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7734906-6 English 01-1998 Diesel Engines TAD1030G/P, TWD1210G/P, TWD1211G/P, TAD1230G/P INSTRUCTION BOOK

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Page 1: INSTRUCTION BOOK - Volvo Penta

7734906-6

Eng

lish

01-1998

Diesel Engines TAD1030G/P, TWD1210G/P, TWD1211G/P, TAD1230G/P

INSTRUCTION BOOK

Page 2: INSTRUCTION BOOK - Volvo Penta

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

Page 3: INSTRUCTION BOOK - Volvo Penta

26

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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.

Page 4: INSTRUCTION BOOK - Volvo Penta

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

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Page 5: INSTRUCTION BOOK - Volvo Penta

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.

Page 6: INSTRUCTION BOOK - Volvo Penta

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

✱✱✱✱✱✱✱✱✱✱

Page 7: INSTRUCTION BOOK - Volvo Penta

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

Page 8: INSTRUCTION BOOK - Volvo Penta

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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Page 9: INSTRUCTION BOOK - Volvo Penta

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ing

Ele

ctro

nic

Spe

ed G

over

nor,

see

pag

e 6)

Wir

ing

dia

gra

ms

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)

Page 10: INSTRUCTION BOOK - Volvo Penta

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

Page 11: INSTRUCTION BOOK - Volvo Penta

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.

Page 12: INSTRUCTION BOOK - Volvo Penta

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

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r.*T

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is s

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ly r

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bric

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g oi

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lity,

and

als

oto

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le a

bove

.

2

1

17

Page 13: INSTRUCTION BOOK - Volvo Penta

To

ensu

re m

axim

um o

pera

ting

relia

bilit

y an

d se

rvic

e-lif

e it

is im

port

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ine

and

itseq

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are

mai

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as p

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s pr

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to

whe

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to

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erat

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, an

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rica

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No

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ger

oil c

hang

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terv

als

than

wha

t are

giv

en h

ere

are

requ

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the

cond

ition

of t

he o

il m

ust

be c

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e oi

l man

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qu

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: fir

st r

each

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VD

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AP

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100

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Tot

al B

ase

Num

ber)

.

A.

Coo

lant

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ap f

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and

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ters

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: lo

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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.

Page 14: INSTRUCTION BOOK - Volvo Penta

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

Page 15: INSTRUCTION BOOK - Volvo Penta

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.

Page 16: INSTRUCTION BOOK - Volvo Penta

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