Volvo Penta TAMD103A Operator's Manual
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Volvo Penta TAMD103A Operator's Manual

Volvo Penta TAMD103A Operator's Manual

Genset engine
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OPERATOR'S MANUAL
TAMD103A Genset Engine
Non-classifiable control system

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Summary of Contents for Volvo Penta TAMD103A

  • Page 1 OPERATOR’S MANUAL TAMD103A Genset Engine Non-classifiable control system...
  • Page 2 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

  • Page 3: Foreword

    For information on genset and/or generator specific items refer to generator information supplied by genset builder and/or generator manufacturer. In case of contradictions, the information in this Volvo Penta Operator’s Manual overrules any information given in the documentation provided by the generator manufacturer. Do not hesitate to consult your Volvo Penta dealer.

  • Page 4: Table Of Contents

    Safety regulations during engine operation ..... 6 Cooling system TAMD103A RC ......38 Safety directions for maintenance and service ..7 Cooling system TAMD103A KC (1,5 circuit) ..38 Warning labels ............. 10 Freshwater system ..........39 General information of the coolant ...... 39 Introduction ............

  • Page 5: Safety Information

    This Operator’s Manual is only valid for the auxiliary engine built in the Volvo Penta factory. Make sure you are in possession of the right operator’s manual before reading on. If this is not the case, please get in touch with your Volvo Penta dealer.

  • Page 6: Safety Regulations During Engine Operation

    Get Avoid violent and rapid rudder movement and gear in touch with your Volvo Penta dealer for help in ob- shifting. There is a risk of the passengers falling down taining the best solution for your vessel.

  • Page 7: Safety Directions For Maintenance And Service

    More detailed service literature is avail- able from your Volvo Penta dealer. Never perform a fitted. The rotating compressor wheel in the turbochar- ger can cause severe personal injury.
  • Page 8 Safety information Start spray Lubricating system Never use start spray or similar start help. Explosions Hot oil can cause burn injuries. Avoid skin contact can occur in the intake manifold. Risk for personal with warm oil. Make sure the lubricating system is de- injury.
  • Page 9 Safety information Handle antifreeze carefully! Antifreeze contains alkali. Avoid contact with skin and eyes to prevent personal injury. Dispose of drained antifreeze coolant according to local regula- tions. For disposal, consult your dealer. Dress properly for the job! Wear protective devices - hard hat, face shield, safety shoes, goggles, heavy gloves, ear protectors, etc.

  • Page 10: Warning Labels

    Safety information Warning labels The engine carries ‘Warning Labels’ at places where you are required to pay special attention. Please read them carefully and make sure you understand the content of each label and the meaning of their position. Make sure the labels are legible. If you find any letter or picture illegible in a label, remove soil from the label, or replace it.

  • Page 11: Introduction

    Introduction This operator’s manual has been produced to give you the greatest benefit of your Volvo Penta auxiliary engine. It contains the information necessary to handle and maintain your engine in a safe and correct manner. We would like you to read this operator’s manual thoroughly and learn how to handle the engine, controls and other equip- ment in a safe manner before starting the engine.

  • Page 12: Certified Engines

    Warranty and Service Book. Note that AB Volvo Penta’s responsibility is limited to what is specified in the Warranty and Service Book. Read it carefully as soon as possible after delivery. It contains important information concerning the warranty card, servi- ce, maintenance and what the owner is responsible to be aware of, check and perform.

  • Page 13: Presentation

    Presentation TAMD103A HE Genset Engine TAMD103A HE is an in-line, direct injection, 6-cylinder, 4-stroke marine diesel engine. It has a turbocharger and is equipped with either a heat exchanger for thermostat regulated freshwater cooling or connections for keel cooling. An optimal combination of combustion chambers, fuel injection system, effective turbocharger and charge air cooling, provide excellent fuel consumption over the whole range of power output.

  • Page 14: Tamd103A Rc Genset Engine

    Presentation TAMD103A RC Genset Engine TAMD103A RC is an in-line, direct injection, 6-cylinder, 4-stroke marine diesel engine. It has a turbocharger and is equipped with radiator cooling. The engine has a charge air cooler. The charge air cooler lowers the temperature of the engine’s induction air, after compression in the turbocharger.

  • Page 15: Tamd103A Kc Genset Engine

    Presentation TAMD103A KC Genset Engine TAMD103A KC is an in-line, direct injection, 6-cylinder, 4-stroke marine diesel engine. It has a turbocharger and is equipped with keel cooling. The engine has a charge air cooler. The charge air cooler lowers the temperature of the engine’s induction air, after compression in the turbocharger.

  • Page 16: New Engine Initial Service

    New engine initial service General Before starting a new or reconditioned engine for the first time, give it an initial inspection. This to guarantee your own safety as well as the maximum service life of the engine. External inspection Electrical wiring 1.

  • Page 17: Starting

    Starting Before starting WARNING! Before starting the genset make sure that neither people, nor tools, are in contact with moving parts of the engine or the generator. Notify the people in the vicinity of the genset when starting. WARNING! Make sure that you know how to stop the genset before you start it (in case of emergency). If you are starting the genset for the first time, be prepared to stop the engine immediately in case abnormal noise should occur during start up.
  • Page 18 Starting Start using auxiliary batteries WARNING! Ventilate well. Batteries generate oxyhydrogen gas, which is extremely flammable and explosive. A short circuit, naked flame or spark can cause a powerful explosion. Never reverse the polarity of the battery. Risk of sparks and explosion. 1.

  • Page 19: Non-Classifiable Control System

    Non-classifiable control system This chapter describes the standard, non-classifiable control system available for your genset. Instrument box 1. Oil pressure gauge 2. Low coolant level warning (optional) 3. Engine coolant temperature gauge 4. High coolant temperature warning (optional) 5. Tachometer 6.

  • Page 20: Starting Procedure

    Non-classifiable control system Starting procedure Instrument panel 1. Push the “Interlock button” (1) to check the warning lamps. 2. Hot engine Push the interlock button (1) and hold it while pushing the starter button (2). Cold engine Push the interlock button (1) and hold it for approx.

  • Page 21: Operation

    Operation General Learn how to handle the engine, controls and other equipment in a safe and correct manner before starting the engine WARNING! Stay clear of all rotating and moving WARNING! A hot engine may cause burns. parts during operation. Beware of hot surfaces.

  • Page 22: Stopping

    Stopping Allow the genset to run at no load for a couple of minutes before turning it off. This will keep the engine temperatu- re in balance and prevent it from boiling. IMPORTANT! The procedure described above is IMPORTANT! If the genset stops abnormally, try especially important if the genset has been run to locate the problem and make the repairs at heavy loads.

  • Page 23: Maintenance

    Volvo Penta recommends that accurate maintenance records are kept. With accurate maintenance records your Volvo Penta Dealer can help in fine tuning the recommended service intervals to meet the specific operating situ- ation. This should result in a lower engine operation cost.

  • Page 24: Maintenance Schedule

    Check the manometer and change filter if necessary, but change filter at least every 1000 operating hours or at least once a year. To be carried out at an authorized Volvo Penta workshop. Refer to chapter ”Technical Data: Lubrication oil specification”...
  • Page 25 Check the manometer and change filter if necessary, but change filter at least every 1000 operating hours or at least once a year. To be carried out at an authorized Volvo Penta workshop. Refer to chapter ”Technical Data: Lubrication oil specification”...

  • Page 26: Recommendation Of Daily Operation Records

    Maintenance: General Recommendation of Daily Operation Records Daily recording is a preventive maintenance program and when comparing values with engine history it will help you recognize conditions, signs or indications of approaching trouble. Daily operation records also make trouble shooting easier and will lessen the down time (to save time and money for servicing). Items to be recorded The following items are recommended to be recorded once a day:...

  • Page 27: Engine

    Maintenance: Engine Engine General inspection Make a habit of “visually” inspecting the engine and engine room before starting the engine and after stop- ping when the engine has been turned off. This will help you to quickly detect abnormalities that have oc- curred or are about to occur.

  • Page 28: Checking/Adjusting/Changing Drive Belts

    Maintenance: Engine Checking/Adjusting/Changing drive belts WARNING! Stop the engine before commencing maintenance work. General Check belt tension and condition regularly. If the belt is too taut it can damage bearings and if it is too loose it may slip. Check and adjust after operation when the belt is warm.

  • Page 29: Lubrication System

    Maintenance: Lubricating system Lubrication system Oil change intervals can vary from 60 to 500 hours, depending on oil grade and sulfur content of the fuel. Note that oil change intervals must never exceed a period of 12 months. For information about oil grade, change volume, change interval and viscosity, please see “Technical data: Lubri- cation oil specification”.

  • Page 30: Changing Engine Oil

    Maintenance: Lubricating system Changing engine oil Always follow the recommended oil change interval and change the oil filter at the same time. IMPORTANT! Use only oil of the recommended grade. The engine is equipped with a manual and an electric oil bilge pump that can be used as follows: Manual oil bilge pump Turn the knob under the pump housing to position (1)

  • Page 31: Changing Oil Filter

    Maintenance: Lubricating system Changing oil filter WARNING! Hot oil and hot surfaces can cause burns. IMPORTANT! Place a receptacle under the fil- ters when dismantling to avoid oil spill. NOTE! Leave the old filter to a destruction plant. Standard oil filters 1.

  • Page 32: Fuel System

    Maintenance: Fuel system Fuel system Use only fuel recommended in the fuel specification. Please refer to “Technical Data: Fuel Specification”. Always observe cleanliness when refuelling and working with the fuel system. All work concerning the engine injection pump or injectors is to be carried out at an authorized workshop. Breaking the seal on the injection pump will void the warranty.

  • Page 33: Changing Fuel Filters

    Maintenance: Fuel system Changing fuel filters Clean the filter bracket and place a receptacle under the filter. NOTE! Leave the old filters to a destruction plant. Standard fuel filters 1. Unscrew the filters. 2. Make sure the new filters are absolutely clean and that the gaskets are free from faults.

  • Page 34: Checking The Fuel Pre-Filter

    Maintenance: Fuel system Checking the fuel pre-filter WARNING! Working on or approaching a running engine is a safety hazard. Beware of rotating parts and hot surfaces. The fuel pre-filter/water separator are accessories and available as single or dual models. The dual filter is equipped with a pressure gauge (1) indicating when it is time to change the filter insert.

  • Page 35: Changing Filter Elements Of The Fuel Pre-Filter

    Maintenance: Fuel system Changing filter elements of the fuel pre-filter The fuel pre-filter/water separator are accessories and available as single or dual models. The dual filter inserts can be changed while running as the flow of fuel can be cut off to one filter container at a time.

  • Page 36: Air Inlet And Exhaust System

    Maintenance: Air inlet and exhaust system Air inlet and exhaust system Turbocharger inspection WARNING! Check the turbocharger only when the engine is cool and the compressor wheel is not running. Check shaft play, take a hold of the compressor wheel nut and turn the wheel to feel rattle and listen for abnormal noise.

  • Page 37: Cooling System, General

    It cools the internal cooling system in an engine mounted or externally mounted heat exchanger. The Volvo Penta Genset comes with an internal freshwater system connected to an engine mounted heat exchan- ger, a radiator cooler, or prepared for external cooling, e.g. keel cooling or central cooling.

  • Page 38: Cooling System Tamd103A Rc

    The system must be filled with Volvo Penta coolant and can NOT be connected to a central cooling system or be directly cooled by rawwa- ter.

  • Page 39: Freshwater System

    Maintenance: Freshwater system Freshwater system The freshwater system is the internal engine cooling system. It is a closed system and must always be filled with a coolant that protects it against internal corrosion and freezing when the climate demands. The circulation pump ensure good circulation in the system. The thermostat will start to open at a certain tempe- rature and will be fully open when the engine has attained normal operating temperature.

  • Page 40: Anti-Freeze Mixture

    Maintenance: Freshwater system Anti-freeze mixture When there is risk of freezing, a mixture of 50% Volvo Penta anti-freeze (glycol) and 50% water (complying with ASTM D4985) must be used. This mixture will protect against freezing down to approx. –40 ° C and is to be used all year round.

  • Page 41: Checking The Coolant Level

    Maintenance: Freshwater system Checking the coolant level WARNING! Never open the pressure cap when the engine is warm. Steam or hot fluid may spurt out. IMPORTANT! Check the coolant level on a cold stationary engine. Make sure the coolant level is approx. 5 cm (2") be- low the top of the filler cap.

  • Page 42: Draining The Coolant

    Maintenance: Freshwater system 5. When coolant that is free from air flows out, the ventilation cocks must be closed. Refit the plug (2) in the heat exchanger. 6. Cease filling when the correct level is attained. 7. Start the engine and run it until it reaches operat- ing temperature.

  • Page 43: Flushing The Freshwater System

    Maintenance: Freshwater system Flushing the freshwater system The system should be flushed before changing cool- ant to avoid inferior cooling performance due to de- posits in the cooling system. IMPORTANT! Certain parts of the system are made of light alloy. Chemical additives must therefore not be used when cleaning.

  • Page 44: External Cleaning Of Charge Air Cooler

    Maintenance: Freshwater system External cleaning of charge air cooler (engines with radiator) 1. Remove the required guards to access the ra- diator. 2. Clean with water and a mild cleaning agent. Use a soft brush. Take care not to damage the cooling vanes.

  • Page 45: Rawwater System

    Maintenance: Rawwater system Rawwater system The rawwater system is the engine’s external cooling system. The rawwater pump draws in water via the rawwater intake and pump it on through the charge air cooler, oil cooler and the heat exchanger. The system is protected against galvanic corrosion by zinc anodes located in the charge air cooler, oil cooler and in the heat exchanger.

  • Page 46: Checking/Changing Zinc Anodes

    Maintenance: Rawwater system Checking/Changing zinc anodes WARNING! Risk of water entering. Close the rawwater cock before starting work on the rawwater system. 1. Close the rawwater cock. 2. Screw out the zinc anodes on the: • Heat exchanger end cover – 2 pcs. •...

  • Page 47: Checking/Changing Impeller

    Maintenance: Rawwater system Checking/Changing impeller WARNING! Risk of water entering. Close the rawwater cock before starting work on the rawwater system. 1. Remove the end cover of the pump. Pull and twist out the impeller with adjustable pliers. 2. Inspect the impeller. Change the impeller if there are any visible cracks or other defects.

  • Page 48: Checking Drain Hole Of Charge Air Cooler

    Maintenance: Rawwater system Checking drain hole of charge air cooler Condensation can form in the charge air cooler during operation. The condensation is drained from a nipple on the bottom of the charge air cooler. Make sure the nipple is not blocked. IMPORTANT ! If considerable amounts of water run out of the drain hole, the insert must be re- moved and test pressurised.

  • Page 49: Cleaning Heat Exchanger

    Maintenance: Rawwater system Cleaning heat exchanger WARNING! Close the sea cock and drain off the water in the sea and freshwater system be- fore working on the cooling system. Clean if there are signs of clogging, a gradual increa- se in engine temperature and high rawwater pressu- re.

  • Page 50: Electrical System

    Checking the electrical wiring Make sure electrical connections are tightened, dry and free from oxide. If necessary, spray these con- nections with water-repellant (Volvo Penta all-round oil). Main switches The main switches must never be turned off until the engine has been stopped.

  • Page 51: Batteries

    Maintenance: Electrical system Batteries WARNING! Fire and explosion hazard. Batteries must never be exposed to open flames or sparks. WARNING! Never confuse the positive and neg- ative poles on the batteries. Risk of arcing and explosion. WARNING! Battery electrolyte is highly corro- sive.
  • Page 52 Maintenance: Electrical system Battery charging WARNING! Explosion risk! Hydrogen is given off when batteries are charged. This forms an ex- plosive mixture with air. A short circuit, open flame or spark could cause a violent explosion. Ventilate well. WARNING! Battery electrolyte is highly corro- sive.

  • Page 53: Inhibiting

    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. WARNING! Read the chapter “Maintenance” thoroughly before starting any maintenance work. It contains directions for performing maintenance in a safe and correct manner.
  • Page 54 Inhibiting Conserving the lubricating and fuel systems for stops longer than eight months: 1. Drain the oil from the engine and fill with preservative* to just over the MIN mark on the dipstick. 2. Connect suction and return fuel lines to a fuel can filled with 1/3 preservative* and 2/3 diesel fuel.

  • Page 55: Troubleshooting

    A number of symptoms and possible causes for engine disturbances are described in the table below. If faults or hitches arise that you cannot solve alone, you must always get in touch with your Volvo Penta dealer. Symptoms and possible causes...

  • Page 56: Technical Data

    Technical Data TAMD103A Genset engine General Number of cylinders ..........Displacement ............9.6 litres (586 in Valve clearance (cold or warm engine): inlet ................ 0.50 mm (0.020 in) exhaust ..............0.80 mm (0.031 in) Compression pressure at starter motor speed (230 rpm) ......

  • Page 57: Fuel Specification

    Technical Data Fuel specification Fuel must comply with national and international standards at the least, e.g.: JIS KK 2204....... Type1, Type2, Type3 ASTM, D975 ........No.1-D, No.2-D EN590 ......with national environment and cold requirements Note! It is necessary to use a fuel that has a pour point suitable for ambient temperature during the operation of the engine.

  • Page 58: Lubrication Oil Specification

    Standard Control System Lubrication oil specification Oil change volume Deep sump Shallow sump Oil capacity incl. oil filters, approx: no engine inclination ........50 liters (13.2 US gals) 38 liters (10.0 US gals) volume difference min.–max....20 liters (5.3 US gals) 13 liters (3.4 US gals) engine inclination 15°...

  • Page 59: Coolant Specification

    The mixture of Volvo Penta Coolant and water should contain 40-55% Volvo Penta Coolant. If the coolant contains less than 40% Volvo Penta Coolant, the cooling galleries in the engine or radiator may be blocked by contamination. If the coolant contains more than 60% Volvo Penta Coolant the cooling ability of the coolant mixture is impaired, this may cause the engine to overheat.

  • Page 60: Identification Numbers

    Technical Data Identification numbers Type plates with identification numbers and labels with information on certificates and classification, can be found on the engine. This information must always be used as a reference when ordering service and spare parts. Engine plate Product designation (1) ..........

  • Page 61: Notes

    Notes ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
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