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Stamford D5A T, Operator'S Manual, Page: 42 / 70

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42

Maintenance: Cooling system general

Drain points freshwater system

Drain points rawwater system

1. Engine

2. Freshwater pump

3. Thermostat valve

4. Expansion tank

5. Charge air cooler

6. Heat exchanger

7. Rawwater pump

8. Freshwater circuit

9. Rawwater circuit

Cooling system D5A TA HE

The system includes two circuits. The freshwater system is cooling the charge air, the cylinder liners and the cy-
linder heads. An engine driven cooling water pump circulates the coolant through the heat exchanger and through
the engine. The rawwater system is cooling the coolant in the freshwater cooling system. The rawwwater system
is connected to a seawater inlet or a central cooling system.

Summary of Contents for D5A T

Page 1: ...OPERATOR SMANUAL D5A T TA Marine Genset Non classifiable control system...

Page 2: ...CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm...

Page 3: ...upplied 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 manufac...

Page 4: ...eding the fuel system 36 Changing fuel filter 36 Fuel pre filter water separator 37 Air inlet and exhaust systems 39 Changing air filter 39 Cleaning the compressor 39 Checking drain hole of charge air...

Page 5: ...r 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...

Page 6: ...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...

Page 7: ...owledge 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 l...

Page 8: ...e 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...

Page 9: ...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 i...

Page 10: ...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 disturb...

Page 11: ...ls 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 Negl...

Page 12: ...e 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 retu...

Page 13: ...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...

Page 14: ...uel 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 M...

Page 15: ...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...

Page 16: ...gle 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...

Page 17: ...erator 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 F...

Page 18: ...ew 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...

Page 19: ...ORTANT 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...

Page 20: ...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...

Page 21: ...e of the warning lamps comes on 8 Alarm display see section Alarm display 9 Key switch see section Key switch 10 Press button for instrument illumination Shutdown Shutdowns are available as follows Au...

Page 22: ...minate the acous tic alarm The corresponding warning lamp will conti nue to flash until the fault has been rectified Reset To reset the shutdown the starter key must be turned to the 0 position IMPORT...

Page 23: ...t in a safe and correct manner before taking it into operation Checking the instruments Check the instruments and warning display directly af ter start and regularly during operation NOTE For informat...

Page 24: ...is running this may damage the starter Applying load If possible do not apply heavy loads until the engine has reached operating temperature During load operation make sure that 1 No engine related a...

Page 25: ...to a stop The warning display lamps for No charge voltage and Low oil pressure will turn on when the engine stops 3 Turn the key to position 0 and remove The warning display lamps will turn off WARNI...

Page 26: ...ING If the raw water system bursts due to freezing the vessel could sink IMPORTANT If the coolant does not give sufficient anti freeze protection it may cause costly damage to the engine Check the cha...

Page 27: ...oney for servicing Maintenance records Volvo Penta recommends that accurate maintenance records are kept With accurate maintenance records your Volvo Penta Dealer can help in fine tuning the recommend...

Page 28: ...mperature and pressure 5 Rawwater pressure and rawwater temperature before and after heat exchanger Ambient temperature and engine room temperature at turbo charger inlet 6 Parts serviced and kinds of...

Page 29: ...brication oil for abnormal smell or waterdilution Check settings of valves and operate valves to keep them movable After first 10 operating hours Check lubrication oil level Check coolant level After...

Page 30: ...g hours or every 12 months Check adjust valve clearances Every 2000 operating hours Pressure test fuel injectors refer to note 2 Every 12 months Check turbocharger refer to note 2 Check clean charge a...

Page 31: ...nsioned if they can be pressed down 10 mm 3 8 by thumb pressure Clean the belt grooves before fit ting a new belt Coolant pump Fuel pump Adjusting 1 Loosen screws 1 and 2 2 Push the fuel pump 3 to the...

Page 32: ...n The oil temperature should not exceed 80 C 176 F Checking 1 Remove crankcase ventilation oil trap housing A 2 Remove the cylinder head cover 3 Position crankshaft as in the figure at the bottom of t...

Page 33: ...st valve about to close inlet valve about to open Adjust clearance of valves marked in black on schematic Mark respective rocker arm with chalk to show that adjustment has been carried out Crankshaft...

Page 34: ...r to chapter Technical Data Changing oil Always observe the recommended oil change interval Use the oil drain pump to drain the oil from the sump IMPORTANT Onlyuserecommendedgradesof oil refer to chap...

Page 35: ...ubber seal of the new filters and make sure its mating surfaces on the filter brack ets are clean 5 Mount the new filter by hand until the gasket is in contact with the sealing surface Then tighten th...

Page 36: ...delivery pipes If the delivery pipes are loose they must bechanged Changing fuel filter Clean the filter bracket and place a receptacle under the filters NOTE Leave the old filters to a destruction p...

Page 37: ...uel pre filter water separator The pre filter water separator is installed between the fuel tank and the engine and works in three stages Centrifugal separation coagulation and filtration Water and im...

Page 38: ...hanging the filter elements If the engine is not running close the fuel cocks on the tank before changing filters If the engine is running cut off the flow of fuel through the filter to be changed wit...

Page 39: ...artridge and pull off the cartridge 2 Replace the air filter cartridge and tighten the hose clamp 3 Press the button on the service indicator to reset the signal after service The indicator is now rea...

Page 40: ...r The Volvo Penta Genset comes with an internal freshwater system connected to an engine mounted heat exchan ger a radiator cooler or prepared for external cooling e g keel cooling or central cooling...

Page 41: ...s the coolant through the heat exchanger and through the engine The rawwater system is cooling the coolant in the freshwater cooling system The rawwater system is connected to a seawater inlet or a ce...

Page 42: ...9 Rawwater circuit Cooling system D5A TA HE The system includes two circuits The freshwater system is cooling the charge air the cylinder liners and the cy linder heads An engine driven cooling water...

Page 43: ...n engine driven cooling air fan The charge air is cooled in an air to air charge air cooler mounted in front of the radiator and it make use of the air flow from the engines cooling fan before it ente...

Page 44: ...ooled by e g a box cooler a grid cooler or any other external heat ex changer The system is cooling the cylinder liners and the cylinder heads An engine driven freshwater pump cir culate the coolant t...

Page 45: ...h the thermostat valve opens and allows water of a lower temperature from the LT circuit to enter the HT circuit The HT circuit is cooling the cylinder liners the cylinder heads and the lubrication oi...

Page 46: ...oling the cylinder liners the cylinder heads and the lubrication oil An engine driven HT pump circulates the coolant through the engine The LT circuit is cooling the charge air An engine driven LT pum...

Page 47: ...el through the filler opening in the expansion tank for correct level refer to section coolant level check Fill slowly so that evacuated air is able to pass the filler opening NOTE For coolant specifi...

Page 48: ...eally does drain out Deposits may need to be cleared away inside the drain plug s tap s 3 Drain all other systems connected to the freshwa ter system HT circuit e g heater water heater etc 4 Close all...

Page 49: ...and the inside of the cover with water resistant grease non aggressive on rub ber 5 Push the impeller into position while rotating it in the normal operating direction 6 Fit the cover with a new seal...

Page 50: ...w O ring 11 Fit the connecting socket with a new gasket 12 Install the coolant pipes to and from the raw water pump Rawwater pump LT pump Disassembly 1 Drain the water from theraw water system 2 Remov...

Page 51: ...necting cover 3 3 Gently drive out the raw water bundle 4 4 Clean the raw water bundle and the heat exchanger housing 5 Make sure that there are no cracks or other damages replace if necessary 5 Reins...

Page 52: ...n stopped Breaking the circuit bet ween the generator and the batteries while the engine is running can damage the generator For the same reason the charge circuits must never be switched while the en...

Page 53: ...of the battery first Then connect the cable black to the pole of the battery Disconnect the cable black first and then the cable red Cleaning Keep batteries dry and clean Contaminants and oxi de on b...

Page 54: ...batteries will be harmed if left discharged and can also freeze and crack in cold weather IMPORTANT Follow the battery charger user instructions carefully Disconnect the battery cables before connect...

Page 55: ...up to eight months Change oil and oil filter on the engine and then run it warm Stop over eight months Treat the lubricating and fuel systems with conservation oil See directions on next page 2 Make...

Page 56: ...ries 10 Start the genset and run it at idling speed until it reaches operating temperature before loading it 11 Check for oil fuel or coolant leaks 12 When the engine has run long enough to warm up ap...

Page 57: ...es 4 Main switch turned off 5 A fuse circuit breaker has blown tripped 6 Lack of fuel 7 Blocked fuel filter 8 Defective fuel filter 9 Blocked fuel pipes 10 Defective fuel pipes 11 Blocked fuel supply...

Page 58: ...ard Power 340 C 644 F at 100 of ISO Standard Power 385 C 725 F at 110 of ISO Standard Power 400 C 752 F Approximated values temperatures varies with ambient temperature and back pressure in the exhaus...

Page 59: ...rd Power 325 C 617 F at 100 of ISO Standard Power 365 C 689 F at 110 of ISO Standard Power 380 C 716 F Approximated values temperatures varies with ambient temperature and back pressure in the exhaust...

Page 60: ...F at 75 of ISO Standard Power 340 C 644 F at 100 of ISO Standard Power 385 C 725 F at 110 of ISO Standard Power 400 C 752 F Approximated values temperatures varies with ambient temperature and back pr...

Page 61: ...of ISO Standard Power 340 C 644 F at 100 of ISO Standard Power 385 C 725 F at 110 of ISO Standard Power 400 C 752 F Approximated values temperatures varies with ambient temperature and back pressure i...

Page 62: ...tandard Power 325 C 617 F at 100 of ISO Standard Power 365 C 689 F at 110 of ISO Standard Power 380 C 716 F Approximated values temperatures varies with ambient temperature and back pressure in the ex...

Page 63: ...tandard Power 325 C 617 F at 100 of ISO Standard Power 365 C 689 F at 110 of ISO Standard Power 380 C 716 F Approximated values temperatures varies with ambient temperature and back pressure in the ex...

Page 64: ...supplier to select the right type JIS KK 2204 Type1 Type2 Type3 ASTM D975 No 1 D No 2 D EN590 with national environment and cold requirements Sulfur content Complying with legal requirements in each c...

Page 65: ...as with increased wear and reduced output as a result SAE5W 30 30 20 10 0 10 20 30 40 22 4 14 32 50 68 86 104 15o C SAE15W 40 25o C SAE10W 30 10o C SAE20W 30 0o C SAE30 SAE40 10o C o C o F Refers to s...

Page 66: ...l solid particle content 340 ppm Total hardness 9 5 dH Chloride 40 ppm Sulphate 100 ppm pH value 5 5 9 Silica 20 mg SiO2 l Iron 0 10 ppm Manganese 0 05 ppm Conductivity 500 mS cm Organic content CODMn...

Page 67: ...and spare parts Engine Type Plate 1 1 Engine designation 2 Product number 3 Serial number 4 Rated power 5 Rated engine speed Engine plate 2 1 Product designation 2 Product number 3 Serial base eng No...

Page 68: ...Notes...

Page 69: ......

Page 70: ...7744195 English 07 2004...

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