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Volvo Penta TAMD60A Instruction Book

Marine diesel engine
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INSTRUCTION BOOK
TAMD60A/B, TAMD70C/D, AQD70C/D

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Summary of Contents for Volvo Penta TAMD60A

  • Page 1 INSTRUCTION BOOK TAMD60A/B, TAMD70C/D, AQD70C/D...

  • Page 2: Ab Volvo Penta

    Do not wait until something has gone wrong before you consult the instruction book to see what you should do. Volvo Penta has built up an extensive service organization in order to be able to give your engine the service needed. At all major places all over the world there are modern workshops with specially trained personnel at your service.

  • Page 3: Table Of Contents

    Instruction book Marine diesel engines TAMD60A, TAMD60B, TAMD70C, TAMD70D, AQD70C, AQD70D Contents Presentation Page Servicing Page Safety information ............. 2 Type designation .............. 7 Servicing scheme ............20 Lubrication and checks ..........21 Location of serial number ..........7 Engine description ............8 Engine ..............

  • Page 4: 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 instruction manual and on the product to bring your atten- tion to points of safety-related information.
  • Page 5 Safety regulations for boat trips The new boat Filling fuel Read instruction manuals and other information ac- There is a risk of fire and explosion when filling fuel. companying the new boat thoroughly. Accustom your- Smoking is prohibited and the engine must be turned self with handling the engine, controls and other equip- off.
  • Page 6 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.

  • Page 7: Safety Directions For Maintenance And Service

    All fuel, most lubricants and many chemicals are Never perform a task unless you are absolutely sure flammable substances. Always read and follow the di- how it is to be carried out, call your Volvo Penta deal- rections on the packaging. er for assistance instead.

  • Page 8: Fuel System

    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.

  • Page 9: Type Designation

    10. Oil dipstick, engine 11. Stop solenoid 12. Injection pump 13. Alternator 14. Charging regulator Fig. 2. Engine TAMD60A 1. Turbo-compressor 2. Air cleaner 3. After-cooler 4. Expansion tank (cooling system) 5. Oil cooler for engine 6. Connection for expansion vessel (extra equipment) 7.

  • Page 10: Engine Description

    Fig 3. Engine AQD70C, TAMD70C 1. Oil scavenging pump 2. After-cooler 3. Heat exchanger 4. Oil cooler, engine 5. Thermostat housing 6. Vibration damper 7. Seawater pump 8. Oil filters 9. Relay box 10. Electric connection box with fuses The engines are fitted with a heat exchanger for thermosta- cooled by oil fed through special nozzles located in the engine block.
  • Page 11 Fig. 5. Engine TAMD70D 1. Voltage regulator 2. Thermostat housing 3. Fuel fine filters 4. Water-cooled exhaust manifold 5. Oil filler cap 6. Turbo-compressor 7. Reverse gear TD MG506 8. Stop solenoid 9. Oil dipstick 10. Fuel injection pump 11. Oil cooler 12.

  • Page 12: Instruments

    Instruments and controls Before starting to run your new marine engine, become acquainted with the controls and instruments. Make a habit of checking the instruments now and again while running - any abnormal readings will then be detected in time. Instruments The most important instruments for the engine are grouped The location of the panels in relation to each other can be...
  • Page 13 Pressure gauge - engine lubricating oil pressure, 15. Pressure gauge - reverse gear oil pressure. The should be at 300-500 kPa (3-5 kp/cm = 43-71 psi) pressure should be around the values given in during normal operation. At idling speed it should be ”Technical Data”, pages 40 and 41.

  • Page 14: Controls

    Controls When it is desired to use the lever again for operating the Volvo Penta single lever control (single or twin), operates reverse gear, keep the button (2) pushed in and move the both the reverse gear and the engine speed. When there are two engines a twin control is used.
  • Page 15 On the TAMD60 engines, small quantities required for topping-up can be added to the expansion tank, but other- wise coolant should always be filled directly into the heat exchanger through the hole for the hexagon plug, until the engine is completely full and vented. Then close the ven- ting cock at the turbo and screw the hexagon plug on the heat exchanger.

  • Page 16: Starting

    Fig. 21. Disengaging the reverse gear from the control. lamp 17 goes out. If a second starting attempt has to be made on engine TAMD60A, the control should be moved back to “Neu- tral” and then re-set to full speed in order to engage the cold-starting device again.

  • Page 17: Procedure After Starting

    Procedure after starting Never race a cold engine. Run it warm under light loading or at rapid idling speed. Check that the warning lamp for the oil pressure (17, figs. 7 & 8) goes out immediately after the engine has started.

  • Page 18: During Running

    Change the oil again after running 100–150 hours and The oil in the reverse gear (and the filter element on SCG) change the oil filter (filters) at the same time. Never flush should be changed for the first time after 100-150 hours of out the engine with flushing oil since the bearing pressures operation.

  • Page 19: Stopping

    Stopping Let the engine run for a few minutes without load to enable the engine temperature to drop, thereby avoiding after-boiling. Press in the stop button and keep it pressed in until the engine has stopped, Close the cock on the trickle-feed line to the bilge pump, if such a pump is fitted.
  • Page 20 –30°C (–22°F) –40°C (–40°F) number 283241 in cans of 4.5 litres = 1 Imp.gall. = 1.2 U.S.gall.), which have the right amount of additive for neu- TAMD60A, B 20 8.5 (1.9 = 2.1) 9.5 (2.2 = 2.5) 11 (2.4 = 2.9) (4.4 = 5.3)

  • Page 21: Lubricating Oil And Fuel Lubricating Oil For Engine And Reverse Gear

    Sulphur content Max. 0.5 % by weight We recommend that you use Volvo Penta diesel engine lubricating oil which is on sale at our service stations. The fuel oil property requirements stated above are also covered, to a large extent, by the following standards.

  • Page 22: Servicing Scheme

    Servicing scheme The numbering in the scheme below lists the servicing operations described in the following pages under the cor- responding numbers. Servicing work requiring the attention of experienced mechanics and the use of special tools is marked with an ”A” and should, therefore, be carried out by authorized service personnel. Daily Every 600 hours Check the oil level in the engine...

  • Page 23: Lubrication And Checks

    Lubrication and checks Daily 1. Engine oil level Check the oil level daily with the engine switched off. Wipe the oil dipstick with a clean cloth. Do not use cotton waste. The level should be between the two marks on the dipstick. Never below the lower mark.

  • Page 24: Coolant Level

    Reverse gear lubricating oil Engine oil of same quality Oil capacity, approx. and viscosity as in (incl. cooler) engine* (litres) Imp.gall. USgall. Borg Warner 73CR* Venting cocks Borg Warner 10-05* V-drive Twin Disc, MG 502 Twin Disc, MG 506 SCG MRF 350 HDMK3 12.5 * Oil viscosity for Borg Warner, SAE 30.
  • Page 25 4. Lubricating-disengageable clutch, reduction gear Optional equipment, TAMD70D. Lubricate the throw-out bearing (nipple 1) daily, before starting. NOTE! Lubricate sparingly, to avoid risk of excess grease finding its way onto the dry clutch linings and causing slip. Use multi-purpose heat resistant grease. Extra power take-off at front end.

  • Page 26: Hydraulic System

    7. Hydraulic system, oil level AQD70. Optional equipment for all other engines. Check the level after every 50 hours of operation. The eng- ine should be idling. Remove the filler cap on the hydraulic tank. Wipe the dipstick, and check the level which should be at the max.

  • Page 27: 10. Fuel Filters

    All other engines, changing oil Remove the oil dipstick and connect the hose from the oil scavenging pump to the pipe for the dipstick. (Outer diameter of pipe, 13 mm). An electric scavenging pump is available as optional equipment. Start the pump and collect the oil in a vessel. Fill oil through the hole for the ventilation cap on the rocker arm casing.

  • Page 28: Venting

    Both elements of the double filter and the lower element of the single filter should be changed after 200 hours of ope- ration or at least once every season, preferably at the be- ginning. Close the fuel cocks at the tank and loosen the fil- ter housing by screwing out the centre screw.

  • Page 29: V-Belts

    15. V-belts, checking After every 200 hours of operation check that the belts are properly tensioned and that they are not worn. It should be possible to depress the belts about 10 mm midway between the pulleys if they are properly tensioned. The belts for the circulation pump are tensioned, after nut (1) has first been slackened, by moving the tensioning pul- ley (2) outwards.

  • Page 30: Lubricating Oil Filters

    Seawater filter The filter (optional equipment) should be taken apart and cleaned after every 200 hours of operation or more often if necessary. First close the bottom valve. Then screw the attaching screws out of the cover (1). Lift up the cover and the ele- ment and clean the element in the housing (2) carefully.

  • Page 31: Air Cleaner

    21. Air cleaner TAMD70C, AQD70C Clean the cleaner after every 600 hours of operation. Undo the clamps round the cleaner and remove and wash the filter element in white spirit or diesel fuel oil. Allow the filter element to drip-dry and then moisten it with engine lubricating oil and refit it.

  • Page 32: Electrical System

    24. Starter motor, lubrication* Lubricate the starter motor after every 600 hours of opera- tion using Bosch oil 5944 290 000. Screw out the slotted screw in the mounting flange against the flywheel housing and fill the hole with oil, refit the screw and tighten it. *Applies to starter motor type KG(R) which are provided with a lubricating hole as shown in the figure.
  • Page 33 Every 1200 hours 26. Hydraulic system AQD70. Optional equipment on other engines. Change the oil and the filter element after every 1200 hours, or at least once a year. See the instruction book for the Aquamatic drive type 750, where venting and changing are described in greater detail.
  • Page 34 28. Starter motor, alternator and fuses NOTE! Disconnect both battery cables before carrying out any work on the electrical system. Starter motor, checking brushes and commutator This check should be carried out after every 1200 hours of operation. Disconnect the starter motor cables and remove the starter motor.

  • Page 35: Heat Exchanger And After-Cooler

    Lubrication The large alternator should be lubricated after every 1200 hours of operation. (The small alternator is only lubricated in connection with an overhaul.) Unscrew the plug above the lubricating hole at the bearing, close to the belt pulley. Use a small quantity of Shell Re- tinax A or equivalent lubricant.

  • Page 36: Oil Cooler

    Remove the cover with the oil trap from the block (applies to TAMD60A) and pull out the cooler insert. The Inserts in after-cooler and insert can only be pulled out forwards because it is heat exchanger, AQD70, TAMD70 provided with a flange at the front end.
  • Page 37 Use new gaskets and fit the housing to the engine. Fit new sealing rings on the ends and then fit the end covers. The covers for this cooler lie tight against the housing. Oil cooler for AQD70D, TAMD70D engines Drain the coolant from the fresh water system. Remove the oil cooler coolant pipes.

  • Page 38: 34. General Checking

    32. Fuel injection pump NOTE! Any repair work required to be done on the fuel injection pump should be carried out by specially trained mechanics who have the necessary tools and testing devices at their disposal. All warranty on the engine be- comes null and void if the seals are broken by unauthori- zed persons.

  • Page 39: Inhibiting And De-Inhibiting

    The The engine fresh water system must either be fresh water system should be filled with a Volvo Penta ethy- completely drained or have anti-freeze added, suitable lene glycol mixture. The concentration of glycol used in the form of Volvo Penta ethylene glycol.

  • Page 40: Technical Date Engine And Reverse Gear

    Technical Data Engine Type designation ................. TAMD60A AQD70C AQD70D TAMD60B TAMD70C TAMD70D Number of cylinders ..............Cylinder bore ................mm 98.4 104.77 Stroke ..................mm Displacement ..............dm (litre) 5,48 6.73 Idling speed ..............r/s (r/min) 10.9 (650) 9.2 (550) Compression pressure at starter motor , p.s.i.)
  • Page 41 Fuel system TAMD60A AQD70C, TAMD70C Fuel injection pump Bosch ............PES6MW 100/320 PE6P 110 A 320RS 260Z RS5Z PE6P 110A 320RS 260Y* Injectors (holders) Bosch .............. KBAL 112S 28/4 KBAL 112S 28/4** Nozzles Bosch ................DLLA 150S 204 DLLA 150S 634 (early prod.)
  • Page 42 Turbo-compressor TAMD60 AQD70, TAMD70 Manufacturer, type (TAMD60A-AQD70C, TAMD70C) ....Holset 3LD-530A/ Holset 3LD-530A/ 2.5 WSO 2.5 WSO (TAMD60B-AQD70D, TAMD70D) ..........KKK-K27-2970 N/14.7 KKK-K27-3068/14.7 Lubrication ..................From engine lubricating system Cooling ..................From engine fresh water cooling system Charging pressure Charging pressure at 100% engine load and an ambient air temperatu- re of approx.
  • Page 43 TAMD60 AQD70, TAMD70 Borg Warner, model ..............73 CR V-drive 10-05 Ratios .................... 2:1, 3:1 1.5:1, 2:1 Oil quality ..................Same as in engine (viscosity, however SAE 30) Oil capacity (including cooler) ....dm (Imp.gall,US gall.) 2.5 (0.6-0.7) 5.5 (1.2-1.5) Oil pressure, normal during running ....

  • Page 44: Wiring Diagram

    Wiring diagram Fig. K1. Block diagram (same for all engines in this book) 1. Contact (male and female) Red, 8-pole A. Basic instrument panel 2. Contact (male and female) Red, 8-pole B. Panel with supplementary instruments (alarm, etc) 3. Contact (male and female) Black, 4-pole C.
  • Page 45 14. Oil pressure sensor 15. Pressure sender – turbo 16. Engine coolant temperature sensor 17. Starter cut-out relay (only TAMD60B) * TAMD60A engines The cable from terminal 105 connects to the starter motor terminal 50 and the cable from terminal 110 connects di- rectly to the alternator terminal 61.
  • Page 46 Fig. K2B. Wiring diagram TAMD70C*, TAMD70D, AQD70C*, AQD70D 1. Batteries. For capacity see ‘Tech. data”. 2. Master switch 3. Starter motor 4. Alternator 4x. Alternator (1600 W, optional equipm.) 5. Voltage regulator 5x. Voltage regulator (optional equipm.) Must not be fitted to engine. 6.
  • Page 47 Fig. K3. Wiring diagram. Instruments, basic instrument panel 31. Instrument lighting 32. Voltmeter 33. Oil pressure gauge 34. Engine coolant temperature gauge 35. Stop button 36. Time relay (not on TAMD60) 37. Holding current relay (Omitted on TAMD60 but green cable 2.5 from 35 is connected to + on 33) 38.
  • Page 48 Fig. K4. Wiring diagram. Panel with supplementary instruments (alarm, etc) 51. Instrument lighting 52. Oil pressure gauge – reverse gear 53. Alarm separator 54. Pressure gauge – turbo 55. Extra switches (max. 5 A per switch) 56. Charging warning lamp 57.
  • Page 49 Fig. K5. Wiring diagram. Panel with fuel gauge and rudder indicator. 71. Instrument lighting 72. Fuel gauge 73. Rudder indicator 74. Extra switches (max. 5 A per switch) 75. Sender, fuel gauge 76. Sender, rudder indicator (The free, blue 1.5 cable should be connected to 104 on the engine terminal box) Fig.

  • Page 50: Index

    Index After-cooler ............9, 33, 34 Inhibiting ................. 37 Air cleaner ..............29 Injection pump ............36,39 Anti-freeze ..............18 Injectors ..............29, 39 Instruments ............... 10, 11 Battery ..............19, 24, 39 Maintenance, see Servicing ........... 20 wiring up (wiring diagram) ........43, 44 Manoeuvring (Forward/Reverse) ........
  • Page 51 (kiloponds per square centimetre) earlier unit p.s.i. (lbf/in ) (pounds per square inch) Personal Information: Name ......................................Address ..................................... Tel......................................Nearest Volvo Penta Dealer/Service Workshop Name ......................................Address ..................................... Tel......................................Information-Engine: Type of engine ..................................Serial Number ..................................

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