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Related Manuals for Volvo Penta TAMD162C
Summary of Contents for Volvo Penta TAMD162C
- Page 1 INSTRUCTION BOOK TAMD162C, TAMD163A, TAMD163P...
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Page 3: Table Of Contents
Contents Safety information ............ After operation ............23 Introduction ............... Propeller shaft brake ..........23 Important ..............When there is a danger of freezing ......24 General information ..........Mechanical safety clutch ......... 25 Running-in ..............Maintenance ............. 28 Fuel and lubricants ........... Periodic maintenance .......... -
Page 4: Safety Information
Turbo can cause serious personal injury. any opertion or information in this manual, please Foreign objects entering the intake ducts can also contact your Volvo Penta dealer who will be able to cause mechanical damage. assist with an explanation and demonstration of the operation. - Page 5 WARNING! The components in the electrical when attempting to start the engine (spark risk) system and in the fuel system on Volvo Penta and do not lean over any of the batteries. Refer to products are designed and manufactured to instructions in the Instruction Book.
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Page 6: General Information
In 1907. Quality, operating reliability and innovation have the case of MPM reverse gears, the oil screen should made Volvo Penta a world leader in the marine engine be cleaned after 10 and 50 hours of operation, and the industry. -
Page 7: Warranty And Guarantee
Wher- It is an absolute condition for the Volvo Penta Interna- ever you land or cruise, please show consideration and tional Limited Warranty to apply that the Pre-Delivery... -
Page 8: Certificated Engines
This information is necessary when engine. In order for Volvo Penta as the manufacturer to you contact your Volvo Penta or boat sales representa- take responsibility for engines in use, certain require- tive for service and spare parts. -
Page 9: Introduction
For a more detailed description of the engine, its fuel, lubrication, and cooling systems, etc., see under “Technical Specification” on pages 36–62. * Note: TAMD162C and TAMD163A can also be delivered for connection to keel cooling systems. Certification plate (TAMD163P) EMISSION APPROVED IN ACCORDANCE TO THE BODENSEE SCHIFFAHRTS ORDNUNG ANLAGE C. - Page 10 Fig. 1. TAMD162C from starboard (classifiable version). Air cleaner (ACL) Freshwater system bleed tap Emergency start button Stop solenoid Injection pump Intake manifold with charge air cooler (CAC) Fine fuel filters Coolant filler cap Expansion tank Heat exchanger Seawater pump...
- Page 11 1 2 3 Fig. 4. TAMD163A from port. Heat exchanger Coolant filler cap Electronics terminal box Coolant filter Oil filler, engine Charge Air Cooler (CAC) Turbobocharger Exhaust elbow for dry exhaust gases Oil filter, reverse gear Reverse gear, Twin Disc MG 516 Oil dipstick Lubricating oil filters Oil scavenging pump...
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Page 12: Instrumentation
Instrument panels supplied only with classifiable engines are not described in this section. See “Electrical system, function and installation, TAMD162” instead. The instrumentation is also supplied separately in sets if Volvo Penta instrument panels are not used. These sets in- clude three smaller panels for starting, stopping and alarm functions. - Page 13 Extra alarm panel This panel has four “windows”. If the acoustic alarm comes on, one of the windows starts to flash (red) to show the cause of the alarm. 15. Lubricating oil level too low. Top up to correct level before starting. 16.
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Page 14: Instrument Kits
Instrument kits The instrumentation is also supplied separately in sets. There are also the following three smaller panels for starting and stopping the engine and using the alarm functions. Control panel for pilot house (main panel) The pilot control panel has the same functions as the main panel (pos. -
Page 15: Controls
The code must not be divulged to unauthor- ized persons. Controls Volvo Penta uses two types of controls, single lever and dual lever. With single lever controls, both acceleration and reverse gear maneuvers are controlled using one lever, while the dual lever controls have a separate le- ver for each function. - Page 16 Single lever control Volvo Penta single lever controls have functions for ac- celeration and reverse gear maneuvers combined in one lever. When starting, for example, the shift function can be easily disengaged so that only the engine speed (rpm) is affected by the lever. When maneuvering the...
- Page 17 Engine speed (rpm) control on pump Engine speed can be controlled by hand with a single engine speed control on the pump. This control is pri- marily intended for engines with fixed engine speeds. To change its setting – hold the wheel. Undo the wing nuts and screw them one way or another until the cor- rect engine speed is achieved.
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Page 18: Fuel, Lubricating Oils, Engine Coolant
Diesel fuel in Sweden and City Diesel in Finland) can result in a reduction in output of approx. 5% and in- Use a mixture of 50% Volvo Penta antifreeze (glycol) crease in fuel consumption of approx. 2–3%. and 50% pure water (as neutral as possible). This mix- ture will protect against freezing to a temperature of approx. -
Page 19: Operation
Operation Before starting Open the cooling water intake sea cock. Check that all the drain cocks are closed and all the drain plugs are fitted. For location of cocks/plugs see illustrations on page 24. Open the fuel cocks. Check that no fuel, water or oil is leaking out. Check the coolant level. - Page 20 TAMD162C and TAMD163A with centrifugal seawater pump: Before starting for first time Fill seawater pump intake side with water. Turn on the main switches. Check the amount of fuel.
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Page 21: Starting The Engine
Starting the engine Warning! Never use start spray or similar to start the engine. There may be an explosion in the inlet manifold. Danger of personal injury. Single lever control: Check that the lever is in neutral “N”. This means that the throttle control is set to idling and the reverse gear is disengaged. -
Page 22: Starting Using Auxiliary Batteries
When warming up the engine, check that the instru- ments display normal values. The needle on the temperature gauge should rise slowly to operating temperature, 75 –90°C (167 – 194°F). At operating speed, the engine’s oil pressure gauge should show at least approx: 300–500 kPa (3.1 kp/cm = 43.5–72.5 psi) At low idle approx. -
Page 23: Checks During Operation
Checks during operation Check instruments. Normal operating values are: Engine coolant temperature Oil pressure, engine System voltage 75–90° (167–194° F) 300–500 kPa (3–5 kp/cm = 43.5– 72.5 psi), at low idle approx. 190 kPa (1.9 kp/cm = 27.5 psi) If the oil pressure drops, the temperature rises above the permitted values or there is a loss of charge, the alarm will sound and one of the warning lamps will start to flash to indicate the source of the malfunction. - Page 24 Note The equipment shown on this page can be ob- tained only for propulsion engines in working boats. Trolling valve If the reverse gear has a trolling valve (accessory), this should be used when the boat is to move very slowly. Engage the trolling valve to max.
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Page 25: After Operation
After operation Let the engine idle for a few minutes with the reverse gear in neutral after landing. This will even out the engine temperature and prevent local overheating which may cause the coolant to boil. Turn the key to stop position “S”. Release the key when the engine has stopped (key will spring back automatically into the 0 position). -
Page 26: When There Is A Danger Of Freezing
When there is a risk of freezing Check the antifreeze in the freshwater system after the engine has stopped if there is a risk of freezing. See un- der the heading. “Coolant” on page 16. Drain the water from the seawater system as described below. -
Page 27: Mechanical Safety Clutch
Safety systems Mechanical safety clutch Engaging the emergency clutch (get-you-home device) Twin Disc MG516 The MPM IRM 350A and Twin Disc MG516 have a Rotating parts. Take care not to avoid person- mechanical safety clutch for both Forward and Reverse al injury. - Page 28 * Note. Applies to classifiable engines. ** Classifiable engines are fitted with a fuel shut-off valve for normal stop). Emergency stop/-start (TAMD162C, TAMD163A) 1. Emergency stop (stop solenoid) 2. Emergency start button Emergency start* TAMD162C, TAMD163A There is an emergency start button at the starter motor.
- Page 29 The following components must be obtained by the boat Install pipe elbow (4) with seal at lower pump hole. owner, Volvo Penta does not keep them in stock. Make the other necessary pipes. Cut two hoses to the right length (5). Use two hose clamps on either end of the hoses.
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Page 30: Maintenance
For further information, see under the heading “Maintenance” in accordance with the respective section in “Technical Description”. New engine with reverse gear See “Running-in” on page 4. Layout of the maintenance schedule No. Action TAMD162C TAMD163P Instructions Info. pages Open vent screw (1). Pump with hand pump (2) until fuel containing no air flows out. - Page 31 “Condition Test”, which is part of the “Cost Control Programme”. This when and how to carry out maintenance. Always consult an authorized Volvo Penta ser- program is carried out every 6 months, and every other time in accordance with an ex- vice dealer, who will have the equipment and trained staff to help you.
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Page 32: Maintenance Schedule
The description applies generally for all engines unless otherwise stated. Some of the maintenance points deal with extra equipment or options, for example, for classifiable engines. The Maintenance schedule also shows which service intervals apply for the TAMD162C, TAMD163A or TAMD163P engines. - Page 33 No. Action TAMD162C, TAMD163P Instructions Info. TAMD163A pages Use CD, CE or CC engine oil, but not multigrade oil. For oil quality, see “Technical Data”. Use the engine scavenging pump with hose to the re- verse gear pipe for the dipstick. Or unsrew the drain plug. Check the oil level with the dipstick.
- Page 34 No. Action TAMD162C, TAMD163P Instructions Info. TAMD163A pages Adjustments must be made with the engine stopped. Remove the inspection cover. Release the catch (A) and turn the adjust- 11. Check/adjust disengagea- er ring (B) clockwise. Engage the catch. The clutch plates must not slip after engagement.
- Page 35 No. Action TAMD162C, TAMD163P Instructions Info. TAMD163A pages Open vent screw (1). Pump with hand pump (2) until fuel containing no air flows out. Then pump a further 10–20 times with the hand pump. Tighten the venting screw (1). Check for leaks. If the engine does not start, vent the pressure pipes on the injectors.
- Page 36 No. Action TAMD162C, TAMD163P Instructions Info. TAMD163A pages 23. Inspect/Replace impeller Close the sea cock and drain the water from the freshwater system. wheel in the seawater pump and in the bilge/scavenging pump where fitted. Note. Does not apply to centrifugal type seawater pumps.
- Page 37 No. Action TAMD162C, TAMD163P Instructions Info. pages TAMD163A Take care that no contaminants enter the engine. Reset the air cleaner 29. Check/replace air cleaner (ACL) filter indicator by pressing the button. (ACL) filter. Note. The filter must be changed when the ACL indicator shows completely red field when engine stopped.
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Page 38: Technical Description
Technical description Engine Cylinder block The cylinder block and crankcase is cast as one unit us- Cylinder heads ing a special alloy cast iron. This construction together with reinforcements in the form of steel plates (foot plates) make for great durability. TAMD163P as of and incl. - Page 39 Pistons The pistons are of aluminum and have two compression rings and one oil scraper ring. The upper compression ring, a Keystone ring, is coated with molybdenum which contributes to reduced cylinder wear. There is a ring carrier of a special tempered cast iron alloy for the up- per compression ring which considerably increases the service life of the pistons, rings and liners.
- Page 40 Alternatively the crankcase ventilation emissions can be removed from the engine compartment by a hose in the same way as for the TAMD162C, -163A. A pipe bend with hose mounting is supplied with the engine for this reason. This can be installed on the rear inspection hatch on the right of the engine instead of the standard crankcase ventilation device.
- Page 41 Turbocharger Charge air cooler (CAC) The turbocharger (TC) unit consists of an exhaust tur- The intake air enters the charge air cooler (CAC) after bine, bearing housing and compressor. compression in the turbocharger. The charge air cooler lowers the temperature of the air and thereby consider- The turbine wheel is rotated by the stream of exhaust ably improves the output ratio as the volume of the air is gas entering the turbine housing on its way to the ex-...
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Page 42: Maintenance, Engine
TAMD163A, TAMD163P: Filter insert replacement Air cleaner (ACL) replacement 1. Pressure drop indicator 2. Reset button TAMD162C Detach clamps on the air cleaner (ACL) mounting. Remove the old air filter. Install the new filters. Tighten the clamps. Reset the pressure drop indicator by pressing in the button. - Page 43 However when cleaning/replacing the filter a cursory check of the turbocharger may be carried out as follows: TAMD163A, TAMD163P: Remove the air cleaner (ACL) filter housing. TAMD162C: Remove the air cleaner (ACL)and its holder. Warning! Check that the turbocharger’s impeller is stationary before checking.
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Page 44: Lubrication System
Technical description Lubrication system The engine has a pressurized lubrication system with piston cooling. The oil pump is located at the front end of the oil sump and driven via a gear from the engine’s timing gears. The lubricating oil is continuously filtered through two full-flow oil filters and one partial flow filter. The injection pump camshaft housing and regulator housing are connectied to the engine’s pressurized lubrication system and are lubricated directly, as is the turbocharger. - Page 45 Oil cooler The engine oil temperature is maintained at a relatively low level by the oil cooler which ensures less wear and retention of the oil’s lubricating properties. 1. Hot oil from the engine lubrication system 2. Cooled oil to the engine lubrication system 3.
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Page 46: Maintenance, Lubrication Systems
Maintenance – Lubrication System Oil Change – Engine The oil should be changed when the engine is hot. Warning! Hot oil can cause burns. Engines with manual oil scavenger pump: Turn the knob to position (A) for engine pumping, see illustration. - Page 47 Replacement of full-flow oil filters Oil Change – Reverse Gear while engine is running Connect a hose from the oil scavenging pump to the oil dipstick tube on the reverse gear. Turn the knob under (switchable filters) the pump housing to the position for pumping the re- Note: Place a container beneath the filters when re- verse gear (B).
- Page 48 Reverse gear oil filter replacement MPM IRM350A, Twin Disc MG 516 Remove the oil filter using the special tool. Moisten the filter gasket with oil and screw into position by hand. Tighten filter in place with a further 3/4 turn. MPM IRM 350A 1.
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Page 49: Fuel System
Technical description Fuel system The fuel is drawn up by the feed pump from the fuel tank through the pre-filters and is forced through the fine filters to the injection pump. The injection pump then forces the fuel at high pressure into the injectors. The fuel is atomized when it is sprayed into the combustion chamber where a powerful air rotation assists uniform combustion of the mix- ture. - Page 50 Injection pump (1) Hand pump (3) The injection pump is located on the right side of the en- The feed pump’s hand pump can be used on a stopped gine and is driven by the timing gears. The pump, which engine to pump fuel to the filters and injection pump when venting the fuel system, for example after replac- is of piston type, has a centrifugal governor.* This gov-...
- Page 51 Injectors The job of the injectors is to atomize and spray the fuel, Injectors metered precisely by the injection pump, into the en- 1. Injector mounting gine’s combustion chambers. This injection takes place 2. Hollow screw under extremely high pressure so that atomization and 3.
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Page 52: Maintenance, Fuel System
Maintenance – Fuel system Fuel pre-filter. Checking/draining Check the fuel filter and drain off any water and contam- inants through the drain plugs (5). The engine should be off and allowed to stand for a few hours before carrying out this check. Install plugs. Fuel pre-filter. - Page 53 Switchable fine fuel filters (replacement while engine is running) Place a container beneath the fuel filters. Carefully clean the filter mounting. Valve lever (2) in the filter cover to its right end position. Unscrew the left fuel filter and discard it. If neces- sary, use special tool to remove.
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Page 54: Cooling System
A freshwater filter which is connected as a partial flow filter, maintains the correct pH value in the coolant and protects the coolant system from clogging and corrosion. * Note: TAMD162C and TAMD163A can also be delivered for connection to keel cooling systems. 1. Seawater pump 6. - Page 55 The TAMD162C and TAMD163A can be equipped with ture. The heat exchanger insert consists of a number of a centrifugal type seawater pump. This pump has an cooling pipes which the seawater flows through.
- Page 56 Oil cooler, engine Oil cooler, reverse gear The lubricating oil transports heat from the high tem- The reverse gear oil cooler is installed on a mounting perature parts in the engine and equalizes the temper- on the right side of the reverse gear. The cooler is con- ature differences within the engine.
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Page 57: Maintenance. Cooling System
TAMD163P: On the front side of the collector pipe from the cylinder heads 2. On the thermostat housing cover (Not TAMD162C) 3. TAMD163A (keel cooled ): On pipe at the charge air cooler Seawater filter 4. On the coolant pipe from the turbocharger... - Page 58 Cleaning the charge air cooler (CAC) Close the sea cock and drain the water from the seawater system. Remove the end cover and pipes to the heat exchanger and seawater pump. Connect a hosepipe to the charge air cooler insert drain cock on the charge air cooler rear end.
- Page 59 Checking/replacing zinc anodes Close sea cock before working on cooling system. Open the drain cock (A) on the reverse gear’s oil cooler. Unscrew and inspect the zinc anodes (Z) on: – heat exchanger’s starboard side. – heat exchanger’s port side –...
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Page 60: Electrical System
The fuses break the circuit on overload and can be reset by pushing in the buttons on the side of the ter- minal box. The TAMD162C (with a stop solenoid) is also fitted with a ceramic 8A fuse for the stop solenoid. - Page 61 The voltage increases at low temperatures and is reduced at higher temperatures. Fuel shut-off valve TAMD162C*, TAMD163A, -163P – for normal stop The engine is stopped via a solenoid valve (fuel shut-off valve) which is activated during stopping. The valve...
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Page 62: Electrolytic Corrosion
Stop solenoid TAMD162C – for normal stop* or as emergency stop** TAMD163A – as emergency stop** Normal stop: The solenoid is connected via the stop relay when the key switch is turned and held in the stop position (S). Emergency stop: The solenoid is engaged by pressing the separate “STOP”-button at the control position, in... -
Page 63: Electrical System - Important
Charging circuits must not be switched over while the engine is running, for the same reason. To simultaneously charge two independent battery circuits, fit a Volvo Penta charge distributor to the regular generator (accessory). 2. Batteries Never mix up the positive and negative battery terminals when installing. -
Page 64: Maintenance. Electrical System
Also read the section entitled “Electrical sys- nections. If necessary, spray these connections with a tem – Important” on the previous page. water-repellent spray (Volvo Penta Universal oil). Charge condition Resetting semi-automatic fuses Check the batteries’ charge condition using a hydrome- Semi-automatic fuses ter. -
Page 65: Wiring Diagrams
Wiring diagrams This section does not include wiring diagrams for the TAMD162C and TAMD163A engine with classifiable electrical system. For more information refer to the manual “Electrical systems, Function and installation”. Block diagram A. Main panel B. Auxiliary panel C. Control panel for auxiliary control position (Flying Bridge) D. - Page 66 Instrument panel, (Main panel) Instrument panel lighting Cable color Voltmeter Blue Oil pressure gauge Engine coolant termperature (ECT) gauge Connector for connecting extra warning display (accessory) Light-blue Control module (alarm) Black Warning light, engine coolant termp. (ECT) Warning light, oil pressure Brown Warning light, charge Control lamp (not used)
- Page 67 Instrument panel for alternative control position (Flying Bridge) Instrument panel lighting Connector for connecting extra warning display (accessory) Control module (alarm) Warning light, engine coolant termp. (ECT) Warning light, oil pressure Warning light, charge Control lamp (not used) Instrument lighting switch Alarm test/acknowledgement switch Tachometer with built-in...
- Page 68 Instrument kit for pilot house Control module (alarm) Cable color Warning light, coolant temperature Blue Warning light, oil pressure Warning light, charging Light-blue Control lamp (not used) Connector for connecting extra Brown warning display (accessory) LBN = Light-brown Instrument panel lighting Connector (cannot be opened) Green Engine coolant termperature (ECT) gauge...
- Page 69 Flying Bridge instrument kit Control module (alarm) Cable color Connector for connecting extra Blue warning display (accessory) Warning light, engine coolant termp. (ECT) Light-blue Warning light, oil pressure Warning light, charge Brown Control lamp (not used) Light-brown Alarm Alarm test/acknowledgement switch Green Instrument lighting switch Connector (cannot be opened)
- Page 70 TAMD162C*, engine (non-classifiable engine specification) * Applies up to and incl. engine No. 1101052586/xxxx. Battery Cable color Main switch Blue Starter motor Semi-automatic fuses (8A)* LBL = Light-blue Black Generator (GEN) Stop relay (16S)* Brown VO = Violet Start relay (16MS)
- Page 71 TAMD162C*, TAMD163A, engine (non-classifiable engine specification) TAMD163P, engine * Applies as of engine No. 1101052587/xxxx. Cable color Battery Main switch Blue Starter motor Generator (GEN) LBL = Light-blue Black Starter relay* Brown VO = Violet Semi-automatic fuses (8A)* Oil pressure sender, reverse gear (accessory)
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Page 72: Inhibiting
Bringing out of storage Boat unused max. 8 months: Replace the Remove any protective cover over the engine, air lubricating oil filter and fill with Volvo Penta lubri- intake and exhaust pipe. cating oil to the normal level. Warm the engine up Remove any external inhibitors using white spirit. -
Page 73: Troubleshooting
Fault-tracing 1. Engine does not start Starter motor does not turn engine over CAUSE REMEDY The reverse gear is not disengaged (applies to Put the reverse gear control lever into neutral control with neutral position switch) Discharged batteries Charge/replace the batteries (or connect up auxiliary batteries as shown on page 20) Main switches off Switch on the main switches... - Page 74 2. Engine starts but stops again/ runs unevenly CAUSE REMEDY Air in fuel system Vent the fuel system as shown on page 51 Fuel starvation or no fuel – fuel cocks closed Open the fuel cocks – fuel tank empty/wrong tank on line Fill with fuel/connect the correct fuel tank –...
- Page 75 – incorrectly adjusted Contact authorized service personnel 6. Engine runs on CAUSE REMEDY TAMD162C: Stop solenoid fuse defective Replace the fuse (8A) One of the semi-automatic fuses in the junction box Reset the fuse by pressing in the button has tripped Poor contact/break open circuit in wiring Rectify any open-circuits/loose connections.
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Page 76: Technical Data
Technical Data General Type designation TAMD162C TAMD163A TAMD163P-A No. of cylinders ............ Cylinder displacement .......... 16.123 dm (liter), 16.123 dm (liter), 16.123 dm (liter), (984 in (984 in (984 in Firing order ............1–5–3–6–2–4 1–5–3–6–2–4 1–5–3–6–2–4 Rotation, viewed from in front ...... - Page 77 Fuel system TAMD162C TAMD163A TAMD163P-A Injection pump Designation ............PE6P130A720RS7150 PE6P130A720RS7571 PE6R130/720RS 1506 Injection angle ..........23° ±0.5° B.T.D.C. 17° ±0.5° B.T.D.C. 21° ±0.5° B.T.D.C. Injectors Injector holders ..........KBAL 116 S 66 KBAL 116 S 75 KBAL 116 S 75 Nozzles .............
- Page 78 ..........82°C (180°F) 73–77°C (163–171°F) fully opening at ..........95°C (203°F) 86–90°C (187–194°F) Scavenger pump/bilge pump TAMD162C, TAMD163A, TAMD163P-A Type ..............Impeller Clutch ..............Electromagnetic Capacity (liters/minute) at engine speed: Column pressure 5 m (16.4 ft) Column pressure 10 m (32.8 ft) 900 rpm.
- Page 79 Twin Disc Type designation ..........MG5114A MG516 Gear ratios ............1.48:1, 1.92:1, 2.50:1 3.07.1; 3.50:1; 4.04:1; 4.52:1; 5.05:1; 6.00:1 Angle (output shaft) ..........7° 0° Oil capacity, approx..........10.5 liters (2.3 Imp. gals/ 26 liters (5.7 Imp. gals/6.85 US gals) 2.75 US gals) Oil grade (in accordance with API system) ..
- Page 80 Volvo Penta accessories Below is a range of products available as accessories. Note Not all accessories can be fitted to all engines. Ask your Volvo Penta service dealer for advice. Volvo Penta lubricating oils: – VDS*, SAE 15W/40 Volvo Penta antifreeze (glycol) for the freshwater sys-...
- Page 81 Maintenance – Equipment, Accessories Controls On Volvo Penta controls, the control lever has an adjust- able friction brake. Lever movements can thereby be adapted according to personal requirements. Dual lever controls have individually adjustable friction brakes for each lever. Adjusting the friction brake...
- Page 82 Notes ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................