Table of Contents
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OPERATOR’S MANUAL
p
Generating set and industrial engines
12 litre (EDC III)
Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
either.
Revised (10-12)
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Table of Contents
Related Manuals for Volvo TAD1240GE
Summary of Contents for Volvo TAD1240GE
- Page 1 OPERATOR’S MANUAL Generating set and industrial engines 12 litre (EDC III) Doosan purchased Bobcat Company from Ingersoll-Rand Company in 2007. Any reference to Ingersoll-Rand Company or use of trademarks, service marks, logos, or other proprietary identifying marks belonging to Ingersoll-Rand Company in this manual is historical or nominative in nature, and is not meant to suggest a current affiliation between Ingersoll-Rand Company and Doosan Company or the products of either.
- Page 2 This is not by chance. After more than 90 years of producing engines the name Volvo Penta has come to symbolize reliability, technical ingenuity, first-class perfor- mance and longevity.
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Page 3: Table Of Contents
Starting procedure EDCIII ........13 Diagnostic function ..........47 Instrument box ............ 14 Regarding the diagnostic button’s indication Volvo Penta start lock ......... 14 blinker ..............47 Start-up under extreme cold ........ 15 Readout of error codes ........47 Never use starting fluid ........16 Erasing error codes .......... -
Page 4: Safety Information
If there is anything that you are unclear on or unsure about even af- ter reading the book, please contact your Volvo Penta dealer for assistance. This symbol is used in the instruction book and on the product to let you know that it con- cerns safety information. -
Page 5: Safety Instructions For Operation And Maintenance
Hair, fingers, loose-fitting clothing or a dropped tool severe injury. Volvo Penta recommends that all ser- can get caught in rotating parts causing severe injury. vice work that requires that the engine be running be If the engine has been delivered without protective co- assigned to an authorized Volvo Penta repair facility. - Page 6 Safety information Safety instructions for operation and maintenance (cont.) Lifting the engine Batteries When lifting the engine use the lifting eyes that are Batteries contain and develop oxyhydrogen gas, espe- mounted on the engine. Always make sure that the cially while charging. Oxyhydrogen gas is easily flam- lifting device is in good condition and has sufficient mable and very explosive.
- Page 7 Safety information Cooling system Electric welding Avoid opening the coolant filler cap when the engine is Remove the positive and negative cables from the warm. Steam or hot coolant can squirt out causing batteries. Next, remove all connections to the genera- burns.
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Page 8: Introduction
Introduction This instruction book has been compiled to give you the best possible use of your Volvo Penta industrial engine. It contains the information you need to operate and take care of the engine in a safe and correct manner. We the- refore ask you to read the instruction book carefully and to learn to handle the engine, controls and additional equipment in a safe manner before you start the engine. -
Page 9: Certified Engines
AB Volvo Penta may otherwise completely or partially deny warranty claims. Contact your Volvo Penta dealer if you do not have a Warranty and Service book as well as a customer copy of the warranty card. -
Page 10: Presentation
Presentation TAD1240GE, TAD1241GE/VE, TAD1242GE/VE and TWD1240VE are inline, direct-injected, 6-cylinder industrial diesel engines. They are equipped with electronically controlled fuel management, turbochargers, intercoolers and thermostati- cally regulated cooling systems and electronic RPM regulation. Technical description Engine and cylinder block –... -
Page 11: Identification Numbers
D Computer kit number E Product number The above plate shows: (K) Engine family Explanation of engine designation: (J) Swept volume Ex. TAD1240GE/TWD1240VE (A) Engine designation T – Turbo (F1) Valve clearance, inlet A – Air-to-air Charge air cooler (F2) Valve clearance, outlet W –... -
Page 12: Edc Iii
EDC III stands for ”Electronic Diesel Control” and is an electronic system with CAN (Controller Area Network) communication for diesel engine management. The system was developed by Volvo Penta and includes such pa- rameters as fuel management and diagnostic functions. -
Page 13: Orientation
Presentation Orientation The picture shows TAD1240GE, TAD1241GE and TAD1242GE variants. 1. Expansion tank 2. AC generator 3. Control unit 4. Air filter 5. Starter motor 6. Fuel pre-filter with water sensor 7. Fuel filter with fuel pressure sensor 8. Oil dipstick 9. -
Page 14: Instrument
Instrument Instrumentbox 1. Engine oil pressure. 9. Pre-heat button. Used to pre-heat the engine prior to start. Pre-heating is automatically adjusted by 2. Diagnosis lamps. The error codes are read from the system. The system also has after-heating. the diagnosis lamp. 10. -
Page 15: Starting The Engine
Starting the engine Make a habit of always visually checking the engine and engine compartment prior to starting the engine. This will help you to quickly notice if any abnormal conditions have occurred or are occurring. Check also to verify that the instruments show normal values after start-up. -
Page 16: Instrument Box
Following this, warm up the engine using low rpm and low loading. IMPORTANT! Never rev-up the engine when it is cold. Volvo Penta start lock: 1. Turn the key to the ”I” position and check the indicator lamps. 2. Position”II”. Pre-heating is activated (pre-heating is an option). -
Page 17: Start-Up Under Extreme Cold
Pre-heat the coolant by using a separately mounted electric engine heater. In extreme cases it can be ne- cessary to use a diesel-powered engine heater. Con- sult your Volvo Penta dealer. IMPORTANT! Make sure that the cooling sys- tem is filled with a glycol mixture. See the chapter ”Maintenance, cooling system”. -
Page 18: Never Use Starting Fluid
Starting the engine Never use starting spray WARNING! Never use starting spray or other similar substances to help start an engine. This could cause an explosion in the intake tract. This poses a risk of injury. Start with booster batteries WARNING! Batteries (especially booster batteries) contain oxyhydrogen gas that is very explosive. -
Page 19: Operation
Additio- nal information on error codes and location of pro- blems is in the chapter ”Problem location”. The following conditions apply when the Volvo Penta instrument box is used: • In case of excessively low oil pressure or... -
Page 20: Rpm Regulation
Operation Throttle The throttle (A) is mounted on the right side of the in- strument box. Avoid sudden and extreme changes in throttle position. Clutch A clutch is optional. Engage the clutch at a 1000–1200 rpm max. N = Neutral E = Engaged Low-load operation Avoid prolonged operation at idle or at low loading. -
Page 21: Shutting Down The Engine
Stopping the engine In case of extended time between uses the engine should be run until warm at least once every 14 days. This pre- vents corrosion of the engine. If the engine will not be used for more than two months preservation should be performed. See the chapter ”Storage”. -
Page 22: Maintenance Schedule
Maintenance schedule General Your Volvo Penta engine and its equipment are built to provide a high degree of reliability and a long useful life. They are built to have the minimum possible effect upon the environment. Preventative maintenance according to the maintenance schedule and use of original Volvo Penta parts will preserve these qualities and help to avoid un- necessary operational disturbances. -
Page 23: Newly Rebuilt Engine
Maintenance Every 800th operational hour / at least every 12th month • Charge air pipes, check for leaks ..............page 22 • Fuel pre-filter, change filter element ............... page 37 • Fuel filter, change ..................page 36 Fuel system, purging ..................page 38 •... -
Page 24: Maintenance
Maintenance This chapter contains general technical information and instructions detailing how the recommended maintenance should be performed. Read carefully through the instructions before starting the task. The time frames for when each maintenance point should be performed are given in the previous chapter: Maintenance schedule. WARNING! Read through the safety instructions for maintenance and service work in the chapter: Safety in- formation, before starting to work. - Page 25 Maintenance Drive belts, check/adjust. Check and adjustments should be done when the drive belts are warm. The drive belt to the generator should be able to press in 3-4 mm between the drive belt pulleys. The drive belt to the generator must be adjusted manually but the other drive belt is automatically adjusted.
- Page 26 Maintenance 6. Mount the new drive belt and tighten it with the tightening screws (3). The play should be 3 mm for new belts and 3-4 mm for old belts. The play is measured where the drive belts are at their long- est between pulleys.
- Page 27 It may not be cleaned or reused. IMPORTANT! Under continuous operation the filter should be checked every 8 hours. For operation in extremely dirty environments such as coal mines and stone crushers a special filter is available (not sold by Volvo Penta).
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Page 28: Lubrication System
Oil with TBN 14–20 must be used NOTE! Mineral-based, as well as completely or partially synthetic oil can be used as long as it satisfies the grade requirements listed above. VDS = Volvo Drain Specification ACEA = Association des Constructeurs Européenne d’Automobiles = American Petroleum Institute... -
Page 29: Lubrication Oil
Maintenance Oil level, check and add The oil level should be within the marked area on the dipstick and should be checked daily before the first start. Add oil using the filler opening on the side of the engine. Check that the correct level is reached. Wait a few minutes so that the oil has time to run down into the oil pan. - Page 30 Maintenance Oil filter/Bypass filter, change WARNING! Hot oil can cause severe burns. 1. Clean the oil filter housing. 2. Remove all oil filters using appropriate filter wrenches (1). 3. Clean the sealing surface on the filter housing, making sure that no gasket residue remains. 4.
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Page 31: Coolant, General
The cooling system should be filled with a coolant that protects the engine from internal corrosion and frost dama- ge where the climate so demands. Never use water only. The anti-corrosion additives become less effective with time, necessitating periodic coolant changes. Assuming that Volvo Penta’s recommendations regarding coolant are adhered to the following change in- tervals apply: Coolant... -
Page 32: Cooling System
Maintenance Anti-freeze If there is a risk of frost, use a mixture of 40% Volvo Penta anti-freeze (glycol) and water (to ASTM D4985). This mixture prevents against frost bursting down to about –25°C (–13°F), and should be used all year round. - Page 33 NOTE! Do not open the pressure cap. 1. Open the filler cap (1). NOTE! Use only Volvo Penta recommended coolant and mixtures. 2. Mix the correct amount of coolant ahead of time (see the table below) so that it can be assured that the system has been filled.
- Page 34 2. Open all of the drain valves. Drain the coolant from the radiator. Use drain hose that can be orded from Volvo Penta, the drain cock (P) is located under the radiator. 3. Make sure that all coolant runs out. Deposits may exist just inside of the cocks/plugs that must be cleaned away.
- Page 35 5. If impurities still exist repeat the cleaning procedure until the system is free from impurities. 6. When the cooling system is completely clean, fill it with new coolant. In markets where Volvo Penta’s concentrated coolant is not available, use anti-corrosive additives and water.
- Page 36 Maintenance Coolant filter, change 1. Turn the valve (1) 90° to stop the flow through the coolant filter. 2. Remove the coolant filter using an appropriate fil- ter wrench. Make sure that no residue from the old gasket remains on the housing. 3.
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Page 37: Fuel System
Maintenance Fuel system Only use fuel of the recommended grade according to the fuel specification below. Always make sure to maintain a high level of cleanliness when fueling and when working with the fuel system. All work involving the engine’s unit injectors must be performed by an authorized service location. WARNING! Risk of fire. - Page 38 Maintenance Fuel filter, change NOTE! Do not fill the new fuel filter with fuel prior to mounting, there is a risk that impurities can be intro- duced into the system causing operational interrup- tions or damage. WARNING! Fuel filter replacement should be carried out on a cold engine to avoid the risk of fire caused by fuel spilling onto hot surfaces.
- Page 39 Maintenance Fuel pre-filter with water monitor, change 1. Clean the area around the fuel filter. 2. Disconnect the water monitor(1). 3. Drain the fuel filter, see ”Fuel system, draining”. 4. Remove the fuel filter using an appropriate filter wrench. NOTE! If the entire filter unit with the water separator is not going to be changed the water monitor should be moved to the new fuel filter.
- Page 40 Maintenance Fuel system, bleeding 1. Clean around the air bleeding nipples on the cylin- der head and the fuel filter bracket. 2. Bleed the fuel system at the fuel filter. Connect a transparent plastic hose between the bleed nipple (1) and a collection vessel. 3.
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Page 41: Electric System
The fuse is placed adjacent to the engine control unit on the engine’s left side. Note: The engine will stop if the fuse (+) blows out. If the fuse blows out often an authorized Volvo Penta repair facility should be contacted to investigate the cause of the overload. - Page 42 Maintenance Batteries, maintenance WARNING! Fire and explosion risk. Batteries may never be exposed to open flame or sparks. WARNING! Never confuse the plus and minus poles of the batteries. Risk of causing sparks and explosion. WARNING! Battery electrolytes is strongly corrosive.
- Page 43 Maintenance Batteries, charging WARNING! Explosion risk. During charging oxyhydrogen gas is formed. Short-circuits, open flame or sparks can cause a powerful explosion. Ventilate well. WARNING! Battery electrolyte is strongly corrosive. Protect eyes, skin and clothing. Always use safety glasses and gloves. In case of skin contact, wash with soap and large quantities of water.
- Page 44 Maintenance Electric component schematic Coolant level sensor Control unit RPM sensor, camshaft Fuel pressure alarm Diagnostic outlet 8-pin connector Programming connection 23-pin connector Boost pressure/intake temperature sensor Coolant temperature sensor Extra stop Starter motor Main relay Starter motor, relay Generator RPM sensor, flywheel Safety fuse 10A Water monitor, fuel filter...
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Page 45: Clutch
Maintenance Clutch Lubrication Use lithium-based grease such as Mobilux EP2, Statoil Uniway EP2N, Texaco Multifac EP2, Q8 Rem- brandt EP2. Main bearing and clutch mechanism Grease the inner support bearing (where there are grease fittings), main bearing, declutching shaft and the clutch mechanism’s moving parts with grease. -
Page 46: Preparation For Storage
It is important that this be done correctly and that no part of it be forgotten. We have therefore created a checklist covering the most important points. Before the engine is taken out of service for an extended period an authorized Volvo Penta service facility should perform a check. -
Page 47: Preparation After Storage
Preparation for storage Preparation for use after storage • • Remove any covers from the engine, air filter and Close the drain valves and replace any drain exhaust pipe. plugs. • • Fill the engine with the proper grade of lubricating Check the coolant levels. -
Page 48: Troubleshooting
A number of symptoms and possible causes for engine problems are described in the table below. Always contact your Volvo Penta dealer if problems occur that you are not able to solve on your own. WARNING! Read through the safety instructions for maintenance and service work in the chapter ”Safety in- formation”... -
Page 49: Diagnostic Function
Diagnostic function Diagnostic function The diagnostic function checks that the EDC III sys- tem is functioning normally. The diagnostic function has the following func- tions: • To detect and localize disturbances • To inform that disturbances have been detected • To assist in the determination of the cause of the problem •... -
Page 50: Erasing Error Codes
Diagnostic function NOTE! If the warning display and the instrumentation indicates normal function. The operator can choose to continue operation and take corrective actions later on. If the engine is shut down certain error codes can disappear Reading out error codes If the diagnosis button (2) is pushed and then released an error code blinks out (1). -
Page 51: Diagnostic Trouble Codes
Diagnostic Trouble Codes (DTCs) WARNING! Read the safety instructions for maintenance and service work in the chapter ”Safety information” before starting to work. Code 2.1 Code 2.5 Cause: Water detected in the fuel or insufficient fuel Cause: RPM sensor, camshaft. pressure. - Page 52 Diagnostic function Code 2.8 Code 3.4 Cause: Throttle potentiometer connected to CIU. Cause: Charge air sensor. Response: The engine goes to idle. If the pedal is first re- Response: The engine smokes more than it usually does leased and then pushed down again the engine can be when accelerating/under loading.
- Page 53 Diagnostic function Code 4.3 Code 4.7 Cause: Run-indication. Cause: Start initiation EMS. Response: None. Response: Engine will not start. The engine can only be stopped using the emergency stop on the engine. Corrective action: Corrective action: • arning lamp Check the w •...
- Page 54 Diagnostic function Code 5.4 Code 6.2 Cause: Pre-heating relay. Cause Intake air temperature is too high. Response: Pre-heating can not be activated. Response: Engine output is limited to 50% (if this protecti- ve feature has not been disabled by the parameter setting Corrective action: tool).
- Page 55 Diagnostic function Code 6.6 Code 7.3 Cause: Oil pressure is too low. Cause: Problem with the compression or the injector for cylinder #3. Electric error. Response: The engine shuts down (if this protective fea- ture has not been disabled by the parameter setting tool). Response: Cylinder balance is adversely affected ->...
- Page 56 Diagnostic function Code 7.6 Cause: Problem with the compression or the injector for cylinder #6. Electric error. Response: Cylinder balance is adversely affected -> une- ven running at low RPM and low load. The engine runs on 5 cylinders, sounds uneven and has decreased performance.
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Page 57: Technical Data
Technical Data General Type designation ........TAD1240GE TAD1241-42GE TAD1241-42VE TWD1240VE Number of cylinders ......... Cylinder diameter ........131 mm (5.16") 131 mm (5.16") 131 mm (5.16") 131 mm (5.16") Stroke ............150 mm (5.91") 150 mm (5.91") 150 mm (5.91") 150 mm (5.91") -
Page 58: Fuel System
Technical data Fuel system Injection order Injection order ............1-5-3-6-2-4 Feed pump Feed pressure after fuel filter at 1000 RPM, min............350 kPa (51 psi) Feed pressure after fuel filter at full load, min.............. 350 kPa (51 psi) Overflow valve Opening pressure ............ -
Page 59: Electric System
Technical data Electrical system System voltage ............24 V Alternator: voltage/max. current ..........28 V/60 A power approx............1700 W Battery capacity ............2 serial-connected 12 V, max. 152 Ah Battery electrolyte density at +25°C: fully charged battery ..........1.28 g/cm (1.24 g/cm the battery discharges at ........ - Page 60 Notes ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
- Page 61 Notes ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
- Page 62 Notes ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
- Page 63 Yes please, I would like an operator’s manual in English at no charge. Publication number: 7741212 Post or fax this coupon to: Document & Distribution Center Name Order Department ARU 2, Dept. 64620 Address SE-405 08 Göteborg Sweden Fax: +46 31 545 772 Orders can also be placed via the Internet: http://www.volvopenta.com/...
- Page 64 Sí gracias, deseo recibir gratuitamente un libro de instrucciones en español. Número de publicación: 7741215 Franquear o enviar fax a: Document & Distribution Center Nombre Order Department ARU 2, Dept. 64620 Direc- SE-405 08 Göteborg ción Suecia Fax: +46 31 545 772 El pedido puede hacerse también por internet: http://www.volvopenta.com/...
- Page 65 Ja graag, Ik wil kosteloos een instructieboek in het Nederlands ontvangen. Publicatienummer: 7741218 Stuur of fax de coupon naar: Document & Distribution Center Naam Order Department ARU 2, Dept. 64620 Adres SE-405 08 Göteborg Zweden Fax: +46 31 545 772 U kunt ook bestellen via internet: http://www.volvopenta.com/...
- Page 66 Íáé, Èá Þèåëá Ýíá áíôßôõðï ôïõ åã÷åéñéäßïõ ÷ñÞóçò óôçí áããëéêÞ ãëþóóá ÷ùñßò êáìéÜ ÷ñÝùóç. Áñéèìüò Ýêäïóçò: 7741221 Ôá÷õäñïìÞóôå áõôü ôï êïõðüíé óôçí ðáñáêÜôù ¼íïìá äéåýèõíóç Þ óôåßëôå ôï ìå öáî óôïí ðáñáêÜôù áñéèìü Äéåýèõíóç öáî: Document & Distribution Center Order Department ARU 2, Dept.