Volvo Penta D5A T User manual

OPERATOR’S MANUAL
D5A T/TA Marine Genset
Control system MCC

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.

3
Foreword
Thank you for purchasing this Volvo Penta Marine Genset.
The Operator’s Manual contains operation instructions and maintenance and inspection informa-
tion. In order to ensure safety and bring out the maximum performance of the genset, do not ope-
rate it until you have read and fully understood the contents of this manual. Also do not operate
the genset unless in compliance with local regulations.
For information on generator specific items refer to generator information supplied by 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.
Failure to follow the instructions and cautions in this manual may result in serious accidents.
* Keep this manual at hand for easy reference.
* If this manual is damaged or misplaced, immediately order a new one from your dealer.
All information and illustrations in this manual are based on the specifications that were available
at the time of printing. This manual does not cover all available variants of accessories and op-
tions.

Safety Information ................................................... 5
Safety regulations during engine operation ............. 6
Safety directions for maintenance and service ....... 7
Introduction ............................................................ 10
Certified engines .................................................. 11
Warranty .............................................................. 11
Presentation ........................................................... 12
D5A T HE ............................................................ 12
D5A TA HE .......................................................... 13
D5A T RC ............................................................ 14
D5A T KC (1-circuit) ............................................. 15
D5A TA KC (1½-circuit) ....................................... 16
D5A TA KC (2-circuit) .......................................... 17
New genset initial service ...................................... 18
Starting .................................................................. 19
Marine Commercial Control .................................... 21
MCC system overview ......................................... 22
MCU Panel layout ................................................ 23
Menus .................................................................. 26
Operation ............................................................. 28
MCU menu flow chart ........................................... 29
Setpoints ............................................................. 31
Shutdown system overview.................................. 32
SDU indications ................................................... 33
Operation ............................................................... 34
Stopping ................................................................ 35
Emergency stop ................................................... 35
After stopping ........................................................ 35
Anti-freezing measures ........................................ 36
Breaks in operation [not using the genset] ........... 36
Maintenance .......................................................... 37
Recommendation of Daily Operation Records ...... 38
Maintenance schedule ........................................... 39
Engine ................................................................... 41
Drive belts............................................................ 41
Valve clearance ................................................... 42
Lubrication system ................................................. 44
Checking oil level ................................................. 44
Filling oil .............................................................. 44
Changing oil ......................................................... 44
Changing oil filter ................................................. 45
Fuel system ........................................................... 46
Bleeding the fuel system...................................... 46
Changing fuel filter ............................................... 46
Fuel pre-filter/water separator ............................... 47
Air inlet and exhaust systems ................................ 49
Changing air filter ................................................. 49
Cleaning the compressor ...................................... 49
Checking drain hole of charge air cooler ............... 49
Cooling system, general ......................................... 50
Freshwater system ................................................ 57
Checking coolant level ......................................... 57
Filling coolant ....................................................... 57
Draining the coolant ............................................. 58
Flushing the freshwater system ........................... 58
Rawwater system................................................... 59
Draining the rawwater system .............................. 59
Rawwater pump (LT-pump) impeller ..................... 59
Rawwater pump (LT-pump) ................................... 60
Engine mounted heat exchanger .......................... 61
Electrical system ................................................... 62
Checking the electrical wiring ............................... 62
Main switches ...................................................... 62
Fuses .................................................................. 62
Electric welding .................................................... 62
Battery maintenance ............................................ 63
Inhibiting ................................................................ 65
Troubleshooting ..................................................... 67
Technical Data ....................................................... 68
D5A T HE ............................................................ 68
D5A TA HE .......................................................... 69
D5A T RC ............................................................ 70
D5A T KC (1-circuit) ............................................. 71
D5A TA KC (1½-circuit) ....................................... 72
D5A TA KC (2-circuit) .......................................... 73
Fuel specification ................................................. 74
Lubrication oil specification .................................. 75
Coolant specification ............................................ 76
Identification numbers .......................................... 77
Notes ..................................................................... 78
Contents

5
Safety Information
Read this chapter thoroughly. It concerns your safety. This section describes how safety information is presented
in this manual and on the product. It also includes a summary of basic safety regulations for operation and main-
tenance of the engine.
This Operator’s Manual is only valid for complete gensets 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.
If operations are performed incorrectly it could result in personal injury or damage to property or the engine. Read
the Operator’s Manual carefully before operating or servicing the engine. For safety information on operation and
maintenance of the generator, refer to the generator documentation.
If anything is unclear please contact your Volvo Penta dealer for assistance.
This symbol is used in the book and on the engine to make you aware of safety infor-
mation. Always read these safety precautions very carefully.
In the Operator’s Manual warning texts have the following priority:
WARNING! If these instructions are not followed there is a danger of personal injury, ex-
tensive damage to the product or serious mechanical malfunction.
IMPORTANT! Used to draw your attention to something that can cause damage, pro-
duct malfunction or damage to property.
NOTE! Used to draw your attention to important information that will facilitate work or ope-
rations.
This symbol is used in certain cases on our products and refers to important informa-
tion in the Operator’s Manual. Ensure that warning and information symbols on the engine
and transmission are always visible and legible. Replace symbols that have been damaged
or painted over.

6
Safety information
Safety regulations during engine operation
Filling fuel
There is a risk of fire and explosion when filling fuel.
Smoking is prohibited and the engine must be turned
off. Never overfill the tank. Close the filler cap
securely. Use only fuel recommended in the operators
manual. The incorrect grade of fuel can disturb opera-
tion or cause breakdown. This can also lead to the
control rod jamming on diesel engines, which will cau-
se the engine to overspeed and risk damaging machi-
nery and causing personal injury.
Combustible enviroment
Due to the risk of fire and/or explosion, do not start or
continue to run the engine if there is a suspected leak
or discharge of combustible media, e.g. fuel oil or
LPG, in the engine surroundings.
Carbon monoxide poisoning
When a vessel is moving forward, it will cause a cer-
tain vacuum to form behind the vessel. In unfortunate
circumstances, the suction from this vacuum can be
so great that the exhaust gases from the vessel are
drawn into the bridge or cabin and cause carbon mon-
oxide poisoning. This problem is most prevalent on
high, wide vessels with abrupt stern. Other factors
that can increase the effect of the suction are wind
conditions, load distribution, swells, trim, open hat-
ches and portholes, etc. Most modern vessels, howe-
ver, are designed in such a way that this problem is
very rare. If suction should arise anyway, do not open
hatches or portholes at the fore of the vessel. Surpri-
singly, this will otherwise increase the suction. Try
changing speed, trim, or load distribution instead. Get
in touch with your Volvo Penta dealer for help in ob-
taining the best solution for your vessel.
The new engine
Read instruction manuals and other information ac-
companying the new vessel thoroughly. Accustom
yourself with handling the engine, controls and other
equipment in a safe and correct manner.
Remember that when operating a vessel, you have a
legal responsibility to be aware of and follow regula-
tions concerning traffic and safety at sea. Inform your-
self of the regulations applicable to your vessel and
the waters your in by getting in touch with the relevant
authorities or marine safety organization.
Accidents and other incidents
Sea rescue statistics show that deficient maintenance
of vessels and engines together with defective safety
equipment often causes accidents and other incidents
at sea.
Make sure your vessel and engine are maintained in
accordance with directions in the instruction manuals
and that the safety equipment on board is in good
working order.
Daily inspection
Make a habit of visually inspecting the engine and
engine room before starting and after stopping the
engine. This will help you to quickly detect any fuel,
coolant or oil leaks and any other abnormalities that
have occurred or are about to occur.
WARNING! Accumulations of fuel, oil and grease
on the engine or in the engine room is a fire
hazard and must be removed immediately they
are detected.
IMPORTANT! If an oil, fuel or coolant leak is
detected, the cause must be investigated and
the fault rectified before the engine is started.
Maneuvering
Avoid violent and rapid rudder movement and gear
shifting. There is a risk of the passengers falling down
or falling overboard. A rotating propeller can cause se-
rious injury. Make sure there is nobody in the water
before engaging forward/reverse. Never run close to
bathers or in places where you have reason to believe
there are people in the water.

7
Safety information
Safety directions for maintenance and service
Before starting
Refit all guards and covers that have been removed
before starting the engine. Make sure there are no
tools or other objects left on the engine. A turbochar-
ged engine must never be started without the air filter
fitted. The rotating compressor wheel in the turbochar-
ger can cause severe personal injury.
There is also a risk of foreign objects being drawn in
and causing mechanical damage.
Fire and explosion
Fuel and lubricants
All fuels, most lubricants, and many chemicals are
flammable substances. Always read and follow the
directions on the packaging. Work performed on the
fuel system must be done on a cold engine. Fuel
leaks and spills on hot surfaces or electrical
components can cause fires.
Keep oil- and fuel drenched rags and other hazardous
materials where they are safe in case of fire. Oil dren-
ched rags can selfignite in certain conditions. Never
smoke when refueling, topping up with oil or when in
the vicinity of the fuel station or the engine room.
Non-original parts
Components in fuel, lubrication, ignition and electrical
systems on Volvo Penta engines are designed and
manufactured to minimize the risk of explosion and
fire in compliance with existing legislation.
The use of non-original parts can result in explosion
or fire.
Batteries
Batteries contain and generate oxyhydrogen gas, es-
pecially when charging. Oxyhydrogen is easily ignited
and extremely explosive. Smoking, open flames and
sparks must never occur in, or close to, the batteries
or battery compartment. A faulty battery connection or
jumper cable can generate sparks that can cause the
battery to explode.
Start spray
Never use start spray or similar start help. Explosions
can occur in the intake manifold. Risk for personal
injury.
Preparations
Knowledge
The operator’s manual contains directions for perfor-
ming normal maintenance and service in a safe and
correct manner. Read the directions carefully before
starting work. More detailed service literature is avail-
able from your Volvo Penta dealer. Never perform a
task unless you are absolutely sure how it is to be
carried out; call your Volvo Penta dealer for assistan-
ce instead.
Stop the engine
Stop the engine before opening or dismantling the
engine hatch/hood. Maintenance and service must be
carried out with the engine stationary unless stated
otherwise in the instructions. Prevent inadvertent start
of the engine by removing the starter key and turning
off the power with the main switch, locking it in the off
position. Place warning signs stating that service is in
progress in every position from which the engine can
be started. Working on or approaching a running engi-
ne is a safety hazard. Loose clothing, hair, fingers or
a dropped tool can be caught in rotating parts and
cause serious bodily injury. Volvo Penta recommend
leaving all work requiring the engine to be running to
an authorized Volvo Penta dealer.
Lifting the engine
Always use the lifting eyes mounted on the engine
when lifting the engine. Always make sure lifting
equipment is in good condition and constructed for the
lift (engine weight together with possible reverse gear
and extra equipment). Use an adjustable lifting boom
to ensure safe handling when lifting the engine. All
chains and wires must run parallel with each other and
as much at right angle as possible to the top of the
engine. Note that any extra equipment mounted on the
engine can change the center of gravity. Special lifting
devices may be required to obtain the right balance
and safe handling. Never perform service on an engi-
ne suspended only from a lifting device.
IMPORTANT! Engine must only be lifted
horizontally.
IMPORTANT! Engine lifting eyes are designed
only for lifting an engine. Do not use the engine
lifting eyes when lifting a complete genset.

8
Safety information
Hot surfaces and fluids
At operating temperature, the engine and its compo-
nents are hot. A hot engine always involves risk for
burn injuries. Take care with hot surfaces. E.g.: ex-
haust manifold, turbocharger, oil pan, charge air pipe,
starting heater, hot coolant and warm lubricant in pi-
pes and hoses.
WARNING! Do not open the crankcase
covers while the engine is still hot.
Carbon monoxide poisoning
Start the engine in well-ventilated spaces only. When
running in confined spaces, the exhaust gases and
crankcase gases must be evacuated.
Chemicals
Most chemicals such as glycol, anti-corrosion agent,
preservatives, degreasing agent, etc., are hazardous
to health. Always read and follow the directions on
the packaging.
Certain chemicals such as preservatives are
flammable and harmful to inhale. Provide good
ventilation and use breathing protection when
spraying. Always read and follow the directions on the
packaging. Store chemicals and other hazardous
materials out of reach of children. Leave left over or
used chemicals to a destruction plant.
Cooling system
There is a risk of water entering when working on the
seawater system. Therefore, stop the engine and
close the seawater cock before starting work.
Avoid opening the coolant filler cap when the engine is
warm. Steam or hot coolant may spurt out and cause
burn injuries.
If the filler cap, coolant pipe, cock, etc., must
nevertheless be opened or dismantled while the
engine is warm, the filler cap must be opened
carefully to release the pressure before removing it
completely and starting work. Note that the coolant
can still be hot and cause burn injuries.
Lubricating system
Hot oil can cause burn injuries. Avoid skin contact
with warm oil. Make sure the lubricating system is
depressurized before starting work. Never start or run
the engine with the oil filler cap removed or there will
be a risk of the oil being thrown out.
Fuel system
Always protect your hands when carrying out leak de-
tection.
Escaping fluids under pressure can pierce bodily tis-
sue and cause serious injury. Risk of blood poisoning.
Always cover any electric component if it is located
under the fuel filter. Otherwise it might be damaged by
fuel spills.
Electrical system
Turn off the power before commencing work on the
electrical system, the engine must be stopped and the
powered turned off with the main switch/switches.
Shore power to the engine heater, battery charger or
other extra equipment fitted to the engine must be dis-
connected.
Batteries
Batteries contain a highly corrosive electrolyte. Pro-
tect your eyes, skin and clothing when charging and
handing batteries. Always use protective goggles and
gloves.
In case of splashes on the skin, wash with soap and
plenty of water. In case of splashes in the eyes, rinse
immediately with plenty of water and call a doctor.
Avoid burns and crushing or cutting!
At operating temperature, the engine coolant is hot
and under pressure. Steam can cause personal
injury. Check the coolant level only after the engine
has been stopped and the coolant filler cap has coo-
led enough to touch with your hand. Never adjust the
V-belts while the engine is running.
Service batteries carefully!
If you spill electrolyte on yourself, flush skin immedia-
tely with lots of water. Apply baking soda to help neu-
tralize the acid. If electrolyte gets in your eyes, rinse
immediately with large amounts of water then contact
a doctor at once.
Handle antifreeze carefully!
Antifreeze contains alkali. Avoid contact with skin
and eyes to prevent personal injury. Dispose of
drained antifreeze coolant according to local
regulations. For disposal, consult your dealer.

9
Safety information
Dress properly for the job!
Wear protective devices - hard hat, face shield, safety
shoes, goggles, heavy gloves, ear protectors, etc. -
for your own safety.
Recommended fuel, lubrication oil and
coolant!
Use of any other fuel oil, lurication oil or coolant than
the recommended can cause engine damage and re-
duce engine service life.
Perform all recommended inspections!
Perform pre-start inspection and periodic inspection
on items listed in this manual. Failure to follow this
recommendation can cause serious engine damage.

10
Introduction
This operator’s manual has been produced to give you the greatest benefit of your Volvo Penta Marine Genset. It
contains the information necessary to handle and maintain your genset in a safe and correct manner. We would
like you to read this operator’s manual thoroughly and learn how to handle the genset, controls and other equip-
ment in a safe manner before operating the genset.
Keep the operator’s manual within reach at all times.
Care of the environment
We would all like to live in a clean and healthy envi-
ronment. An environment where we can breathe cle-
an air, see healthy trees, have clean water in our la-
kes and oceans, and enjoy the sunshine without being
worried about our health. Unfortunately, this cannot be
taken for granted nowadays but it is something we
must work together to achieve.
As a manufacturer of marine engines Volvo Penta has
a special responsibility. That is why care of the envi-
ronment is a core value in our product development.
Volvo Penta has a broad range of engines where pro-
gress has been made in reducing exhaust emissions,
fuel consumption, engine noise, etc. We hope you will
take part in preserving these qualities.
Always follow any advice given in the operator’s ma-
nual concerning fuel grades, operation and mainte-
nance and you will avoid causing unnecessary inter-
ference to the environment. Get in touch with your
Volvo Penta dealer if you notice any changes such as
increased fuel consumption and/or exhaust smoke.
Adapt speed and distance to avoid wash and noise
disturbing or injuring animal life, moored boats, jetties,
etc. Leave islands and harbours in the same condi-
tion as you want to find them. Remember to always
leave hazardous waste such as waste oil, coolant,
paint and wash residue, flat batteries, etc., for dispo-
sal at a destruction plant. Our joint efforts will make a
valuable contribution to our environment.
Fuel and oil
Use only fuel and lubrication oil grades recommended
in the technical data section of this Operator’s Manu-
al. Other grades can cause operational problems, in-
crease fuel consumption and have long-range effects
on engine service life.
Service and spare parts
Volvo Penta marine engines are designed for high
operational reliability and long service life. They are
constructed to withstand the marine environment whi-
le affecting it as little as possible. Through regular
service and the use of Volvo Penta approved spare
parts, these qualities will be retained.
The worldwide Volvo Penta network of authorized
dealers is at your service. They are specialists in
Volvo Penta products and stock accessories, original
spare parts, test equipment and the special tools re-
quired to perform high-quality service and repairs.
Always follow the maintenance intervals specified in
the operator’s manual and remember to specify the
engine number when ordering service and spare
parts.

11
Introduction
Certified engines
It is essential that owners and operators of emission certified engines, used in areas where exhaust emissions
are regulated by law, are aware of the following points:
A certification involves the engine type being checked and approved by applicable authorities. Engine manufac-
turers guarantee that all engines of the same type correspond with the certified engine.
This puts special demands on the maintenance and service of your engine:
* Maintenance and service intervals recommended by Volvo Penta must be followed.
* Only spare parts approved by Volvo Penta may be used.
* Service of injector pumps, pump settings and injectors must always be performed by an authorized Volvo
Penta service person.
* The engine must not be modified in any way with the exception of accessories and service kits approved by
Volvo Penta for use on the engine.
* Installation modifications must not be made to the engine exhaust pipe or inlet channels.
* Sealed sections must not be broken by anyone other than authorized personnel.
Otherwise, general directions concerning running, care and maintenance given in the operator’s manual apply.
IMPORTANT! Neglected or deficient maintenance/service and the use of spare parts not approved by
Volvo Penta will entail Volvo Penta renouncing any responsibility for the engine corresponding to the
certified version. Volvo Penta will not compensate for damage and/or costs arising from the above.
Warranty
Your new Volvo Penta Marine Genset is covered by a limited warranty complying with the conditions and instruc-
tions given in the 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. AB Volvo Penta will oth-
erwise decline warranty liability completely or fully.
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.

12
Presentation
D5A T HE
The D5A T HE is a turbocharged, in-line, direct injection, 4-cylinder, 4-stroke marine genset. It is equipped with an
engine mounted heat exchanger suitable for rawwater cooling or connection to a central cooling system.
An optimal combination of combustion chambers, fuel injection system, and effective turbocharger, provide excel-
lent fuel consumption over the whole range of power output.
The engine is mounted on a frame with a Stamford single or double bearing marine generator. Different starting
and control systems are available.
1. Air outlet generator
2. Governor & Stop solenoid
3. Electrical connection box
4. Fuel return
5. Oil cooler
6. Fresh water pump
7. Fuel pump & Fuel inlet
8. Lifting eyes
9. Vibration damper
10. Fuel filter
11. Oil filter
12. Oil dip stick
13. Raw water pump
14. Raw water inlet
15. Electrical connection unit
16. Air inlet generator
17. Heat exchanger
18. Expansion tank
19. Exhaust manifold
20. Air filter
21. Air filter indicator
22. Turbocharger
23. Flexible mounting
24. Electrical starter
25. Engine oil drain pump
26. Alternator
27. Raw water outlet

13
Presentation
D5A TA HE
The D5A T HE is a turbocharged, aftercooled, in-line, direct injection, 4-cylinder, 4-stroke marine genset. It is
equipped with an engine mounted heat exchanger suitable for rawwater cooling or connection to a central cooling
system.
An optimal combination of combustion chambers, fuel injection system, effective turbocharger and charge air coo-
ling, provide excellent fuel consumption over the whole range of power output.
The engine is mounted on a frame with a Stamford single or double bearing marine generator. Different starting
and control systems are available.
1. Air outlet generator
2. Governor & Stop solenoid
3. Electrical connection box
4. Fuel return
5. Oil cooler
6. Fresh water pump
7. Fuel pump & Fuel inlet
8. Lifting eyes
9. Vibration damper
10. Fuel filter
11. Oil filter
12. Oil dip stick
13. Raw water pump
14. Raw water inlet
15. Electrical connection unit
16. Air inlet generator
17. Heat exchanger
18. Expansion tank
19. Charge air cooler
20. Exhaust manifold
21. Air filter
22. Air filter indicator
23. Turbocharger
24. Flexible mounting
25. Electrical starter
26. Engine oil drain pump
27. Alternator
28. Raw water outlet

14
D5A T RC
The D5A T RC is an in-line, direct injection, 4-cylinder, 4-stroke marine diesel engine. It has a turbocharger and is
equipped with radiator cooling.
An optimal combination of combustion chambers, fuel injection system, effective turbocharger and charge air coo-
ling, provide excellent fuel consumption over the whole range of power output.
The engine is mounted on a frame with a Stamford single or double bearing marine generator. Different starting
and control systems are available.
1. Maintenance indicator air filter
2. Air filter
3. Governor & stop
solenoid
4. Oil dip stick
5. Oil cooler
6. Oil filter
7. Fuel filter
8. Freshwater pump
9. Pressure cap
exp. tank
10. Air inlet generator
11. Lifting eye
12. Electrical connection unit
13. Air outlet generator
14. Flexible mounting
2 951
16
6
38
15. Oil filler
16. Oil drain pump
15
10 11 12 13
74
14

15
Presentation
D5A T KC (1-circuit)
The D5A T KC is a turbocharged, in-line, direct injection, 6-cylinder, 4-stroke marine genset. It is fitted with con-
nections for keel cooling.
An optimal combination of combustion chambers, fuel injection system, effective turbocharger and charge air coo-
ling, provide excellent fuel consumption over the whole range of power output.
The engine is mounted on a frame with a Stamford single or double bearing marine generator. Different starting
and control systems are available.
1. Air outlet generator
2. Governor & Stop solenoid
3. Electrical connection box
4. Fuel return
5. Oil cooler
6. Fresh water pump
7. Fuel pump & Fuel inlet
8. Lifting eyes
9. Vibration damper
10. Fuel filter
11. Oil filter
12. Oil dip stick
13. Electrical connection unit
14. Air inlet generator
15. Expansion tank
16. Fresh water inlet
17. Exhaust manifold
18. Air filter
19. Air filter indicator
20. Turbocharger
21. Flexible mountings
22. Electrical starter
23. Engine oil drain pump
24. Alternator
25. Fresh water outlet

16
Presentation
D5A TA KC (1½-circuit)
The D5A TA KC is a turbocharged, aftercooled, in-line, direct injection, 4-cylinder, 4-stroke marine genset. It is fit-
ted with connections for 1-circuit 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.
The engine is mounted on a frame with a Stamford single or double bearing marine generator. Different starting
and control systems are available.
1. Air outlet generator
2. Governor & Stop solenoid
3. Electrical connection box
4. Fuel return
5. Oil cooler
6. HT-pump
7. Expansion tank
8. Fuel pump & Fuel inlet
9. Lifting eyes
10. Vibration damper
11. Fuel filter
12. Oil filter
13. Oil dip stick
14. LT-pump
15. Coolingwater inlet (LT-circuit)
16. Electrical connection unit
17. Air inlet generator
18. Charge air cooler
19. Exhaust manifold
20. Air filter
21. Air filter indicator
22. Turbocharger
23. Flexible mountings
24. Electrical starter
25. Cooling water outlet (LT-circuit)
26. Engine oil drain pump
27. Alternator

17
Presentation
D5A TA KC (2-circuit)
The D5A TA KC is a turbocharged, aftercooled, in-line, direct injection, 4-cylinder, 4-stroke marine genset. It is fit-
ted with connections for 2-circuit 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.
The engine is mounted on a frame with a Stamford single or double bearing marine generator. Different starting
and control systems are available.
D5A TA Genset
1. Air outlet generator
2. Governor & Stop solenoid
3. Electrical connection box
4. Fuel return
5. Oil cooler
6. HT-pump
7. Fuel pump & Fuel inlet
8. Lifting eyes
9. Vibration damper
10. Fuel filter
11. Oil filter
12. Oil dip stick
13. LT-pump
14. Coolingwater inlet (LT-circuit)
15. Electrical connection unit
16. Air inlet generator
17. Coolingwater inlet (HT-circuit)
18. Cooling water outlet (LT-circuit)
19. Charge air cooler
20. Exhaust manifold
21. Air filter
22. Air filter indicator
23. Turbocharger
24. Flexible mountings
25. Electrical starter
26. Engine oil drain pump
27. Alternator
28. Cooling water outlet (HT-circuit)

18
General
Before starting a new or reconditioned genset for the first time, give it an initial inspection. This to guarantee your
own safety as well as the maximum service life of the genset.
New genset initial service
External inspection
1. Check the control system for loose terminals.
2. Check defects of engine parts.
3. Check the following components for loose bolts or
nuts:
* Plugs and covers of fuel, lubrication and cooling
system
* Coupling of fuel injection pump and shaft
* Mounting brackets
* Fuel control link
* Turbocharger
* Timing gear case
* Exhaust manifolds
* Cylinder heads
* Air-duct connection-hose clamp
* Flexible coupling from engine to generator
4. Check for fuel, oil, coolant and air leaks and repair
if needed.
5. Make commissioning report for new or overhauled
engine.
IMPORTANT! All covers on engine and generator
must be mounted before attempting to start your
genset.
Valves and plugs
Make sure the following valves and plugs are open or
closed properly:
Fuel supply valve Open
Coolant drain cocks Closed
IMPORTANT! If the coolant drain cocks are not
closed the coolant will drain from the engine and
this may cause severe damage to the engine.
Electrical wiring
Check for loose or damaged electrical wiring on the
engine and on the generator. If necessary firmly re-
connect to terminals or cable-joint portions. Damaged
cables must be replaced.
If your genset is reconditioned, make sure the wiring
is according to the drawings.
Filling fuel system
Refer to chapter ”Maintenance: Fuel system”.
Filling lubrication system
Refer to chapter ”Maintenance: Lubrication system”.
Filling cooling system
Refer to chapter ”Maintenance: Cooling system”.
Generator
Refer to manual supplied by generator manufacturer.

19
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.
IMPORTANT! If the starter motor has been engaged for the maximum time (30 seconds), it must be
allowed to cool down for at least one minute before a new attempt is made at starting.
Warming-up
WARNING! Do not conduct warm-up operation for an extended period of time. Prolonged warm-up
operation causes carbon buildup in the cylinders that leads to inperfect combustion.
NOTE! To warm up the engine operate at no load for a short time and then apply a low load.
NOTE! If the lubrication oil pressure does not increase when you have started the engine, immediately stop
the engine and do not restart until the problem has been fixed.
NOTE! Make sure that the cooling water flow is sufficient.

20
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. Make sure the rated voltage of the auxiliary bat-
tery is the same as the system voltage of the
engine.
2. Connect the red auxiliary cable to the discharged
battery’s + terminal and then to the auxiliary
battery’s + terminal.
3. Connect the black jump lead to the auxiliary bat-
tery negative terminal and then to a position
slightly away from the discharged batteries, for
example at the negative cable’s connection to the
starter motor.
WARNING! The black auxiliary cable (–) must not
come in contact with the positive connection on
the starter motor.
4. Start the engine and run at no load for about ten
minutes to charge the batteries.
WARNING! Do not touch the connections while
attempting to start; Risk of sparks. Do not bend
over the batteries either.
5. Stop the engine. Remove the auxiliary cables in
reverse order to connecting.