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Summary of Contents for Volvo Penta TAMD122A
- Page 1 OPERATOR’S MANUAL TAMD103A TAMD122A, TAMD122P...
- 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 Volvo Penta marine engines are used all over the world today. They are used in all possible operating conditions for professional as well as leisure purposes. That’s not surprising. After more than 90 years as an engine manufacturer and after delivering over 500,000 marine engines, the Volvo Penta name has become a symbol of reliability, technical innovation, top of the range performance and long service life.
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Page 4: Table Of Contents
Alarms and fault indication ........20 Cruising speed ............ 21 Manoeuvring ............21 Accessories ............23 © 2004 AB VOLVO PENTA We reserve the right to make revisions. Printed on environment-friendly paper (Cover: National Administration of Shipping and Navigation, permit 9809095) -
Page 5: Safety Information
If anything is still not clear or if you are not sure of any points, please get in touch with your Volvo Penta dealer for assistance. This symbol is used throughout the operator’s manual and on the product to bring your atten- tion to points of safety-related information. -
Page 6: Boat Trips
Safety information Safety regulations for boat trips The new boat Filling fuel Read operator’s manuals and other information ac- There is a risk of fire and explosion when filling fuel. companying the new boat thoroughly. Accustom Smoking is prohibited and the engine must be turned yourself with handling the engine, controls and other off. - Page 7 Safety information Carbon monoxide poisoning Most modern boats, however, are designed in such a When a boat is moving forward, it will cause a certain way that this problem is very rare. If suction should vacuum to form behind the boat. In unfortunate cir- arise anyway, do not open hatches or portholes at the cumstances, the suction from this vacuum can be so fore of the boat.
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Page 8: Maintenance And Service
Always read and follow the di- Never perform a task unless you are absolutely sure rections on the packaging. how it is to be carried out, call your Volvo Penta deal- er for assistance instead. Work performed on the fuel system must be done on a cold engine. - Page 9 Safety information Hot surfaces and fluids Fuel system A hot engine always involves risk for burn injuries. Always protect your hands when carrying out leak de- Take care with hot surfaces. E.g.: exhaust manifold, tection. Escaping fluids under pressure can pierce turbocharger, oil pan, charge air pipe, starting heater, bodily tissue and cause serious injury.
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Page 10: Introduction
Introduction The operator’s manual has been produced to give you the greatest benefit of your Volvo Penta marine 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 casting off for your maiden voyage. -
Page 11: Certified Engines
Warranty liability will otherwise be declined completely or fully by AB Volvo Penta. Get in touch with your Volvo Penta dealer if you have not received a Warranty and Service Book or a copy of the warranty card. -
Page 12: Identification Numbers
Product number (3) ......................Transmission Product designation (4) ....................... Serial number (5) ......................... Product number (6) ......................Engine and transmission label Engine plate (TAMD122A, TAMD122P) Certification plate (TAMD122P): EMISSION APPROVED IN ACCORDANCE TO THE REQUIREMENTS OF SAV. xxxxxxxxxx APPROVAL NO:... -
Page 13: Presentation
Presentation The exhaust manifold and turbocharger are freshwa- TAMD103A, TAMD122A, TAMD122P-A are in-line, ter cooled to reduce heat radiation to the engine direct injection, 6-cylinder, 4-stroke marine diesel en- room. gines. They are equipped with turbocharger and fitted with either a heat exchanger for thermostat-regulated The engines are equipped with a seawater cooled freshwater cooling or connections for keel cooling. - Page 14 Presentation TAMD122P-A 1. Air filter 2. Filter for crankcase ventilation 3. Charge air cooler (after-cooler) 4. Oil cooler 5. Inlet pipe 6. Coolant filler cap 7. Level glass, coolant 8. Heat exchanger 9. Vibration damper 10. Seawater pump 11. Oil filter 12.
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Page 15: Instrumentation
Instrumentation This chapter describes the Volvo Penta instruments that are available for your engine. Note that that tachometer, oil gauge, temperature gauge, charge gauge, starting switch, etc., that are shown here as panel mounted may be mounted separately in some boats. -
Page 16: Control Panels
Instrumentation Control panels Control panels for the main control position and auxil- iary control position. 1. Siren for acoustic alarm that sounds if one of the warning lamps comes on. 2. Push button for instrument illumination. 3. Push button for testing and acknowledging alarms (see “Warning displays”... -
Page 17: Starting Switch
Instrumentation Starting switch Delivered with the starter keys is a plate containing the key code required when ordering additional start- er keys. Do not keep the code where unauthorized persons can access it. S = Stop position. 0 = Key can be inserted and removed. I = Voltage on (drive position). -
Page 18: Controls
Controls This chapter describes the Volvo Penta controls that are available for your engine. If your boat is fitted with con- trols not described here and you are not sure of their function, please get in touch with your boat dealer. -
Page 19: Dual Lever Control
Controls Friction brake The control is fitted with an adjustable friction brake for en- gine speed control. 1. Remove the cover on the control. 2. Set the lever to half acceleration/reverse. 3. Adjust the friction brake. Turn clockwise for stiffer lever movement and anticlockwise for lighter movement. -
Page 20: Starting The Engine
Starting the engine Make a habit of “visually” inspecting the engine and engine room before starting This will help you to quickly de- tect abnormalities that have occurred or are about to occur. Make sure instruments and warning displays indicate normal values after starting the engine. - Page 21 Starting the engine 2. Turn on the power Turn on the power by putting the starter key in position “I”. 3. Check warning lamps and alarms Press the “Alarm test” button on the instrument panel to make sure the warning lamps come on and the acous- tic alarm sounds.
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Page 22: Operation
Operation Learn how to handle the engine, controls and other equipment in a safe and correct manner before casting off for your maiden voyage. WARNING! Avoid violent and rapid rudder movement and gear shifting. There is a risk of the passengers falling down or falling overboard. -
Page 23: Cruising Speed
Wide open throttle range: TAMD103A (Rating 1, 2) ......1700–1800 rpm TAMD122A (Rating 1, 2) ......1700–1800 rpm TAMD122P-A (Rating 3) ......1900–2000 rpm TAMD122P-A (Rating 4, 5) ....... 2150–2250 rpm There could be several reasons for the engine failing to reach the wide open throttle range, see the chapter “Trou-... - Page 24 Operation Forward-Reverse 1. Slow the engine speed to idling and allow the boat to loose most of its speed. 2. Move the lever to neutral. Wait for approximately two seconds. 3. Move the lever to reverse. Wait for approximately two seconds and then increase the engine speed gradually.
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Page 25: Accessories
Operation Accessories Slip valve Certain Twin Disc reverse gears can be fitted with a slip valve so that the lowest speed of the boat can be variably reduced by 1–80% at engine speeds up to 1100 rpm. IMPORTANT! Risk of overheating the reverse gear if the slip valve is used at higher engine speeds than 1100 rpm. -
Page 26: Stopping The Engine
Stopping the engine Let the engine run at low idling speed (in neutral) for at least three minutes before turning it off. This will keep the engine temperature in balance and prevent it boiling. IMPORTANT! The procedure described above is especially important if the engine has been run hard and/ or exerted to heavy loads. -
Page 27: Anti-Freezing Measures
Stopping the engine Anti-freezing measures If the engine room cannot be protected from frost, the sea- water system must be drained and the coolant in the fresh- water system must contain sufficient anti-freeze to prevent it from freezing. Refer to chapter Maintenance “Seawater system”... -
Page 28: Maintenance Schedule
Maintenance schedule Your Volvo Penta engine and associated equipment is designed to provide high operational reliability and long service life. They are constructed to withstand the marine environment while also affecting it as little as possible. Preventive maintenance in accordance with the maintenance schedule will ensure that it retains these qualities and avoid unnecessary operational disturbances. - Page 29 Maintenance schedule Every 50 operating hours Fuel pre-filter. Check and drain ..............page 52 Batteries. Check charge condition ..............page 57 Reverse gear (Twin Disc). Lubrication ............page 63 Disengageable clutch. Lubrication ............. page 65 Applies to output shaft seal. Applies to release bearing when operated more than 15 times a day.
- Page 30 Maintenance schedule Every 1000 operating hours / at least every 12 months (continued) Fuel pre-filter. Change filter element ............. page 53 Reverse gear (Twin Disc). Cleaning oil strainer ..........page 61 Reverse gear. Changing oil ................page 62 Reverse gear. Change oil filter ..............page 62 Disengageable clutch.
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Page 31: Maintenance
Maintenance This chapter contains general technical information and directions for carrying out the prescribed maintenance points. Read the directions carefully before starting work. The times at which the maintenance points are to be carried out can be found in the previous chapter “Maintenance schedule”. CAUTION! Read the safety directions for maintenance and service in the chapter “Safety information”... -
Page 32: Every 200 Operating Hours / At Least Every 12 Months Crankcase Ventilation. Change Filter
Maintenance: Engine, general Crankcase ventilation. Change filter Change the filter (1) earlier than recommended if oil is forced out of the relief valve (2). 1. Dismantle the filter (1) by screwing it anti-clock- wise. 2. Check the rubber gasket in the bracket and change if necessary. -
Page 33: Air Filter (Tamd103). Cleaning
Maintenance: Engine, general Air filter indicator. Checks TAMD122A/P is equipped with a pressure drop indi- cator (1). When the indicator is completely in the red zone when the engine is stationary, the air filter must be changed earlier than recommended. The indicator can be reset by pressing the button. -
Page 34: Lubricating System
If the sulphur content in the fuel exceeds 1.0 wt.%, an oil with TBN >15 must be used (TBN = Total Base Number). The oil must be changed at least once a year. Applies to TAMD103A and TAMD122A. Applies to TAMD122P-A. - Page 35 Maintenance: Lubricating system Engine oil. Check level The oil level must be within the marked range on the dipstick and must be checked daily before starting the first time. Engine oil. Filling Top up the oil through the filler opening (1) in the ven- tilation cover.
- Page 36 Maintenance: Lubricating system Electric oil bilge pump (accessory) Take out the dipstick and undo the disptick pipe. Turn the pipe over and insert it into the oil sump. Connect the suction line to the pipe and pump out the oil. Turn off the pump.
- Page 37 Maintenance: Lubricating system Oil filter. Change 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.
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Page 38: Freshwater System
In its standard version, the engine is fitted with an internal freshwater system. Volvo Penta also supply engines with the cooling system prepared for external cooling, e.g. keel cooling. - Page 39 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.
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Page 40: Coolant (Anti-Corrosion Mixture). Topping Up 1)
Make sure the coolant level is approx. 5 cm (2") be- low the top of the filler cap. Fill as necessary as de- cribed below. TAMD103, TAMD122A TAMD122P On TAMD122P, the coolant level can be checked on a level glass located on the left and right-hand side of the expansion tank. - Page 41 Maintenance: Freshwater system 5. When coolant that is free from air flows out, the ventilation cocks must be closed. TAMD103: Refit the plug 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.
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Page 42: Every 1000 Operating Hours / At Least Every 12 Months Valve Clearances. Check/Adjust
Maintenance: Freshwater system Freshwater system. Flushing clean 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 43 (1). Fill if necessary with the same type of coolant that is already in the system. IMPORTANT! Check the coolant level on a cold stationary engine. TAMD122A Coolant. Filling WARNING! Stop the engine and allow it to cool down before filling. Hot fluids and hot surfaces can cause burns.
- Page 44 7. Start the engine and run it until it reaches operat- ing temperature. IMPORTANT! The engine must not be start- ed before the system has been bled and filled. 8. Stop the engine and allow it to cool down. Check the coolant level and top up if needed. TAMD122A TAMD122P...
- Page 45 Maintenance: Freshwater system Coolant. Drain WARNING! Stop the engine and allow it to cool down before draining. Hot fluids and hot surfac- es can cause burns. WARNING! Glycol is a health hazard (poison). Collect the old coolant and leave it to a destruc- tion plant.
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Page 46: Seawater System
Maintenance: Seawater system Seawater system The seawater system is the boat’s external cooling system. The seawater pump draws in water via the seawater intake and pump it on through the charge air cooler, heat exchanger and the reverse gear oil cooler. The system is protected against galvanic corrosion by zinc anodes located in the charge air cooler, heat exchanger and the reverse gear oil cooler. -
Page 47: Impeller (Seawater Pump). Check/Change
Maintenance: Seawater system Zinc anodes. Check/Change WARNING! Risk of water entering. Close the seawater cock before starting work on the sea- water system. 1. Close the seawater cock. 2. Open the drain cock (S) on the reverse gear oil cooler. 2. -
Page 48: Seawater Filter. Check/Clean
Maintenance: Seawater system Impeller. Check/Change WARNING! Risk of water entering. Close the seawater cock before starting work on the sea- water 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 49: Charge Air Cooler. Check Drainage
Maintenance: Seawater system Charge air cooler. Check the drain hole 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 50: Heat Exchanger. Cleaning
Maintenance: Seawater system Heat exchanger. Cleaning 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 in- crease in engine temperature and high seawater pressure. -
Page 51: Oil Cooler (Engine/Reverse Gear). Cleaning
Maintenance: Seawater system Oil cooler, engine and reverse gear. Cleaning CAUTION! Close the sea cock before working on the cooling system. If a leak is suspected, the oil cooler must be disman- tled from the engine or reverse gear and test pressurised separately. -
Page 52: Fuel System
Maintenance: Fuel system Fuel system Use only fuel recommended in the fuel specifications below. 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 authorised workshop. Break- ing the seal on the injector pump will void the warranty. -
Page 53: Fuel Filters. Change
Maintenance: Fuel system Fuel system. Bleeding The fuel system must be bled e.g. after changing fuel filter, if the fuel tank has been run dry and after long stops. Refer to the next page for bleeding when re- placing a switchable fuel filter during operation. 1. -
Page 54: Every 50 Operating Hours Fuel Pre-Filter. Check And Drain
Maintenance: Fuel system Switchable type fuel filter Switchable fuel filters can be changed while running as the flow of fuel can be cut off to one filter at a time. WARNING! Working on or approaching a run- ning engine is a safety hazard. Beware of rotat- ing parts and hot surfaces. -
Page 55: Fuel Pre-Filter. Change Filter Element
Maintenance: Fuel system Fuel pre-filter. Drainage Place a receptacle under the filter. Drain off water and contaminants through the plug (1) in the bottom of the glass bowl. IMPORTANT! Do not drain until a few hours af- ter stopping. Fuel pre-filter. Change filter elements The fuel pre-filter/water separator are accessories and available as single or dual models. - Page 56 Maintenance: Fuel system 4. Drain off water and contaminants through the drain plug (4). 5. Fit a new filter insert and fill the container with clean fuel. IMPORTANT! Cleanliness! No contaminants must be allowed in the fuel system. 6. Change the gasket on the cover and the O-ring on the T-bolt.
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Page 57: Electrical System
Classified electrical system Classifiable propulsion engines have a comprehensive electrical system for monitoring the engine. These engines are not covered completely in this section. Refer to Volvo Penta publication “Installation Electrical System TMD102A, TAMD102A, TMD122A, TAMD122A (Classifiable propulsion engines)“. Main switch The main switch must never be turned off until the en- gine has been stopped. -
Page 58: Batteries. Checking Electrolyte Level
Maintenance: Electrical system Batteries. Maintenance WARNING! Risk for fire and explosion. Never expose the battery to naked flames or sparks. WARNING! Never reverse the polarity of the battery. Risk of sparks and explosion. WARNING! Battery electrolyte is extremely cor- rosive. Protect eyes, skin and clothes when handling batteries. -
Page 59: Batteries. Check Charge Condition
Maintenance: Electrical system Batteries. Charging WARNING! Risk for explosion. Charging gener- ates hydrogen gas (oxyhydrogen gas). A short circuit, naked flam or spark can cause a power- ful explosion. Ventilate well. WARNING! Battery electrolyte is extremely cor- rosive. Protect eyes, skin and clothes. Always use protective goggles and gloves. - Page 60 Maintenance: Electrical system Electric welding Disconnect the positive and negative battery cables. Then disconnect all the leads to the generator. Always connect the weld clamp to the component be- ing welded and as close to the welding point as pos- sible.
- Page 61 Maintenance: Electrical system 3. Protective earth for e.g. radio, navigation equip- ment, rudder, bathing ladder or other equipment in which there are separate cables for protective earth must be collected on an earth connection that is not connected to the engine, gear wheels or reverse gear.
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Page 62: Electrical Component Diagrams
5. Fuel cut-off valve (solenoid valve) for stopping the engine 6. Main terminal box with 2 semi-automatic fuses 7. Oil pressure switch, engine 8a. TAMD103, TAMD122A , keel-cooled model: Temperature switch, charge air 8b. TAMD122P, keel-cooled model: Temperature switch, charge air 9a. -
Page 63: Reverse Gear
Maintenance: Reverse gear Reverse gear Oil level. Check and filling Check The oil level should be checked once the reverse gear has attained operating temperature with the en- gine idling and the controls in neutral. WARNING! Working on or approaching a run- ning engine is a safety hazard. -
Page 64: Reverse Gear. Changing Oil
Maintenance: Reverse gear Oil. Change Drain 1. Remove the dipstick. Connect a hose from the oil bilge pump (where applicable, the electric oil pump) to the dipstick pipe. Set the knob under the pump housing in position for pumping the reverse gear. -
Page 65: Reverse Gear (Twin Disc). Lubrication 1)
Maintenance: Reverse gear 3. Apply a little oil to the new filter gaskets. 4. Screw on the filters by hand until the gaskets make contact with the sealing surface on the filter bracket. Then screw a further half turn, not any more! 5. -
Page 66: Accessories
Maintenance: Accessories Accessories Disengageable clutch. Adjusting Stop the engine and put the clutch lever in neutral. Remove the inspection hatch and turn the clutch until the locking device on the adjusting ring is accessible. The locking devices have slightly different appearanc- es depending on the make (see illustrations). -
Page 67: Disengageable Clutch. Lubrication 2)
Maintenance: Accessories Disengageable clutch. Lubrication Use lithium-based grease such as Mobilux EP2, Statoil Uniway EP2N, Texaco Multifac EP2, Q8 Rembrandt EP2. Main bearing and clutch mechanism Lubricate the inner support bearing (with lubricating nipple), the main bearings, release shaft and the moving parts in the clutch mechanism with grease. -
Page 68: Inhibiting
Before taking the boat out of service for long periods, it should be left to a Volvo Penta workshop for an overhaul of the engine and other equipment. Have any faults and defects seen to so that the equipment is in good order when next started. - Page 69 Inhibiting Taking out of storage Remove any protection on the engine, air intake Connect the fully charged batteries. and exhaust pipe. Open the seawater cock. Top up with lubricant of the correct grade in the Start the engine (if the boat is in the water) and engine if necessary.
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Page 70: 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. WARNING! Read the safety directions for maintenance and service in the chapter “Safety information” be- fore starting work. -
Page 71: Start Using Auxiliary Batteries
Troubleshooting 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 72: Emergency Engagement Of Reverse Gear
Troubleshooting Emergency engagement of reverse gear Twin Disc reverse gear MG514 is equipped as stan- dard with a mechanical safety clutch for the “Forward” and “Reverse” clutches. Only the clutch being used for forward running is to be locked. NOTE! If the boat has more than one control position, it may be possible to control the reverse gear from there. -
Page 73: Technical Data
Technical Data General Engine designation TAMD103A TAMD122A TAMD122P-A Number of cylinders ..........Cylinder displacement ........... 9.60 dm (586 in 11.97 dm (730 in ) 11.97 dm (730 in Weight* ..............1190 kg (2624 lbs) 1360 kg (2998 lbs) 1310 kg (2888 lbs) Low idling speed ............ -
Page 74: Reverse Gear
Technical Data Reverse gear ZF (MPM) Type designation 310 AL 311 AL Oil capacity, approx..........9 liters (2.4 US gals) 9 liters (2.4 US gals) Oil grade (to API system) ........CC, CD, CE CC, CD, CE Viscosity ..............SAE30* SAE30* Working oil pressure .......... - Page 75 Technical Data Type designation MG5114DC Oil capacity, approx..........19.7 liters (5.2 US gals) Oil grade (to API system) ........CC, CD, CE Viscosity at oil temperature 66–85°C ....SAE30* Viscosity at oil temperature 85–100°C ....SAE40* Working oil pressure** “Neutral” ......0.207–0.634 MPa (30–92 psi) Working oil pressure** “Forward”...
- Page 76 Notes ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
- Page 77 Notes ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
- Page 78 Notes ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
- Page 79 Yes please, I would like an operator’s manual in English at no charge. Publication number: 7744251 Post or fax this coupon to: Document & Distribution Center Name Order Department ARU2, Dept. 64620 Address SE-405 08 Göteborg Sweden Fax: +46 31 545 772 Orders can also be placed via the Internet: http://www.volvopenta.com/...
- Page 80 Sí gracias, deseo recibir gratuitamente un libro de instrucciones en español. Número de publicación: 7744254 Franquear o enviar fax a: Document & Distribution Center Nombre Order Department ARU2, Dept. 64620 Dirección SE-405 08 Göteborg Suecia Fax: +46 31 545 772 El pedido puede hacerse tam- bién por internet: http://www.volvopenta.com/...
- Page 81 Ja graag, Ik wil kosteloos een instructieboek in het Nederlands ontvangen. Publicatienummer: 7744258 Stuur of fax de coupon naar: Document & Distribution Center Naam Order Department ARU2, Dept. 64620 Adres SE-405 08 Göteborg Zweden Fax: +46 31 545 772 U kunt ook bestellen via internet: http://www.volvopenta.com/ manual/coupon...
- Page 82 Sim, obrigado(a)! Gostaria de receber gratuitamente um manual de instruções em português. Número de publicação: 7744259 Envie o talão pelo correio ou um fax para: Nome Document & Distribution Center Order Department Endereço ARU2, Dept. 64620 SE-405 08 Göteborg Sweden Fax: +46 31 545 772 A encomenda também pode ser feita através da Internet:...
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