Electrical System And Battery Maintenance of Volvo Generator Set

Electrical System of Volvo Diesel Generator Set

Volvo engine is equipped with a 2-pole electrical system and an alternator. System voltage is 24V.

WARNING! Always stop the engine and break the current using the main switches before working on the engine.

Main switch

IMPORTANT! Never disconnect the current with the main switches when the engine is running, the alternator and electronics could be damaged.

The main switches must never be switched off before the engine has stopped. If the circuit between the alternator and the battery is disconnected when the engine is running, the alternator and electronics can be damaged. For the same reason the charging circuits must never be re-connected with the engine running.

Electrical Connections

Check that electrical connections are dry, free from oxide, and that they are securely tightened.

Battery, Maintenance

WARNING! Risk of fire and explosion. Never allow an open flame or electric sparks near the battery or batteries.

WARNING! Never confuse the positive and negative poles on the batteries. Risk of arcing and explosion.

WARNING! The battery electrolyte contains extremely corrosive sulfuric acid. Protect your skin and clothes when charging or handling batteries.

Always use protective goggles and gloves. If battery electrolyte comes into contact with unprotected skin wash off immediately using plenty of water and soap. If battery acid comes in contact with the eyes, flush immediately with plenty of water and obtain medical assistance without delay.

Connecting and disconnecting the battery

Connecting

1 Connect the + cable (red) to the + pole on the battery.

2 Connect the – cable (black) to the – pole on the battery.

Disconnecting

1 Remove the – cable (black).

2 Remove the + cable (red).

Cleaning

Keep the batteries clean and dry. Contamination and oxide on the batteries and battery poles can cause stray currents, voltage drop and discharge, especially in wet weather. Remove oxidation from the battery poles and terminals, using a brass brush. Tighten the terminals securely and grease them with terminal grease or petroleum jelly.

Filling

The electrolyte level should be 5–10 mm (0.2– 0.4”) above the cell plates in the battery. Top up with distilled water as required. After filling, the battery should be charged for at least 30 minutes by running the engine at idle. Some maintenance-free batteries have special instructions, which must be followed.

Battery, Charging

WARNING! Risk of fire and explosion. Never allow an open flame or electric sparks near the battery or batteries.

WARNING! The battery electrolyte contains extremely corrosive sulfuric acid. Protect your skin and clothes when charging or handling batteries.

Always use protective goggles and gloves. If battery electrolyte comes into contact with unprotected skin wash off immediately using plenty of water and soap. If battery acid comes in contact with the eyes, flush immediately with plenty of water and obtain medical assistance without delay.

IMPORTANT! Observe the instruction manual for the battery charger carefully. To avoid the risk of electrochemical corrosion when an external charger is connected, the battery cables should be removed from the batteries before the charger is connected.

Always switch off the charging current before the charging clips are removed.

• Charge batteries if they have become discharged. During charging, unscrew the cell plugs but leave them in the plug holes. Ventilate well, especially if the batteries are charged in an enclosed space.

• If the engine is not used for a longer period of time, the batteries should be fully charged, then possibly trickle charged. Refer to the battery manufacturer’s recommendations). Batteries are damaged by being left discharged, and can also freeze and burst more easily in cold weather.

• Special instructions apply to boost charging. Boost charging can shorten battery life, and should therefore be avoided.

Storage

To prevent the engine and other equipment from being harmed during long (2 months or more) periods out of service, it must be conserved. Because it is of utmost importance that the conservation be performed correctly, we have compiled a checklist covering the most important points. 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.

CAUTION! Read the chapter on Maintenance before starting work. It contains instructions on how to carry out maintenance and service operations in a safe and correct manner.

WARNING! Conservations oils can be flammable and dangerous to inhale. Ensure good ventilation. Use a protective face mask when spraying.

IMPORTANT! Remember the following must be considered when cleaning with a high-pressure water jet: Never point high pressure water jets directly at seals, rubber hoses or electrical components. Never use the high-pressure function when washing the engine.

• For up to 8 month’s stoppage:

Change the oil and oil filter on the engine, then run the engine until warm.

More than 8 month's stoppage:

Conserve the lubrication and fuel systems with conservation oil. Refer to the section Conservation of the lubrication and fuel systems for more than 8 months’ stoppage.

• Make sure the coolant has adequate antifreeze properties. Top up as necessary. Alternatively, you can drain the coolant (also drain the coolant filter).

• Drain any water and contamination from the fuel filters and fuel tank. Fill the fuel tank completely, to avoid condensation.

• Disconnect the battery cables, clean and charge the batteries. Trickle charge the batteries while the equipment is in storage. A poorly charged battery can freeze and burst.

• Clean the outside of the engine. Do not use a high pressure washer for engine cleaning. Touch up paint damage with Volvo Penta original paint.

• Check and rust-proof any control cables.

• Put a note on the engine with the date, type of conservation and the conservation oil used.

• Cover the air filter, exhaust pipe and engine if necessary.

Bringing out of storage

• Remove any covers from the engine, air filter and exhaust pipe.

• Fill the engine with the correct grade of oil into the engine, as necessary, refer to  Technical Data, Lubrication System. Install a new oil filter if the filter was not changed during conservation.

• Install new fuel filters and bleed the fuel system.

• Check the drive belt(s).

• Check the condition of all rubber hoses, and retighten the hose clamps.

• Close the drain taps and install any drain plugs.

• Check the coolant level. Top up as necessary.

• Connect the fully charged batteries.

• Start the engine and warm it up at fast idle with no load.

• Check that no oil, fuel or coolant leakage occurs.

Conservation of the lubrication and fuel systems for more than 8 months’ stoppage:

• Drain the engine oil and fill up with  conservation oil* to just over the MIN marking on the dipstick.

• Connect the fuel suction and return hoses to a 1/3 full jerrican containing conservation oil* and 2/3 diesel fuel.

• Bleed the fuel system.

• Start the engine and run at a fast idle until about 2 liters (0.6 US gal) of the fluid in the jerrican have been used. Stop the engine and re-connect the fuel suction and return lines.

• Drain the conservation oil from the engine.

• Follow the other instructions on the previous page.

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