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Maintenance Schedule of Volvo Penta Power Generation Engine

Oct. 15, 2019

As we know that regular maintenance of engine is necessary and important. In this article, we mainly introduce the maintenance schedule of Volvo Penta power generation TD/TAD series engine.

Extended service intervals

The interval between engine oil changes may be extended in certain circumstances. To determine whether the service interval may be extended, Volvo Penta's conditions for extended service intervals must be met and an oil analysis performed. Contact your Volvo Penta dealer for further information.

Where both operational and calendar times are specified, perform the maintenance item at whichever time is the sooner.

Special Interval Service S1 - Every 125-500 Hours / at Least Every 12 Months(1)(2)

Special Interval Service S2 - Oil analysis.

Special Interval Service S3 - After the first 500 hours.

Type A service - Every 500 hours of operation.

Type B service - Every 1000 hours of operation.

Type C service - Every 1500 hours of operation.

Type D service - Every 2000 hours of operation.

Type E service - Every 8000 hours of operation

1) Oil change intervals vary, depending on oil grade and sulfur content of the fuel. Please refer to Oil recommendations.

2) Change oil filters every time the oil is changed.

Service Protocol

C = Clean

R = Replace

A – Adjustment

L – Lubrication

I – Inspection (includes, if necessary, cleaning, adjustment, lubrication and change)


Every 125 -600 hours at least every 12 month

Engine Oil and Oil Filter/By-pass filer




Oil analysis

See dealer’s information




After the first 500 hours

Valve clearance




Every 500 hours/

At least every month




Inspection with VODIA (Diagnostic Tool)



Coolant level and antifreeze mixture



Drive belts, belts tensioner and idle wheels



Batteries, electrolyte level



Air filter



Fuel pre-filter, draining water/contamination



Start and warm up engine

Engine and transmission, abnormal noises



Engine and transmission, oil/fuel/water leakage



1) Readout if any fault codes and LVD


Every 1000 hours/

At least every month




Fuel pre-filter, filter insert



Fuel fine filter



Air filter



Engine and transmission, inspect hoses and cable clamping



Engine and transmission, cleaning/painting




Every 1500 hours/

At least every month




Valve clearance



Every 2000 hours/

At least every month




Drive belts



Air filter, Tank Breather



Air filter, Compressor (Does not apply to all models.)



AdBlue/DEF filter (Does not apply to all models.)



Turbocharger, inspect/clean as required




Every 8000 hours/

At least every month




Coolant VCR (yellow)



1) Different type of coolant must not be mixed with each other.



Volvo engine.jpg

Examples of 5 -liter engines

1. Charge air cooler

2. Exhaust Manifold

3. Turbocharger

4. Closed crank case breather system 5 Air filter indicator

6. Alternator

7. Starter motor

8. Flywheel Housing SAE 3

Volvo engine.jpg

9. Air Filter

10. Fuel regulator

11. Stop solenoid

12. Coolant heater (option)

13. Engine Oil, Filling

14. Oil cooler

15. Expansion tank

16. Engine Transmission

17. Oil filter

18. Fuel Filter

19. Radiator

Examples of 6 and 7-liter engines 

Volvo generator engine.jpg

1 Fan hub

2 Coolant Pump

3 Lifting eye

4 Fuel Filters

5 Turbocharger

6 Exhaust Manifold

7 Lifting eye

8 Coolant inlet

9 Clutch protection

10 Smoke limiter

11 Oil cooler

12 Fuel line for tank connection

13 Injection Pump

Volvo genset engine.jpg

14 Silencer

15 Start Relay

16 Electrical starter element

17 Air Filter

18 Cable retrainer

19 Coolant pipe, outlet

20 Fan guard

21 Radiator

22 Flywheel housing

23 Instrument Panel

24 Starter motor

25 Crankcase ventilation

26 Lubricating oil filter, full flow

27 Lubricating oil filter, part flow

28 Oil filler cap, engine

29 Vibration Damper

30 Belt Tensioner (automatic)

31 Frame

Instrument box

1. Location for level switch relay: coolant (accessory) 

2. Relay for automatic stop: engine coolant temperature (ECT) switch, oil pressure switch and low coolant temperature switch (accessory)

3. Holding current relay (operating current and instruments)

4. Terminal block for engine cable harness

5. Terminal block for automatic stop and extra power output (maximum 16 A)

6. Negative (-) for extra power output (black cable)

7. Connection for any extra switches — automatic stop (white cable)

8. Positive (+) for extra power output (red cable). Maximum 16 A.


Instrument box.jpg

Alarm separator for the instrument box (accessory)


1. Relay for engine coolant level switch (accessory)

2. Relay for engine coolant temperature (ECT) switch, oil pressure switch

3. Holding current relay (operating current and instruments)

4. Alarm separator

5. Splice section

6. Terminal block for auxiliary power output (16 A fuse) and output for automatic stop, (closes in the event of a fault).

7. Warning lamp, high engine coolant temperature (accessory)

8. Warning lamp, low engine coolant level (accessory) 9 Warning lamp, low lubrication oil pressure (accessory)

10. Terminal block for engine cable harness

11. Engine coolant temperature (ECT) switch (normally open)

12. Oil pressure switch (normally open)

13. Joint splice

14. Warning lamp, generator not charging

alarm separator.jpg


Time relay kit for engagement of the starter (accessory)


1. Time relay

2. Connector. 8 pin

3. Ignition switch

4. Temperature switch (accessory)

5. Starter element

6. Indicator lamp (engaged starter element) 7 Battery

Time relay.jpg


Wiring Diagram

Example (TD520GE, TAD720–21VE engines)

1. Battery

2. Main switch

3. Starter motor

4. Alternator

8. Fuse

10. Oil pressure sensor

11. Temperature Sensor/Engine connector

14. Oil pressure switch

15. Temperature Sensor/Engine connector

16. Relay

17. Stop solenoid

18. Horn

46. Water level sender (720)

52. Start button

52a. Start Relay

53. Interlocking button

54. Stop button

57. Charging lamp

58. Oil pressure sensor

59. Water temperature gauge

61. Hour Meter

65. Instrument light

66. Instrument light

84. Holding current relay

wire diagram.jpg

Example (6–7 liter engines)

Not for TAD720

1. Oil pressure gauge

2. Engine coolant temperature gauge

3. Tachometer with built-in hours run meter

4. Charge warning lamp

5. Semi-automatic fuse

6. Stop button

7. Interlocking button

8. Start button

9. Relay, Coolant Level (Accessory)

10. Relay, Coolant temperature/Oil pressure

11. Holding current relay (operating current and instruments)

12. Terminal block (auxiliary power output, with 16A fuse, output for automatic stop, closes in the event of a fault) 13. Relay, Starter element

14. Starter element

15. Starter motor

16. Batteries

17. Alternator

18. Engine speed sensor

19. Coolant temperature sensor

20. Coolant temperature (normally open)

21. Oil pressure sensor

22. Oil pressure switch (normally open)

23. Coolant level switch (Accessory)

24. Stop solenoid (current bearing during operation)

25. Horn

26. Joint splice

27. Main switch

28. Engine speed sensor

29. Relay

30. Engine speed governor

31. Fuse

*1 Remove when setting the UT governor

Volvo engine.jpg

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