INSTRUCTION BOOK TAMD60A/B, TAMD70C/D, AQD70C/D
Foreword Read the instruction book before you attempt starting! The book contains the information you need in order to run and maintain the engine in the best possible way. 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.
Instruction book Marine diesel engines TAMD60A, TAMD60B, TAMD70C, TAMD70D, AQD70C, AQD70D Contents Presentation Page Safety information ............................................................. 2 Type designation .............................................................. 7 Location of serial number ................................................. 7 Engine description ........................................................... 8 Instruments ..........................................................
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 boat trips and maintenance of the engine. Make sure you are in possession of the right instruction manual before reading on. If this is not the case, please get in touch with your Volvo Penta dealer.
Safety regulations for boat trips The new boat Read instruction manuals and other information accompanying the new boat thoroughly. Accustom yourself with handling the engine, controls and other equipment in a safe and correct manner. If this is your first boat or if it is a type you are not used to, we recommend practising manoeuvring the boat in a peaceful environment.
Carbon monoxide poisoning When a boat is moving forward, it will cause a certain vacuum to form behind the boat. In unfortunate circumstances, the suction from this vacuum can be so great that the exhaust gases from the boat are drawn into the cockpit or cabin and cause carbon monoxide poisoning. This problem is most prevailant on high, wide boats with abrupt stern. In certain conditions, however, this suction can be a problem on other boats, e.g. when running with the cover up.
Safety directions for maintenance and service Preparations Knowledge The instruction manual contains directions for performing normal maintenance and service in a safe and correct manner. Read the directions carefully before starting work. More detailed service literature is available 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 assistance instead.
Hot surfaces and fluids A hot engine always involves risk for burn injuries. Take care with hot surfaces. E.g.: exhaust manifold, turbocharger, oil pan, charge air pipe, starting heater, hot coolant and warm lubricant in pipes and hoses. 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.
Presentation The engines described in this instruction book are six-cylinder, in-line marine diesel engines with direct fuel injection and fresh water cooling and equipped with a turbo-compressor and after-cooler for the intake air. Type designations Aquamatic engines Inboard engines AQD70C AQD70D TAMD60A TAMD60B TAMD70C TAMD70D Locating of number plate Engine: On the block above the injection pump. TAMD60: On the block in front of the oil filters.
Fig 3. Engine AQD70C, TAMD70C 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Oil scavenging pump After-cooler Heat exchanger Oil cooler, engine Thermostat housing Vibration damper Seawater pump Oil filters Relay box Electric connection box with fuses The engines are fitted with a heat exchanger for thermostatically controlled fresh water cooling of the engine block, cylinder heads and exhaust manifold. The exhaust manifold cooling jacket is designed so that it also cools all the exhaust ports.
Fig. 5. Engine TAMD70D 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. The engines have wet replaceable cylinder liners which are cooled by fresh water. The turbo-compressor supplies fresh air to the engine during the induction stroke. Air is supplied under pressure, resulting in a greater degree of volumetric efficiency. The cylinders thus receive a greater quantity of air and consequently more oxygen per stroke. In consequence the amount of fuel injected can also be increased, which leads to increased output.
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 on a basic panel (A).
8. 9. Pressure gauge - engine lubricating oil pressure, should be at 300-500 kPa (3-5 kp/cm2 = 43-71 psi) during normal operation. At idling speed it should be min. 150 kPa (1.5 kp/cm2 = 21 psi). The engine must not be run with excessively low oil pressure. Starter button - pushing it engages the starter motor. 10. Temperature gauge engine coolant - During normal operation the temperature should be between 65° and 95°C (149-203°F).
Fig. 10. Twin control Fig. 9. Single control Controls Volvo Penta single lever control (single or twin), operates both the reverse gear and the engine speed. When there are two engines a twin control is used. When it is desired to use the lever again for operating the reverse gear, keep the button (2) pushed in and move the lever to neutral again. Lever (1) at N – neutral position. From N to F – reverse gear engaged for running forward. From N to R – reverse gear engaged for running in reverse.
On the TAMD60 engines, small quantities required for topping-up can be added to the expansion tank, but otherwise 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 venting cock at the turbo and screw the hexagon plug on the heat exchanger. Thereafter, fill the expansion tank at the side of the engine (1, fig. 11) with approx. 3 litres (0.66 Imp. galls = 0.80 US galls) and replace the cap. 1.
Starting With the exception of TAMD60, the engines have an air pre-heater fitted in the intake manifold and this should always be used in order to provide a rapid and easy start and to reduce exhaust smoke from a cold engine. If the engine is warm, the pre-heater does not have to be engaged, in which case the key is turned to position II, running position. Point 2 is excluded and the engine is started regardless of the warning lamps mentioned in point 4. 1.
Procedure after starting 1. Never race a cold engine. Run it warm under light loading or at rapid idling speed. 2. Check that the warning lamp for the oil pressure (17, figs. 7 & 8) goes out immediately after the engine has started. The oil pressure for the engine should be between 300-500 kPa (3-5 kp/cm2 = 43-71 p.s.i.) at normal operation. The warning lamp lights and the siren sounds if the pressure drops below 150 kPa (1.5 kp/cm2 = 21 p.s.i.
Change the oil again after running 100–150 hours and change the oil filter (filters) at the same time. Never flush out the engine with flushing oil since the bearing pressures in a diesel engine are too high for the use of this kind of oil to be suitable. The oil in the reverse gear (and the filter element on SCG) should be changed for the first time after 100-150 hours of operation. The oil is subsequently changed at the normal intervals given in the servicing scheme.
Stopping 1. Let the engine run for a few minutes without load to enable the engine temperature to drop, thereby avoiding after-boiling. 2. Press in the stop button and keep it pressed in until the engine has stopped, 3. Close the cock on the trickle-feed line to the bilge pump, if such a pump is fitted. The scribed mark on the cock should be at right-angles to the pipe when the cock is closed. 4. When the engine has stopped switch off the current by turning the key switch to the 0-position.
Fig. 29. TAMD60 F = Fresh water cocks S = Seawater cocks 1 = Cap, topping-up, fresh water 2 = Plug for filling larger amounts of fresh water Fig. 31. All engines (The cocks are similarly placed.) The dotted lines apply only to AQD70D, TAMD70D engines F = Fresh water cocks 2 = Venting cock Anti-freeze During the cold season, suitable anti-freeze should be added to the cooling water in the fresh water system. We recommend that you use our ethylene glycol (red, part number 283241 in cans of 4.
Engine lubricating oil The engine requires high-class diesel engine oil in order to maintain good running economy and maximum performance. It is an absolute requirement that the correct quality of lubricating oil is used according to our recommendations. Note that our warranty does not apply if the engine is run with the wrong lubricating oil. We recommend that you use Volvo Penta diesel engine lubricating oil which is on sale at our service stations.
Servicing scheme The numbering in the scheme below lists the servicing operations described in the following pages under the corresponding 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 1. Check the oil level in the engine 18. Replace the engine lubricating oil filters. 2. Check the oil level in the reverse gear 3.
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. For changing the oil, see pages 19 and 20. The fuel injection pump and the turbo-compressor are automatically lubricated through the engine lubricating system.
Reverse gear lubricating oil Engine oil of same quality Oil capacity, approx. and viscosity as in (incl. cooler) engine* dm3 (litres) Imp.gall. USgall. Borg Warner 73CR* 2.5 0.5 0.7 Borg Warner 10-05* V-drive 5.5 1.2 1.5 Twin Disc, MG 502 2.5 0.5 0.7 Twin Disc, MG 506 6.5 1.4 1.7 SCG MRF 350 HDMK3 12.5 2.7 3.3 Venting cocks * Oil viscosity for Borg Warner, SAE 30. 3. Engine coolant level Check the level daily before starting.
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. Rockford/BW (1:1) 5. Checking oil level in reduction gear Optional equipment, TAMD70D Check the level daily before starting.
7. Hydraulic system, oil level AQD70. Optional equipment for all other engines. Check the level after every 50 hours of operation. The engine should be idling. 1. Remove the filler cap on the hydraulic tank. 2. Wipe the dipstick, and check the level which should be at the max. mark on the dipstick. 3. Fill with engine oil, if necessary. The oil quality is the same as in the engine, 8. Checking batteries Check the electrolyte level in the batteries every 50 hours or more often.
All other engines, changing oil 1. 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. 2. Start the pump and collect the oil in a vessel. 3. Fill oil through the hole for the ventilation cap on the rocker arm casing. It is also possible to use the scavenging pump when filling with oil by reversing the polarity of the pump motor (reversing the + and cables.
Both elements of the double filter and the lower element of the single filter should be changed after 200 hours of operation or at least once every season, preferably at the beginning. Close the fuel cocks at the tank and loosen the filter housing by screwing out the centre screw. Clean the filter housings carefully. The upper element of the single filter should be changed once a year. Use new gaskets when reassembling. Vent the filters before starting through the plug 1 or the cock 3. 13.
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 pulley (2) outwards. The belts for the large alternator (1600W) are tensioned after first having loosened the 4 attaching screws.
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 element and clean the element in the housing (2) carefully. Refit the parts, open the bottom valve and check that there is no leakage. Every 600 hours 18.
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. All other engines Replace the filter with a new one after 600 hours of operation. Under favourable conditions the time between the changes can be extended. 1. Clean the rubber tube to the filter.
24. Starter motor, lubrication* Lubricate the starter motor after every 600 hours of operation 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. Slotted screw for lubricating starter motor KG(R) 25.
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. 27. Reverse gear, changing oil Change the oil after every 1200 hours of operation or at least once a year.
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. Take off the starter motor protective cover. Lift the brush springs and pull out the brushes. These should run easily in their holders.
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 Retinax A or equivalent lubricant. Refit the plug. Fuses The fuses are positioned in the black plastic box at the side of the engine.
AQD70, TAMD70 1. Remove the screws securing the cooling water pipe between the heat exchanger end cover and the reverse gear oil cooler. 2. Carefully bend loose the pipe from the end cover. 3. Undo the hose clamp between the after-cooler and the heat exchanger and the clamp on the cooling water line under the after-cooler. 4. Remove the screws securing the end cover at the front of the heat exchanger and the cover over the after-cooler and remove these. Pull out the inserts. 5.
5. Use new gaskets and fit the housing to the engine. 6. 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 1. Drain the coolant from the fresh water system. Remove the oil cooler coolant pipes. 2. Place a collecting vessel under the oil cooler and loosen the oil distribution housing from the cylinder block. Pull out the connections from the oil cooler cover. 3.
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 becomes null and void if the seals are broken by unauthorized persons. Since operating conditions vary considerably, it is difficult to indicate any definite interval, but the pump settings, max. and idle speeds, exhaust smoke, etc.
35. Inhibiting 6. Corrosion of the engine components must be prevented as otherwise the engine will gradually be destroyed. For this reason, the engine should be protected against such damage by the following measures: Vent the fuel system and start the engine. See chapter ”Running”. Let the engine run at rapid idle until about 2 litres (2 quarts) have been consumed from the vessel. 7. Stop the engine and pump out the rust-proofing oil from the oil sump. Connect the ordinary fuel lines.
Technical Data Engine Type designation ......................................................................... TAMD60A TAMD60B 6 98.4 120 5,48 10.9 (650) Number of cylinders ..................................................................... Cylinder bore .......................................................................... mm Stroke ...................................................................................... mm Displacement ..............................................................
Fuel system TAMD60A Fuel injection pump Bosch ........................................................... Injectors (holders) Bosch .............................................................. Nozzles Bosch .......................................................................... Hole diameter (4 holes) .......................................................... mm Opening pressure ........................................... MPa (kp/cm2, p.s.i.) Injectors (holders) Bosch (without rod filter)*** ..........
Turbo-compressor Manufacturer, type (TAMD60A-AQD70C, TAMD70C) ................. (TAMD60B-AQD70D, TAMD70D) ................................................ Lubrication .................................................................................... Cooling ......................................................................................... TAMD60 AQD70, TAMD70 Holset 3LD-530A/ Holset 3LD-530A/ 2.5 WSO 2.5 WSO KKK-K27-2970 N/14.7 KKK-K27-3068/14.
Borg Warner, model .................................................................... Ratios ............................................................................................ Oil quality ...................................................................................... Oil capacity (including cooler) .................. dm3 (Imp.gall,US gall.) Oil pressure, normal during running .............. MPa (kp/cm2, p.s.i.) Weight .......................................................................
Wiring diagram Fig. K1. Block diagram (same for all engines in this book) A. B. C. D. E. F. Basic instrument panel Panel with supplementary instruments (alarm, etc) Panel with fuel gauge and rudder indicator Flying Bridge instrument panel Engine Connection box with fuses If panel D is fitted but not B, contact No. 1 from the Flying Bridge instrument panel is wired to contact No. 2 from the engine. However, contacts Nos. 1 and 7 should not be wired together when panel D is not fitted. 42 1.
Fig. K2A. Wiring diagram. Engine TAMD60A*, TAMD60B 1. Batteries. Capacity see ”Technical 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. Fuses 50 A for standard alternator (80 A for 1600 W alternator) 7. Fuses 25 A (in both cases) 8. Oil pressure sender, engine 9. Stop solenoid 10. Engine coolant temperature sender 11. Oil pressure sensor (for hour meter) 12.
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. Fuses 50 A for standard alternator (80 A for 1600 W alternator) 7. Fuses 25 A (in both cases) 8. Oil pressure sender, engine 9. Stop solenoid 10. Engine coolant temperature sender 11.
Fig. K3. Wiring diagram. Instruments, basic instrument panel 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. Instrument lighting Voltmeter Oil pressure gauge Engine coolant temperature gauge Stop button Time relay (not on TAMD60) Holding current relay (Omitted on TAMD60 but green cable 2.5 from 35 is connected to + on 33) Series resistance Starter button Indicating lamp (pre-heater, not on TAMD60) Rev counter Indicating lamp (start engine, not on TAMD60) Key switch Rheostat for instrument lighting.
Fig. K4. Wiring diagram. Panel with supplementary instruments (alarm, etc) 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 46 Instrument lighting Oil pressure gauge – reverse gear Alarm separator Pressure gauge – turbo Extra switches (max.
Fig. K5. Wiring diagram. Panel with fuel gauge and rudder indicator. 71. 72. 73. 74. 75. 76. Instrument lighting Fuel gauge Rudder indicator Extra switches (max. 5 A per switch) Sender, fuel gauge Sender, rudder indicator (The free, blue 1.5 cable should be connected to 104 on the engine terminal box) Fig. K6. Wiring diagram Flying Bridge instrument panel 81. 82. 83. 84. 85. 86. 87. 88. 89. 90. 91.
Index A I After-cooler ........................................................... 9, 33, 34 Air cleaner ...................................................................... 29 Anti-freeze ...................................................................... 18 Inhibiting ......................................................................... 37 Injection pump ........................................................... 36,39 Injectors .................................................................
SI unit system Units according to the international SI system have been used in this book. The earlier units are given after the SI units. Power is given in kW (kilowatt) earlier unit hp (horse-power) Speed is given in r/s (revolutions per second) earlier unit r/min (revolutions per minute) Torque is given in Nm (newton metre) earlier unit kpm (kilopond metre) earlier unit lbf.ft (poundfoot) Volume is given in dm3 (cubic decimetre) earlier unit l (litre) earlier unit Imp.
7731201-5 English 7-1979
