Volvo TAD1240GE, Operator'S Manual

Page 1: ... reference to Ingersoll Rand Company or use of trademarks service marks logos or other proprietary identifying marks belonging to Ingersoll Rand Company in this manual is historical or nominative in nature and is not meant to suggest a current affiliation between Ingersoll Rand Company and Doosan Company or the products of either Revised 10 12 ...

Page 2: ...y 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 t...

Page 3: ...o shut down 19 Shut down 19 Aftershut down 19 Extrashut down 19 Contents Maintenanceschedule 20 Maintenanceschedule 20 Newlyrebuiltengine 21 Maintenance 22 Engine general 22 Lubrication system 26 Lubricationoil 27 Cooling system 30 Coolant general 30 Fuel system 35 Electric system 39 Clutch 43 Preparationforstorage 44 Preparationforstorage 44 Preparationafterstorage 45 Troubleshooting 46 Symptoms ...

Page 4: ...ta dealer for assistance This symbol is used in the instruction book and on the product to let you know that it con cerns safety information Always read this information very carefully In the instruction book warning texts are handled according to the following priority system WARNING Warns of risk of injury extensive damage to the product or other property or that serious functional problems can ...

Page 5: ... that the engine be running be assigned to an authorized Volvo Penta repair facility Safety instructions for operation and maintenance Daily checks Make a habit of always visually checking the engine and engine compartment prior to operation before starting the engine and after operation after shut ting down the engine This will help you to quickly notice if fuel coolant or oil leaks or any other ...

Page 6: ...imity to the filling station or in the engine compart ment Non original parts Components of the fuel and electrical systems on Vol vo Penta engines are designed and manufactured to minimize the risk of explosion or fire according to app licable requirements Use of non original parts can result in explosion or fire Batteries Batteries contain and develop oxyhydrogen gas espe cially while charging O...

Page 7: ...should be stopped and the electrical power switched off using the main switch breakers External power to the engine heater battery charger or other equipment mounted on the engine must be switched off Batteries Batteries contain a very strong corrosive electrolyte Protect your eyes skin and clothing during charging or other handling of batteries Always use safety glas ses and gloves In case of ski...

Page 8: ...coolant used batteries etc to an environ mental station for destruction Through our mutual efforts we can make a valuable contribution to the environment Running in The engine should be run in during the first 10 hours of operation according to the following Run the engine as with normal operation Full throttle operation should not occur for more than short peri ods Do not run the engine for long ...

Page 9: ...ust or intake air systems No seals may be broken by non authorized personnel In all other cases follow the advice in the instruction book regarding operation maintenance and service IMPORTANT In cases of neglected or deficient maintenance service as well as use of non origi nal parts AB Volvo Penta will no longer be able to assure that the engine meets conditions of certification Volvo Penta will ...

Page 10: ...keystone variety Induction hardened overhead camshaft with roller rocker arms Four valves per cylinder Replaceable valve seats and valve guides Fuel system Microprocessor based control unit for fuel delivery EDCIII Gear driven feeder pump EDC III Electronic Diesel Control see separate description Centrally placed unit injector with electromagnetically controlled fuel valves Fuel filter of spin on ...

Page 11: ...1240VE T Turbo A Air to air Charge air cooler W Water to air intercooler D Diesel engine 12 Swept volume liter 4 Generation 0 Version G Gen Set engine V Stationary and mobile operation E Emissions check Location of engine plates The plate below shows 1 Engine designation 2 Serial number 3 Specification number Identification numbers The plate below shows 1 Engine designation 2 Specification number ...

Page 12: ...ly via fuel valves in the unit injectors This means that the engine always receives the cor rect amount of fuel under all operating conditions providing benefits including improved fuel economy and minimized exhaust emissions Diagnostic function The diagnostic system s function is to detect and lo calize disturbances within the EDC III system to pro tect the engine as well as to insure the ability...

Page 13: ...or 3 Control unit 4 Air filter 5 Starter motor 6 Fuel pre filter with water sensor 7 Fuel filter with fuel pressure sensor 8 Oil dipstick 9 Oil filler 10 Intercooler TAD only Orientation The picture shows TAD1240GE TAD1241GE and TAD1242GE variants ...

Page 14: ...efore be held down until the main relay is activated This takes about one second 9 Pre heat button Used to pre heat the engine prior to start Pre heating is automatically adjusted by the system The system also has after heating 10 Diagnosis button Used to read out error codes See Reading out error codes 11 Stop Off button 12 Warning lights x6 from the left oil pressure oil temperature battery char...

Page 15: ...Maintenance cooling system WARNING Do not open the coolant filler cap 1 when the engine is warm Steam or hot coolant can squirt out NOTE Do not open the pressure cap 2 Turn on the main switches IMPORTANT Never switch off the power with the main switch while the engine is running The generatorcanbedamaged Set the throttle to idle and disengage the clutch put the transmission in neutral Start up pro...

Page 16: ...ent upon engine temperature 3 Start the engine with position III Let the key re turn to position I immediately once the engine has started NOTE The engine has a built in starter motor inter lock to prevent inadvertent activation of the starter motor while the engine is running The key must be turned to the O position before attempting to start again Let the engine run at 500 700 rpm for the first ...

Page 17: ... synthetic oil of the recommended viscosity for the temperature in question see chapter Maintenan ce lubrication system Synthetic oils retain their lub ricating properties over a wider range of temperatures than mineral oils Pre heat the coolant by using a separately mounted electric engine heater In extreme cases it can be ne cessary to use a diesel powered engine heater Con sult your Volvo Penta...

Page 18: ...the dead battery Then connect the black booster cable to the booster battery then to a place that is a distance away from the dead battery i e next to the main switch on the negative wiring or at the negative cable s connection to the starter motor 3 Start the engine WARNING Do not disturb the connections while attempting to start the engine risk for creating sparks and do not lean over any of the...

Page 19: ...l begin to blink Pushing the Diagnostic button 2 will give a error code that can assist in locating the problem Additio nal information on error codes and location of pro blems is in the chapter Problem location The following conditions apply when the Volvo Penta instrument box is used In case of excessively low oil pressure or excessively high coolant temperature the engine is shut down automatic...

Page 20: ...ude fuel dilution of the lubrication oil as well as lea kage from the exhaust pipe If the following items are performed as a comple ment to the normal care of the engine there will be no risk of operational disturbances due to opera tion at low loads Keep low load operations to a minimum If periodic test operation of the engine is done without load every week the operating time should be limited t...

Page 21: ...cooling system must have sufficient anti freeze See the chapter Maintenance cooling system A poorly charged battery can freeze and break Before shut down Allow the engine to run a few minutes with no load be fore it is shut down This permits an evening out of temperatures within the engine which prevents after boiling as well as cooling the turbocharger somewhat This contributes to a lengthened us...

Page 22: ...Volvo Penta Every 50 600 operational hours at least every 12th month Engine oil change 1 page 27 Oil filter Bypass filter change 2 page 28 1 Oil change intervals will vary depending upon the grade of the oil and the amount of sulfur in the fuel See page 26 2 The filter must be changed with every oil change Every 400th operational hour at least every 12th month Fuel tank sludge collector drain not ...

Page 23: ...onal hours Turbocharger check not shown Valve play check adjust not shown Coolant change Anti corrosive liquid pages 29 32 Every 12th month EDC system Check with diagnosis tool not shown Engine general check not shown Air filter element change page 25 Engine cleaning painting not shown Air Filter tank ventilation change not shown Air filter air compressor change not shown Every 48th month or every...

Page 24: ...tment a visual inspection before starting the engine and after operation when the engine has stopped This will help you to quickly realize if somet hing unusual has happened or is happening Look especially carefully for oil fuel and coolant lea kage loose screws worn or loose drive belts loose connections or damaged hoses and wires The in spection only takes a few minutes but can mean that serious...

Page 25: ... Loosen the lock screws 2 so that the tightening screws 3 can turn freely Loosen the tightening screws and remove the drive belts TAD TWD Drive belts check adjust Check and adjustments should be done when the drive belts are warm The drive belt to the generator should be able to press in 3 4 mm between the drive belt pulleys The drive belt to the generator must be adjusted manually but the other d...

Page 26: ... and the outer fan ring around the cooling fan 8 Start the engine and perform a functional check Drive belt replacing 1 Switch the main switch es off and make sure that the engine has no electrical power 2 Remove the protective grill and the outer fan ring from around the cooling fan 3 Remove the protective guards from around the drive belts 4 Place a 1 2 wrench in the belt tensioner Lift up the w...

Page 27: ...g the indicator by prssing the button NOTE The filter should not be touched before the in dicator is in the red Dispose of the old filter It may not be cleaned or reused IMPORTANT Undercontinuousoperationthe filter should be checked every 8 hours For operation in extremely dirty environments such as coal mines and stone crushers a special filter is available not sold by Volvo Penta 1 ...

Page 28: ...re than 1 0 1 Oil change interval During operation first reached VDS 2 and ACEA E3 2 600 hours or 12 months 300 hours or 12 months 150 hours or 12 months VDS and ACEA E3 2 400 hours or 12 months 200 hours or 12 months 100 hours or 12 months3 ACEA E4 E3 E2 API CE CF CF 4 CG 4 CH 4 200 hours or 12 months 100 hours or 12 months 50 hours or 12 months3 1 If the sulfur content is 1 0 by weight oil with ...

Page 29: ...use oil of the recommended grade seepreviouspage Engine oil change WARNING Hot oil can cause severe burns NOTE Oil should be changed while the engine is warm 1 Connect the drain hose to the oil bilge pump and make sure that leakage can not occur 2 Pump out the oil or remove the drain plug and drain the oil NOTE Collect all the used oil and deliver it to a used oil collection facility 3 Remove the ...

Page 30: ...et residue remains 4 Spread a thin layer of engine oil on the new filter s sealing rings 5 Install the new oil filter The two full flow filters should be tightened 1 2 to 3 4 turn following seal contact The bypass filter should be tightened 3 4 to 1 turn following seal contact 6 Fill with oil start the engine and operate it for 20 30 seconds 7 Shut off the engine check the oil level and fill with ...

Page 31: ...otal solid particles 340 ppm Totalhardness 9 5 dH Chloride 40 ppm Sulfates 100 ppm PH value 5 5 9 Silicon 20 mg SiO2 l Iron 0 10 ppm Manganese 0 05 ppm Conductance 500 µS cm Organic contents CODMn 15 mg KMnO4 l Every year or at least every 2000 operational hours Coolant Change interval Volvo Penta coolant glycol mixture with coolant filter Every fourth year or at least every 10 000 operational hou...

Page 32: ...ystem Anti corrosion mixture When there is never a risk of freezing water accor ding to ASTM D4985 mixed with Volvo Penta corrosi on protection may be used as coolant We recommend however that an anti freeze mixture of 40 be used year round even in frost free climates Mix according to the instructions on the package Operate the engine until it is warm after filling to prov ide the best possible pe...

Page 33: ...xtures 2 Mix the correct amount of coolant ahead of time see the table below so that it can be assured that the system has been filled Filling must not be done so quickly that air pockets form in the system Air must be given the chance to flow out through the filler opening and drain valves When adding coolant the coolant level should be between the MIN and MAX markings 3 Start the engine when the...

Page 34: ...Penta the drain cock P is located under the radiator 3 Make sure that all coolant runs out Deposits may exist just inside of the cocks plugs that must be cleaned away If this is not done there is a risk that coolant will be left in the engine where it can cause serious damage Check to see if the installation has additional cocks or plugs at the lowest points of the coolant system 4 Close the cocks...

Page 35: ...st 2 hours after normal opera ting temperature has been reached NOTE As an alternative the cooling system can be filled with 15 20 concentrated coolant which is drai ned after 1 2 days of operation 4 Empty the cooling system and then rinse out the system with a neutralizing mixture 5 If impurities still exist repeat the cleaning procedure until the system is free from impurities 6 When the cooling...

Page 36: ...ins on the housing 3 Spread a thin layer of engine oil on the new coolant filter s gasket Tighten the coolant filter by hand until the rubber seal contacts the sealing surface on the filter bracket Tighten the coolant filter 1 2 turn 4 Turn the valve 1 90 to start the flow through the coolant filter again 5 Start the engine and check for leaks 6 Shut off the engine and check the coolant level see ...

Page 37: ...ity fuel urban diesel in Sweden and citydiesel in Finland can cause a power reduc tion of approximately 5 and a decrease in fuel eco nomy of approximately 2 3 Only use fuel of the recommended grade according to the fuel specification below Always make sure to maintain a high level of cleanliness when fueling and when working with the fuel system All work involving the engine s unit injectors must ...

Page 38: ... fuel filter 2 Drain the fuel filter see Fuel system draining condensation water 3 Remove the filter using an appropriate filter wrench 4 Clean the filter s sealing surface on the filter housing 5 Spread a thin layer of oil on the sealing ring and mount the new fuel filter Tighten the fuel filter ac cording to the instructions on the filter 6 Purge the fuel system in proximity to the fuel fil ter ...

Page 39: ...the new fuel filter according to the instructions on the filter 7 Connect the water monitor 1 8 Start the engine and check for leaks Fuel pre filter draining of condensation water IMPORTANT Wait a few hours after the engine has been turned off before draining the filter 1 Open the drain nipple 2 in the bottom of the fuel pre filter and let the condensation water run out NOTE Place a container unde...

Page 40: ...ump with the hand pump until air free fuel flows out Close the bleed nipple while the fuel is flowing out 5 Remove the hose and replace the protective cap on the bleed nipples NOTE When changing the fuel filter no additional bleedingisrequired 6 Move the hose to the cylinder head s bleed nipple 2 and bleed in the same manner as with the fuel filter bracket 7 Run the engine at a higher idle speed f...

Page 41: ...e battery is broken while the engi ne is running the generator and the electronics can be damaged For the same reason reconnection of the charging circuits must never be carried out while the engine is running IMPORTANT Never switch off the power with the main switch while the engine is running Fuses The engine is equipped with a 10A fuse that shuts off the power in case of an overload in the elec...

Page 42: ... the cable black to the battery s pole When disconnecting batteries disconnect the cable black first then the cable red Cleaning Keep the batteries dry and clean Contamination and oxidation on the battery and the battery poles can cause current leaks a reduction in voltage and dis charge especially during times of humid weather Cle an oxidation from the battery poles and cable ends using a brass b...

Page 43: ...ng see the battery manufac turers recommendations A discharged state damages batteries and they can also freeze and break during cold weather IMPORTANT Carefully follow all instructions for the battery charger To avoid risk for electrochemical corrosion when using an external charger when an external charger is used the battery cables should be removed from the battery before the charger is connec...

Page 44: ...xtra stop 7 Main relay 8 Generator 9 Safety fuse 10A 10 Oil pressure Oil temperature sensor 11 Control unit 12 Fuel pressure alarm 13 8 pin connector 14 23 pin connector 15 Coolant temperature sensor 16 Starter motor 17 Starter motor relay 18 RPM sensor flywheel 19 Water monitor fuel filter 20 Unit injector one for each cylinder 6 4 5 1 2 9 11 12 8 16 19 3 10 18 7 15 13 14 17 20 ...

Page 45: ...e Grease sparingly 20 30 grams for the main bearing Grease the inner link arms with a few drops of oil Declutching bearing Lubricate sparingly so that no grease squeezes out Use grease matching the recommendation above Check adjust WARNING Adjustment must be done on a stoppedengine Engagement force at the end of the lever should be 36 45 kp during engagement Adjustment Remove the inspection cover ...

Page 46: ...e of preservation and type of preservation oil is provided Cover the air filter exhaust pipe and the engine if called for To prevent the engine and other equipment from suffering damage during periods of storage exceeding two months a preservation procedure should be performed It is important that this be done correctly and that no part of it be forgotten We have therefore created a checklist cove...

Page 47: ...structions on the previous page Preservation oil is distributed by oil manufacturers Preparation for use after storage Remove any covers from the engine air filter and exhaust pipe Fill the engine with the proper grade of lubricating oil as needed Mount a new oil filter if a filter change was not performed in conjunction with the preservation process Mount a new fuel filter and purge the fuel syst...

Page 48: ...Insufficient lubricating oil pressure 17 Excessive coolant temperature 18 19 20 21 Insufficient coolant temperature 21 Absent or poor charging 2 24 A number of symptoms and possible causes for engine problems are described in the table below Always contact your Volvo Penta dealer if problems occur that you are not able to solve on your own WARNING Read through the safety instructions for maintenan...

Page 49: ...ponse and measures to be taken The diagnostic function affects the engine in the following manner when 1 The diagnostic function has detected a minor disturbance that will not damage the engine Response The engine is not affected 2 The diagnostic function has detected a serious disturbance that can not immediately damage the engine i e high coolant temperature Response TAD1240 42GE The engine shut...

Page 50: ...osis button and note the error code that blinks out 1 3 Repeat points above A new error code blinks out if more codes are stored Repeat until the first error code reappears NOTE When the first error code reappears all error codes have been read out Erasing error codes The diagnosis function s error code memory is reseted every time the engine power is turned off NOTE The power must be completely d...

Page 51: ...rrective action Check that the sensor connector is engaged correctly Check the wiring to the sensor Check that the sensor is located correctly in the flywheel cover Check that the sensor is functional Code 2 5 Cause RPM sensor camshaft Response The engine takes longer than normal to start The engine runs normally once underway Corrective action Check that the sensor connector is engaged correctly ...

Page 52: ...rective action Check that the sensor connector is engaged correctly Check the wiring to the sensor Check that the sensor is mounted correctly Check that the sensor is functional Code 3 4 Cause Charge air sensor Response The engine smokes more than it usually does when accelerating under loading Corrective action Check that the wiring to the sensor is not damaged Check that the sensor is functional...

Page 53: ...k the wiring to the relay Check that the relay is unbroken Check that the cable to the starter motor yellow black cable is connected correctly Check that the yellow black cable is not damaged Check that the starter motor relay is unbroken Code 4 7 Cause Start initiation EMS Response Engine will not start The engine can only be stopped using the emergency stop on the engine Corrective action Check ...

Page 54: ...f this protective feature has not been disabled by the parameter setting tool The alarm indicator lights up Corrective action Check coolant level Check the radiator cleanliness Check for air in the coolant system Check the pressure cap Check the coolant temperature sensor Check the thermostat function Code 6 2 Cause Intake air temperature is too high Response Engine output is limited to 50 if this...

Page 55: ...d pressure Check valve lash Check the injector and the connector wiring Do a compression test and check cylinder 2 Code 7 3 Cause Problem with the compression or the injector for cylinder 3 Electric error Response Cylinder balance is adversely affected une ven running at low RPM and low load The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action Check fuel fee...

Page 56: ...formance Corrective action Check fuel feed pressure Check valve lash Check the injector and the connector wiring Do a compression test and check cylinder 6 Code 9 8 Cause EEPROM error CIU Controller failure CIU Response The engine goes to idle The engine can not be started if the engine is running idle Corrective action Change the CIU unit Code 9 9 Cause Memory error in the engine control unit Res...

Page 57: ...00 1200 600 1200 600 900 600 900 High idle adjustable rpm 1500 16201 1500 16201 1800 21001 1800 1920 1800 1920 Highest full load RPM 1500 1800 1500 1800 1800 2100 Dry weight kg 12302 2706 lbs 12302 2706 lbs 12302 2706 lbs 1270 2794 lbs 1 Not adjustable 2 Weight of TAD engines without cooling package and air filter Lubrication system Oil Change volume including change of three filters With horizont...

Page 58: ... of approximately 2 3 Cooling system General TAD1240 42GE TWD1240VE TAD1241 42VE Type Overpressure closed Pressure valve opens at 75 kPa 11 psi 75 kPa 11 psi Volume engine 20 liters 5 3 US gal 20 liters 5 3 US gal Volume engine radiator and hoses 44 liters 11 6 US gal 44 liters 11 6 US gal Thermostat Type Piston thermostat Piston thermostat Number 1 1 Openingtemperature 82 C 187 F 75 C 167 F Coola...

Page 59: ...ge max current 28 V 60 A powerapprox 1700W Batterycapacity 2 serial connected 12 V max 152 Ah Battery electrolyte density at 25 C fully charged battery 1 28 g cm3 1 24 g cm3 the battery discharges at 1 24 g cm3 1 20 g cm3 Note Applies to batteries with tropical electrolyte ...

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Page 63: ... als Fax an Document Distribution Center Order Department ARU2 Dept 64620 SE 405 08 Göteborg Schweden Fax 46 31 545 772 Die Bestellung kann auch über das Internet erfolgen http www volvopenta com manual coupon Ja ich will kostenlos eine Betriebsanleitung in deutscher Sprache erhalten Publikationsnummer 7741213 Name Anschrift Land 42200 615001 155099900192 Notez que l offre est valable pendant 12 m...

Page 64: ...cación y posteriormente solamente mientras duren las existencias Franquear o enviar fax a Document Distribution Center Order Department ARU2 Dept 64620 SE 405 08 Göteborg Suecia Fax 46 31 545 772 El pedido puede hacerse también por internet http www volvopenta com manual coupon Sí gracias deseo recibir gratuitamente un libro de instrucciones en español Número de publicación 7741215 Nombre Direc ci...

Page 65: ...ution Center Order Department ARU2 Dept 64620 SE 405 08 Göteborg Ruotsi Fax 46 31 545 772 Tilauksen voi tehdä myös Internetissä http www volvopenta com manual coupon Kyllä kiitos haluan suomenkielisen ohjekirjan veloituksetta Julkaisunumero 7741217 Nimi Osoite Maa 42200 615001 155099900192 Observar que esta oferta é válida durante um período de 12 meses a contar da data de entrega do barco Após es...

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