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Volvo Penta D12-AUX Operator's Manual

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OPERATOR'S MANUAL
D12-AUX Marine Genset

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Summary of Contents for Volvo Penta D12-AUX

  • Page 1 OPERATOR’S MANUAL D12-AUX Marine Genset...
  • Page 2 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

  • Page 3: Foreword

    For information on generator specific items refer to generator information supplied by generator manufacturer. In case of contradictions, the information in this Volvo Penta Operator’s Manual overrules any information given in the documentation provided by the generator manufacturer. Do not hesitate to consult your Volvo Penta dealer.

  • Page 4: Table Of Contents

    Warranty .............. 11 Drive belts. Check/adjust/change ......35 Presentation ............12 Fuel system ............36 D12-AUX HE Genset ........... 12 Fuel filter.............. 37 D12-AUX RC Genset .......... 13 Twin fuel pre-filter/water separator ......40 D12-AUX KC Genset .......... 14 Lubrication system ..........
  • Page 5 Return the Engine to Service ....... 56 Stops longer than eight months: ......56 Troubleshooting ............. 57 Technical Data ............58 D12-AUX HE Genset engine ........ 58 D12-AUX RC Genset engine ........ 59 D12-AUX KC Genset engine ........ 60 Fuel specification ..........61 Lubrication oil specification ........

  • Page 6: Safety Information

    This Operator’s Manual is only valid for complete gensets built in the Volvo Penta factory. Make sure you are in possession of the right operator’s manual before reading on. If this is not the case, please get in touch with your Volvo Penta dealer.

  • Page 7: Safety Regulations During Engine Operation

    Get are detected. in touch with your Volvo Penta dealer for help in ob- taining the best solution for your vessel. IMPORTANT! If an oil, fuel or coolant leak is detected, the cause must be investigated and the fault rectified before the engine is started.

  • Page 8: Safety Directions For Maintenance And Service

    More detailed service literature is avail- ger can cause severe personal injury. able from your Volvo Penta dealer. Never perform a There is also a risk of foreign objects being drawn in task unless you are absolutely sure how it is to be and causing mechanical damage.
  • Page 9 Safety information Always cover any electric component if it is located Hot surfaces and fluids under the fuel filter. Otherwise it might be damaged by At operating temperature, the engine and its compo- fuel spills. nents are hot. A hot engine always involves risk for burn injuries.

  • Page 10: Introduction

    Introduction This operator’s manual has been produced to give you the greatest benefit of your Volvo Penta Marine Genset. It contains the information necessary to handle and maintain your genset in a safe and correct manner. We would like you to read this operator’s manual thoroughly and learn how to handle the genset, controls and other equip- ment in a safe manner before operating the genset.

  • Page 11: Certified Engines

    Warranty and Service Book. Note that AB Volvo Penta’s responsibility is limited to what is specified in the Warranty and Service Book. Read it carefully as soon as possible after delivery. It contains important information concerning the warranty card, servi- ce, maintenance and what the owner is responsible to be aware of, check and perform.

  • Page 12: Presentation

    Presentation D12-AUX HE Genset The D12-AUX HE is a turbocharged, in-line, direct injection, 6-cylinder, 4-stroke marine genset. It is equipped with an engine mounted heat exchanger suitable for seawater cooling or connection to a central cooling system. The engine is mounted on a frame with a Stamford single or double bearing marine generator. Different starting and control systems are available.

  • Page 13: D12-Aux Rc Genset

    Presentation D12-AUX RC Genset The D12-AUX RC is an in-line, direct injection, 6-cylinder, 4-stroke marine genset equipped with radiator cooling. The engine is mounted on a frame with a Stamford single or double bearing marine generator. Different starting and control systems are available.

  • Page 14: D12-Aux Kc Genset

    Presentation D12-AUX KC Genset The D12-AUX KC is a turbocharged, in-line, direct injection, 6-cylinder, 4-stroke marine genset. It is fitted with connections for keel cooling. The engine is mounted on a frame with a Stamford single or double bearing marine generator. Different starting and control systems are available.

  • Page 15: New Genset Initial Service

    New Genset Initial service General Before starting a new or reconditioned genset for the first time, give it an initial inspection. This to guarantee your own safety as well as the maximum service life of the genset. External Inspection Electrical Wiring 1.

  • Page 16: Starting

    Starting Before starting WARNING! Before starting the genset make sure that neither people, nor tools, are in contact with moving parts of the engine or the generator. Notify the people in the vicinity of the genset when starting. WARNING! Make sure that you know how to stop the genset before you start it (in case of emergency). If you are starting the genset for the first time, be prepared to stop the engine immediately in case abnormal noise should occur during start up.

  • Page 17: Control System

    Control system The control system consists of two separate sub-systems that each have its own senders and switches. The sys- tem for monitoring and presenting the genset operational data gives easy access to all operational data and also sets off an alarm when those data do not match set values. The SDU (shutdown unit) monitor vital engine data such as engine speed, cooling water temperature and lubrication oil pressure.
  • Page 18 Control System Control panel for genset in emergency operation This is the control panel used when the genset is configured for emergency use. The SDU comes with shutdown functions only for overspeed. The system will also detect and indicate broken wires. 1.
  • Page 19 Control panel for genset in combined auxiliary and emergency operation This is the control panel used when the genset is configured for both auxiliary and emergency use. In auxiliary mode the SDU includes shutdown functions for overspeed, high coolant temp, and low oil pressure. In emergency mode all shutdowns except overspeed are disabled.

  • Page 20: Shutdown Unit (Sdu)

    Control System Shutdown unit (SDU) The shutdown unit (SDU) will shut down the engine by cutting off the fuel supply. Shutdown functions include shutdowns for OVERSPEED, COOLANT TEMP, and OIL PRESSURE, in auxiliary mode and for OVERSPEED only, in emergency mode. Lamp test To make sure the lamps and the buzzer on the panel are working, push and hold the LAMP TEST button (1).
  • Page 21 Control System Overspeed shutdown test On a running engine, open the electrical connection box on the engine and remove the SDU cover. Then push and hold the OVERSPEED TEST button (A). This will lower the overspeed setting by 25% and trig- ger an overspeed shutdown.

  • Page 22: Lcd Screen

    Control System LCD screen The control unit is equipped with an LCD screen with adjustable lighting and contrast. Signals are displayed either graphically or as numerical values. All alarms are displayed on the screen as text messages. Contrast and lighting control Push the CONFIGURATION button(11) to access the lighting and contrast menu.
  • Page 23 Control System System In the system configuration page it is possible to reset default values for viewing of the display. Demo: Demo ON/OFF. Off = normal operation mode Restore defaults: Reset configuration default values Com viewer: Latest messages received on CAN port About: Displays vital service information.
  • Page 24 Control System Multi page display parameters The page has an adjust mode which provides for any available engine data to be displayed in any of the four data windows. The adjust mode is entered by pushing the CONFIGU- RATION PAGE button (11) when the pop-up menu is visible.
  • Page 25 J1587. In both cases the engine can still be opera- ted but with the loss of monitoring or alarm functions respectively. In the event of a communications failure, check all ca- bles for lost connections and if that does not solve the problem, contact a Volvo Penta Service Dealer.

  • Page 26: Start The Genset

    Control System Operating the genset Learn how to handle the genset, controls and other equipment in a safe and correct manner before taking it into operation. Start the genset 1. Turn on the main power supply to the engine, this will also power up the panel (not indicated).

  • Page 27: Operation

    Operation General Learn how to handle the engine, controls and other equipment in a safe and correct manner before starting the engine WARNING! Stay clear of all rotating and moving WARNING! A hot engine may cause burns. parts during operation. Beware of hot surfaces.

  • Page 28: Start Using Auxiliary Batteries

    Operation Start using auxiliary batteries WARNING! Ventilate well. Batteries generate oxyhydrogen gas, which is extremely flammable and explosive. A short circuit, naked flame or spark can cause a powerful explosion. Never reverse the polarity of the battery. Risk of sparks and explosion. 1.

  • Page 29: Stopping

    Stopping Let the genset run at no load for a couple of minutes before turning it off. This will keep the engine temperature in balance and prevent it from boiling. IMPORTANT! The procedure described above is IMPORTANT! If the genset stops abnormally, try especially important if the genset has been run to locate the problem and make the repairs at heavy loads.

  • Page 30: After Stopping

    After stopping General * Check the genset and engine room for leaks. * Close the fuel cock and seawater cock. * Read off the hour counter and carry out preventive maintenance according to the maintenance schedule. * Turn off the main switch if the genset is not to be used for a long period. IMPORTANT! Never turn the power off using the main switch while the genset is running.

  • Page 31: Maintenance

    Volvo Penta recommends that accurate maintenance records are kept. With accurate maintenance records your Volvo Penta Dealer can help in fine tuning the recommended service intervals to meet the specific operating situ- ation. This should result in a lower engine operation cost.

  • Page 32: Maintenance Schedule

    Topping up coolant (corrosion protection mixture) ......... (refer to note 5) Check the manometer and change filter if necessary. To be carried out at an authorized Volvo Penta workshop. Oil change intervals vary, depending on oil grade and sulphur content of the fuel. Refer to chapter ”Tech- nical Data Lubrication oil specification”...
  • Page 33 Maintenance schedule Every 1000 operating hours or every 12 months Check/adjust valve clearances .............. (refer to note 2) Check/clean heat exchanger Check/clean seawater filter Change fuel pre-filter/water separator filter element Change coolant filter ................(refer to note 6) Change fuel fine filter Every 2000 operating hours Check turbocharger ................

  • Page 34: Daily Operation Records

    Maintenance: General Recommendation of Daily Operation Records Daily recording is a preventive maintenance program and when comparing values with engine history it will help you recognize conditions, signs or indications of approaching trouble. Daily operation records also make trouble shooting easier and will lessen the down time (to save time and money for servicing). Items to be recorded The following items are recommended to be recorded once a day:...

  • Page 35: Engine

    Maintenance: Engine Engine Crankcase ventilation filter change If oil and air begin to find their way out of the over- pressure valve (2), change the filters (1) earlier than recommended. IMPORTANT! Change both filters at the same time. 1. Remove the old filters by unscrewing them anti- clockwise.

  • Page 36: Fuel System

    Maintenance: Fuel System Fuel system WARNING! Fire hazard. Work on the fuel system should be carried out on a cold engine. Fuel leaks and spills on hot hot surfaces or electrical componentsmay cause fire. WARNING! Hot fuel may cause burns. IMPORTANT! All unit injector maintenance must be carried out at an authorized workshop Fuel system venting The fuel system must be vented, e.g.

  • Page 37: Fuel Filter

    Maintenance: Fuel System Fuel filter. Drain Stationary engine 1. Put a suitable vessel underneath the filter. 2. Drain water and contamination from the water trap (1) through the tap (2) by pumping with the hand pump (3) until clean fuel flows out. Running engine (switchable filters only) 1.
  • Page 38 Maintenance: Fuel System Change the filter elements Stationary engine: (Single and switchable filters) 1. Close the fuel valve/valves. 2. Clean the filter bracket and put a suitable vessel under the filter. Remove the protective cap from the venting nipple. Connect a transparent plastic hose to the nipple and lower the he into the ves- sel.
  • Page 39 Maintenance: Fuel System Running engine: (Switchable filters only) 1. Clean the filter bracket and put a suitable vessel under the filter. Remove the protective cap from the venting nipple. Connect a transparent plastic hose to the nipple and lower the he into the ves- sel.

  • Page 40: Twin Fuel Pre-Filter/Water Separator

    Maintenance: Fuel System Twin fuel pre-filter/water separator The twin filter is equipped with a pressure gauge (1). The filter inserts must be changed according to the maintenance schedule or earlier if the pressure gauge indicates a vacuum of 6–10 inHg at no load or 16–20 inHg at full load.

  • Page 41: Lubrication System

    Maintenance: Lubrication system Lubrication system Lubrication oil level check The oil level must be within the marked range on the dipstick(1) and should be checked daily. Lubrication oil filling Fill lubrication oil through the filler opening on the side of the engine(2). Wait a few minutes to allow the oil to run into the oil sump then make sure you have filled to the right level.

  • Page 42: Filters And By-Pass Filter Change

    Maintenance: Lubrication system Filters and by-pass filter change Change the oil filter (2) and by-pass filter (1) every oil change. 1. Stop the engine. 2. Put a suitable vessel underneath the filters to av- oid oil spill. Clean the filter bracket. 3.

  • Page 43: Cooling System

    The Volvo Penta Genset comes with an internal freshwater system connected to an engine mounted heat ex- changer, a radiator cooler, or prepared for external cooling, e.g. keel cooling or central cooling.

  • Page 44: Engine Mounted Heat Exchanger

    Maintenance: Cooling system general Engine mounted heat exchanger The system includes two circuits. The freshwater system is cooling the charge air, the cylinder liners and the cy- linder heads. An engine driven cooling water pump circulate the coolant through the heat exchanger and through the engine.

  • Page 45: Radiator Cooling

    Maintenance: Cooling system general Radiator cooling The engine cooling water is cooled by a radiator in a one-circuit cooling system. Air is forced through the radiator by an engine driven cooling air fan. The charge air is cooled in an air-to-air charge air cooler mounted in front of the radiator and it make use of the air flow from the engines cooling fan before it enters the radiator.

  • Page 46: Keel Cooled

    Maintenance: Cooling system general Without engine mounted heat exchanger (Keel cooled) The engine cooling water is cooled by, e.g, a box cooler, a grid cooler, or any other external heat exchanger. The same coolant (fresh water) is cooling the complete engine (charge air, cylinders, etc.). 1.

  • Page 47: Freshwater System

    Maintenance: Freshwater system Freshwater system Coolant level check Coolant level can be checked through a level glass on top of the expansion tank. The green float must be vi- sible in the level glass. The coolant level should be about five centimetres (2”) below the pressure cap sealing plane in the ex- pansion tank.

  • Page 48: Coolant Drain

    Maintenance: Freshwater system Coolant drain 1. Remove the filler cap from the expansion tank and open the vent tap by the turbocharger. 2. Connect a suitable hose to each drain point, refer to section ”Drain points”. Open the drains and al- low the coolant to drain off into a suitable vessel.

  • Page 49: Raw Water System

    Maintenance: Raw water system Raw water system The raw water system is the engine’s external cooling system and it is either a seawater system or a central coo- ling system. It cools the internal cooling system in an engine mounted or externally mounted heat exchanger. The system is protected against galvanic corrosion by zinc anodes located in the heat exchanger.

  • Page 50: Seawater Filter Check/Clean

    Maintenance: Raw water system Seawater filter check/clean If the vessel is equipped with a seawater filter refer to the maintenance description delivered by the supplier of the filter. NOTE! If the water wherein the vessel operates is se- verely polluted, contains large amounts of seaweed, etc., the filter must be checked more often than is specified.

  • Page 51: Air Inlet And Exhaust Systems

    Maintenance: Air Inlet and Exhaust system Air Inlet and Exhaust Systems Air filter change Check the air filter indicator. If indicator is all red after the engine is stopped, change filter. 1. Undo the clamps and remove the lid from the filter housing.

  • Page 52: Electrical System

    Check the electrical wiring Make sure electrical connections are tightened, dry and free from oxide. If necessary, spray these con- nections with water-repellant (Volvo Penta all-round oil). Main switches The main switches must never be turned off until the engine has been stopped.

  • Page 53: Battery Maintenance

    Maintenance: Electrical system Battery maintenance WARNING! Risk for fire and explosion. Never expose the battery to naked flames or sparks. WARNING! Never reverse the polarity of the battery. Risk of sparks and explosion. WARNING! Battery electrolyte is extremely corrosive. Protect eyes, skin and clothes when handling batteries.
  • Page 54 Maintenance: Electrical system Battery charging WARNING! Risk for explosion. Charging generates hydrogen gas (oxyhydrogen gas). A short circuit, naked flame or spark can cause a powerful explosion. Ventilate well. WARNING! Battery electrolyte is extremely corrosive. Protect eyes, skin and clothes. Always use protective goggles and gloves.

  • Page 55: Inhibiting

    Before taking the genset out of service for long periods, it should be checked by a Volvo Penta dealer for possible need of overhaul or repair. WARNING! Read the chapter “Maintenance” thoroughly before starting any maintenance work. It contains directions for performing maintenance in a safe and correct manner.

  • Page 56: Return The Engine To Service

    Inhibiting Return the Engine to Service 7. Check the coolant level and anti-freeze. Top up if 1. Remove any protective covers on the engine, air necessary. intake and exhaust pipe. 8. Check under and around the engine for such items 2.

  • Page 57: Troubleshooting

    If faults or hitches arise that you cannot solve alo- ne, you must always get in touch with your Volvo Penta dealer. WARNING! Read the safety directions for maintenance and service in the chapter “Safety information”...

  • Page 58: Technical Data

    Technical Data D12-AUX HE Genset engine General Number of cylinders ..........Displacement ............12,1 liters (740 in Valve clearance (cold engine): inlet ................ 0,2 mm (0,008’’) exhaust ..............0,5 mm (0,020’’) Compression pressure at starter motor speed (120 rpm) ......

  • Page 59: D12-Aux Rc Genset Engine

    Technical Data D12-AUX RC Genset engine General Number of cylinders ..........Displacement ............12,1 liters (740 in Valve clearance (cold engine): inlet ................ 0,2 mm (0,008’’) exhaust ..............0,5 mm (0,020’’) Compression pressure at starter motor speed (120 rpm) ......

  • Page 60: D12-Aux Kc Genset Engine

    Technical Data D12-AUX KC Genset engine General Number of cylinders ..........Displacement ............12,1 liters (740 in Valve clearance (cold engine): inlet ................ 0,2 mm (0,008’’) exhaust ..............0,5 mm (0,020’’) Compression pressure at starter motor speed (120 rpm) ......

  • Page 61: Fuel Specification

    Technical Data Fuel specification Fuel must comply with national and international standards at the least, e.g.: JIS KK 2204......Type1, Type2, Type3 ASTM, D975 ........No.1-D, No.2-D EN590 ......with national environment and cold requirements Note! It is necessary to use a fuel that has a pour point suitable for ambient temperature during the operation of the engine.

  • Page 62: Lubrication Oil Specification

    Technical Data Lubrication oil specification Recommended types of engine oil Important! Use of improper or inferior oil can cause excessive wear of bearings and moving parts, thus shortening the engine life. It can also result in sticking of piston rings and seizing of pistons in the cylinders, thus causing major damage.

  • Page 63: Coolant Specification

    The mixture of Volvo Penta Coolant and water should contain 40-55% Volvo Penta Coolant. If the coolant con- tains less than 40% Volvo Penta Coolant, the cooling galleries in the engine or radiator may be blocked by con- tamination. If the coolant contains more than 60% Volvo Penta Coolant the cooling ability of the coolant mixture is impaired, this may cause the engine to overheat.

  • Page 64: Identification Numbers D12-Aux Genset

    Technical Data Identification numbers D12-AUX Genset Type plates with identification numbers and labels with information on certificates and classification, can be found on the engine and the generator. This information must always be used as a reference when ordering service and spare parts.
  • Page 65 Notes ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 66 Notes ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 67 Notes ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

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