Volvo TAD1240GE User manual

Generating set and industrial engines
12 litre (EDC III)
OPERATORSMANUALp
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)

Enginedata
Engine designation ........................... Product number ....................................
Serial number .........................................................................................................
Clutch, type/nr. .......................................................................................................
NearestVolvoPentaservicelocation
Name .......................................................................... Telephone....................
Address...................................................................................................................
© 2001 AB VOLVO PENTA
Volvo reserves the right to make changes
Printed on environmentally friendly paper
Foreword
Volvo Penta industrial engines are relied upon throughout the world,
in both mobile and stationary applications, under some of the most
rigorous conditions imaginable. 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. We believe that these characteristics are also
ultimately your requirements and expectations for new Volvo Penta
industrial engines.
To make certain that your expectations are matched, we ask that
you read carefully through the instruction book before starting
the engine.
Sincerely
AB VOLVO PENTA

1
Safetyinformation.................................................. 2
Safety instructions for operation and
maintenance ......................................................... 3
Introduction............................................................ 6
Environmentalresponsibility ................................. 6
Running-in............................................................. 6
Fuel and oils ......................................................... 6
Maintenanceandreserveparts ............................. 6
Certifiedengines ................................................... 7
Presentation ........................................................... 8
Technicaldescription ............................................ 8
Identificationnumbers........................................... 9
EDC III................................................................ 10
Orientation .......................................................... 11
Instrument ............................................................ 12
Instrumentbox ..................................................... 12
Startingtheengine............................................... 13
Beforestarting .................................................... 13
StartingprocedureEDCIII ................................... 13
Instrumentbox.................................................... 14
Volvo Penta start lock......................................... 14
Start-upunderextremecold ................................ 15
Never use starting fluid ....................................... 16
Start-upwithhelperbatteries............................... 16
Operation .............................................................. 17
Checkingtheinstruments ................................... 17
Alarmsandtroubleindicators .............................. 17
RPMregulation ................................................... 18
Clutch ................................................................. 18
Low-loadoperation .............................................. 18
Shutting down the engine ................................... 19
Prior to shut-down .............................................. 19
Shut-down........................................................... 19
Aftershut-down................................................... 19
Extrashut-down .................................................. 19
Contents
Maintenanceschedule ......................................... 20
Maintenanceschedule ........................................... 20
Newlyrebuiltengine ............................................ 21
Maintenance ......................................................... 22
Engine,general ................................................... 22
Lubricationsystem.............................................. 26
Lubricationoil...................................................... 27
Coolingsystem ................................................... 30
Coolant,general .................................................. 30
Fuel system........................................................ 35
Electric system................................................... 39
Clutch ................................................................. 43
Preparationforstorage ........................................ 44
Preparationforstorage....................................... 44
Preparationafterstorage..................................... 45
Troubleshooting................................................... 46
Symptoms and possible causes ......................... 46
Diagnosticfunction.............................................. 47
Diagnosticfunction ............................................. 47
Regardingthediagnosticbutton’sindication
blinker ................................................................. 47
Readoutoferrorcodes........................................ 47
Erasingerrorcodes............................................. 48
Diagnostictroublecodes..................................... 49
Technicaldata ...................................................... 55
General ............................................................... 55
Lubricationsystem.............................................. 55
Fuel system........................................................ 56
Coolingsystem ................................................... 56
Electric system................................................... 57
CALIFORNIA
Proposition 65 Warning
Dieselengineexhaust and some of itsconstituentsare known to
theStateof California to cause cancer, birth defects,andother
reproductiveharm.

2
Safety information
Read this chapter very carefully. It concerns your safety .How safety information is presented in the instruction
book and on the product is described here. You will also find an overall picture of the basic safety procedures for
operation of the engine.
Make sure that you have the correct instruction book before reading any further. If you do not, please con-
tact your Volvo Penta dealer.
Incorrect operation can lead to injuries and/or product or property damage. It is therefore impor-
tant to read through the instruction book very carefully before you start the engine or perform
maintenance or service work. 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. Always read this information very carefully.
In the instruction book warning texts are handled according to the following priority system:
WARNING! Warns of risk of injury, extensive damage to the product or other property, or
that serious functional problems can occur if the instruction is not followed.
IMPORTANT! Used to call attention to things that can cause damage or functional
problemstothe productorproperty.
NOTE!Used to call attention to important information that can make the work process or opera-
tion go more smoothly.
This symbol is used in certain cases on our products and refers to important information in
the instruction book. Make sure that warning and information symbols on the engine and trans-
mission are always visible and legible. Replace symbols that have been damaged or painted
over.

Safety information
3
Starting lock
If the instrument panel does not have a key switch
the engine compartment should be lockable to pre-
vent unauthorized personnel from starting the engine.
A lockable main switch may be used as an alterna-
tive.
Maintenance and service
tasks
Knowledge
In the instruction book you will find instructions for
how the most common maintenance and service
tasks can be carried out in a safe and correct man-
ner. Read the instructions carefully before initiating
work.
Literature covering more extensive work is available
from your Volvo Penta dealer.
Never attempt a procedure if you are not completely
certain regarding how it should be performed. Contact
your Volvo Penta dealer for assistance.
Shut down the engine
Shut down the engine before opening or removing the
engine access panel/hood. Maintenance and service
procedures should be carried out on a stopped engi-
ne unless otherwise specified.
Prevent an undesired start-up by removing the star-
ting key and disconnecting the electricity with the
main switch and locking it in the disconnected posi-
tion. A warning notice should also be placed at the
operating station advising that work is being carried
out.
Working with or getting close to a running engine is a
safety risk. Hair, fingers, loose-fitting clothing or a
dropped tool can get caught in rotating parts causing
severe injury. Volvo Penta recommends that all ser-
vice work that requires that the engine be running be
assigned to an authorized Volvo Penta repair facility.
Safety instructions for operation and maintenance
Daily checks
Make a habit of always visually checking the engine
and engine compartment prior to operation (before
starting the engine) and after operation (after shut-
ting down the engine). This will help you to quickly
notice if fuel, coolant or oil leaks or any other abnor-
mal conditions have occurred or are occurring.
Fuel filling
There is a risk of fire and explosion when filling tanks
with fuel. Smoking is forbidden and the engine must
be stopped.
Never overfill the tank. Make sure that the cap is cor-
rectly closed.
Use only the fuel recommended in the instruction
book. Fuel of the wrong grade can cause the engine to
run incorrectly or not at all. On a diesel engine it can
also lead to seizure of the injection system and over-
revving the engine, putting both the machine and near-
by people at risk.
Carbon monoxide poisoning
Only start the engine in a well-ventilated space.
During operation in an enclosed space both exhaust
and crankcase gases must be properly vented.
Operation
The engine should not be operated in environments
with surrounding explosive substances due to the fact
that the electrical and mechanical components can
cause sparks.
Getting close to a running engine is a safety risk.
Hair, fingers, loose-fitting clothing or a dropped tool
can get caught in rotating parts causing severe injury.
If the engine has been delivered without protective co-
verings, all rotating parts and hot surfaces should be
covered as necessary following installation to insure
personal safety.