7734906-6
Eng
lish
01-1998
Diesel Engines TAD1030G/P, TWD1210G/P, TWD1211G/P, TAD1230G/P
INSTRUCTION BOOK
IntroductionRead this bookThis Instruction Book provides helpful information for running and maintaining yourVolvo Penta product(s).
The contents herein do not apply to any particular specification. Each engine issupplied from Volvo Penta in accordance with the order.
Check engine and components to be able to find relevant parts of this book. Read thisbook carefully before taking the engine into operation.
WarrantyA Service and Warranty Book which states the Volvo Penta International LimitedWarranty should have been provided by the selling dealer. If you have not receivedthis publication contact the nearest Volvo Penta importer for a copy.
Some markets provide due to local laws and regulations other warranty conditionswhich are issued by the local Volvo Penta importer as a supplement to the Volvo Pentawarranty. Contact the local Volvo Penta importer to obtain such conditions whereapplicable.
For products operating in the USA special warranty conditions and documentsapply. To be sure of obtaining the correct US documentation contact the localdistributor.
Warranty Registration Card −−−−− Delivery cardThe Warranty Registration Card (US markets) Delivery Card (other markets) shouldbe filled out and sent in by the selling dealer. Ensure this has been done, as refusalof warranty can occur if no proof of delivery date can be provided.
Volvo Penta serviceVolvo Penta has built up an extensive dealer net to support you with service and parts.These dealers have the necessary special tools, test equipment and stocks of partsto provide the service. When requesting service or parts always quote the completetype and serial No. from the number plate.
AB VOLVO PENTATechnical Information
OwnerName: ...................................................................... Tel: ...................................
Address: ..................................................................................................................
Nearest Volvo Penta Service DealerName: .......................................................................... Tel: ................................
Address: ..................................................................................................................
Engine dataEngine type: ............................................................................................................
Serial Nos.: .............................................................................................................
Volvo Penta reserve the right to make changes without prior notice.
© AB Volvo Penta
26
Notes
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Publ. No. 7736711-8 English01-1998
CALIFORNIAProposition 65 Warning
Diesel engine exhaust and some of its consistituents are known to
the state of California to cuse cancer, birth defects, and otherreproductive harm.
Important Safety Information
Supplement to Instruction Book
Read the entire instruction manual andsafety information carefully before startingor conducting service work on the engine.
The instruction manual contains the information you requireto handle the engine correctly. Incorrect handling can resultin personal injury or damage to the machine.
This symbol is used when there is a risk of personalinjury, or draw attention. The symbol may be found in the in-struction manual or on the engine.
If a safety instruction or warning described in the instructionmanual or safety information is not followed there is a riskof personal injury.
If you do not understand, or are unsure, of anything in thisinstruction manual please contact your dealer, who can ex-plain or demonstrate the procedure in question.
The following is a list of the risks and precautionary measureswhich shall always be observed or implemented:
Make sure that the warning or information labels on theengine are always clearly visible. Replace labels whichhave been damaged or painted over.
Always stop the engine before starting the service work.Avoid burn injuries. Observe care with hot surfaces andhot liquids in pipes and hoses when the engine has justbeen stopped and is hot.
Bofore starting the engine refit all guards dismantled duringservice work. Inform yourself as to other risks such asrotating parts and hot surfaces (radiator, exhaust manifold,turbo and intercooler or induction pipe and starter element,etc.)
Approaching an engine which is running is a safety risk.Remember that loosely hanging clothes, or long hair, canfasten in rotating parts and cause severe bodily injury.
Allow authorized workshop personnel to conduct more ex-tensive work operations which require the engine to berunning. If work is conducted in the vicinity of an enginewhich is running an unintentional movement, or a droppedtool, can in extreme cases lead to bodily injury.
Prevent starting of the engine by switching off the powerwith the main switch, or remove the cable at battery’s plusterminal before service work is begun.
Engines with turbo compressors: Never start the engineunless the air filter is fitted. The rotating compressor wheelin the turbo can result in severe personal injury. Foreignobjects in the intake pipe can also result in damage to themachine.
Stop the engine and switch off the power with the mainswitch or remove the cable from the battery’s plus terminalbefore working on the electrical system.
Adjustments to the coupling shall be conducted when theengine is idle.
When lifting the engine the existing lifting eyes shall beused. Always check that the lifting tackle is in good condi-tion and has the correct capacity for the lift (weight of theengine plus other extra equipment).
For safe handling, and to avoid damage to componentsfitted on the top of the engine, the engine must be liftedwith an adjustable lift boom. All chains or wires must runparallel with each other, and as far as possible at right-angles to the top of the engine.
If other equipment is connected to the engine which chan-ges its centre of gravity it may be necessary for speciallifting devices to achieve the correct balance and safehandling.
Never conduct work on engines which are only hanging inthe lifting tackle.
A fork-lift truck must always be used when handling engi-nes mounted on a frame.
The engine must not be run in environments with explosi-ve mediums since all the electrical and mechanical com-ponents are not spark-proof.
Replacement of the fuel filter should be conducted on acold engine to avoid the fire risk resulting from fuel spill onthe exhaust manifold. Always cover the generator if it isplaced under the fuel filter. Fuel spill can damage the gene-rator.
Always protect the hands when searching for leakage.Outflowing pressurised liquids can penetrate body tissueand result in serious injuries. Risk of blood poisoning.
Always use Volvo Penta’s recommended fuel. See instruc-tion manual. The use of fuel of inferior quality can damagethe engine. On diesel engines the use of inferior fuel canresult in the control rod seizing and the engine racing, withthe risk of both personal injury and damage to the machi-ne. Inferior fuel can also lead to higher maintenance costs.
High-pressure washing must not be used to clean theengine and equipment. The radiator, hoses and electricalcomponents etc. can be damaged.
An automatic stop must be installed for unmanned opera-tion. Over-reving protection must always be used for elec-tronic rev controlling. Other signals which can be used forautomatic stop are the oil pressure, coolant temperatureand coolant level.
When engines are delivered without protection all rotatingparts and hot surfaces must be protected if after beingbuilt into the respective application this is necessary forpersonal safety.
Engines with pre-heated air (starter element): Never usestart spray or the like to facilitate starting. An explosioncan occur in the intake pipe as a result of the starter ele-ment. Risk of personal injury.
Avoid opening the replenishment cap for coolant when theengine is hot. Steam or hot coolant can spray out as thebuilt-up pressure escapes. Open the replenishment capslowly and release the overpressure in the cooling systemif the replenishment cap or tap must be opened, or if plugor coolant pipe must be dismantled on a hot engine. Steamor hot coolant can spray out.
Only start the engine in a well-ventilated area. When run-ning the engine in a closed area the exhaust fumes andcrankcase gases must be led out of the engine room.
Make sure that no foreign objects come in the vicinity ofrotating fans. This can damage the fan blades, and tools orfan blades can be ejected with personal injury as a result.
Lubricant is hazardous to health. Not to be consumed. Av-oid prolonged contact with the skin. Avoid inhaling oil mist.Read the instructions on the packaging!
Anti-rust agent is hazardous to health. Not to be consu-med. Avoid contact with the eyes and skin. Read the ins-tructions on the packaging!
Antifreeze is hazardous to health. Not to be consumed.Avoid contact with the eyes and skin. Read the instruc-tions on the packaging!
Certain preserving oils are inflammable. Some of these arealso hazardous to inhale. Ensure good ventilation. Use aprotective mask when spraying.
Hot oil can cause burn injuries. Avoid skin contact with hotoil. Make sure that the oil system is pressureless prior towork. Never start or run the engine with the oil replenishingcap removed in view of the risk for oil splash.
The battery compartment must never be exposed to anaked flame or electric spark. Do not smoke in the vicinityof batteries. Batteries develop hydrogen gas during char-ging, which in combination with air forms oxyhydrogengas. This gas is highly inflammable and very explosive. Aspark resulting from the incorroct connection of a batteryis sufficient to cause the battery to explode and result ininjury. Do not interfere with the connections when attemp-ting to start (risk for spark formation) and do not lean overany of the batteries. See the directions in the instructionmanual.
Never confuse the plus and minus terminals of the batte-ries when fitting the batteries. This can result in serious da-mage to the electrical equipment. Compare with the wiringdiagram.
Always use protective glasses during the charging andhandling of batteries. The battery electrolyte containsstrongly corrosive sulphuric acid. On contact with the skinwash with soap and plenty of water. If battery acid comesinto the eyes rinse at once with water and contact a doctorimmediately.
25
Notes
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24
Electrical system
TAD1030G/P TWD1210/1211G/P TAD1230G/P
System voltage 24 V
A.C. alternator,voltage/max. power ............................. 28V/60A
rated output, approx. ........................... 1700 WBattery capacity ........................................................... 2 pcs in-series 12 V,
max. 152 AhBattery electrolyte density at +25oC:
fully charged battery .................................................. 1.28 g/cm3 (1.24 g/cm3)*battery recharges at .................................................. 1.24 g/cm3 (1.20 g/cm3)*
*Note: refers to batteries with tropic acid.
Clutches
Disengageable clutches at rear of engine (accessory)
Type designation .......................................................... AP D14A1 -Type ............................................................................. Twin plate clutch -Ratio ............................................................................. 1:1 -Size .............................................................................. 355 mm (14") -Weight, approx. ............................................................ 159 kg -
Type designation .......................................................... - AP T14A1 -Type ............................................................................. - Triple plate clutch -Ratio ............................................................................. - 1:1 -Size .............................................................................. - 355 mm (14") -Weight, approx. ............................................................ - 209 kg -
1
Instruction Book
Diesel Engines
TAD1030G/P, TWD1210G/P, TWD1211G/P, TAD1230G/P
Contents
Presentation
Description of engine ..................................................... 2Number plate and engine designation ........................... 3
General information
Installation ...................................................................... 5Fuel ................................................................................ 8Lubricating oil ................................................................. 8Coolant ........................................................................... 8Instruments .................................................................... 9
Operating
Running-in .................................................................... 10Starting ......................................................................... 11During operation .......................................................... 11Stopping ....................................................................... 12Procedures for freeze risk ............................................ 13
Maintenance
Maintenance schedule ............................................... 17Inhibiting ....................................................................... 22Re-commissioning ....................................................... 22
Electrical system
Wiring diagrams ........................................................... 20Starting with auxiliary batteries .................................... 15Electric welding ............................................................ 15Fuses ........................................................................... 15Important info on the electrical system ........................ 15
Technical data
Engine .......................................................................... 23
CAUTION!
The instrument panel has no key switch. The engine room shalltherefore be locked to prevent unauthorized starting of the engine.
Alternatively a lockable main switch can be used.
2
PresentationThe intercooler is reducing the temperature of the intake air,thus allowing a higher air volume to enter the cylindercontributing to higher output with exhaust temperaturesand emissiones still at appropriate levels.
The engines are provided with an electric starter elementto facilitate the starting and to reduce emissions whenstarting in cold weather.
The engines are in-line, 6-cylinder, 4-stroke, diesel engineswith direct injection. The engines are designed with oilcooled pistons and wet, replaceable cylinder liners, separatecylinder heads, one for each cylinder and exhaust driventurbo chargers.
Engine models TAD1030 and TAD1230 are equipped withan intercooler, located behind the radiator and cooled byair via a thrust type of fan. Engine models TWD1210 andTWD1211 are equipped with an intercooler, cooled bywater.
Fig. 1. TAD1030G
1. Tropical radiator2. Intercooler3. Fuel filters4. Lift eyelet5. Coolant pump6. Pressure drop indicator for air filter7. Turbocharger8. Exhaust manifold9. Lift eyelet
10. Coolant pipe, inlet11. Injection pump12. Fuel pipes for tank connection13. Electronic speed governor14. Flywheel housing
Fig. 2. TAD1030P
1. Silencer2. Air filters3. Relay for electric starter element4. Starter element5. Pressure drop indicator for air filters6. Vibration damper7. Filler cap for lubricating oil8. Oil cooler9. Lubricating oil filters
10. Pipe for crankcase ventilation11. Starter motor12. Instrument panel13. Speed control
23
Technical dataGeneral
Type designation .......................................................... TAD1030G/P TWD1210/1211G/P TAD1230G/PNumber of cylinders ..................................................... 6Swept volume .............................................................. 9.60 ltr 11.98 ltr 11.98 ltrLow idling speed, approx. ............................................ Gen: 1300 rpm
............................................ Pow: 600 rpmValve clearance, engine off, cold or at operating temp.
inlet ........................................................................... 0.40 mmoutlet ......................................................................... 0.70 mm
Weight, engine only (dry) approx. ................................ Gen: 1107 kg Gen: 1140 kg Gen: 1250 kg................................ Pow: 1062 kg Pow: 1105 kg Pow: 1215 kg
Fuel system
Injection pump, setting ........................................ Gen: 15° B.T.D.C. 20° B.T.D.C.1) 14.5° B.T.D.C........................................ Pow: 15° B.T.D.C. 22° B.T.D.C.2) 14.5° B.T.D.C.
stroke position .................................... 3.45 (±0.05) mm 3,55 (±0.05) 4.05 (±0.05) mmInjectors, opening pressure .......................................... 25.5 MPa, 27 MPa, 25.5 MPa,
(260 kp/cm2) (275 kp/cm2) (260 kp/cm2)adjustment pressure (new spring) ................ 26 (+0.8) MPa, 27.5 (+0.8) MPa, 26 (+0.8) MPa,
(265 (+8) kp/cm2) 280 (+8) kp/cm2 (265 (+8) kp/cm2)nozzle hole diameter .................................... 5 pcs 0.30 mm 5 pcs 0.38 mm 5 pcs 0.38 mm
1) TWD1211G: 22°2) TWD1211P: 18°
Cooling system
Volume of cooling system incl. VP standard cooler,approx. ......................................................................... 37.5 ltr TWD1210: 49 ltr 48 ltr
....................................................................... TWD1211: 55 ltrThermostats, number ................................................... 1 1 1
marking .................................................. Red Blue (1211P: Red) RedThermostats, begin to open at ..................................... 82°C 75°C (1211P: 82°C) 82°C
fully open at ............................................ 95°C 88°C (1211P: 95°C) 95°C
Lubricating system
Oil pressure,warm engine at operating revs ................ 300−500 kPa(3−5 kp/cm2)idling speed ............................................ min. 150 kPa ( 1.5 kp/cm2)
Oil change volume, approx.:without oil filters ........................................................ 34 ltrwith oil filters ............................................................. 38 ltr
Volume difference, min−max ....................................... 9 ltr
Oil quality ..................................................................... VDS (Volvo Drain Specification),alt. CD or CE as per API system
Viscosity at different ambient air temperatures ............(Temperatures refer to stable ambienttemperature).
*Refers to semi-synthetic oil.NOTE! Only SAE 5W/30 may be used. SAE5W/30
−−−−−30 −−−−−20 −−−−−10 ±0 +10 20 30 40
−−−−−22 −−−−−4 +++++14 32 50 68 86 104
−−−−−15oC SAE15W/40
−−−−−25oC SAE10W/30
−−−−−10oC SAE20W/30
±0oC SAE30
SAE40+10oC
oC
oF
✱✱✱✱✱✱✱✱✱✱
22
Preferably remove the batteries and hand them in formaintenance charging as per the instructions of themanufacturer.
See also item 2 under the heading ”Important infor-mation on the electrical system” on page 15.
7. Improve where necessary the external rust protectionby applying rust protection oil. The surfaces shall beclean and dry before they are treated.
NOTE! Certain inhibiting oils are inflammable. Certainoils are also dangerous to inhale. Ensure adequateventilation. Use a safety mask during spraying.
8. Attach a note to the engine stating the date, type ofinhibiting, and the inhibiting oil used.
9. Cover the air inlet to the engine, the exhaust pipe andthe engine, if so required.
Re-commissioning1. Remove covers from engine, air inlet and exhaust pipe.
2. Wash off external inhibiting agent with white spirit.
3. Close the drain cock and fit the drain plugs.
Fill the cooling system if the coolant has been drainedoff. See ”Replenishing of coolant” on page 14. Seepage 8 for coolant.
4. Fill where necessary with lubricating oil of the correctquality in the engine. Fit new oil filters if the filters werenot changed in connection with the oil change duringinhibition.
5. Check the batteries as per the instructions on page 15.See also item 6 in the maintenance schedule on page17. Connect the batteries.
6. Fit new fuel filters and vent the fuel system. See items17 and 18 in the maintenance schedule on page 17.
7. Start the engine (see ”Operating”) and run warm at highidling speed before the engine is loaded.
8. Check that no oil, fuel, or coolant leakage occurs.
Inhibiting
Inhibiting up to two monthsIf the period of inhibition is assumed to be not longer thantwo months it is sufficient to start the engine and run warmabout every two weeks.
Check/replenish the cooling system’s freeze protection toavoid damage in the event of low temperatures.
Check the charge status of the batteries. A flat battery caneasily be damaged as a result of freezing.
Inhibiting more than two months1. Run the engine to normal operating temperature.
2. Stop the engine and drain off or pump out the lubricatingoil from the oil pan.
3. Max. inhibition period of 8 months: replace thelubricating oil filters and fill the engine to the normallevel with Volvo Penta lubricating oil. Run warm afterthe oil change.
4. Inhibition period of more than 8 months: fill inhibitingoil in the engine to just over the lower mark on thedipstick. Inhibiting oils are marketed by the oilcompanies.
Connect the fuel lines (suction and return line) to a canfilled with 1/3 inhibiting oil and 2/3 diesel fuel. Certainoil companies have a ready-mixed oil for this purpose.
Vent the fuel system. See item 18 in the maintenanceschedule on page 17. Start the engine and run on highidling speed until approx. 2 litres have been consumedfrom the can.
Stop the engine and drain off or pump out the inhibitingoil from the oil pan. Connect the standard fuel lines.
5. Check that the coolant has a sufficient freeze protection.Replenish if necessary. Alternatively, the coolant canbe drained off.
6. Check that the batteries are well charged. A flat batterycan easily be damaged as a result of freezing.
A battery always has a certain inherent discharge,which increases with rising temperatures. Batterieswhich are stored should therefore be kept at the lowesttemperature possible. They shall be kept dry and clean,and normally be charged every other month. Alter-natively, the batteries can be charged with amaintenance charge of approx. 1 mA per Ah.
3
EN
GIN
E TAD1230PXXXXXXXXXX
868632
Engine designation Product No.
Serial No. Basicengine No.
TAD1230P 868632
No. xxxxxxxxxx / xxxx
Enginedesignation
Serial No.
Product No.
Fig. 3. TWD1210G/TWD1211G
1. Fan hub2. Coolant pump3. Fuel filters4. Turbocharger5. Intercooler6. Injection pump7. Feed pump (hand pump)8. Oil pan9. Coolant pipe, inlet
10. Vibration damper11. Belt tensioner
Fig. 4. TWD1210P/TWD1211P
1. Silencer2. Air filter3. Relay for electric starter element4. Intercooler5. Coolant pipe, outlet6. Tropical radiator7. Belt tensioner8. Filler cup for lubricating oil9. Oil cooler
10. Lubricating oil filters11. Instrument panel12. Speed control
4
Fig. 5. TAD1230G
1. Tropical radiator2. Intercooler3. Coolant pump4. Pressure drop indicator for air filters5. Fuel filters6. Turbocharger7. Exhaust manifold8. Lift eyelet9. Coolant pipe, inlet
10. Injection pump11. Fuel pipes for tank connection12. Electronic speed governor13. Flywheel housing
Fig. 6. TAD1230P
1. Silencer2. Air filter3. Relay for electric starter element4. Starter element5. Filler cap for lubricating oil6. Vibration damper7. Oil dipstick8. Oil cooler9. Lubricating oil filters
10. Pipe for crankcase ventilation11. Starter motor12. Instrument panel13. Speed control
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20 5
Installation
General installation instructionsFor more detailed installation information refer to VolvoPenta Installation Manual.
Fig. 7. Bracing of the engine
frame
1. Engine frame2. Steel spacer plate3. Base (reinforced concrete)
Fig. 9. Engine room with air intake and air discharge (suction fan)
1. Air outlet 4. Protective cover2. Connection elbow 5. Air intake (with air drum to3. Air filter avoid re-circulation of cooling air)
Fig. 8. Engine room with air intake and air discharge (thrust fan)
1. Air intake 4. Air filter2. Intake pipe 5. Air discharge (with air drum to3. Connection elbow avoid re-circulation of cooling air)
6
Fig. 10. Fuel system
1. Fuel fine-filters 6. Suction strainer 11. Fuel tank2. Feed pump (max. suction height 2 m) 7. Drain cock 12. Inspection port3. Flexible fuel hoses 8. Suction pipe 13. Electronic overflow protection4. Extra fuel pre-filters 9. Return pipe from engine 14. Venting pipe5. Fuel cocks 10. Fuel gauge 15. Replenishing pipe
Fig. 12. Connecting the actuator for 24V system voltage
Fig. 11. The stop solenoid (8) connected live during operation (optional). Engine stops with switch (6).
Electronic speed governorWiring
is required.Note. Later version stop solenoid has a built-in transient protection. Therefore, only a separate transient protection (7) for the Control Unit
1. Control Unit2. Actuator3. Pickup4. Multi-turn potentiometer*
5. Fuse (fast) 8A6. Main switch7. Transient protection (849394-2)8. Stop solenoid
9. Engine speed pickup for overspeed protection10. Engine speed switch (overspeed protection)11. Relay
ToControl Unit
*Not from Volvo Penta
19
.C
heck
/adj
ust
dise
ngag
eabl
e cl
utch
.
War
ning
! A
djus
tmen
t sh
all b
e ca
rrie
d ou
t w
ith e
ngin
e of
f.
The
eng
agin
g fo
rce
at th
e en
d of
the
leve
r sh
all b
e 34
−41
kp (
twin
pla
te c
lutc
h), o
r 36
−45
kp
(trip
le p
late
clu
tch)
. Adj
ustm
ent:
rem
ove
insp
ectio
n co
ver.
Rel
ease
the
catc
h (A
)an
d tu
rn t
he r
ed a
djus
ter
ring
(B)
cloc
kwis
e. L
ock
the
catc
h. T
he p
late
s m
ust
not
slip
afte
r en
gage
men
t.
20
.A
llow
aut
hori
zed
pers
onne
l to
che
ck v
alve
cle
aran
ce.
Eng
ine
off!
Col
d or
at
oper
atin
g te
mpe
ratu
re.
21
.A
llow
aut
hori
zed
pers
onne
l to
che
ck i
njec
tors
.R
epla
ce w
ith a
djus
ted
inje
ctor
s if
nece
ssar
y. H
and
in o
ld i
njec
tors
to
auth
oriz
edw
orks
hop.
Tig
hten
ing
torq
ue: i
njec
tors
50
Nm
(5
kpm
), pr
essu
re p
ipes
15−
20 N
m (
1.5−
2.0
kpm
).
22
.A
llow
aut
hori
zed
pers
onne
l to
che
ck c
ondi
tion
of t
urbo
char
ger
and
carr
y ou
tge
nera
l ins
pect
ion
of t
he e
ngin
e an
d its
equ
ipm
ent.
23
.R
epla
ce c
oola
nt f
ilter
(ac
cess
ory)
.*C
lose
the
cock
s 1
and
2. R
emov
e th
e fil
ter
with
spe
cial
tool
. Oil
in g
aske
t with
oil
and
scre
w o
n th
e ne
w f
ilter
by
hand
. T
ight
en 1
/2 −
3/4
of
a tu
rn w
hen
gask
et b
ites.
Ope
nco
cks.
Sta
rt an
d ch
eck
that
no
leak
age
occu
rs.
Che
ck c
oola
nt l
evel
.*N
ot i
n co
nnec
tion
with
cha
nge
of c
oola
nt.
24
.C
lean
coo
ling
syst
em/c
hang
e co
olan
t.C
heck
that
no
leak
age
occu
rs. H
igh
cool
ant t
empe
ratu
re c
an b
e th
e re
sult
of lo
w c
oola
ntle
vel,
defe
ctiv
e th
erm
osta
ts,
defe
ctiv
e co
olin
g fa
n or
blo
ckin
g of
inte
rcoo
ler/r
adia
tor
orot
her
parts
of
the
cool
ing
syst
em.
See
pag
e 8
for
cool
ants
.
25
.C
hang
e of
air
filt
er o
n co
mpr
esso
r (a
cces
sory
).R
elea
se h
ose
clip
, re
mov
e fil
ter
and
scra
p. F
it ne
w f
ilter
and
re-
tight
en c
lip.
Eve
ry80
0h
ou
rs
Eve
ry12
00h
ou
rsE
very
2400
ho
urs
or
wh
enre
quir
ed
Eve
ry6
mo
nth
s
On
ce aye
ar
19.
20.
21.
22.
23.
25.
Pro
ced
ure
sT
he
nu
mb
ers
un
der
”P
roce
du
res”
ref
er to
dia
gra
ms
bel
ow
.O
per
atin
gti
me
19
10
.C
han
ge
oil
filt
ers.
Rem
ove
the
oil
filte
rs w
ith s
peci
al t
ool.
Gre
ase
the
gask
et a
nd s
crew
on
the
new
filte
rs b
y ha
nd.
Tig
hten
3/4
tur
n w
hen
gask
et b
ites.
Rep
leni
sh o
il, s
tart
and
che
ckth
at n
o le
akag
e oc
curs
. S
top
engi
ne a
nd c
heck
oil
leve
l.
11
.C
hec
k th
at o
il lin
es t
o a
nd
fro
m t
he
turb
och
arg
er d
o n
ot
leak
.
12
.C
hec
k th
at r
adia
tor
and
in
terc
oo
ler
(air
-co
ole
d)
are
no
t b
lock
ed o
n o
uts
ide.
*R
elea
se i
nter
cool
er i
n th
e ev
ent
of s
ever
e fo
ulin
g. R
emov
e fa
n gu
ard.
Rel
ease
inte
rcoo
ler
pipe
s fr
om
inte
rcoo
ler.
R
elea
se
inte
rcoo
ler
from
ra
diat
or
and
tipba
ckw
ards
. Cle
an w
ith w
ater
and
mild
det
erge
nt. O
bser
ve c
are
so th
at r
adia
tor
fins
are
not
dam
aged
. N
ote
: D
o no
t us
e hi
gh-p
ress
ure
was
h.
13
.C
hec
k th
at a
ir p
ipes
an
d h
ose
co
nn
ecti
on
s d
o n
ot
leak
.C
heck
all
hose
s fo
r da
mag
e. R
epla
ce i
f ne
cess
ary.
Re-
tight
en a
ll cl
ips.
14
.A
dd
an
ti-c
orr
osi
on
pro
tect
ion
to
co
olin
g s
yste
m.*
*F
ill 1
/2 l
tr a
nti-c
orro
sion
pro
tect
ion
(par
t. N
o. 1
1415
26-2
).
15
.G
reas
e d
isen
gag
eab
le c
lutc
h (
if u
sed
).G
reas
e in
ner s
uppo
rt b
earin
g (if
gre
ase
nipp
le a
vaila
ble)
, mai
n be
arin
gs, d
isen
gagi
ngsh
aft
and
mov
ing
part
s in
clu
tch
mec
hani
sm.
Gre
ase
light
ly (
20−3
0 g
for
mai
nbe
arin
gs).
Qua
lity:
see
und
er i
tem
5
abov
e. A
pply
a f
ew d
rops
of
oil
to i
nner
lin
kar
ms.
*T
he n
eed
for c
lean
ing
is s
tron
gly
rela
ted
to o
pera
ting
cond
ition
s. T
he ti
me
inte
rval
shou
ld t
here
fore
be
adju
sted
on
the
basi
s of
exp
erie
nce
for
each
sep
arat
een
gine
afte
r so
me
time
of u
se.
**N
OT
E! O
nly
whe
n th
ere
is n
o a
ntifr
eeze
in e
ngin
e. N
ote
: ant
i-cor
rosi
on p
rote
ctio
ndo
esn
ot
need
to
be a
dded
in
engi
nes
with
coo
lant
filt
er (
acce
ssor
y).
16
.D
rain
sed
imen
t ch
amb
er i
n f
uel
tan
k w
hen
ever
po
ssib
le.
17
.C
han
ge
fuel
filt
ers.
Rem
ove
the
fuel
filte
rs w
ith s
peci
al to
ol. G
reas
e ga
sket
and
scr
ew o
n th
e ne
w fi
lter
by h
and.
Tig
hten
1/2
turn
whe
n ga
sket
bite
s. O
bser
ve c
are
to k
eep
clea
n! N
o w
aste
part
icle
s sh
all
ente
r fu
el s
yste
m.
Ven
t th
e sy
stem
(se
e ite
m 1
8 be
low
).
18
.V
enti
ng
th
e fu
el s
yste
m.
Ope
n th
e ve
nt-s
crew
(1)
. A
pply
han
d pu
mp
(2)
and
pum
p un
til n
o ai
r bu
bble
s flo
wou
t in
fuel
. Clo
se s
crew
whi
le fu
el is
flow
ing
out.
Pum
p an
add
ition
al 1
0−20
str
okes
.C
heck
tha
t no
lea
kage
occ
urs.
13.
14.
15.
16.
17.
18.
Eve
ry40
0h
ou
rs
Pro
ced
ure
sT
he
nu
mb
ers
un
der
”P
roce
du
res”
ref
er to
dia
gra
ms
bel
ow
.
10.
11.
12.
Op
erat
ing
tim
e
Eve
ry80
0h
ou
rs
18 7
Electronic speed governorBefore the first startCheck that the wiring is correct according to figs 11and 12.
Provided that a fast fuse is used in the battery cables asshown in the Wiring Diagram (fig. 11) reversed polaritywill not ruin the Control Unit. However, other incorrectconnections can cause irreparable damage to theControl Unit.
1. Set the switch "C1" (fig. 13) to the "ON" position. Note!Move the switch to the "OFF" position if there is fastinstability in the system.
2. Set the switch "C2" to the "ON" position. In thisposition the sensitivity is being redused in order toeliminate fast erratic engine behaviour which can becaused by a very soft or worn coupling between engineand generator.
3. Set the potentiometers ”GAIN” and ”STABILITY"(fig.13) to the centre position.
4. Temporarily strap terminals ”L” and ”M” on the ControlUnit to get low idle (approx. 400 rpm).
Fig 13. Control Unit
First start1. Connect the batteries and start the engine. The gover-
nor should keep the engine at idle. If desired, the idlespeed can be increased by turning the ”IDLE”potentiometer clockwise. Note, this is a single turnpotentiometer. Turn carefully and not to its endposition.
Warning! Long periods of running at criticalspeeds can damage any flexible coupling fitted,the engine or the generator.
2. After the engine has been checked and its function isnormal, remove the strap between the ”L” and ”M”terminals on the Control Unit. The speed will increaseto approx. 1567 rpm or 1870 rpm depending on theoperating speed ordered.
For new, not previously adjusted Control Unit, the”SPEED” potentiometer should be turned 15-20 turnsclockwise from its end position.
3. Perform a final adjustment of the ”GAIN” and ”STABIL-ITY” in the Control Unit as follows:
- Run the engine without load and turn the ”GAIN”control clockwise until instability occurs. Then turnback the control until stability is obtained and then anadditional 1/8 turn.
- Adjust the ”STABILITY” control in the same way asfor the gain above.
NOTE! When adjusting the sensitivity ”GAIN”, theset speed may be changed. Adjust, if necessary,using the ”SPEED” potentiometer.
After these adjustments have been completed, load can beapplied.
It may be necessary to repeat the previous adjustments.Normally, there is a critical point for these adjustments withan unloaded, cold engine.
NOTE!
Turning the ”GAIN” control clockwise will increase thegovernor reaction with changes in load. Turning counter-clockwise will give a slower reaction.
Turning the ”STABILITY” control clockwise will shortenthe time for the system’s recovery after a change in load.Turning counter-clockwise will give a longer recoverytime for the system.
8
Fuel, Oils, Coolant
CoolantThe coolant has a double purpose. On the one hand it shallprotect the cooling system from freezing, and secondly itprevents corrosion. To avoid freezing and corrosiondamage to the engine the following recommendationsmust be followed:
Freeze risk
Use a mixture of 50% Volvo Penta antifreeze (glycol) and50% pure water (as neutral as possible). This mixtureprovides protection from freezing down to approx.−−−−−40oC and should be used all year round.
Note: At least 40% antifreeze shall be used in the systemto ensure satisfactory corrosion protection.
Mix the antifreeze with water in a separate containerbefore filling in the cooling system.
With respect to replenishing of coolant, see instructions onpage 14.
NOTE! Glycol is hazardous to health (dangerousto consume).
No freeze risk
When there is no freeze risk water with the addition ofVolvo Penta anti-corrosion agent* (part. No. 1141526-2)must be used where a mixture of water/glycol is notused all year round. Mixing ratio 1:30.
With respect to replenishing of coolant, see instructions onpage 14. Run engine warm after replenishing to ensurebest effect.
NOTE! Anti-corrosion agent is hazardous to health(dangerous to consume)
*Note: Never mix anti-corrosion agent with antifreeze (glycol).The formation of foam can seriously diminish the cooling effect.
Replacement of coolant
Replacement of coolant and flushing of the system shallbe carried out at least once a year. See also under heading”Cooling system” on page 13, and the maintenanceschedule.
Fuel specificationThe fuel must meet national and international standards forcommercial fuel, such as:
– EN590 (with nationally adapted environmental and coldrequirements)
– ASTM-D975-No 1-D, 2-D.
– JIS KK 2204
Sulphur content: In accordance with the legal require-ments in each country. If the sulphur content exceeds 0.5percent by weight, the oil change intervals are changed,please refer to page. 16.
Note. Fuel with an extremely low sulphur content (urbandiesel in Sweden, City diesel in Finland) can cause a lossof power of about 5% and an increase in fuel consumptionof 2-3%.
Lubricating oil, engineLubricating oil of a quality as per the following table shallbe used:
Designation Standard
VDS* Volvo Drain Specification
CD, CE API (American Petroleum Institute)
MIL−L−2104D US Government’s Military Spec.
* If long oil change intervals are applied a VDS oil must be used. See also maintenance schedule and ”Technical Data”.
The use of an oil of a quality which does not comply with theabove stated requirements is an inferior solution, both witha view to economy and operating reliability.
With respect to viscosity and volumes, see ”TechnicalData” on page 23 .
Oil for power steering system, hydraulicpump (accessory)
ATF oil* shall be used for the power steering system.
*ATF = Automatic Transmission Fluid (oil for automatic gearboxes).
Pro
ced
ure
sT
he
nu
mb
ers
un
der
”P
roce
du
res”
ref
er to
dia
gra
ms
bel
ow
.
1.2.
3.
4.5.
6.
7.8.
9.
Op
erat
ing
tim
e
Dai
lyb
efo
rest
arti
ng
Eve
ry50
ho
urs
Eve
ry20
0h
ou
rs
Mai
nte
nan
ce s
ched
ule
Th
e ti
me
inte
rval
s ar
e g
uid
e-lin
es w
hic
h a
re a
pp
licab
le u
nd
er n
orm
al o
per
atin
g c
on
dit
ion
s.F
or
new
or
new
ly o
verh
aule
d e
ng
ine
see
un
der
hea
din
g ”
Ru
nn
ing
-in
” o
n p
age
10.
All
pro
ced
ure
s b
elo
w, w
ith
the
exce
pti
on
of i
tem
s 20
, 21
and
22,
sh
all b
e ca
rrie
d o
ut a
t lea
st
on
ce a
yea
r if
the
op
erat
ing
tim
e in
the
sch
edu
le is
no
t rea
ched
. Fo
r it
ems
20, 2
1 an
d 2
2 at
leas
t o
nce
eve
ry o
ther
yea
r is
ap
plic
able
.
No
te! S
top
the
eng
ine
bef
ore
ser
vice
wo
rk is
beg
un
!
1.
Che
ck l
ubri
catin
g oi
l le
vel
in e
ngin
e.*
Bet
wee
n m
arks
on
dips
tick.
Oil
qual
ity:
VD
S,
CD
or
CE
as
per
AP
I sy
stem
.
2.
Che
ck c
oola
nt l
evel
.*Le
vel s
hall
lie a
ppro
x. 5
cm
bel
ow s
ealin
g su
rface
of
fille
r ca
p.
3.
Che
ck t
hat
radi
ator
and
inte
rcoo
ler
(air
-coo
led)
are
not
clo
gged
on
the
outs
ide.
See
ite
m 1
2 be
low
for
cle
anin
g.
4.
Che
ck c
logg
ing
on a
ir f
ilter
s.*
Che
ck t
hat
filte
rs a
re n
ot c
logg
ed.
Rep
lace
filt
ers
whe
n in
dica
tor
rem
ains
in
fully
red
sect
or(1
) af
ter
engi
ne i
s st
oppe
d. R
eset
ind
icat
or a
fter
chan
ging
filt
ers
by p
ress
ing
butto
n (2
).N
OT
E! D
o no
t tou
ch fi
lters
bef
ore
indi
cato
r sh
ows
red
sect
or. S
crap
the
old
filte
rs. N
otto
be
clea
ned
or r
euse
d.N
ote.
For
ope
ratin
g in
ext
rem
ely
dirty
env
ironm
ents
(e.
g. c
oal m
ines
) a
spec
ial a
ir fil
ter
is r
equi
red
(not
mar
kete
d by
Vol
vo P
enta
).*
Eve
ry 8
hou
rs d
urin
g co
ntin
uous
ope
ratio
n.
5.
Gre
ase
rele
ase
bear
ing
on d
isen
gage
able
clu
tch.
*G
reas
elig
htly
so
that
no
grea
se is
forc
ed o
ut. G
reas
e w
ith li
thiu
m b
ase:
Mob
ilux
EP
2,S
tato
il U
niw
ay E
P2N
, T
exac
o M
ultif
ak E
P2,
Q8
Rem
bran
dt E
P2.
6.
Che
ck b
atte
ries
.B
atte
ry w
ater
app
rox.
10
mm
ove
r ce
ll pl
ates
.W
arni
ng!
Alw
ays
use
prot
ectiv
e gl
asse
s w
hen
hand
ling
batte
ries.
Bat
terie
sco
ntai
n ex
plos
ive
gas
and
stro
ngly
cor
rosi
ve s
ulph
uric
aci
d. N
aked
fla
mes
or
spar
ks i
n th
e vi
cini
ty o
f th
e ba
tterie
s ca
n ca
use
expl
osio
n.
7.
Che
ck t
hat
no le
akag
e of
coo
lant
, lub
rica
ting
oil o
r fu
el o
ccur
s.*
App
licab
le fo
r mor
e th
an 1
5−20
sw
itchi
ngs
per d
ay. O
ther
wis
e ev
ery
400
hour
s.
8.
Cha
nge
oil
in e
ngin
e.*
Oil
qual
ity: e
ngin
e oi
l VD
S,
alt.
CD
or C
E a
s pe
r AP
I sys
tem
. Dra
in o
ff th
e oi
l whe
n en
gine
is w
arm
. War
ning
! H
ot o
il ca
n ca
use
burn
inju
ries.
9.
Che
ck/te
nsio
n V
-bel
ts.
Rel
ease
scr
ews
(A)
befo
re t
ensi
onin
g of
alte
rnat
or b
elts
. T
he b
elts
sha
ll be
abl
e to
be
push
ed d
own
appr
ox. 1
0 m
m b
etw
een
the
pulle
ys. W
orn
belts
wor
king
in p
airs
sha
ll bo
thbe
rep
lace
d. F
an b
elts
hav
e an
aut
omat
ic b
elt
tens
ione
r.*T
he o
il ch
ange
inte
rval
is s
trong
ly r
elat
ed t
o fu
el a
nd lu
bric
atin
g oi
l qua
lity,
and
als
oto
ope
ratin
g co
nditi
ons.
See
tab
le a
bove
.
2
1
17
To
ensu
re m
axim
um o
pera
ting
relia
bilit
y an
d se
rvic
e-lif
e it
is im
port
ant
that
the
eng
ine
and
itseq
uipm
ent
are
mai
ntai
ned
as p
er t
he m
aint
enan
ce s
ched
ule.
Thi
s pr
ovid
es i
nstr
uctio
n as
to
whe
n an
d ho
w m
aint
enan
ce is
to
be c
arrie
d ou
t.
Alw
ays
use
an a
utho
rized
Vol
vo P
enta
wor
ksho
p, w
hich
has
the
nec
essa
ry e
quip
men
t an
dtr
aine
d pe
rson
nel.
A w
ell e
xecu
ted
serv
ice
and
mai
nten
ance
pro
gram
me
ensu
res
grea
ter
oper
atin
g ec
onom
y an
dfe
wer
uns
ched
uled
int
erru
ptio
ns t
o op
erat
ions
.
Oil
chan
ge
inte
rval
sD
epen
din
g o
n ti
me,
su
lph
ur c
on
ten
t of t
he
fuel
, an
d q
ual
ity
of t
he
lub
rica
tin
g o
il.
No
te. I
f lon
ger
oil c
hang
e in
terv
als
than
wha
t are
giv
en h
ere
are
requ
ired,
the
cond
ition
of t
he o
il m
ust
be c
heck
ed b
y th
e oi
l man
ufac
ture
r by
reg
ular
lubr
icat
ing
oil t
ests
.
Oil
qu
alit
yS
ulp
hu
r co
nte
nt o
f fu
el in
% b
y w
eig
ht
< 0
.5%
0.5
−1.0
%>
1.0
%*
Oil
chan
ge
inte
rval
: fir
st r
each
ed d
uri
ng
op
erat
ion
VD
S24
mon
ths
or 4
00 h
24 m
onth
s or
200
h12
mon
ths
or 1
00 h
AP
I: C
D o
r C
E12
mon
ths
or 2
00 h
12 m
onth
s or
100
h−
*Lu
bric
atin
g oi
l with
TB
D >
15 is
rec
omm
ende
d w
hen
usin
g fu
el w
ith s
ulph
ur c
onte
nt >
1.0%
by
wei
ght.
(TB
N =
Tot
al B
ase
Num
ber)
.
A.
Coo
lant
. C
ap f
or c
heck
ing
and
repl
enis
hing
.B
.In
terc
oole
r.C
.In
dica
tor i
ndic
atin
g th
e cl
oggi
ng o
fth
e ai
r fil
ters
.D
.F
ine-
filte
rs f
or f
uel.
E.
Oil
scav
engi
ng p
ump.
F.
Fee
d pu
mp.
G.
Alte
rnat
or.
H.
Air
filte
rs.
I.R
adia
tor.
K.
Eng
ine
lubr
icat
ing
oil.
Fill
er c
ap.
L.O
il di
pstic
k.T
AD
1030
: lo
cate
d on
lef
t ha
ndsi
de o
f en
gine
.M
.O
il co
oler
.N
.Lu
bric
atin
g oi
l filt
ers.
O.
Sem
i-au
tom
atic
fu
ses.
P
ress
butto
n if
fuse
has
trig
gere
d.
Pre
ven
tati
ve m
ain
ten
ance
16 9
Instrument panel
8. Warning lamp which lights if charging current from thealternator ceases.
9. Interlock button (black). The automatic stop is discon-nected when this button is pressed. The button mustbe held down when starting until the oil pressurehas reached normal.
Note: the button also connects the electric starterelement (pre-heating).
10. Warning lamp for low oil pressure (accessory).
11. Stop button (red). When the button is pressed the stopsolenoid is connected. This breaks the fuel supply fromthe injection pump and the engine stops.
Note: if the engine has been stopped by triggering theautomatic stop the alarm will also be silenced bypushing the stop button.
12. Semi-automatic fuses (2 pcs 8A and 1 pc 16A). If a fusehas triggered it can be manually reset by pushing thebutton on the fuse.
Instruments
1. Oil pressure gauge. Normally within green sector (300−500 kPa).
2. Warning lamp for low coolant level (accessory).
3. Coolant temperature gauge. Normally within greensector (70−95oC).
4. Warning lamp for high coolant temperature (accessory).
5. Rev counter, engine speed. Multiply the reading by100 to obtain rpm.
6. Hour counter. Built into the rev counter housing. Showsthe engine’s operating time.
7. Start button (green). Note: the start button must neverbe pressed when the engine is running. The startermotor and ring gear on the flywheel can be seriouslydamaged.
The instruments for monitoring the engine’s oil pressure,coolant temperature, rpm and operating time, includingstart and stop controls, are collected on the instrumentpanel. This is placed on a column at the rear of the engineframe on the right-hand side.
Instrument panel, opened
Note: the bold figures (in brackets) refer to the component designationin the wiring diagram on page 20.
1. Relay for level switch, coolant (accessory) (9).2. Relay for automatic stop (coolant temperature switch, oil pressure
switch, and switch for low coolant level, accessory) (10).3. Holding current relay (operating current and instruments) (11).4. Terminal block for engine cabling (12.A).5. Terminal block for automatic stop and extra power outlet (max.
16A) (12.B).6. Minus (−) for extra power outlet, (black wire).7. Connection for extra switches − automatic stop, (white wire).8. Plus (+) for extra power outlet, (red wire). Max. 16A.
10
Running-inWhen the engine is new it shall be operated in normaloperation, but full load shall not be applied more than forshort periods during the first 10 hours, if possible.Unnecessary idling with an unloaded engine shall also beavoided.
Check the instruments carefully during this period so thatany irregular conditions can be discovered in good time.
Check also that no leakage occurs.
NOTE! On a new or newly overhauled engine the valveclearance shall be checked for the first time after 100−−−−−200 hours of operation. Re-tighten the injectors at thesame time (50 Nm/5 kpm).
When a disengageable clutch is installed this should begiven an additional check during the first days. Adjustmentmay be necessary to compensate for wear on the plates.See item 19 in the maintenance schedule on page 17.
1.
3. 4.
5. 6.
7. 8.
9. 10.
Operating
Procedures prior to starting
1. Check the oil level in the engine.* The level shall liebetween the two lines on the dipstick. The oil levelmust never fall below the lower mark.
TWD1210/1211, TAD1230: the dipstick can be re-moved either during operation (side marked ”OPE-RATING”) or when the engine is stopped* (sidemarked ”STOP”).
*Reading to be carried out not before at least 3 minutes afterstop.
2. Check that the drain cock(s) is closed and that alldrain plugs are fitted.
With respect to positioning of cocks and plugs seediagrams on page 13.
3. Check the coolant level. The level shall lie approx. 5cm below the filler cap’s sealing surface. With respectto replenishing see page 14.
Warning! Open the filler cap very carefullyif the engine is warm. Steam or hot liquidcan spray out.
4. Check that the radiator and the intercooler (TAD1030,TAD1230) are not clogged on the outside.
5. Check the condition of the air filters. Replace thefilters when the indicator shows a completely redsector. Reset the indicator after changing the filtersby pressing the button.
6. Check the fuel volume. Replenish with fuel asrequired. Never allow the engine to stop from lack offuel. If this happens the fuel system must be vented*to enable start.
*See item 18 in the maintenance schedule on page 17.
7. Open the fuel cocks.
8. Check that no leakage of water, fuel or oil occurs.
9. Switch on the main switches.
10. Disengage the disengageable clutch (where appro-priate) and set the speed control in idling position.
11. Check the alarm equipment if available.
15
Semi-automatic fuses
Important information on the electricalsystem
Stop the engine and disconnect the power withthe main switches before interfering with theelectrical system.
1. Main switches. Never break the power circuit betweenalternator and batteries when the engine is running. Themain switches shall for this reason never be switched offbefore the engine has stopped. If the power circuit isbroken when in operation the voltage regulator can bedestroyed and the alternator seriously damaged.
2. Batteries. Never confuse the plus and minus poles ofthe batteries when fitting the batteries. This can result inserious damage to the electrical equipment. Refer to thewiring diagram. The battery poles shall be well cleanedand the cable lugs always tightened and well greased.There must be no loose connections.
Quick charging of batteries shall be avoided. If quickcharging must be used, both battery cables shall alwaysbe removed first.
NOTE! Follow the stipulated safety regulations whencharging batteries. During charging the cell-plugs shouldbe unscrewed but remain in the plug holes. Ventilatewell, especially if the batteries are charged in a closedroom. Always break the charging current before thecharging clips are removed.
Warning! The battery compartment must neverbe exposed to a naked flame or electric spark.Never smoke in the vicinity of the batteries. Duringcharging the batteries generate hydrogen gas,which on contact with air forms oxyhydrogen gas.This gas is highly inflammable and very explosive.
Always use protective goggles when charging orhandling batteries. The battery electrolytes containstrongly corrosive sulphuric acid. On contact withthe skin, wash with soap and plenty of water. Ifbattery acid has come into your eyes, rinseimmediately with plenty of water and seek medi-cal attention immediately.
Checking of batteries and electricalconnectionsThe lifetime of the batteries is to a large extent related tohow they are maintained. Keep batteries dry and clean.Impurities on the batteries can result in spark-over anddischarge the batteries, especially in wet weather.
Clean the battery poles and connections with appropriatewire brushes. Poor contact can result in an unnecessaryloss of voltage. Tighten the cable lugs well and spray thebattery poles and connections with anti-corrosion agent, orbrush with Vaseline.
Check that the batteries are well secured.
Check also that all other electrical connections are freefrom oxidization and that there are no loose connections.Spray when necessary these connections with water-repellent spray (Volvo Penta universal oil).
Starting with auxiliary batteriesWarning!
The batteries (especially auxiliary batteries) contain oxy-hydrogen gas which is very explosive. A spark, which canbe caused by the incorrect connection of the auxiliarybatteries, is sufficient to explode a battery and causedamage.
1. Check that the auxiliary batteries are connected (inseries, or in parallel) so that the rated voltage correspondwith the engine’s system voltage.
2. First connect the red auxiliary cable (+) to the auxiliarybattery and then to the flat battery. Now connect theblack auxiliary cable (−) to the auxiliary battery, andfinally to a point a reasonable distance from the flatbatteries (e.g. at the main switch on the minus cable orat the connection of the minus cable to the startermotor).
3. Start the engine. NOTE! Do not interfere with theconnections when trying to start (risk for sparks)and do not lean over any of the batteries.
4. Remove the cables in the exact reverse order to whichthey were fitted. NOTE! Do not under any circum-stances remove the cables to the standard batteries.
Electric weldingRemove the plus and minus cables from the batteries. Nowremove all cables to the alternator.
Always connect the welding clip to the component which isto be welded and as close the weld as possible. The clipshall never be connected to the engine or so that the currentcan pass over any bearing.
After welding: always connect the cables to thealternator again before the battery cables are re-placed.
FusesThe engine is equipped with three semi-automatic fuses*placed in the instrument box. The fuses break the currentin the event of overloading.
Resetting of the fuses takes place manually by pressing thebutton on the respective fuse.
Note: If any of the fuses triggers repeatedly this impliesfault which must be corrected.
*2 pcs 8A for the engine and instrument panel, and 1 pc 16A foraccessory.
Electrical system
14
Replenishing of coolantWarning: Open the filler cap very carefully if theengine is warm. Steam or hot fluid can spray out.
Note. Check that the drain cock is closed and that the drainplugs are fitted and tightened before replenishing thecoolant system.
Replenishing shall be carried out when the engine isstopped. TWD1210/1211: Open the venting cock (seediagram on page 13). Do not replenish too quickly to avoidair-locks in the system. The air shall be enabled to flow outthrough the venting cock (TWD1210/1211) or filler opening.
If a heater is connected to the engine’s cooling system the
heat control valve shall be opened and the system ventedduring replenishing.
Fill with coolant to approx. 5 cm under the sealing surfaceof the filler cap. For coolants, see heading ”Coolant” onpage 8.
The engine must not be started before the system isvented and completely replenished.
Start and run the engine warm. TWD1210/1211: Open theventing cock (see diagram on page 13) for a moment afterstarting for the venting of any remaining air. Check thecoolant level and replenish if necessary.
Replenish with the same mixture already used in thecooling system.
Disengageable triple-plate clutch
1. Inner support bearing 8. Release bearing2. Plates (3 pcs) (ball bearing release)3. Lever for engaging/ 9. Cross shaft
disengaging 10. Lever4. Grease nipple and hose 11. Rear thrust plate
for release bearing 12. Intermediate thrust5. Grease nipple for the plates
main bearings 13. Drive ring6. Main bearings 14. Flywheel7. Drive shaft
Disengageable clutchesAt rear of engine (accessory)
Disengageable twin-plate clutch
1. Inner support bearing 6. Drive shaft2. Flywheel 7. Release bearing3. Plates (2 pcs) 8. Rear thrust plate4. Lever for engaging/ 9. Intermediate thrust
disengaging plate5. Main bearings 10. Drive ring
11
Starting the engine(Starting prosedure may vary dependig on application i.e.genset/stand-by etc.).
Engine with alarm separator (accessory): press the inter-lock button and check that the warning lamps on theinstrument panel go on.
1. Cold engine: press the interlock button (black) andhold down about 50 sec. This connects the electricstarter element (pre-heating).
Warning! Never use start spray or the like inview of explosion risk in the inlet pipe anddanger of personal injury.
Warm engine: go directly to item 2.
2. Hold the interlock button down. Press down at thesame time the ”Start” button (green), (max. 40 sec.).
3. Release the start button immediately when the enginestarts. The interlock button must, however, always beheld down about 5 sec. after start (engine with coolantlevel switch, accessory), or until the the oil pressurehas stabilized (other engines). The automatic stop willotherwise connect and stop the engine.
Note: in the event of severe cold, pre-heating canwhere necessary be connected for several minutesafter start by holding the interlock button down.
NOTE! The start button must never be helddown when the engine is running. The startermotor and gear ring on the flywheel can beseriously damaged.
4. Do not race the engine after start! Run the engineinstead unloaded at approx. 1300−1500 rpm for severalminutes to ensure that all components are satisfactorilylubricated.
Do not run the engine with critically low revs. This isparticularly applicable for an engine connected toequipment with high inertia.
5. Connect the disengageable clutch (if available) atmax. 800 rpm.
Starting with auxiliary batteries
With respect to starting with auxiliary batteries, see instruc-tions on page 15.
During operationCheck that the instruments show normal readings (indicatorswithin green sector). The warning lamps shall be off.
Note: in the event of low oil pressure, high coolant tempera-ture or low coolant level*, the engine will be automaticallystopped by the automatic stop at the same time as thewarning horn is activated.
NOTE! For engines which are run continuously thelubricating oil level must be checked at least every 8 hours.
Warning! Never start or run the engine with the oilfiller cap off, in view of the risk for oil splash.
*The coolant level switch is an accessory.
12
Speed control (Power Pack)The speed can be adjusted by hand with a mechanicalcontrol mounted on the left of the instrument column on theright-hand side of the engine.
Changing of engine revs: move the control lever (A)upwards until the required revs are obtained; see Fig.
Control for adjusting engine revs
A. Control lever
Operating with low loadAvoid long-term idling or operating with low load. Suchoperating conditions can result in increased oil consumptionor subsequent leakage from the inlet and exhaust pipe.
This is caused by oil passing the turbocharger’s seals andenter the inlet pipe together with the charging air at low load(low turbo charge).
As a result of this carbon can be deposited on the valves,piston crowns and in exhaust ports.
At low loads the combustion temperature also becomes lowso that a complete combustion of the fuel cannot beensured, with fuel dilution of the lubricating oil as a result.
To limit the above consequences when operating at lowload the following procedures shall be taken:
1. Reduce operating with low load to a minimum. Ifperiodic test runs of the engine is carried out each weekwithout load, the operating time shall be restricted toapprox. 10 minutes.
2. Run the engine at full load for approx. 4 hours once ayear. The carbon deposits in the engine and exhaustpipe will therefore have the opportunity to be combusted.
Note: if these items are carried out in addition to normalinspection there will be no risk for interruptions to opera-tions as a result of operating with low loading.
Stop
1. Allow the engine to run several minutes withoutload at approx. 1300 −−−−−1500 rpm before stopping.This is important to achieve an inner temperatureequalization in the engine. Detrimental ”after-boiling” is thereby avoided, at the same time asthe turbocharger cools somewhat. This contributestowards an extended operating time without inter-ruptions.
2. Disengage the engine if possible.
Disengageable clutch:
N = Neutral positionE = Engaged
3. Press the stop button (red) and hold down until theengine has stopped.
4. Note: When the engine is not operated for severaldays the main switches should be switched off.
The main switches must never be switched offwhen the engine is in operation. The voltage regu-lator and alternator can be seriously damaged.
AAAAA
13
Freeze protection and anti-corrosionprotection, cleaningThe coolant shall be changed at least once a year to avoidthe deterioration of the cooling capacity as a result ofdeposits in the cooling system. An additional reason tochange the coolant is to avoid the risk of corrosion damagein the cooling system, since the anti-corrosion protectionadditives become consumed with time.
The system shall be carefully flushed with water whenchanging the coolant. Flush until the water running out ofthe drain outlet is clean.
Freeze riskCheck in good time that the coolant is sufficiently freezeresistant. The freezing point can be reduced to approx.max. −56°C (60% antifreeze).
See also under heading ”Coolant” on page 8. Spirit shallnot be used in the cooling system.
Draining of coolantBefore draining, the engine shall be stopped and thefiller cap unscrewed.
Warning! Open the filler cap very carefully if theengine is warm. Steam or hot fluid can spray out.
Now open the drain cock(s) and remove the drain plugs.TWD1210/1211: Also open the venting cock. Unscrew andempty the coolant filter (accessory) where appropriate.
For positioning of cocks and plugs, see under heading"Drain points" below and diagrams.
Note. There may be deposits inside the cock/plug, whichmust be cleaned. Connect a hose to the drain cocks to avoidspilling water on the engine and electrical parts.
Check that all coolant actually runs out in order to avoidfreeze damage where Volvo Penta antifreeze is not used inthe system.
Cooling system
Drain cock on the cylinder block
Drain pointsDrain cocks:
− On left-hand side of the cylinder block, rear part.
− TWD1210/1211: At front end of the intercooler.
Drain plugs:
− Under the radiator.− Under the oil cooler.− 2 pcs (front and rear) on the compressor (accessory)
Venting cock:
− TWD1210/1211: At rear end of the intercooler (V).
Coolant filter (accessory):
− Individual positioning.
TWD1210/1211TAD1230 TAD1030
Drain plugs on oil cooler, radiator and compressor(accessory)
TWD1210/1211: Drain cock on the intercooler, front endVenting cock,V, on the intercooler, rearend