Volvo penta Tamd63l User manual

INSTRUCTION BOOK

TAMD63L, TAMD63P

TAMD71B, TAMD72P, TAMD72WJ

Structure of this Instruction Book

The first part of this Instruction Book contains impor-

tant information on functions, fuel, oils and coolants.

The operating instructions are important even if you

know what you are doing. They may contain some

information which is different to what you are used

to. Read the first section before operating the engine

for the first time.

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.

Contents

Safety precautions ............................................. 2

General information ........................................... 4

Running-in............................................................ 4

Warranty and guarantee ...................................... 5

Certificated engines ............................................. 6

Introduction ........................................................ 8

Instrumentation .................................................. 11

Key switch, starter keys ....................................... 15

Controls .............................................................. 15

Calibrating controls, TAMD72P ............................ 17

Fuel, lubricating oils, coolant............................ 20

Operation

Before starting...................................................... 21

Starting the engine ............................................... 22

Checks during operation ...................................... 24

Manoeuvering during operation ........................... 24

Safety systems, TAMD72P .................................. 26

After operation...................................................... 27

When there is a danger of freezing ...................... 28

Maintenance and care

Periodic care and maintenance............................ 30

Maintenance schedule ....................................... 32

Technical description

Engine .................................................................. 39

Lubrication system ............................................... 43

Fuel system.......................................................... 47

Cooling system..................................................... 52

Electrical system .................................................. 60

Wiring diagrams ................................................. 69

Inhibiting ............................................................. 85

Launching............................................................. 85

Bringing out of storage ......................................... 86

Troubleshooting ................................................. 87

Technical data .................................................... 96

Accessories ........................................................101

The rest of the manual – “Technical description and

maintenance” – can be read once you have had time

to acquaint yourself with your boat. This section will

give you more information on the design and opera-

tion of your engine. Here you will also find a kind of

“Do-It-Yourself” description of many aspects of main-

tenance.

Safety Precautions

Introduction

This Instruction Book contains the information you

will need to operate the engine correctly. Check that

you have the correct Instruction Book for your en-

gine.

Read the book carefully before operating or serv-

icing the engine. If operations are performed incor-

rectly it could result in personal injury, or damage to

property or the engine.

If you do not understand or are uncertain about

any operation or information in this manual,

please contact your Volvo Penta dealer who will

be able to assist with an explanation and demon-

stration of the operation.

Important!

In this book and on the engine you will find the fol-

lowing special warning symbols.

WARNING! Possible danger of personal inju-

ry, damage to property or mechanical mal-

function if the instructions are not followed.

Read the Instruction Book.

Below is a summary of the risks and safety precau-

tions you should always observe or carry out when

operating or servicing the engine.

Check that the warning or information labels on

the engine are always clearly visible. Replace

labels which have been damaged or painted

over.

Always turn the engine off before starting ser-

vice procedures. Avoid burns. Take precau-

tions to avoid hot surfaces and liquids in supply

lines and hoses when the engine has been

turned off immediately prior to starting work on

it and it is still hot.

Reinstall all protective parts removed during

service operations before starting the engine.

Make a point of familiarizing yourself with other

risk factors, such as rotating parts and hot sur-

faces (turbocharger, charge air pipe, starter el-

ement, charge air cooler, intake pipe exhaust

pipe etc.).

Approaching an engine which is operating is a

safety risk. Loose clothing or long hair can fas-

ten in rotating parts and cause serious person-

al injury.

If the service operation requires that the engine

is operating, let your Volvo Penta authorized

dealer carry out the work. If working in proximi-

ty of an engine which is operating, careless

movements or a dropped tool can result in per-

sonal injury.

Immobilize the engine by turning off the power

supply to the engine at the main switches so it

is impossible to start, and lock them in the OFF

position before starting work. Set up a warning

notice at the engine control point or helm.

Never start the engine without installing the air

cleaner (ACL) filter. The rotating compressor

wheel in the turbo can cause serious personal

injury. Foreign objects entering the intake ducts

can also cause mechanical damage.

Never use start spray or similar to start the en-

gine. The start spray may cause an explosion

in the inlet manifold. Danger of personal injury.

Avoid opening the coolant filler cap when the

engine is hot. Steam or hot coolant can spray

out and the system pressure will be lost. Open

the filler cap slowly and release coolant system

pressure, if the filler cap or a drain cock/venting

cock must be opened, or if a plug or engine

coolant line must be removed on a hot engine.

It is difficult to anticipate in which direction

steam or hot coolant can spray out.

Stop the engine and close the sea cock before

carrying out operations on the engine cooling

system.

Only start the engine in a well-ventilated area.

If operating the engine in a closed area ensure

that there is exhaust ventilation leading out of

the work area to remove exhaust gases and

crankcase ventilation emissions.

Anti-corrosion agents are hazardous to health.

Read the instructions on the product packag-

ing!

Anti-freeze agents are hazardous to health.

Read the instructions on the product packag-

ing!

Certain engine conservation oils are inflamma-

ble. Some of them are also dangerous if

breathed in. Ensure good ventilation in the

work place. Use a protective mask when spray-

ing.

Hot oil can cause burns. Avoid getting hot oil

on the skin. Ensure that the lubrication system

is not under pressure before carrying out any

work. Never start or operate the engine with

the oil filler cap removed, otherwise oil could be

ejected.

Never allow an open flame or electric sparks

near the batteries. Never smoke in proximity to

the batteries. The batteries give off hydrogen

gas during charging which when mixed with air

can form an explosive gas -oxyhydrogen. This

gas is easily ignited and highly volatile. Incor-

rect connection of the battery can cause a sin-

gle spark which is sufficient to cause an explo-

sion with resulting damage. Do not shift the

connections when attempting to start the en-

gine (spark risk) and do not lean over any of

the batteries. Refer to instructions in the In-

struction Book.

Always ensure that the Plus (positive) and Mi-

nus (negative) battery leads are correctly in-

stalled on the corresponding terminal posts on

the batteries. Incorrect installation can result in

serious damage to the electrical equipment.

Refer to the wiring diagrams.

Always use protective goggles when charging

and handling the batteries. Battery electrolyte

contains sulfuric acid which is highly corrosive.

Should the battery electrolyte come into con-

tact with unprotected skin wash off immediately

using plenty of water and soap. If battery acid

comes in contact with the eyes, immediately

flush with plenty of water and obtain medical

assistance without delay.

Turn the engine off and turn off the power at

the main switches before carrying out work on

the electrical system.

Clutch adjustments, where a clutch is fitted,

must be carried out with the engine turned off.

Use the lifting eyes fitted on the engine/reverse

gear when lifting the drive unit. Always check

that the lifting equipment used is in good condi-

tion and has the load capacity to lift the engine

(engine weight including reverse gear and any

extra equipment installed).

Use a lifting beam to raise the engine to ensure

safe handling and to avoid damaging engine

parts installed on the top of the engine.

All chains and cables should run parallel to

each other and as perpendicular as possible

against the side of the engine.

If extra equipment is installed on the engine

which alters its center of gravity a special lifting

device is required to obtain the correct balance

for safe handling.

Never carry out work on an engine suspended

on a hoist.

Warning! The components in the electrical

system and in the fuel system on Volvo Penta

products are designed and manufactured to

minimize risks of fire and explosion.

The engine must not be run in areas where

there are explosive materials.

Fuel filter replacement should be carried out on

a cold engine in order to avoid the risk of fire

caused by fuel spillage on the exhaust mani-

fold. Always cover the generator (alternator), if

it is located under the fuel filter. The generator

(alternator) can be damaged by spilled fuel.

Always use protective gloves when detecting

leaks. Liquids ejected under pressure can pen-

etrate the body tissues and cause serious inju-

ry. Danger of blood poisoning.

Always use fuels recommended by Volvo

Penta. Refer to the Instruction Book. Use of fu-

els that are of a lower quality can damage the

engine. On a diesel engine poor quality fuel

can cause the control rod to seize and the en-

gine to overrev with resulting risk of damage to

the engine and personal injury. Poor fuel quali-

ty can also lead to higher maintenance costs.

Observe the following when cleaning with high-

pressure water jets: Never point the water jet at

seals, rubber hoses or electrical components.

Never use high pressure jets when washing the

engine.

General Information

Welcome aboard

Thank you for choosing a Volvo Penta marine en-

gine. Volvo Penta have been building marine en-

gines since 1907. Quality, operating reliability and in-

novation have made Volvo Penta AB a world leader

in the marine engine industry.

As owner of a Volvo Penta marine engine we would

also like to welcome you to a worldwide network of

dealers and service workshops to assist you with

technical advice, service requirements and replace-

ment parts. Please contact your nearest authorized

Volvo Penta dealer for assistance.

We would like to wish you many pleasant voyages.

AB VOLVO PENTA

Technical Information

Running-in

When the engine is new, it should be run normally.

However, full loading should be avoided for more

than brief periods during the first ten hours of use.

Unnecessary idling of an unloaded engine should

always be avoided.

Check the instrumentation extra carefully during this

period so that any abnormal conditions may be dis-

covered in good time.

Check also that there are no leaks.

NOTE! With a new or reconditioned engine, the

valve clearance should first be checked after 150

hours of operation.

The oil and oil filter* in the Twin Disc reverse gear

should first be changed at this point too. Remove

and clean the reverse gear’s oil screen at the same

time. In the case of MPM reverse gears, the oil

screen should be cleaned after 10 and 50 hours of

operation, and the first oil and filter change* should

be made after 50 hours of operation.

The disengageable clutch should be checked more

often during the first few days. It may be necessary

to adjust it to compensate for wear to the laminate.

*Note! Only the TD MG507–1 and MG507A–1 with a trolling

valve have an oil filter, as does the MPM IRM 301A.

Fuel and lubricants

Only use lubricants and fuels recommended on page

20 or under “Technical Data”. Use of other qualities

can cause malfunctions and reduced service life.

Your new boat

Every new boat has it own special characteristics.

Even experienced boat owners are advised to note

carefully how the boat behaves at different speeds,

weather conditions and loads.

If your boat and engine combination permit high-

speed use, we strongly recommend that a safety

breaker is fitted, regardless of the type of boat. If

your boat is not fitted with a safety breaker contact

your Volvo Penta dealer who can assist you in se-

lecting one.

Our joint responsibility

Volvo Penta continually commits a considerable part

of its development resources towards minimizing the

environmental impact of its products. Examples of ar-

eas where we are always looking for improvements

are exhaust emissions, noise levels and fuel con-

sumption.

Regardless of whether your Volvo Penta engine is

installed in a boat used for pleasure or in commercial

operation, incorrect operation or improper mainte-

nance of the engine will result in disturbance or dam-

age to the environment.

In this instruction book there are a number of service

procedures, which, if not followed will lead to a dete-

rioration of engine characteristics with regard to how

it effects the environment, its service life and cost of

operation. Always follow the recommended service

intervals and make a habit of checking that the en-

gine is operating normally every time you use it. One

example is excessively smoky exhaust. Contact an

authorized Volvo Penta workshop if you cannot cor-

rect the fault yourself.

Bear in mind that most of the chemicals used around

boats are harmful to the environment if used incor-

rectly. Volvo Penta recommends the use of bio-de-

gradable degreasing agents for all cleaning. Always

dispose of engine and transmission oil waste, old

paint, degreasing agents and cleaning residue etc. at

proper disposal areas so they do not harm the envi-

ronment.

Adapt speed and distance during your boat trips so

that swell and noise generated by the boat do not

disturb or harm wildlife, moored boats, landing stag-

es etc. Wherever you land or cruise, please show

consideration and always leave the areas you visit as

you would like to find them yourself.

Spare parts

Warning! The components in the electrical

system and in the fuel system on Volvo Penta

products are designed and manufactured to

minimize risks of fire and explosion.

Using parts that are not Original Volvo Penta

parts which do not correspond to the demands

above, can result in fire or explosion on board.

Any type of damage which is the result of using

replacement parts that are not original Volvo

Penta replacement parts for the product in

question will not be covered under any warran-

ty or guarantee provided by AB Volvo Penta.

Safety

Everyone wants and expects to have a problem-free

and pleasant time when they take their boat out. To

help you do this we have provided a pre-journey

check-list below, which can of course be added to

according personal experience. A major area is natu-

rally the engine, its equipment and that the boat in

general is properly maintained.

Planning your trip

– Get out up-to-date charts for the route planned.

– Calculate distance and fuel consumption.

– Note down if there are fuel points on your planned

course.

– Tell friends or relatives about your trip plans.

Boat equipment

– Rescue and emergency items such as lifevests

and signal rockets. Does everyone know where

they are?

– Spare parts on board, for example Kit with water

pump impeller etc.

– TAMD72P with Twin Disc reverse gear with elec-

tronic gear shifting:

Check that the plug for emergency operation

(manual engagement) of the reverse gear is kept

on board (the plug is delivered with the reverse

gear). See page 26.

– Proper tools for the equipment.

– Fire extinguisher (checked and charged).

Warranty and guarantee

A Service and Warranty book with conditions for

Volvo Penta’s International Limited Warranty is sup-

plied with every engine. Contact your nearest Volvo

Penta dealer or importer for your copy if you have

not received one.

Some markets can have other warranty conditions

depending on national legislation and regulations.

These conditions are provided by the Volvo Penta

importer or distributor for the market in question. If

you wish to have a copy of the conditions please

contact your local Volvo Penta representative.

Warranty Registration Card

The Warranty Registration Form (North American

market) or Warranty Card (other markets) should al-

ways be filled out and sent in by the dealer. Make

sure that this has been done, since refusal of warran-

ty can occur if no proof of the delivery date can be

provided.

They also have the special tools and testing equip-

ment required for maintaining a high standard of ser-

vice. Volvo Penta dealers and vendors must maintain

a stock of original spare parts and accessories to

cover most requirements of Volvo Penta owners.

When ordering a service or spare parts always quote

the engine and reverse gear complete type designa-

tion and serial number. You will find this information

on the engine product plate and on a label on the

front valve cover (see page 8).

Certificated engines

Important information for engines certificated for

Lake Constance and Switzerland

All Volvo Penta engines and products are developed

to minimize environmental impact.

National and regional legislation is not identical in all

the markets where Volvo Penta sells its products.

Occasionally legislation requires that we build special

engine variants, or that an engine must be approved

in advance, that is, certificated by the local authori-

ties.

An engine with certification means that we, as the

manufacturer, guarantee that all engines manufac-

tured are of the same type as the certificated and ap-

proved example. Certification is not only a require-

ment covering engines from the factory, but also that

engines in use must meet the environmental de-

mands set for that engine. In order for Volvo Penta

as the manufacturer to take responsibility for engines

in use, certain requirements pertaining to service and

spare parts must be met. We do not wish to discour-

age owners from carrying out service work them-

selves, rather the opposite since an owner can quick-

ly notice if an engine is not operating normally.

However, a number of service operations demand

access to special expertise, workshop manuals, spe-

cial tools and other equipment designed for the en-

gines. These service operations may only be carried

out by an authorized Volvo Penta Service workshop.

Always contact your Volvo Penta dealer if you are

not sure about anything concerning your engine’s

function or maintenance.

Maintenance and care

– PDC (Pre-Delivery Commissioning) delivery un-

dertaking for marine engines: “PDC” enables us to

ensure that Volvo Penta products operate correct-

ly after installation in a boat, and further that the

end-user gets acquainted with the product, its

functions and care (refer to checklist in the War-

ranty and Service book). Delivery undertaking

“PDC” is carried out at the time of the delivery of

the boat to the end-user. The cost of this work is

covered by the Volvo Penta company’s Interna-

tional Limited Warranty.

–First Service Inspection: A first service inspec-

tion should be carried out after running the engine

for 100 hours (TAMD63 and TAMD72) or 150–300

hours (TAMD71) or within 180 days from the date

of delivery or the end of the first season, whichev-

er comes first. Labor and material costs in connec-

tion with the First Service Inspection are not cov-

ered by the Volvo Penta International Limited

Guarantee (for checklist see your Warranty and

Service book).

Regular maintenance should be carried out after the

First Service Inspection in accordance with the main-

tenance schedule in this book. Any work carried out

in addition to maintenance services should be docu-

mented (refer to the Warranty and Service book).

It is an absolute condition for the Volvo Penta Inter-

national Limited Warranty to apply that the Pre-Deliv-

ery Commissioning and First Service Inspection have

been carried out by an authorized Volvo Penta ser-

vice dealer.

Volvo Penta Service

Volvo Penta has a comprehensive dealer network

that offers both service and spare parts for Volvo

Penta engines. These dealers have been carefully

selected and trained to provide professional assist-

ance for service and repairs.

All rights to changes or modifications reserved.

Printed on environmentally-friendly paper

As an owner or operator of a certificated Volvo Penta

engine it is important that you are aware of the fol-

lowing:

●The Service Intervals and maintenance operations

recommended by Volvo Penta must be followed.

●Only Volvo Penta Original Spare parts intended for

the certificated engine may be used.

●Service work on the injection pump and injectors

or pump settings must always be carried out by an

authorized Volvo Penta workshop.

●The engine may not be altered or modified in any

way, with the exception of accessories and service

kits developed by Volvo Penta for that engine.

●No modifications to the exhaust pipes and air sup-

ply ducts for the engine room (ventilation ducts)

may be undertaken as this may effect exhaust

emissions.

●Any seals on the engine may not be broken other

than by authorized persons.

Important! If spare parts are required use only

Volvo Penta Original parts.

Use of spare parts other than AB Volvo

Penta Original spare parts will result in AB

Volvo Penta being unable to assume any li-

ability for the engine meeting requirements

under the engine certification. Any type of

damage which is the result of using replace-

ment parts that are not original Volvo Penta re-

placement parts for the product in question will

not be covered under any warranty or guaran-

tee provided by AB Volvo Penta.

Identifying Numbers

Immediately after you have taken delivery of your

boat, make a note of the serial number and model

designation of the engine and reverse gear. Include

the serial number and model designation of the boat

and any extra equipment. This information is neces-

sary when you contact your Volvo Penta or boat

sales representative for service and spare parts.

Take a copy of the information and keep it in a safe

place so it is available should the boat be stolen.

Engine type ...............................................................