Volvo is one of the best well-known and most respected brands around the world. As Volvo diesel generator set OEM supporting factory, we can provide 68KW to 600KW power generation with Volvo engine. The genset types include open type, silent type and trailer type generator set.
This Operation Manual covers the
industrial engines: 4 cylinders TD520GE, TAD530GE, TAD531GE and TAD532GE. 6
cylinders TAD620VE, TAD730GE, TAD731GE, TAD732GE, TAD720VE and TAD721VE.
The engines are four-stroke,
direct injection in-line diesel engines with replaceable wet cylinder liners
(except TAD620VE, which has dry liners).
The engines are fitted with
turbochargers, piston cooling and a water-cooled charge air cooler that reduces
the temperature of inlet air to provide a greater mass of air to the cylinders.
This makes greater engine output possible at the same time as combustion and
exhaust temperatures can be maintained at suitable levels. Also, NOx emissions
are reduced.
To facilitate start and reduce
exhaust emissions in cold weather, the engines are fitted with electric intake
air heaters (exceptions TAD520GE and TAD720VE).
Instruments
and Controls
This chapter describes the
instrument box and the instrumentation in Volvo Penta’s range. Variations in
the appearance of instrumentation may occur in certain applications (mobile for
example). If this is the case, see the Instruction Manual for the relevant
application.
Warning
If the instrument box does not
have an ignition switch, the engine/operator compartment must have a lock to
prevent unauthorised persons starting the engine. (Alternatively a lockable
main switch can be used.)
Instrument
box
1. Oil pressure gauge. Normally
within the green field (300–500 kPa).
2. Warning lamp: Low engine
coolant level (accessory)
3. Engine coolant temperature
gauge. Normally within the green field (70–95°C).
4. Warning lamp: High engine
coolant temperature (accessory)
5. Tachometer
6. Operating hour counter
7. Starter button
8. Warning lamp: Generator not
charging
9. Interlock: Press in the button
to disengage the automatic stop for low oil pressure and to activate
preheating.
10. Warning lamp: Low oil
pressure (accessory)
11. Stop button
12. Semi-automatic fuses: Reset
by pressing the button on the fuse.
Before
Starting
Check that the oil level is
between the MIN and MAX marks. For filling refer to Oil level, checking and
topping up.
• Open the
fuel cocks.
• Check that
there are no coolant, fuel or oil leaks.
• Check the
air filter pressure drop indicator. Please refer to Engine, General.
• Check
coolant level. Check that the outside of the radiator is not clogged. Please
refer to Coolant Level, Checking and Topping Up, and Charge Air Cooler,
External Cleaning.
WARNING!
Do not open the coolant filler
cap when the engine is hot, except in emergencies as this could cause serious
personal injury. Steam or hot fluid could spray out.
• Turn the
main switch on.
IMPORTANT: Never break the
circuit with the main switch while the engine is running.
Alternator and electronics could
be damaged.
• Set the
engine speed control to idle. Disengage the disengageable clutch/transmission.
Starting the
Engine
1. Press the “Interlock button”
(1) and check that the warning lamps in the instrument box are functioning.
(This applies to engines equipped with alarm separators).
2. If the engine is hot: Press
the “Interlock button” (1) and hold it in while pressing the Starter button
(2). If the engine is cold: Press the Interlock button (1) and hold it in for
approximately 50 seconds to preheat the engine. Then press the “Start button”
(2) as well.
3. Release the Start button
immediately when the engine starts. However the Interlock button must be held
down for a further 5 seconds approximately. This is to allow the oil pressure
to reach the correct level. Otherwise the automatic stop will engage and stop
the engine.
NOTICE! In extreme cold, the
preheating can be re-engaged for a few minutes after start if necessary. Hold
the Interlock button (1) pressed in.
IMPORTANT!
The start button must never be
pressed in when the engine is running. The starter motor and starter gear on
the flywheel may be seriously damaged.
4. Allow the engine to run at
500–700 rpm for the first 10 seconds. Then warm up the engine at low speed and
low load.
IMPORTANT!
Do not race the engine while it
is cold.
NOTICE! Generating set engines
automatically rev up to the preset engine speed (1500 or 1800 rpm).
Volvo Penta
starting lock
1. If the engine is hot: Proceed
directly to point 2. If the engine is cold: Turn the ignition key to position
“II” to engage the preheating. Hold the key in this position for approximately
50 seconds. (If the engine is equipped with a time relay for preheating, the
key can be released. Preheating stops automatically after 50 seconds).
2. Turn the key to position
“III”. Release the key to position “II” immediately when the engine starts.
Hold the key in this position for approximately 5 seconds. This is to allow the
oil pressure to reach the correct level. Otherwise the automatic stop will
engage and stop the engine.
If the engine does not start,
turn the key to the “O” position before trying again.
NOTICE! In extreme cold, the
preheating can be re-engaged for a few minutes after start if necessary. Hold
the ignition key in position “II”.
3. Allow the engine to run at
500–700 rpm for the first 10 seconds. Then warm up the engine at low speed and
low load.
IMPORTANT! Do not race the engine
while it is cold.
NOTICE! Generating set engines
automatically rev up to the pre-set engine speed (1500 or 1800 rpm).
If you are interested in the
starting of Volvo engine, please refer to this article to learn the details.
Operation
Correct operation is the key to
fuel economy and engine service life. Always allow the engine to achieve normal
operating temperature before running it at full power. Avoid opening the
throttle too quickly and running the engine at high engine speeds.
IMPORTANT!
An automatic shut-off for oil
pressure and engine coolant temperature (ECT) must be installed during
unattended operation where the Volvo Penta instrument box is not being used.
Reading the
Instruments
Check all instruments directly
after starting, and then regularly during operation. The pointers must be
within the green areas.
Coolant
temperature
83-95°C (181-203°F) for TAD620VE,
TD520GE, TAD720GE, TAD530GE, TAD531GE, TAD532GE, TAD730GE, TAD731GE, TAD732GE
87-102°C (189-216°F) for
TAD720VE, TAD721VE
Oil pressure, hot engine: 300–500
kPa (44–75 psi). At idle, lower values are normal.
Alarms
If the Volvo Penta instrument box
is used, the following applies:
• If oil
pressure is too low or engine coolant temperature (ECT) too high, the engine
stops automatically and the acoustic alarm goes off. If the engine is equipped
with an alarm separator, the relevant warning lamp also lights.
• If the
engine coolant level is too low and the engine is equipped with an engine
coolant level switch, the engine stops automatically and the acoustic alarm goes
off. The warning lamp lights.
• If
generator charging drops, the warning lamp lights.
NOTICE! For other applications see
the Instruction Manual for the relevant application.
Maneuvering
Speed control
Power pack: The engine speed
(RPM) is adjusted using the mechanical engine speed control (1). This is
mounted on the instrument box.
Other engines: See the relevant
instruction manual.
Disengageable
clutch
The clutch is disengaged when the
control lever is in position “N” and engaged when the lever is in position “E”.
IMPORTANT!
The engine speed must not exceed
1000–1200 rpm during engagement and disengagement.
Engine
Shutdown
MPORTANT!
If there is a risk of freezing
weather, the coolant in the cooling system must have sufficient anti-freeze
protection. Refer to the Maintenance, page 48 chapter. A poorly-charged battery
can freeze and burst. Refer to the Battery, Charging chapter.
Before
Engine Shutdown
Let the engine run without load
at 1300–1500 rpm for a few minutes before stopping. This will even out the
engine temperature and prevent overheating.
IMPORTANT!
This is especially important if
the engine has been operated at high engine speeds and/or loads.
Stop the
Engine
• Disengage
the engine (if possible).
• Press in
the stop button and hold it depressed until the engine has stopped.
Alternatively, turn the key to stop position “S”. Release the key when the
engine has stopped.
Emergency
Stop
If the engine cannot be stopped
normally, it can be stopped by moving the lever on the fuel injection pump
backwards.
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