Volvo Penta D12-AUX, Operator'S Manual

Page 1: ...OPERATOR SMANUAL D12 AUX Marine Genset ...

Page 2: ...CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm ...

Page 3: ...e with local regulations For information on generator specific items refer to generator information supplied by generator manufacturer In case of contradictions the information in this Volvo Penta Operator s Manual overrules any information given in the documentation provided by the generator manufacturer Do not hesitate to consult your Volvo Penta dealer Failure to follow the instructions and cau...

Page 4: ...water system flushing 48 Coolantfilter Change 48 Foreword 3 Safety Information 6 Safetyregulationsduringengineoperation 7 Safety directions for maintenance and service 8 Introduction 10 Care of the environment 10 Fuel and oil 10 Service and spare parts 10 Certifiedengines 11 Warranty 11 Presentation 12 D12 AUX HE Genset 12 D12 AUX RC Genset 13 D12 AUX KC Genset 14 New Genset Initial service 15 Sta...

Page 5: ...drain hole 51 Electrical system 52 General 52 Batterymaintenance 53 Inhibiting 55 General 55 Preparation 55 CareduringStorage 55 Return the Engine to Service 56 Stops longer than eight months 56 Troubleshooting 57 TechnicalData 58 D12 AUX HE Genset engine 58 D12 AUXRCGensetengine 59 D12 AUX KC Genset engine 60 Fuel specification 61 Lubrication oil specification 62 Coolantspecification 63 Identific...

Page 6: ...ator refer to the generator documentation If anything is unclear please contact your Volvo Penta dealer for assistance This symbol is used in the book and on the engine to make you aware of safety infor mation Always read these safety precautions very carefully In the Operator s Manual warning texts have the following priority WARNING If these instructions are not followed there is a danger of per...

Page 7: ...t solution for your vessel The new engine Read instruction manuals and other information ac companying the new vessel thoroughly Accustom yourself with handling the engine controls and other equipment in a safe and correct manner Remember that when operating a vessel you have a legal responsibility to be aware of and follow regula tions concerning traffic and safety at sea Inform your self of the ...

Page 8: ...tor s manual contains directions for perfor ming normal maintenance and service in a safe and correct manner Read the directions carefully before starting work More detailed service literature is avail able from your Volvo Penta dealer Never perform a task unless you are absolutely sure how it is to be carried out call your Volvo Penta dealer for assistan ce instead Stop the engine Stop the engine...

Page 9: ...Escaping fluids under pressure can pierce bodily tis sue and cause serious injury Risk of blood poisoning Always cover any electric component if it is located under the fuel filter Otherwise it might be damaged by fuel spills Electrical system Turn off the power before commencing work on the electrical system the engine must be stopped and the powered turned off with the main switch switches Shore...

Page 10: ...e to the environment Get in touch with your Volvo Penta dealer if you notice any changes such as increased fuel consumption and or exhaust smoke Adapt speed and distance to avoid wash and noise disturbing or injuring animal life moored boats jetties etc Leave islands and harbours in the same condi tion as you want to find them Remember to always leave hazardous waste such as waste oil coolant pain...

Page 11: ...els Sealed sections must not be broken by anyone other than authorized personnel Otherwise general directions concerning running care and maintenance given in the operator s manual apply IMPORTANT Neglected or deficient maintenance service and the use of non original spare parts will entail Volvo Penta renouncing any responsibility for the engine corresponding to the certified version Volvo Penta ...

Page 12: ...ystems are available D12 AUX HE Genset 1 Air outlet generator 2 Emergency stop button 3 Switchable fuel filters w water separator 4 Coolant filter 5 Electrical connection box 6 Conn for crankcase ventilation 7 F W pump 8 Switchable oil filters optional 9 Oil by pass filter 10 Lubrication oil filling 11 Oil drain pump optional 12 Expansion tank 13 Pressure cap expansion tank 14 Heat exchanger 15 Ai...

Page 13: ...AUX RC Genset 1 Air outlet generator 2 Emergency stop button 3 Switchable fuel filters w water separator 4 Electrical connection box 5 Coolant filter 6 Conn for crankcase ventilation 7 Pressure cap expansion tank 8 F W pump 9 Switchable oil filters optional 10 Oil by pass filter 11 Lubrication oil filling 12 Oil drain pump optional 13 Expansion tank 14 Air filter 15 Conn box for generator heating ...

Page 14: ...ailable D12 AUX KC Genset 1 Switchable fuel filters w water separator 2 Emergency stop button 3 Coolant filter 4 Electrical connection box 5 F W pump 6 Switchable oil filters optional 7 Oil by pass filter 8 Lubrication oil filling 9 Oil drain pump optional 10 Expansion tank 11 Pressure cap 12 Air cooler beneath the cover 13 Air filter 14 Air outlet generator 15 Conn box for generator heating 16 Ai...

Page 15: ... for new or overhauled engine IMPORTANT All covers on engine and generator must be mounted before attempting to start your genset Valves and Plugs Make sure the following valves and plugs are open or closed properly Fuel supply valve Open Coolant drain cocks Closed IMPORTANT If the coolant drain cocks are not closed the coolant will drain from the engine and this may cause severe damage to the eng...

Page 16: ...PORTANT If the starter motor has been engaged for the maximum time 30 seconds it must be allowed to cool down for at least one minute before a new attempt is made at starting Warming up WARNING Do not conduct warm up operation for an extended period of time Prolonged warm up operation causes carbon buildup in the cylinders that leads to inperfect combustion NOTE To warm up the engine operate at no...

Page 17: ...r auxiliary use for emergency use and for combined auxiliary and emergency use The system control panel is equipped with buttons for start and stop of the genset an LCD display for display of operational data and LEDs for shutdown indication 1 Lamp test button 2 SDU Acknowledge button 3 LCD display 4 Stop button 5 SDU Buzzer 6 Start button 7 Engine page button engine data 8 Multi page button opera...

Page 18: ...utton fuel consumption 10 Graph page button history graphically 11 Configuration page button configuration 12 Overspeed shutdown indication 13 Broken wire indication Control panel for genset in emergency operation This is the control panel used when the genset is configured for emergency use The SDU comes with shutdown functions only for overspeed The system will also detect and indicate broken wi...

Page 19: ... operation This is the control panel used when the genset is configured for both auxiliary and emergency use In auxiliary mode the SDU includes shutdown functions for overspeed high coolant temp and low oil pressure In emergency mode all shutdowns except overspeed are disabled The system will also detect and indicate broken wires Combined auxiliary and emergency system Turn the EMERGENCY MODE key ...

Page 20: ... Rectify the fault 3 Push the SHUTDOWN RESET button on the electrical connection box on the engine The LED on the SDU and the lamp on the control panel should go out if the fault no longer exists 4 Restart the engine Broken wire IMPORTANT The BROKEN WIRE function only detect lost connection due to cut off electrical wires not faulty or loose contacts The broken wire detection will set an alarm lig...

Page 21: ...utdown test On a running engine open the electrical connection box on the engine and remove the SDU cover Then push and hold the OVERSPEED TEST button A This will lower the overspeed setting by 25 and trig ger an overspeed shutdown ...

Page 22: ...hite buttons simultaneously will reset contrast and lighting to default values Configuration menu To enter the CONFIG MENU push the CONFIGURA TION button 11 for at least three 3 seconds Units The displayed units are user defined Pressure kPa PSI Volume LITRE GAL Imperial GAL Fuel rate L H GAL H IGAL H Temperature C F Settings Language 8 languages available Bleep Buttons are bleeping when pressed O...

Page 23: ...by repeatedly pushing the ENGINE PAGE button 11 Only metric units are shown but other units can be se lected in the configuration menu Scale values for engine rpm and coolant temp can also be changed in the configuration menu System In the system configuration page it is possible to reset default values for viewing of the display Demo Demo ON OFF Off normal operation mode Restore defaults Reset co...

Page 24: ...tomatically depending on the current value Trip page The page displays Trip fuel fuel used since reset not yet available FUEL RATE volume of fuel used per hours Trip engine hours running hours since last reset Total engine hours not re settable NOTE To reset the trip values just press and hold TRIP PAGE button 9 for one second The unit will bleep and the values are reset Graph page Pushing GRAPH P...

Page 25: ...ed alarms black text on grey backgro und The screen cannot be exited until all alarms have been acknowledged The alarm list will be scrollable if the list is longer than the screen size and when faults have been rectified the alarms will be cleared from the alarm list All alarms will be cleared when the system power supply is turned off NOTE The alarm list can be viewed at any time from the config...

Page 26: ...occurs this will be indicated by a flashing pop up window refer to section alarm functions on the display and a high pitched bleep will sound Push any button to open the alarm list Push the display ACKNOWLEDGE button 9 to silence the alarm Rec tify the fault Shutdown If a fault that triggered an alarm gets worse the SDU will shut down the engine by cutting off the fuel supp ly This is indicated by...

Page 27: ...s Beware of hot surfaces E g exhaust manifold turbocharger oil pan charge air pipe starting heater hot coolant and warm lubricant in pipes and hoses IMPORTANT Avoid overloading This can cause incomplete fuel combustion often indicated by black exhaust high fuel consumption and carbon deposits in combustion chambers affecting engine life IMPORTANT Do not push the START button when the engineis runn...

Page 28: ...s terminal and then to the auxiliary battery s terminal 3 Connect the black jump lead to the auxiliary bat tery negative terminal and then to a position slightly away from the discharged batteries for example at the negative cable s connection to the starter motor WARNING The black auxiliary cable must not come in contact with the positive connection on the starter motor 4 Start the engine and run...

Page 29: ...blem and make the repairs needed before starting again After starting the genset make sure it runs properly Emergency stop If the engine can not be stopped by the engine control system the engine can be stopped as follows Push the emergency stop button If the engine cannot be stopped with the emergency stop button shut off the fuel supply or block the air in take to the turbocharger NOTE If the en...

Page 30: ...ystem must be drained if it contains sea water and the coolant in the freshwater system must contain the right mix of anti freeze and water Refer to chapter Maintenance Raw water system and Freshwater system respectively WARNING If the raw water system bursts due to freezing the vessel could sink IMPORTANT If the coolant does not give sufficient anti freeze protection it may cause costly damage to...

Page 31: ...e records Volvo Penta recommends that accurate maintenance records are kept With accurate maintenance records your Volvo Penta Dealer can help in fine tuning the recommended service intervals to meet the specific operating situ ation This should result in a lower engine operation cost Fluids It is also important to keep record of the fluids used in the engine If brand or type of fuel lubrication o...

Page 32: ...every 12 months Change lubrication oil refer to note 3 Change lubrication oil filters by pass filter refer to note 4 Every 500 operating hours or every 12 months Change crankcase breather filter If applicable Check adjust drive belts Check change seawater pump impeller Check change zinc anodes Topping up coolant corrosion protection mixture refer to note 5 1 Check the manometer and change filter i...

Page 33: ...ilter water separator filter element Change coolant filter refer to note 6 Change fuel fine filter Every 2000 operating hours Check turbocharger refer to note 2 Every 12 months General inspection of the genset refer to note 2 Check clean charge air cooler refer to note 2 Change air filter Clean and paint the genset Every 24 months Check clean cooling system refer to note 2 Change coolant ...

Page 34: ...ir temperature and pressure 5 Seawater pressure and seawater temperature before and after heat exchanger Ambient temperature and engine room temperature at turbo charger inlet 6 Parts serviced and kinds of service adjustment repairs or replacement 7 Change in operating conditions for example Exhaust smoke turned black etc Daily recording is a preventive maintenance program and when comparing value...

Page 35: ...arings and a belt which is too loose can slip IMPORTANT Always change a belt which looks worn or cracked belts which operate in pairs must be changed together Alternator belt s The standard alternator plus the extra alternator if in stalled are driven by a Poly Vee belt each for best function and service life The belts are tensioned in the same way 1 Remove the protective cover over the alternator...

Page 36: ...lowing out Repeat with second filter 4 Remove the hose and put the protective cap back on the venting nipple 5 If the tank has been run dry or the engine for some reason has been emptied of fuel open the venting nipple 3 at the front of the engine block and vent in the same way 6 Run the engine at idling speed for a couple of minutes to get any remaining air out of the sys tem Then close the vent ...

Page 37: ... Running engine switchable filters only 1 Shut off fuel to the filter to be changed A 2 Put a suitable vessel underneath the filter 3 Open the tap 1 carefullly pressure on the inside hot fluids might spurt out 4 Drain water and contamination from the water trap by turning the handle to venting position B Tighten the venting nipple when clean fuel flows out 5 Repeat the procedure with the other fil...

Page 38: ...1 2 2 5 4 6 Clean the sealing surface on the filter bracket Make sure the new filter is absolutely clean and that the sealing surfaces are undamaged Moisten the seals with engine oil including the inner rubber seal on the inside of the threaded hole in the cen ter of the filter NOTE Do not fill the new filter with fuel before as sembly Contaminations may get into the system and cause damage and ma...

Page 39: ...ng surface on the filter bracket Make sure the new filter is absolutely clean and that the sealing surfaces are undamaged Moisten the seals with engine oil including the inner rubber seal on the inside of the threaded hole in the cen ter of the filter NOTE Do not fill the new filter with fuel before as sembly Contaminations may get into the system and cause damage and malfunction 7 Screw the new f...

Page 40: ... assembling 7 Fit the cover and tighten it by hand 8 Wipe off any fuel from the heat shield 9 Change the other filter in the same way 10 Open the fuel cocks and put the handle in position for normal running Make sure there are no leaks Twin fuel pre filter water separator The twin filter is equipped with a pressure gauge 1 The filter inserts must be changed according to the maintenance schedule or...

Page 41: ...pter Technical Data Lubrication oil change Always observe the recommended oil change inter val Use the oil drain pump optional to drain the oil from the sump IMPORTANT Only use recommended grades of oil refer to chapter Technical Data 1 Warm the engine up this makes it easier to pump the oil from the sump Then stop the engine 2 Connect a hose to the outlet pipe of the oil drain pump Pump the oil o...

Page 42: ...il filters IMPORTANT Though possible the switchable filters should not be replaced during engine ope ration other than in case of an emergency 1 Clean the filter bracket 2 Disconnect the left filter by turning the lever to the right hand end position To unlock the lever pull the knob beneath the lever downwards 3 Unscrew the left hand oil filter and discard it Use a filter wrench if necessary 4 Ch...

Page 43: ...oler or prepared for external cooling e g keel cooling or central cooling WARNING Never open the pressure cap or drain the cooling system when the engine is warm Steam or hot fluid may spurt out WARNING The coolant is dangerous to your health and an environmental hazard Handle coolant with care and dispose of old coolant in accordance with local regulations IMPORTANT For coolant specification refe...

Page 44: ...hrough the heat exchanger and through the engine The raw water system is cooling the coolant in the freshwater cooling system The raw water system is connected to a seawater inlet or a central cooling system 1 Engine 2 Freshwater pump 3 Lubrication oil cooler 4 Thermostat valve 5 Expansion tank 6 Charge air cooler 7 Heat exchanger 8 Raw water pump 9 Freshwater circuit 10 Raw water circuit Drain po...

Page 45: ...engine driven cooling air fan The charge air is cooled in an air to air charge air cooler mounted in front of the radiator and it make use of the air flow from the engines cooling fan before it enters the radiator 1 Engine 2 Freshwater pump 3 Lubrication oil cooler 4 Thermostat valve 5 Expansion tank 6 Radiator 7 Charge air cooler 8 Radiator fan Drain points fresh water system ...

Page 46: ...ater is cooled by e g a box cooler a grid cooler or any other external heat exchanger The same coolant fresh water is cooling the complete engine charge air cylinders etc 1 Engine 2 Freshwater pump 3 Lubrication oil cooler 4 Thermostat valve 5 Expansion tank 6 Charge air cooler Drain points fresh water system ...

Page 47: ...ication refer to section technical data coolant Filling when the system is empty 1 Open the air ventilation cock that is placed by the turbo charger 2 Make sure that systems connected to the cooling system also are ventilated e g heater water heater 3 Fill the freshwater system with coolant through the filler opening in the expansion tank Fill slowly letting air bleed from the ventilation cock and...

Page 48: ... 1 Drain the coolant as described earlier 2 Insert a hose into the filler opening on the expan sion tank and flush with fresh water 3 Flush until the water running out of the drainage points is clean 4 Close all drain points when the flushing water has run out 5 Fill with coolant See section coolant filling when empty Coolant filter Change IMPORTANT Do not change the filter when the coolant is cha...

Page 49: ...ints Open the drains and al low the raw water to drain off into a suitable ves sel IMPORTANT Check that the raw water really drains Deposits may need to be removed from inside the drain plugs taps Check and Change the zinc anodes NOTE Valid only for gensets with engine mounted heat exchanger 1 Drain the external cooling water as described in the section draining the raw water system 2 Unscrew the ...

Page 50: ...p housing and the inside of the cover with water resistant grease non aggressive on rub ber 5 Push the impeller into position while rotating it in the normal operating direction 6 Fit the cover with a new sealing ring 7 Open the seawater cocks Seawater filter check clean If the vessel is equipped with a seawater filter refer to the maintenance description delivered by the supplier of the filter NO...

Page 51: ...air filter and tighten the lid 4 Reinstate the pressure drop indicator by pressing in the indicator button IMPORTANT Scrap the old filter It must not be cleaned Inlet manifold drain hole Water can condense in the aftercooler during opera tion The condensate is drained via a hose connected to a nipple under the rear of the inlet manifold Check that the nipple is not blocked WARNING If a large amoun...

Page 52: ... water repellant Volvo Penta all round oil Main switches The main switches must never be turned off until the engine has been stopped Breaking the circuit bet ween the generator and the batteries while the engine is running can damage the generator For the same reason the charge circuits must never be switched while the engine is running IMPORTANT Never turn the power off using the main switches w...

Page 53: ...l of the battery first Then connect the cable black to the pole of the battery Disconnect the cable black first and then the cable red Cleaning Keep batteries dry and clean Contaminants and oxi de on batteries and battery terminals can cause short circuits voltage drops and discharging especi ally in damp weather Clean oxide from battery ter minals and cable shoes with a brass brush Tighten cable ...

Page 54: ...e batteries will be harmed if left discharged and can also freeze and crack in cold weather IMPORTANT Follow the battery charger user instructions carefully Disconnect the battery cables before connecting the battery charger to avoid electrochemical corrosion when using an external battery charger The battery plugs must be unscrewed but left in the holes while charging is in progress Ventilate wel...

Page 55: ...run it warm Stop over eight months Treat the lubricating and fuel systems with conservation oil See directions on next page 2 Make sure there is enough anti freeze in the coo lant Add more if necessary An alternative is to drain the coolant 3 Drain the rawwater system 4 Remove the impeller from the rawwater pump Keep the impeller in a cool place in a closed plas tic bag 5 Drain off any water and c...

Page 56: ... Start the genset and run it at idling speed until it reaches operating temperature before loading it 11 Check for oil fuel or coolant leaks 12 When the engine has run long enough to warm up apply the load and bring it to operating speed Conserving the lubricating and fuel systems for stops longer than eight months 1 Drain the oil from the engine and fill with conservation oil to just over the MIN...

Page 57: ... 26 39 40 Coolant temperature too high 27 28 31 32 33 34 35 36 37 47 Coolant temperature too low 36 No charge or poor charge 1 2 41 1 Flat batteries 2 Poor contact broken cables 3 Main switch turned off 4 A fuse circuit breaker has blown tripped 5 Lack of fuel 6 Defective Power Module 7 Faulty starter motor solenoid 8 Defective fuel supply pump 9 Blocked fuel injectors 10 Defective fuel injectors ...

Page 58: ... 684 F Exhaust temperatures 370 kW 1800 rpm at 25 of ISO Standard Power 202 C 396 F at 50 of ISO Standard Power 245 C 473 F at 75 of ISO Standard Power 284 C 543 F at 100 of ISO Standard Power 335 C 635 F at 110 of ISO Standard Power 350 C 662 F Lubricating system Oil capacity approx Including oil filters No engine inclination 56 liters 14 8 US gals volume difference min max 10 liters 2 6 US gals ...

Page 59: ...st temperatures 339 kW 1800 rpm at 25 of ISO Standard Power 216 C 421 F at 50 of ISO Standard Power 240 C 464 F at 75 of ISO Standard Power 268 C 514 F at 100 of ISO Standard Power 317 C 603 F at 110 of ISO Standard Power 347 C 657 F Lubricating system Oil capacity approx Including oil filters No engine inclination 56 liters 14 8 US gals volume difference min max 10 liters 2 6 US gals Oil pressure...

Page 60: ...r 362 C 684 F Exhaust temperatures 370 kW 1800 rpm at 25 of ISO Standard Power 202 C 396 F at 50 of ISO Standard Power 245 C 473 F at 75 of ISO Standard Power 284 C 543 F at 100 of ISO Standard Power 335 C 635 F at 110 of ISO Standard Power 350 C 662 F Lubricating system Oil capacity approx Including oil filters No engine inclination 56 liters 14 8 US gals volume difference min max 10 liters 2 6 U...

Page 61: ...the right type JIS KK 2204 Type1 Type2 Type3 ASTM D975 No 1 D No 2 D EN590 with national environment and cold requirements Sulfur content Complying with legal requirements in each country If the sulfur content exceeds 0 5 wt service intervals must be changed refer to chapter Maintenance lubrication system Fuels with low density urban diesel in Sweden and city diesel in Finland can result in a loss...

Page 62: ...40 10o C o C o F Refers to synthetic or semi synthetic oils Oil grade Sulphur content in fuel by weight up to 0 5 0 5 1 0 more than 1 0 1 Oil change interval Reached first in operation VDS 3 and ACEA E5 E4 2 500 hr or 12 months 250 hr or 12 months 125 hr or 12 months VDS 2 and ACEA E3 2 500 hr or 12 months 200 hr or 12 months 100 hr or 12 months VDS and ACEA E3 2 300 hr or 12 months 150 hr or 12 m...

Page 63: ...h corrosion may occur which would result in impaired cooling performance Total fixed particle content 340 ppm Total hardness 9 5 dH Chloride 40 ppm Sulphate 100 ppm pH value 5 5 9 Silica 20 mg SiO2 l Iron 0 10 ppm Manganese 0 05 ppm Conductivity 500 ìS cm Organic content CODMn 15 mg KMnO4 L Mixing ratio The mixture of Volvo Penta Coolant and water should contain 40 55 Volvo Penta Coolant If the co...

Page 64: ...ber Control unit decal behind heat exchanger 2 Dataset Spec Number ECU batch Engine plate 3 Product designation Product number Serial number Certification plate with classified genset 5 Product designation Serial number Product number Generator plate 3 Product designation Serial number Product number NOTE The genset shown is mounted with a Stam ford generator if other generator brand is used refer...

Page 65: ...Notes ...

Page 66: ...Notes ...

Page 67: ...Notes ...

Page 68: ...7742264 0 English 05 2003 ...