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Volvo Penta TWD1643GE Series User Manual

Volvo Penta TWD1643GE Series
106 pages
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Operator’s manual
16L
TP-6662 1/19d

Table of Contents

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Volvo Penta TWD1643GE Series Specifications

General IconGeneral
Engine ModelTWD1643GE
Number of Cylinders6
Compression Ratio17.5:1
Fuel SystemCommon Rail
GoverningElectronic
Displacement16.1 liters
Bore144 mm
Stroke165 mm
AspirationTurbocharged
Engine Speed at Max Power2, 300 rpm
Engine Speed at Max Torque1300 rpm
Cooling SystemFreshwater cooled
Starting SystemElectric
Emissions ComplianceEPA Tier 3

Summary

Foreword

Safety Information and Precautions

Eye and Skin Protection

Safety measures for protecting eyes and skin from hazards.

Fire and Explosion Hazards

Warnings and precautions related to fire and explosion risks.

Fuel and Chemical Handling Safety

Guidelines for safe handling of fuels, oils, and chemicals.

Engine Operation Safety Rules

Essential safety rules for starting and running the engine.

Hot Surfaces and Rotating Parts Safety

Warnings about hazards from hot engine parts and rotating components.

Start Spray Prohibition

Prohibition of using start spray due to explosion risk.

Fuel System Leak Detection

Safety procedures for detecting leaks in the fuel system.

Battery Safety Procedures

Precautions for safe handling, charging, and connecting batteries.

Cleaning and Adjustment Safety

Safety guidelines for cleaning engine components and adjustments.

Introduction to the Operator's Manual

About This Manual

Explains the content and purpose of the Operator's Manual.

Warranty Information

Details the limited warranty coverage for the engine.

Engine Break-in and Fluid Recommendations

Guidance on initial engine break-in and recommended fluids.

Maintenance and Component Care

Importance of maintenance, using genuine parts, and avoiding strain.

Environmental Care Policy

Volvo Penta's commitment to environmental care and emission reduction.

Certified Engine Requirements

Special demands for emission-certified engines regarding care and maintenance.

Dealer and Service Network

Information on authorized dealers and action service for support.

Engine Model Presentation

Engines Overview

Lists the industrial diesel engine models covered by the manual.

EMS Engine Management System

Describes the electronic system for diesel engine control.

Instruments and Control Units

Display Control Unit (DCU) Overview

Introduction to the DCU digital instrument panel and its functions.

DCU Menus and Engine Data

Navigating DCU menus and viewing engine data.

DCU Functions and Settings

Details on Preheat, Governor mode, Diagnostics, and Trip data reset.

DCU Setup and Parameters

Setting up application, units, language, and parameters.

DCU II Display and Alarms

Describes the DCU II display, menus, and alarm messages.

DCU Configuration and Save Options

Managing configurations, saving settings, and dealer-specific options.

CIU Control Interface Unit

Explanation of the CIU as an interface between EMS and control panel.

Engine Starting Procedures

Before Starting Checks

Essential checks to perform before starting the engine.

Engine Starting Steps

Step-by-step guide for starting the engine, with and without pre-heating.

Starting in Extreme Cold Conditions

Preparations and procedures for starting in very cold temperatures.

Start Spray and Auxiliary Battery Use

Warnings against start spray and instructions for using auxiliary batteries.

Engine Operation Guidelines

Instrument Reading and Alarm Monitoring

How to check instruments and respond to alarms during operation.

Maneuvering and Low Load Operation

Advice on proper maneuvering and avoiding prolonged low load operation.

Engine Shutdown Procedures

Before Engine Shutdown

Steps to take before shutting down the engine to ensure proper cooling.

Auxiliary Stop

Information on the auxiliary stop mechanism.

After Shutdown Checks

Checks and actions required after the engine has been shut down.

Fault Diagnosis and Handling

Diagnostic Function Overview

Purpose and function of the engine diagnostic system.

DCU and DU Fault Reporting

How DCU and DU units display and report engine faults.

CIU Fault Codes and Easy Link Instruments

Reading fault codes via CIU and Easy Link instruments.

Erasing Fault Codes

Procedures for resetting and erasing fault codes from memory.

Fault Tracing Guide

Table of symptoms and possible causes for engine malfunctions.

Fault Code Register

Maintenance Schedule and Intervals

Service Intervals

Recommended service intervals based on operating hours or time.

Extended Service Intervals

Conditions for extending engine oil change intervals.

General Maintenance Procedures

Engine Orientation and Components

Identification of key engine components for maintenance.

Engine General Inspection

Visual inspection guidelines for the engine and compartment.

Air Filter Maintenance

Procedure for checking and replacing the engine air filter.

Charge Air Pipe and Belt Checks

Inspection of charge air hoses and drive belts for damage.

Drive Belt Replacement

Step-by-step guide for changing the drive belt.

Alternator Belt Replacement

Step-by-step guide for replacing the alternator belt.

Lubrication System Maintenance

Oil Level Checking and Topping Up

Procedure for checking and maintaining the engine oil level.

Engine Oil Change

Steps for draining and refilling the engine oil.

Oil Filter and By-pass Filter Change

Procedure for replacing the engine oil filters.

Fuel System Maintenance

Draining Fuel Condensate

How to drain accumulated condensate from the fuel system.

Engine Fuel Filter Replacement

Procedure for replacing the engine fuel filter.

Fuel Pre-filter Change

Steps for changing the fuel pre-filter and water trap.

Fuel System Bleeding

Procedure for bleeding air from the fuel system.

Cooling System Maintenance

Coolant Mixing and Quality

Guidelines for mixing and ensuring the quality of engine coolant.

Coolant Level Check and Topping Up

How to check and refill the coolant level in the system.

Coolant Draining Procedure

Steps for safely draining the engine coolant.

Charge Air Cooler External Cleaning

Instructions for cleaning the charge air cooler without high pressure.

Cooling System Cleaning

Procedure for flushing and cleaning the engine cooling system.

Cooling Air Filter

Installation, removal, and cleaning of the cooling air filter.

Water Quality Requirements

Specifications for water quality used in the cooling system.

Electrical System Components

Main Switch and Fuses

Information on the main switch, fuses, and circuit breaker.

Electrical Connections

Guidelines for checking and tightening electrical connections.

Battery Maintenance and Replacement

Battery Maintenance Recommendations

Tips for increasing battery service life and avoiding accidents.

Battery Replacement Procedure

Step-by-step guide for disconnecting and connecting batteries.

Engine Storage Procedures

Preparing Engine for Storage

Steps for preparing the engine for storage up to 8 months.

Long Term Conservation (>8 Months)

Conservation procedures for lubrication and fuel systems for long periods.

Technical Data Specifications

Engine Specifications

Detailed technical data for various engine models.

Lubrication System Data

Information on oil change volumes, pressure, and recommendations.

Fuel System Specifications

Fuel system requirements, restrictions, and properties.

Cooling System Specifications

Data on cooling system pressure, volume, and thermostat.

Electrical System Specifications

Electrical system voltage, alternator, battery capacity, and platform.

Engine Identification Numbers

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