Volvo 4 Cylinders TD520GE Engines Operator's Manual
This Operator's Manual covers the industrial engines: 4 cylinders TD520GE, TAD530GE, TAD531GE and TAD532GE. 6 cylinders TAD620VE, TAD730GE, TAD731GE, TAD732GE, TAD720VE and TAD721VE.
The engines are four-stroke, direct injection in-line diesel engines with replaceable wet cylinder liners (except TAD620VE, which has dry liners).
The engines are fitted with turbochargers, piston cooling and a water-cooled charge air cooler that reduces the temperature of inlet air to provide a greater mass of air to the cylinders. This makes greater engine output possible at the same time as combustion and exhaust temperatures can be maintained at suitable levels. Also, NOx emissions are reduced.
To facilitate start and reduce exhaust emissions in cold weather, the engines are fitted with electric intake air heaters (exceptions TAD520GE and TAD720VE).
Instruments and Controls
This chapter describes the instrument box and the instrumentation in Volvo Penta’s range. Variations in the appearance of instrumentation may occur in certain applications (mobile for example). If this is the case, see the Instruction Manual for the relevant application.
Warning
If the instrument box does not have an ignition switch, the engine/operator compartment must have a lock to prevent unauthorised persons starting the engine. (Alternatively a lockable main switch can be used.)
Instrument box
1. Oil pressure gauge. Normally within the green field (300–500 kPa).
2. Warning lamp: Low engine coolant level (accessory)
3. Engine coolant temperature gauge. Normally within the green field (70–95°C).
4. Warning lamp: High engine coolant temperature (accessory)
5. Tachometer
6. Operating hour counter
7. Starter button
8. Warning lamp: Generator not charging
9. Interlock: Press in the button to disengage the automatic stop for low oil pressure and to activate preheating.
10. Warning lamp: Low oil pressure (accessory)
11. Stop button
12. Semi-automatic fuses: Reset by pressing the button on the fuse.
Before Starting
Check that the oil level is between the MIN and MAX marks. For filling refer to Oil level, checking and topping up.
• Open the fuel cocks.
• Check that there are no coolant, fuel or oil leaks.
• Check the air filter pressure drop indicator. Please refer to Engine, General.
• Check coolant level. Check that the outside of the radiator is not clogged. Please refer to Coolant Level, Checking and Topping Up, and Charge Air Cooler, External Cleaning.
WARNING!
Do not open the coolant filler cap when the engine is hot, except in emergencies as this could cause serious personal injury. Steam or hot fluid could spray out.
• Turn the main switch on.
IMPORTANT: Never break the circuit with the main switch while the engine is running.
Alternator and electronics could be damaged.
• Set the engine speed control to idle. Disengage the disengageable clutch/transmission.
Starting the Engine
1. Press the “Interlock button” (1) and check that the warning lamps in the instrument box are functioning. (This applies to engines equipped with alarm separators).
2. If the engine is hot: Press the “Interlock button” (1) and hold it in while pressing the Starter button (2). If the engine is cold: Press the Interlock button (1) and hold it in for approximately 50 seconds to preheat the engine. Then press the “Start button” (2) as well.
3. Release the Start button immediately when the engine starts. However the Interlock button must be held down for a further 5 seconds approximately. This is to allow the oil pressure to reach the correct level. Otherwise the automatic stop will engage and stop the engine.
NOTICE! In extreme cold, the preheating can be re-engaged for a few minutes after start if necessary. Hold the Interlock button (1) pressed in.
IMPORTANT!
The start button must never be pressed in when the engine is running. The starter motor and starter gear on the flywheel may be seriously damaged.
4. Allow the engine to run at 500–700 rpm for the first 10 seconds. Then warm up the engine at low speed and low load.
IMPORTANT!
Do not race the engine while it is cold.
NOTICE! Generating set engines automatically rev up to the preset engine speed (1500 or 1800 rpm).
Volvo Penta starting lock
1. If the engine is hot: Proceed directly to point 2. If the engine is cold: Turn the ignition key to position “II” to engage the preheating. Hold the key in this position for approximately 50 seconds. (If the engine is equipped with a time relay for preheating, the key can be released. Preheating stops automatically after 50 seconds).
2. Turn the key to position “III”. Release the key to position “II” immediately when the engine starts. Hold the key in this position for approximately 5 seconds. This is to allow the oil pressure to reach the correct level. Otherwise the automatic stop will engage and stop the engine.
If the engine does not start, turn the key to the “O” position before trying again.
NOTICE! In extreme cold, the preheating can be re-engaged for a few minutes after start if necessary. Hold the ignition key in position “II”.
3. Allow the engine to run at 500–700 rpm for the first 10 seconds. Then warm up the engine at low speed and low load.
IMPORTANT! Do not race the engine while it is cold.
NOTICE! Generating set engines automatically rev up to the pre-set engine speed (1500 or 1800 rpm).
If you are interested in the starting of Volvo engine, please refer to this article to learn the details.
Operation
Correct operation is the key to fuel economy and engine service life. Always allow the engine to achieve normal operating temperature before running it at full power. Avoid opening the throttle too quickly and running the engine at high engine speeds.
IMPORTANT!
An automatic shut-off for oil pressure and engine coolant temperature (ECT) must be installed during unattended operation where the Volvo Penta instrument box is not being used.
Reading the Instruments
Check all instruments directly after starting, and then regularly during operation. The pointers must be within the green areas.
Coolant temperature
83-95°C (181-203°F) for TAD620VE, TD520GE, TAD720GE, TAD530GE, TAD531GE, TAD532GE, TAD730GE, TAD731GE, TAD732GE
87-102°C (189-216°F) for TAD720VE, TAD721VE
Oil pressure, hot engine: 300–500 kPa (44–75 psi). At idle, lower values are normal.
Alarms
If the Volvo Penta instrument box is used, the following applies:
• If oil pressure is too low or engine coolant temperature (ECT) too high, the engine stops automatically and the acoustic alarm goes off. If the engine is equipped with an alarm separator, the relevant warning lamp also lights.
• If the engine coolant level is too low and the engine is equipped with an engine coolant level switch, the engine stops automatically and the acoustic alarm goes off. The warning lamp lights.
• If generator charging drops, the warning lamp lights.
NOTICE! For other applications see the Instruction Manual for the relevant application.
Maneuvering
Speed control
Power pack: The engine speed (RPM) is adjusted using the mechanical engine speed control (1). This is mounted on the instrument box.
Other engines: See the relevant instruction manual.
Disengageable clutch
The clutch is disengaged when the control lever is in position “N” and engaged when the lever is in position “E”.
IMPORTANT!
The engine speed must not exceed 1000–1200 rpm during engagement and disengagement.
Engine Shutdown
MPORTANT!
If there is a risk of freezing weather, the coolant in the cooling system must have sufficient anti-freeze protection. Refer to the Maintenance, page 48 chapter. A poorly-charged battery can freeze and burst. Refer to the Battery, Charging chapter.
Before Engine Shutdown
Let the engine run without load at 1300–1500 rpm for a few minutes before stopping. This will even out the engine temperature and prevent overheating.
IMPORTANT!
This is especially important if the engine has been operated at high engine speeds and/or loads.
Stop the Engine
• Disengage the engine (if possible).
• Press in the stop button and hold it depressed until the engine has stopped. Alternatively, turn the key to stop position “S”. Release the key when the engine has stopped.
Emergency Stop
If the engine cannot be stopped normally, it can be stopped by moving the lever on the fuel injection pump backwards.
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