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Volvo TAD1240GE User Manual

Volvo TAD1240GE
68 pages
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Generating set and industrial engines
12 litre (EDC III)
OPERATORS MANUALp
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 C
ompany and Doosan
Company or the products of
e
ith
er.
Revised (10-12)
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Volvo TAD1240GE Specifications

General IconGeneral
Engine ModelTAD1240GE
Number of Cylinders6
Fuel SystemCommon Rail
Cooling SystemWater-cooled
Stroke150 mm
AspirationTurbocharged
Bore131 mm

Summary

Foreword

Safety information

Safety instructions for operation and maintenance

Crucial safety guidelines for operating and maintaining the engine.

Introduction

Environmental care

Volvo Penta's commitment to environmental protection and user responsibility.

Running-in

Procedures for the initial 10 hours of engine operation.

Fuel and oils

Recommendations for fuel and oil grades to ensure optimal performance.

Maintenance and replacement parts

Importance of using original parts and following maintenance schedules.

Certified engines

Requirements for emissions-certified engines regarding maintenance and parts.

Presentation

Technical description

Detailed breakdown of engine components and systems.

EDC III

Explanation of the Electronic Diesel Control system.

Identification numbers

Location and meaning of engine identification plates.

Instrument

Instrumentbox

Description of the instrument panel layout and controls.

Starting the engine

Before starting

Pre-operation checks and safety precautions.

Start-up procedure EDC III

Step-by-step guide for starting engines with EDC III.

Start-up under extreme cold

Special procedures for starting in very cold conditions.

Never use starting spray

Warning against using starting fluid due to explosion risk.

Operation

Check the instruments

How to monitor gauges and indicators during operation.

Alarms and error indications

Understanding warning lamps and the diagnostic system.

Low-load operation

Risks and recommendations for operating at low loads.

Stopping the engine

Before shut-down

Actions to take before turning off the engine.

Stop

Procedure for safely stopping the engine.

Maintenance schedule

Daily, before the first start-up

Routine checks performed daily before initial engine use.

Every 50-600 operational hours / at least every 12th month

Recurring maintenance tasks based on operational hours or yearly intervals.

Every 400th operational hour / at least every 12th month

Maintenance tasks performed at 400-hour intervals or annually.

Maintenance

Engine, general

General inspection and checks for the engine.

Drive belts, check/adjust

Procedures for inspecting and adjusting drive belts.

Air filter, check/replace

How to check and replace the air filter element.

Lubrication system

Oil level, check and add

Procedure for checking and topping up engine oil.

Engine oil, change

Steps for draining and refilling the engine oil.

Oil filter/Bypass filter, change

Instructions for replacing oil and bypass filters.

Cooling system

Coolant level, check

How to check the coolant level and safety precautions.

Adding, cooling system

Procedure for adding coolant and bleeding air.

Draining, cooling system

Steps for draining the engine's cooling system.

Fuel system

Fuel filter, change

Procedure for replacing the main fuel filter.

Fuel pre-filter with water monitor, change

Steps for changing the fuel pre-filter and water monitor.

Fuel system, bleeding

How to bleed air from the fuel system.

Electrical system

Batteries, maintenance

Safety, cleaning, and electrolyte level checks for batteries.

Batteries, charging

Procedures and warnings for charging engine batteries.

Preparation for storage

For periods of storage up to 8 months

Steps for short-term engine storage.

For periods of storage longer than 8 months

Procedures for long-term engine storage.

Preparation for use after storage

Steps to take before putting a stored engine back into service.

Troubleshooting

Symptoms and possible causes

Table listing common engine problems and their potential causes.

Diagnostic function

Problem identification

How to identify and read error codes from the diagnostic system.

Reading out error codes

Step-by-step guide to retrieve stored error codes.

Diagnostic Trouble Codes (DTCs)

Code 2.1

Cause, response, and corrective action for water in fuel or low fuel pressure.

Code 2.2

Cause, response, and corrective action for low coolant level.

Code 2.4

Cause, response, and corrective action for flywheel RPM sensor issues.

Code 2.5

Cause, response, and corrective action for RPM sensor issues.

Code 2.7

Cause, response, and corrective action for throttle potentiometer issues.

Code 3.4

Cause, response, and corrective action for charge air sensor issues.

Code 6.1

Cause, response, and corrective action for high coolant temperature.

Code 6.6

Cause, response, and corrective action for low oil pressure.

Code 7.1

Cause, response, and corrective action for cylinder #1 compression/injector issues.

Code 7.6

Cause, response, and corrective action for cylinder #6 compression/injector issues.

Technical Data

General

Key technical specifications for various engine models.

Lubrication system

Technical data related to engine lubrication.

Fuel system

Technical data concerning the fuel system.

Cooling system

Technical data for the engine's cooling system.

Electrical system

Technical data for the engine's electrical components.

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