aufbrauchen des Lager-
bestandes.
✂
Oui merci,
Je souhaite recevoir un manuel d’instructions gratuit en français.
Envoyez ou faxez le bon de Numéro de publication: 7745204
42200/615001/155099900192
commande à: Nom
Order Department
ARU 2, Dept. 64620 Adresse
SE-405 08 Göteborg
Suède
Fax: +46 31 545 772
Vous pouvez également pas-
ser la commande par Inter-
net: Pays
manual/coupon
Noter que l’offre est valable 12 mois à partir de la date de livraison du
moteur, puis seulement dans la mesure des stocks disponibles.
✂
Sí gracias,
deseo recibir gratuitamente un libro de instrucciones en español.
Franquear o enviar fax a: Número de publicación: 7745205
42200/615001/155099900192
Document & Distribution Center Nombre
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también por internet:
manual/coupon País
Observe que la oferta es válida durante 12 meses a partir de la fecha de entrega

del motor. A partir de la fecha de finalización de la oferta, la misma es válida siem-
pre que haya existencias.
✂
Sì, grazie,
desidero ricevere gratuitamente un manuale d’istruzioni in lingua italiana.
Spedire il tagliando per posta o Public. No.: 7745206
42200/615001/155099900192
per fax a: Nome e Cognome
Order Department
ARU 2, Dept. 64620 Indirizzo
SE-405 08 Göteborg
Svezia
Fax: +46 31 545 772
L’ordinazione può essere fat-
ta anche su Internet:
http://www.volvopenta.com/ Paese
manual/coupon
Notare che la validità dell’offerta è garantita solo per 12 mesi dalla consegna del
motore, dopodiché si procederà fino ad esaurimento scorte.
✂
Ja tack,
jag vill kostnadsfritt ha en instruktionsbok på svenska.
Posta eller faxa kupongen till: Publikationsnummer: 7745201
42200/615001/155099900192
Dokument & Distribution center Namn

Ordermottagningen
ARU 2, Avd. 64620
SE-405 08 Göteborg Adress
Sverige
Fax: +46 31 545 772
Beställningen kan även göras
via internet:
manual/coupon Land
Observera att erbjudandet gäller i 12 månader från motorns

leveransdatum, därefter endast i mån av tillgång.
✂
Ja graag,
Ik wil kosteloos een instructieboek in het Nederlands ontvangen.
Stuur of fax de coupon naar: Publicatienummer: 7745208
42200/615001/155099900192
Document & Distribution Center Naam
Order Department
ARU 2, Dept. 64620
SE-405 08 Göteborg Adres
Zweden
Fax: +46 31 545 772
U kunt ook bestellen via
internet:
manual/coupon Land
Denk eraan dat de aanbieding geldt tot 12 maanden na levering van de

motor, daarna nog slechts indien beschikbaar.
✂
Kyllä kiitos,
haluan suomenkielisen ohjekirjan veloituksetta.
Postita tai faksaa kuponki Julkaisunumero: 7745207
42200/615001/155099900192
osoitteella: Nimi
Order Department
ARU 2, Dept. 64620 Osoite
SE-405 08 Göteborg
Ruotsi
Fax: +46 31 545 772
Tilauksen voi tehdä myös
Internetissä:
http://www.volvopenta.com/ Maa
manual/coupon
Ota huomioon, että tarjous on voimassa 1 vuoden ajan

moottorin luovutuspäivämäärästä, sen jälkeen vain
tuotteen saatavuuden perusteella.
✂
Sim, obrigado(a)!
Gostaria de receber gratuitamente um manual de instruções em português.
Envie o talão pelo correio ou Número de publicação: 7745209
42200/615001/155099900192
um fax para: Nome

Order Department
ARU 2, Dept. 64620 Endereço
SE-405 08 Göteborg
Suécia
Fax: +46 31 545 772
A encomenda também pode
ser feita através da Internet:
http://www.volvopenta.com/ País
manual/coupon
Notar que a oferta é válida por um período de 12 meses a partir da data de entre-
ga do motor. Depois desse período, a oferta é válida consoante a disponibilidade.
Íáé, ✂
Èá Þèåëá Ýíá áíôßôõðï ôïõ åã÷åéñéäßïõ ÷ñÞóçò óôçí áããëéêÞ ãëþóóá ÷ùñßò
êáìéÜ ÷ñÝùóç.
Áñéèìüò Ýêäïóçò: 7745210
Ôá÷õäñïìÞóôå áõôü ôï
42200/615001/155099900192
êïõðüíé óôçí ðáñáêÜôù ¼íïìá
äéåýèõíóç Þ óôåßëôå ôï
ìå öáî óôïí ðáñáêÜôù
Äéåýèõíóç
áñéèìü öáî:
Order Department
ARU 2, Dept. 64620
SE-405 08 Göteborg
Sweden
Fax: +46 31 545 772 ×þñá
Ìðïñåßôå åðßóçò íá äþóåôå

ôçí ðáñáããåëßá óáò ìÝóù ôïõ Ðáñáêáëïýìå óçìåéþóôå üôé áõôÞ ç ðñïóöïñÜ éó÷ýåé ãéá 12 ìÞíåò áðü ôçí
Internet, óôç äéåýèõíóç: çìåñïìçíßá ðáñÜäïóçò ôçò ìç÷áíÞò. ÌåôÜ èá åßíáé èÝìá äéáèåóéìüôçôáò.
manual/coupon
✂
Äà, ïîæàëóéñòà,
Îòïðàâüòå ýòîò òàëîí ß áû õîòåë èìåòü áåñïëàòíîå ðóêîâîäñòâî îïåðàòîðà íà ðóññêîì ÿçûêå.
ïî÷òîé èëè ôàêñîì íà Íîìåð èçäàíèÿ: 7745212
42200/615001/155099900192
èìÿ: Èìÿ
Öåíòð ïîäãîòîâêè
äîêóìåíòàöèè è Àäðåñ
ðàñïðîñòðàíåíèÿ
Îòäåë îáðàáîòêè çàêàçîâ
ARU2, Îòä. 64620
SE-405 08 Ãåòåáîðã
Øâåöèÿ
Ñòðàíà
Ôàêñ: +46 31 545 772
Çàêàçû òàêæå ìîæíî
Ê Âàøåìó ñâåäåíèþ, ýòî ïðåäëîæåíèå äåéñòâèòåëüíî â òå÷åíèå 12
ðàçìåùàòü ÷åðåç Èíòåðíåò: ìåñÿöåâ îò äàòû ïîñòàâêè äâèãàòåëÿ; â äàëüíåéøåì îíî çàâèñèò îò
íàëè÷èÿ.
manual/coupon
7745131 English 06-2005

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Users guide and and maintenance

7745131 (06-2005) 33522067801_0_1

Serial number .........................................................................................................

Clutch, type/nr. .......................................................................................................

Nearest Volvo Penta service location

© 2005 AB VOLVO PENTA

Safety information ................................................. 2 Maintenance schedule ........................................ 18

Introduction ........................................................... 6 Maintenance ........................................................ 20

Presentation .......................................................... 8 Laying up ............................................................. 36

Starting the engine .............................................. 13 Diagnostic function ............................................. 38

Operation ............................................................. 16 Fault codes .......................................................... 40

Safety rules for operation and maintenance

Daily checks Ignition lock

Care and maintenance

Safety rules for operation and maintenance (contd.)

Lifting the engine Batteries

Fire and explosion Chemicals

Never smoke when filling fuel, lubrication oil or close

Cooling system Electric welding

Environmental responsibility Fuel and oils

Certified engines • The engine must not be converted or modified,

Volvo Penta workshop.

Technical description Control unit

– Five bearing, induction hardened crankshaft – Automatic sensing of 24 V or 12 V.

TD420VE, TAD420VE, TAD620VE

TD520GE, TAD520GE, TAD520VE

Location of engine signs

1. Engine model 9. Air temperature in °C (°F), in accordance with ISO

Summary Diagnostic function

The engines are not supplied with instruments and

A. Engine speed potentiometer (throttle control)

• Open the fuel taps.

• Check that there is no leakage of oil, fuel or cool-

• Check the air filter pressure drop indicator. Please

• Check the coolant level and that the radiator is not

WARNING! Do not open the expansion tank cap

• Turn the main current on.

IMPORTANT! Never disconnect the current with

• Move the engine speed control to idle, and release

Starting method EDC 4

Starting in extreme cold

IMPORTANT! Make sure that the cooling sys-

The batteries should be in good condition. Cold weath-

Never use start spray

Starting with auxiliary batteries

1. Check that the auxiliary batteries are connected

WARNING! Do not move the connections when

4. Remove the jumper cables in the reverse order

WARNING! The ordinary cables to the standard

Checking instruments Engine speed control

IMPORTANT! The lubrication oil level must be

• Depending on the equipment installed; press the

• Turn off the main switches before any long stop-

• Carry out maintenance in accordance with the

WARNING! Working with, or going close to a run-

Daily, before first start

After the first 100-200 hours

Every 50-600 hours or at least every 12 months

Every 500 hours

Every 1000 hours