Volvo Penta TAD734GE Engine Operating Manual

Volvo Penta TAD734GE Engines

This Operator's Manual concerns the Volvo TAD734GE engine, an inline 6-cylinder direct-injection diesel engine. The engine is equipped with a common rail fuel injection system, IEGR (internal exhaust gas re-circulation), electronically- controlled fuel management (EMS 2), a turbocharger, a thermostatically-controlled cooling system and electronic speed control.

Presentation

EMS (Engine Management System)

EMS is an electronic system with CAN communication (Controller Area Network) for diesel engine control. The system was developed by Volvo and includes fuel control and a diagnostic function.

Summary

The system comprises such items as a control unit, sensors and injectors. The sensors send input signals to the control unit, which in turn controls the injectors.

The information from the sensors gives exact data about prevailing operating conditions and allows the processor in the control module to calculate the correct injection amount, injection timing and check engine health.

Input signals

The control unit receives input signals about engine operating conditions from the following components

- coolant temperature sensor

- charge air pressure and temperature sensor

- rpm sensor, camshaft

- rpm sensor, flywheel

- coolant level sensor

- oil pressure sensor

- fuel pressure sensor

- water-in-fuel indicator

- fuel pressure in distributor manifold

Output signals

The control module uses the input signals to control the following components:

- unitinjectors

- starter motor

- main relay

- pre-heating relay

MPROP, high pressure fuel pump

Fuel control

The engine fuel requirement is analyzed up to 100 times per second. The amount of fuel injected into the engine and the injection advance are fully electronically controlled via fuel valves on the unit injectors.

This means that the engine always receives the correct volume of fuel in all operating conditions, which provides lower fuel consumption and minimal exhaust emissions etc.

Diagnostic Function

The task of the diagnostic function is to detect and locate disturbances within the EMS 2 system, to protect the engine, and to provide information about problems that arise.

If a malfunction is detected, it is announced by warning lamps, a flashing diagnostic lamp or in plain language on the instrument panel, depending on the equipment used. If a fault code is obtained as a flashing code or in plain language, it is used for guidance in any fault tracing. Fault codes can also be read by the Volvo VODIA tool at authorized Volvo Penta workshops.

If there is a serious malfunction, the engine will shut down altogether, or the control unit will reduce the power output (depending on application). Here too, a fault code is set for guidance in any fault tracing.

Instruments and Controls

Display Control Unit

The DCU control panel is available as an optional accessory for the EMS (Engine Management System) electronic control system.

The DCU is a digital instrument panel which communicates with the engine control unit. The DCU has several functions, such as engine control, monitoring, diagnostics, and parameter setting.

The menus in the DCU system can be used to check and in some cases to set, a number of different functions in the EMS system.

NOTICE! Settings and what engine data that appears in the display may vary depending on installation and engine model.

NOTICE! The menus and illustrations shown here are the English version. The language can be changed, however; refer to the Setup menu.

Start

When the DCU panel is started, the "Engine Data" menu is displayed; press "ESC" to come to the main menu.

1 LED display

2 START. Starts the engine

3 SPEED - . Reduces engine rpm

4 SPEED +. Increases engine rpm

5 STOP. Stops the engine

6 ON/OFF. Starts and stops the system

7 Scroll downwards in menus

8 SEL. Selects in menus

9 Scroll upwards in menus

10 ESC. Return to previous menu selection

Menus

There are several sub-menus under each main menu. There is not space for all the menu choices on the display. To scroll through the menus, use the 7 and 9 buttons on the display. Press the SEL button 8 to make a selection. Refer to the illustration on the previous page.

NOTICE! The Setup menu can be used to select the language that you want to use on the display.

Main menu

Engine data, current engine data

Preheat, manual activation of pre-heating. Must be activated with temperatures below 0°C (32°F)

Governor mode, activation of droop

Diagnostics, shows fault codes as text

Trip reset, resets trip data

Setup, parameter setting

Information, shows the currently applicable hard/software, data sets and engine identification for the engine and DCU data

Engine data

shows relevant engine data

Engine speed, can be controlled with the SPEED+ and SPEED- buttons (rpm)

Charge pressure (kPa)

Coolant temperature (°C)

Charge air temperature (°C)

Oil pressure (kPa)

Oil temperature (°C)

Engine hours (h)

Battery voltage (V)

Fuel consumption (l/h)

Instantaneous fuel consumption (trip fuel) (l)

Preheat

Manual activation of pre-heating. When it is activated, the EMS system senses at start-up if pre-heating is needed. For automatic pre-heating, refer to the Setup/Preheat on ignition menu.

NOTICE! Must be activated with temperatures below 0°C (32°F).

The pre-heating time is adjusted to suit the engine temperature, and can last for up to 50 seconds both before and after starting. Refer also to Starting procedure EMS 2.

Press SEL, the text Preheat requested will be shown

The display automatically returns to the Engine Data menu.

Governor mode

Activates/shuts off droop. To set the droop level, refer to the Setup / Governor gradient or Governor droop menu.

Select Isochronous mode or Droop mode with the SEL button.

Diagnostics

Shows the error list containing the 10 latest active and inactive faults. The fault codes are shown as text on the display.

Scroll through the fault list with the arrow keys.

Trip Data reset

Resets trip data, such as fuel consumption

Press the SEL button to reset trip data

Setup

Parameter setting in the engine's control systems. Different menus appear under Customer parameter, depending on whether Versatile or Gen set has been selected from Set application. See below.

The parameters that can be set/selected (choice is made with the SEL button) are:

Set application, setting Versatile or Gen set.

Depending on the selection made here, different menus will appear under Customer parameter.

Unit, setting of units (metric or US imperial)

Language, setting the language used on the display. Choose between English, French, German and Spanish.

Stop energized to, setting of external stop input. Activated by Stop or Run.

Stop: The stop input must be connected to voltage to stop the engine.

Run: The stop input must be connected to voltage to run the engine.

Customer parameter, setting alarm limits. Refer to

Customer parameter / Versatile and Customer parameter / Genset.

Throttle input setting, setting of engine-speed control and voltage limits. Refer to Throttle input setting.

Display setting, setting the display. refer to Display setting.

Customer parameter / Versatile

Idle engine speed - setting idle speed

Preheat on ignition - activation of automatic pre-heating. The engine control system senses if pre-heating is needed and activates it directly at switch-on.

Governor gradient (Nm/rpm) - setting of droop level, when activated. For activation, refer to Governor droop in the main menu.

Oil temp warning limit (°C) - setting alarm limit for oil temperature.

Coolant temp warning limit (°C) - setting alarm limit for coolant temperature.

Customer parameter/ Genset

Primary engine speed - selection of engine rpm 1500 or 1800 rpm.

Preheat on ignition - activation of automatic pre-heating. The engine control system senses if pre-heating is needed and activates it directly at switch-on.

Governor droop (%) - setting of droop level, when activated. For activation, refer to "Governor droop" in the main menu.

Over-speed limit (%) - setting of limit for over-speed alarm, % of set engine rpm.

Over-speed shutdown - activation of engine shut-down with over-speed alarm. Refer to "Over-speed limit" to activate the alarm limit for the excess rpm alarm.

Oil temp warning limit (°C) - setting alarm limit for oil temperature.

Coolant temp limit (oC) - setting alarm limit for coolant temperature.

Throttle input setting

rpm control setting (throttle operation)

Set throttle mode - OFF - engine rpm is controlled via the DCU panel.

ext throttle input - engine speed is controlled with a potentiometer (accelerator).

ext voltage input - engine rpm is controlled by an external unit.

Set idle voltage (V) - idle voltage level setting

Set max voltage (V) - full throttle voltage level setting.

Display setting

settings for the display. Adjustment is made with the 7 and 9 buttons; see DCU panel illustration.

Set contrast (%) - contrast setting

Set back light time (sec) - time setting (in seconds) for display back lighting on, lighting is then shut off if the panel is not used.

Set back light brightness - display back lighting brightness setting.

Information

shows the data for the engine and DCU

Engine hardware Id - engine control unit part number.

Engine software Id - engine control unit software part number.

Engine dataset1 Id - engine data set l part number

Engine dataset2 Id - engine data set 2 part number

Vehicle Id - chassis number

DCU hardware Id - DCU part number

DCU software Id - DCU software part number

DCU datasetl Id - DCU data set l part number

DCU dataset2 Id - DCU data set 2 part number

Note: Volvo company is Sweden's largest industrial enterprise with a history of 120 years, and it is one of the world's oldest engine manufactur-ers. So far its engine output has reached more than 1 million units, and it has been widely used in automobile, engineering machinery, ships and other power, it is the ideal power of the generator.