Volvo Penta D12 MG Operator's Manual
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Volvo Penta D12 MG Operator's Manual

Volvo Penta D12 MG Operator's Manual

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OPERATOR'S MANUAL
D12 MG Genset Engine

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  • Page 1 OPERATOR’S MANUAL D12 MG Genset Engine...
  • 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 For information on genset and/or generator specific items refer to generator information supplied by genset builder and/or 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

    Drain points ............48 Radiator cooling ........... 49 Presentation ............12 Drain points ............49 D12 MG HE Genset engine ........12 Keel cooled ............50 D12 MG RC Genset engine ........13 Drain points ............50 D12 MG KC Genset engine ........14 Freshwater system ..........

  • Page 5: Safety Information

    This Operator’s Manual is only valid for the auxiliary engine 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 6: Safety Regulations During Engine Operation

    Get Avoid violent and rapid rudder movement and gear in touch with your Volvo Penta dealer for help in ob- shifting. There is a risk of the passengers falling down taining the best solution for your vessel.

  • Page 7: Safety Directions For Maintenance And Service

    More detailed service literature is avail- able from your Volvo Penta dealer. Never perform a fitted. The rotating compressor wheel in the turbochar- ger can cause severe personal injury.
  • Page 8 Safety information Start spray Lubricating system Never use start spray or similar start help. Explosions Hot oil can cause burn injuries. Avoid skin contact can occur in the intake manifold. Risk for personal with warm oil. Make sure the lubricating system is de- injury.
  • Page 9 Safety information Handle antifreeze carefully! Antifreeze contains alkali. Avoid contact with skin and eyes to prevent personal injury. Dispose of drained antifreeze coolant according to local regula- tions. For disposal, consult your dealer. Dress properly for the job! Wear protective devices - hard hat, face shield, safety shoes, goggles, heavy gloves, ear protectors, etc.

  • Page 10: Introduction

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

  • 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 MG HE Genset engine The D12 MG HE is a turbocharged, in-line, direct injection, 6-cylinder, 4-stroke marine engine. It is equipped with an engine mounted heat exchanger suitable for seawater cooling or connection to a central cooling system.

  • Page 13: D12 Mg Rc Genset Engine

    Presentation D12 MG RC Genset engine The D12 MG RC is an in-line, direct injection, 6-cylinder, 4-stroke marine engine equipped with radiator cooling. Different starting and control systems are available. D12 MG RC Genset engine 1. Lifting eyes 2. Switchable fuel filters w. water separator 3.

  • Page 14: D12 Mg Kc Genset Engine

    Presentation D12 MG KC Genset engine The D12 MG KC is a turbocharged, in-line, direct injection, 6-cylinder, 4-stroke marine engine. It is fitted with con- nections for keel cooling. Different starting and control systems are available. D12 MG KC Genset engine 1.

  • Page 15: New Engine Initial Service

    New engine initial service General Before starting a new or reconditioned engine for the first time, give it an initial inspection. This to guarantee your own safety as well as the maximum service life of the engine. 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 Starting 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 18: Marine Commercial Control

    Control System Marine Commercial Control This chapter describes functions and operation of the Marine Commercial Control system (MCC) and the MCU (Marine Control Unit). Applications and Modes The MCC system can be configured for different applications. Auxiliary (AUX), Emergency (EME), Combined (CMB) and Propulsion (PRP).

  • Page 19: Mcc System Overview

    Control System MCC system overview Terminology MCC ............Marine Commercial Control, name of the over all system. MCU ............Marine Control Unit, the central control unit of the system. SDU ............Shudown Unit, for engine protection. Activates a fuel shut-off valve to shut down the engine.

  • Page 20: Mcu Panel Layout

    Control System MCU Panel layout 1. LCD display 7. LED - Engine running 2. Horn reset (stops sound alarm) 8. Up button (Select and Increase) 3. Mode Left, toggles modes backwards 9. Down button (Select and Decrease) [Off - AUX(EME,HRB,PRP)] 10.
  • Page 21 Control System Info Serial number and software revision In the main view, push and hold ENTER button and then push PAGE button. Controller INFO screen is displayed for 10 seconds. MCU adjustments Backlight - INFO view In the INFO view, push and hold the ENTER button. Adjust the brightness with UP or DOWN button .
  • Page 22 Control System Operational modes Local mode In Local Mode the MCU is operational only from the main panel. All external interfaces are disabled. Local mode is activated by pushing Enter + Mode- Right buttons. Local mode is deactivated by pushing Enter + Mode- Left buttons.

  • Page 23: Menus

    Select MAIN screen. Push Up-button three (3) times. 1. Running hours 2. Successful starts (starter RPM>Starting RPM) 3. Unsuccessful starts (MaxCrank time exceeded ) 4. Service time (hours to service) Statistic values can be adjusted from PC software (password protected), contact your Volvo Penta dea- ler.
  • Page 24 Control System Measurement Push the PAGE button repeatedly to toggle the menu screens. Select MEASUREMENT screen. Use Up and Down buttons to toggle the different screens. Adjustment In the adjustment menu it is possible to view and edit setpoints. 1. Push the PAGE button repeatedly to scroll the menu screens.

  • Page 25: Operation

    Control System Operation Starting the engine 1. In MAIN menu, select mode of operation (AUX, HRB, EME, PRP), refer to section ”Applications & Modes”), using MODE button (left or right)(A). 2. Make sure engine status is ”Ready”(B). 3. Push START button and the engine state should change to ”Running”(C).

  • Page 26: Mcu Menu Flow Chart

    Control System MCU menu flow chart...
  • Page 27 SD. Measurement (B) B1. - B4. Pages display monitoring values from (EMS). B5. & B6. Used by Volvo Penta service technicians. EMS to MCU CAN-bus information. B7. & B8. Used by Volvo Penta service technicians. MCU to EMS CAN-bus information.

  • Page 28: Shutdown System Overview

    SDU is lost. Yellow LED indicates broken wire. Reset alarm on Broken wire reset button (A). NOTE! Use only Volvo Penta tool supplied with SDU for reset (see picture). Tool for broken wire reset...

  • Page 29: Sdu Indications

    SDU indications 1. Green – Power A. Broken wire reset button 2. Red – Overspeed Alarm B. Yellow – Fuel valve Broken wire detected 3. Yellow – Run detection S4 C. Yellow – Speed sender Broken wire detected 4. Green – Run detection S2, S3 D.

  • Page 30: 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 31: 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 32: Stopping

    Stopping Let the engine 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 engine stops abnormally, try especially important if the engine has been run at to locate the problem and make the repairs heavy loads.

  • Page 33: After Stopping

    After stopping General * Check the engine and engine room for leaks. * Close the fuel cock and seawater cock. IMPORTANT! Do not forget to open the cocks before starting the engine again. * Read off the hour counter and carry out preventive maintenance according to the maintenance schedule. * Turn off the main switch if the engine is not to be used for a long period.

  • Page 34: 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 35: Recommendation Of 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 36: Maintenance Schedule

    Check/change zinc anodes 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 ”Technical Data Lubrication oil specification”...
  • Page 37 Maintenance schedule Every 1000 operating hours or every 12 months Check/adjust valve clearances ............... (refer to note 2) Check/clean heat exchanger/radiator 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 38: 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 39: 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 40: 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 41: 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 42: 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 43 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 44 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 45: 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 46: 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 47: 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 48: 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 49: 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 50: 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 51: 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 52: 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 53: 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 54: 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 55: Electrical System

    MODE to prevent remote start. 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 56: 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 57 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 58: Inhibiting

    Before taking the engine 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 59: 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 60: In Case Of Emergency

    In case of emergency Start with auxiliary batteries WARNING! Ventilate well. Battery gas is explosive. WARNING! Never confuse positive and negative poles on the batteries. 1. Connect red jumper cable to positive pole (+) of the flat battery, then to the positive pole of the help start battery.

  • Page 61: Auxiliary Start

    In case of emergency Auxiliary START In case of control system(MCU) failure it is possible to by-pass the control system and start the engine “ma- nually”. In case of battery power loss, refer to section ”Start with auxiliary battery”. 1. Locate AUXILIARY START button on the bracket above the starter.

  • Page 62: Troubleshooting

    A number of symptoms and possible causes for engine disturbances are described in the table below. If faults or hitches arise that you cannot solve alone, 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 63: Technical Data

    Technical Data D12 MG HE Marine genset 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 64: D12 Mg Rc Marine Genset

    Technical Data D12 MG RC Marine genset 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 65: D12 Mg Kc Marine Genset

    Technical Data D12 MG KC Marine genset 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 66: Fuel Specification

    Technical data Fuel specification Fuel must comply with national and international standards for commercially supplied fuels, e.g.: JIS KK 2204....... Type1, Type2, Type3 ASTM, D975 ........No.1-D, No.2-D EN590 ......with national environment and cold requirements Sulfur content Complying with legal requirements in each country. If the sulfur content exceeds 0.5 wt%, service intervals must be changed, (refer to chapter Maintenance lubrication system).

  • Page 67: 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 68: Coolant Specification

    -28 °C (18°F). (Using 60 % glycol lowers the freezing point to -54 °C (65°F)). If the coolant contains less than 40% Volvo Penta Coolant, the cooling galleries in the engine or radiator may be blocked by contamination.

  • Page 69: Identification Numbers

    Technical Data Identification numbers D12 MG Genset engine Type plates with identification numbers and labels with information on certificates and classification, can be found on the engine. This information must always be used as a reference when ordering service and spare parts.

  • Page 70: Notes

    Notes ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
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