Volvo Penta D7A T Operator'S Manual Download Page 42

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D5A T RC Marine Genset

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
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.

P0013764

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

15 Oil filler

16 Oil drain pump

Maintenance

47713337 03-2021 © AB VOLVO PENTA

Summary of Contents for D7A T

Page 1: ...Operator s manual D5A 7A T TA Marine Genset Non Classifiable Control System Control System MCC ...

Page 2: ...r reproductive harm To minimize exposure avoid breathing exhaust when operating servicing and maintaining the engine Always start and operate the engine in a well ventilated area If in an enclosed area vent the exhaust to the outside Wear gloves or wash your hands frequently when servicing the vessel Do not modify or tamper with the exhaust system Do not idle the engine except as necessary For mor...

Page 3: ...on 20 Before Starting 21 Starting the Engine 22 Warming up 22 Starting the Engine 22 Starting Using Auxiliary Batteries 23 Operation 24 Alarms 25 Alarm handling display 25 Engine Shutdown 26 Stop the Engine 26 Emergency Stop 26 After Engine Shutdown 27 Fault handling 28 Fault Tracing 28 In Case of Emergency 30 Starting Using Auxiliary Batteries 30 Maintenance Schedule 31 Maintenance 32 Orientation...

Page 4: ...stem 86 Air Filter Change 86 Compressor Cleaning 87 Charge Air Cooler Checking the Drain Hole 88 Electrical System 89 General 89 Electrical wiring Check 89 Main switch 89 Fuses 89 Battery 90 Electrical Welding 91 Storage 92 Preparation 93 Storage 94 Long Term Storage 94 Bringing Out of Storage 95 Technical Data 96 Engines 96 Lubrication System 102 Oil Grade and Oil Change Interval 102 Viscosity 10...

Page 5: ...fely and correctly Pay careful attention to the safety instructions included in the manual As the owner of a Volvo Penta engine you become part of a worldwide network of dealers and service workshop that assist you with technical advice service requirements and replacement parts Contact your nearest authorized Volvo Penta dealer for assistance It is possible to buy additional literature about your...

Page 6: ...f not avoided result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious personal injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate personal injury IMPORTANT Indicates a situation which if not avoided could result in property damage NOTICE Used to draw attention to important inf...

Page 7: ...opped This helps you to quickly discover fuel coolant or oil leakages or any other abnormality that has occurred or is about to occur Personal safety equipment CAUTION Always use appropriate safety equipment Personal protective equipment does not eliminate the risk of injury but it will reduce the degree of injury if an accident does happen Some examples are ear protection eye and face protection ...

Page 8: ...ore welding or grinding begins Always ensure that there is a fire extinguisher close at hand in the work area Spare parts safety WARNING Always use spare parts with the same quality as genuine Volvo Penta parts to minimize the risk of an explosion or fire Components in fuel systems and electrical systems on Volvo Penta engines are designed and manufactured to minimize the risk of explosions and fi...

Page 9: ...tch out for rotating components and hot surfaces If the engine is in operation and operates another device you must not under any circumstances staying close to the engine Work on running engines is strictly prohibited There are however adjustments that require the engine to be run Approaching a running engine is a safety risk Loose clothing and long hair can get caught in the rotating parts carel...

Page 10: ...tion cause serious personal injuries Before any work on the electrical system WARNING Always stop the engine first Then disconnect the current at the main switches and any external power supply before working on the electrical system to minimize the risk of electrical hazards IMPORTANT Never disconnect the current using the main switches when the engine is running or by disconnecting the battery c...

Page 11: ... the oil filler cap is on There is a risk that hot oil can spray out Refueling WARNING There is always a risk of fire and explosion during refueling Smoking is forbidden and the engine must be stopped Proper fuel quality IMPORTANT Always use the fuel recommended by Volvo Penta See Technical Data in Operator s Manual Other fuel can damage the engine Wrong fuel quality can also lead to higher servic...

Page 12: ...us injuries Do not touch the connections during start attempts Sparking hazard Do not lean over batteries Correct polarity of the batteries IMPORTANT Make sure that the positive and negative battery cables are correctly connected to the corresponding battery terminals Wrong connection may cause severe damage to electrical equipment Risks of electrolyte in batteries WARNING Always wear protective g...

Page 13: ... Cleanliness for sensitive components IMPORTANT Observe meticulous cleanliness when handling system components Even minimal amounts of dirt could cause a breakdown Adjustment of the clutch CAUTION Clutch adjustments must be carried out with the engine stopped P0024486 Safety Information 47713337 03 2021 AB VOLVO PENTA 11 ...

Page 14: ...ions and the purchased product This does however not affect the validity of the information and or instructions in the manual Volvo Penta reserves the right to make alterations to specifications design features and illustrations without prior notice At service software can be updated that affects the functionality described in this manual About this Manual This Operator s Manual has been prepared ...

Page 15: ... Volvo Penta may deny its warranty obligations in part or in full NOTICE Make sure that a Commissioning has been carried out on your Volvo Penta engine This should be done together with your Volvo Penta dealer when finalizing the purchase Without a proper Commissioning registration the warranty will not be valid Contact your Volvo Penta dealer if you have not received the Warranty Information or S...

Page 16: ...ained through regular servicing and the use of spare parts with the same quality as genuine Volvo Penta parts If reliable and purpose built parts are not used your safety health and the machine s function may be compromised Volvo Penta has a world wide network of authorized dealers The authorized dealers are Volvo Penta product specialists and have the accessories genuine parts test equipment and ...

Page 17: ...rding fuel grades operation and maintenance to avoid unnecessary environmental impact Contact your Volvo Penta dealer if you notice any changes such as increased fuel consumption or exhaust smoke Remember always to hand in environmental hazardous waste such as drained oil coolant old batteries etc for treatment at a recycling facility Our united efforts can make a valuable contribution to the envi...

Page 18: ...ility of the operator user to ensure that no intentional misuse of the engine takes place Volvo Penta maintenance and service intervals must be complied with Any case of malfunction must be rectified without delay Only use genuine Volvo Penta parts or spare parts with the same quality as genuine Volvo Penta parts Volvo Penta recommends that service to injection pumps pump settings and injectors al...

Page 19: ...wnload the dealer locator app to your smartphone Volvo Penta Action Service Our global dealer network your first line of contact is backed up by Volvo Penta Action Service a phone based breakdown and support service providing assistance 24 hours a day every day of the year How it works A dedicated operator will support you all the way through your case and keep you updated on status and progress W...

Page 20: ...for testing and acknowledging alarms refer to section Warning display 7 Audible Alarm Siren for acoustic alarm that sounds if one of the warning lamps comes on 8 Warning display Refer to section Warning display 9 Ignition switch Refer to section Ignition switch 10 Press button for instrument illumination 11 Oil pressure gauge Indicates the oil pressure in the reverse gear 12 Charge air pressure ga...

Page 21: ...ode is delivered This code is required when ordering additional starter keys Keep the code in a safe place S Stop position 0 The key can be inserted or removed I Power on Running engine II Not used III Start position Instruments and Controls 47713337 03 2021 AB VOLVO PENTA 19 ...

Page 22: ...w 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 Ele...

Page 23: ...t up WARNING Before starting the genset make sure people and tools are out of contact with moving parts of the engine or the generator Notify people in the vicinity of the genset when starting IMPORTANT Always keep the engine room well ventilated Insufficient airsupply to the engine means imperfect combustion and loss of power IMPORTANT If the starter motor has been engaged for the maximum time 30...

Page 24: ...cooling water flow is sufficient Starting the Engine 1 Turn on the power by putting the starter key in position I 2 Press the Alarm test button to make sure the warning lamps come on and the acoustic alarm sounds 3 Turn the key to position III Release the key immediately after the engine has started IMPORTANT If the starter motor has been engaged for the maximum time 30 seconds it must be allowed ...

Page 25: ...d then to the auxiliary battery s terminal 3 Connect the black jump lead to the auxiliary battery 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 fo...

Page 26: ...ing This can cause incomplete fuel combustion often indicated by black exhaust high fuel consumption and carbon deposits in combustion chambers affecting genset life If possible do not apply heavy loads until the engine has reached operating temperature During load operation make sure that 1 No engine related alarms occur 2 There are no visible leaks of fuel lube oil coolant or exhaust gas 3 No ab...

Page 27: ...gine without alternator lamp 2 will flash After an alarm Acknowledge Push the acknowledge button to terminate the acoustic alarm The corresponding warning lamp will continue to flash until the fault has been rectified Reset To reset the shutdown the starter key must be turned to the 0 position IMPORTANT Do not attempt to restart the engine until the fault has been rectified Alarm test When pushing...

Page 28: ... engine from being stopped normally it can be stopped manually using the speed adjustment lever on the engine 1 Move the speed adjustment lever 1 to idle 2 Move the shut off lever 2 in the direction of the arrow until the engine comes 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...

Page 29: ...m must be drained and the coolant in the freshwater system must contain sufficient anti freeze to prevent it from freezing Refer to chapter General page 67 WARNING 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 charge of the battery A poorly charged batt...

Page 30: ...25 26 48 54 Engine knocks 20 26 49 Engine vibrates 8 16 22 30 31 34 Engine can not be stopped 2 3 4 5 50 High fuel consumption 12 14 16 18 19 20 25 27 30 Black or Dark gray exhaust smoke 12 14 16 17 18 19 20 25 27 Blue or white exhaust smoke 16 18 19 20 21 27 30 40 41 48 54 High lubrication oil consumption 21 29 30 31 41 Lubrication oil pressure too low 21 28 32 42 43 Coolant temperature too high ...

Page 31: ...water system 37 Blocked sea water inlet pipe filter 38 Circulation pump drive belt slips 39 Defective cooling water pump 40 Defective wrong thermostat 41 Too high lubrication oil level 42 Defective lubrication oil pump 43 Defective relief valve 44 Alternator drive belt slips 45 Clutch is engaged 46 Defective bearings or abnormal cylinder friction 47 Fuel supply pump strainer blocked 48 Very cold e...

Page 32: ...to the minus terminal on the auxiliary battery and to a place a little distance away from the discharged battery e g the start motor s negative terminal WARNING The black jumper cable must never come in contact with the positive connection on the starter motor 4 Start the engine and let it run at fast idle for approximately 10 minutes to charge the batteries Make sure there is no extra equipment c...

Page 33: ...tement Service Intervals Service intervals are shown below The service content can be found in the Service Protocol available for download at www volvopenta com NOTICE More information on how to perform service and maintenance can be found in the Service and Maintenance handbook Information on how to purchase the Service and Maintenance handbook can be found at www volvopenta com Extended service ...

Page 34: ...l injection system and effective turbocharger provide excel lent fuel consumption over the whole range of power output 1 Electrical connection box 2 Fuel return 3 Oil cooler 4 Fresh water pump 5 Fuel pump Fuel inlet 6 Vibration damper 7 Fuel filter 8 Oil filter 9 Oil dip stick 10 Raw water pump 11 Raw water inlet 12 Governor Stop solenoid 13 Heat exchanger 14 Expansion tank 15 Exhaust manifold 16 ...

Page 35: ...ir coo ling provide excellent fuel consumption over the whole range of power output 1 Electrical connection box 2 Fuel return 3 Oil cooler 4 Fresh water pump 5 Fuel pump Fuel inlet 6 Vibration damper 7 Fuel filter 8 Oil filter 9 Oil dip stick 10 Raw water pump 11 Raw water inlet 12 Governor Stop solenoid 13 Expansion tank 14 Charge air cooler 15 Exhaust manifold 16 Air filter 17 Air filter indicat...

Page 36: ... injection system effective turbocharger and charge air coo ling provide excellent fuel consumption over the whole range of power output P0013770 1 2 3 4 5 6 7 8 9 10 11 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 Oil filler 11 Oil drain pump Maintenance 34 47713337 03 ...

Page 37: ... lent fuel consumption over the whole range of power output 1 Electrical connection box 2 Fuel return 3 Oil cooler 4 Fresh water pump 5 Fuel pump fuel inlet 6 Vibration damper 7 Fuel filter 8 Oil filter 9 Oil dip stick 10 Governor stop solenoid 11 Expansion tank 12 Exhaust manifold 13 Air filter 14 Air filter indicator 15 Turbocharger 16 Electrical starter 17 Engine oil drain pump 18 Alternator 19...

Page 38: ...uel consumption over the whole range of power output 1 Electrical connection box 2 Fuel return 3 Oil cooler 4 HT pump 5 Fuel pump Fuel inlet 6 Vibration damper 7 Fuel filter 8 Oil filter 9 Oil dip stick 10 LT pump 11 Coolingwater inlet LT circuit 12 Governor Stop solenoid 13 Expansion tank 14 Charge air cooler 15 Exhaust manifold 16 Air filter 17 Air filter indicator 18 Turbocharger 19 Electrical ...

Page 39: ...le range of power output 1 Electrical connection box 2 Fuel return 3 Oil cooler 4 HT pump 5 Fuel pump Fuel inlet 6 Vibration damper 7 Fuel filter 8 Oil filter 9 Oil dip stick 10 LT pump 11 Coolingwater inlet LT circuit 12 Governor Stop solenoid 13 Cooling water outlet LT circuit 14 Charge air cooler 15 Exhaust manifold 16 Air filter 17 Air filter indicator 18 Turbocharger 19 Electrical starter 20 ...

Page 40: ... or double bearing marine generator Different startingand 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 generat...

Page 41: ...ingle or double bearing marine generator Different startingand 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 ge...

Page 42: ... The engine is mounted on a frame with a Stamford single or double bearing marine generator Different starting and control systems are available P0013764 1 2 3 4 5 6 7 8 9 10 12 11 14 13 15 16 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 ey...

Page 43: ...g marine generator Different startingand 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 m...

Page 44: ...rine generator Different startingand 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...

Page 45: ...startingand 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 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 w...

Page 46: ... and effective turbocharger provide excel lent fuel consumption over the whole range of power output 1 Electrical connection box 2 Fuel return 3 Oil cooler 4 Fresh water pump 5 Fuel pump Fuel inlet 6 Vibration damper 7 Fuel filter 8 Oil filter 9 Oil dip stick 10 Raw water pump 11 Raw water inlet 12 Governor Stop solenoid 13 Heat exchanger 14 Expansion tank 15 Exhaust manifold 16 Air filter 17 Air ...

Page 47: ...ir coo ling provide excellent fuel consumption over the whole range of power output 1 Electrical connection box 2 Fuel return 3 Oil cooler 4 Fresh water pump 5 Fuel pump Fuel inlet 6 Vibration damper 7 Fuel filter 8 Oil filter 9 Oil dip stick 10 Raw water pump 11 Raw water inlet 12 Governor Stop solenoid 13 Expansion tank 14 Charge air cooler 15 Exhaust manifold 16 Air filter 17 Air filter indicat...

Page 48: ... injection system effective turbocharger and charge air coo ling provide excellent fuel consumption over the whole range of power output P0013792 1 2 3 4 5 6 7 8 9 10 11 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 Oil filler 11 Oil drain pump Maintenance 46 47713337 03 ...

Page 49: ... lent fuel consumption over the whole range of power output 1 Electrical connection box 2 Fuel return 3 Oil cooler 4 Fresh water pump 5 Fuel pump fuel inlet 6 Vibration damper 7 Fuel filter 8 Oil filter 9 Oil dip stick 10 Governor stop solenoid 11 Expansion tank 12 Exhaust manifold 13 Air filter 14 Air filter indicator 15 Turbocharger 16 Electrical starter 17 Engine oil drain pump 18 Alternator 19...

Page 50: ...el consumption over the whole range of power output 1 Electrical connection box 2 Fuel return 3 Oil cooler 4 HT pump 5 Fuel pump Fuel inlet 6 Vibration damper 7 Fuel filter 8 Oil filter 9 Oil dip stick 10 LT pump 11 Coolingwater inlet LT circuit 12 Governor Stop solenoid 13 Expansion tank 14 Charge air cooler 15 Exhaust manifold 16 Air filter 17 Air filter indicator 18 Turbocharger 19 Electrical s...

Page 51: ...le range of power output 1 Electrical connection box 2 Fuel return 3 Oil cooler 4 HT pump 5 Fuel pump Fuel inlet 6 Vibration damper 7 Fuel filter 8 Oil filter 9 Oil dip stick 10 LT pump 11 Coolingwater inlet LT circuit 12 Governor Stop solenoid 13 Cooling water outlet LT circuit 14 Charge air cooler 15 Exhaust manifold 16 Air filter 17 Air filter indicator 18 Turbocharger 19 Electrical starter 20 ...

Page 52: ... or double bearing marine generator Different startingand 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 generat...

Page 53: ...single or double bearing marine generator Different startingand 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 g...

Page 54: ... The engine is mounted on a frame with a Stamford single or double bearing marine generator Different starting and control systems are available P0013786 1 2 3 4 5 6 7 8 9 10 12 11 14 13 15 16 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 ey...

Page 55: ...marine generator Different startingand 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 Exhaust manifold 16 Air filter 17 Air filter indic...

Page 56: ...rine generator Different startingand 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 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 Charge air cooler...

Page 57: ...startingand 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 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 w...

Page 58: ...m WARNING If an oil fuel or coolant leak is detected the cause must be investigated and the fault rectified before the engine is started Never direct the jet from a high pressure washer at seals rubber hoses or electrical components Never use the high pressure setting for engine cleaning Drive belts Check belt tension and condition regularly Check and adjust belt tension after operation when the b...

Page 59: ... belt for the fuel pump 2 Loosen screw 5 and push the alternator belt pulley 4 to the left and remove the belt 3 Replace it with a new one 4 Push the alternator belt pulley 4 to the right until the correct belt tension is achieved tighten the screw 5 5 Replace the belt for the fuel pump and adjust it 1 2 3 5 4 P0013630 Maintenance 47713337 03 2021 AB VOLVO PENTA 57 ...

Page 60: ...ge 4 Check valve clearance 1 between rocker arm tappet contact face 2 and valve steam 3 with a feeler gauge 6 there should only be slight resistance when blade is inserted For data on valve clearance see Engines Adjusting 1 Release locknut 4 2 Turn the adjustment screw 5 to obtain correct valve clearance 3 Tighten lock nut 4 4 Reinstall cylinder head with a new gasket if necessary 5 Refit crankcas...

Page 61: ...arance of valves marked in black on schematic Mark respective rocker arm with chalk to show that adjustment has been carried out Crankshaft position 2 Turn crankshaft one full revolution 360 Adjust clearance of valve marked in black on schematic P0013778 1 2 2 2 2 2 3 3 3 3 4 4 4 5 5 6 6 4 1 1 1 1 Maintenance 47713337 03 2021 AB VOLVO PENTA 59 ...

Page 62: ...rain the oil from the sump IMPORTANT Only use recommended grades of oil refer to chapter Technical Data page 102 1 Warm the engine up this makes it easier to pump the oil from the sump Then stop the engine 2 Connect a hose to the outlet pipe of the oil drain pump Pump the oil out 3 Change the oil filters at every second oil change refer to section Oil filter Change page 61 4 Fill up with oil to th...

Page 63: ...Fill up with oil refer to Oil level checking and topping up 7 Start the engine idle and make sure that no leakages occur Check the oil level once the engine has stopped Oil Level Check The oil level must be within the marked range on the dipstick and should be checked daily Engine Oil Filling Top up the oil through the filler opening in the ventilation cover Make sure the correct level is attained...

Page 64: ...system IMPORTANT All work on the engine injection system must be done by an authorized workshop Bleeding the Fuel System The fuel system must be bled e g after changing fuel filter if the fuel tank has been run dry and after long stops 1 Put a suitable vessel under the fuel return 1 2 Loosen the bolt 3 Turn the engine over with the starter max 20 sec until fuel free of bubbles comes out 4 Tighten ...

Page 65: ... tensioned 3 Tighten the screws Changing 1 Loosen screws 1 and 2 and push the fuel pump 3 to the right 2 Remove the belt and replace it with a new one 3 Push the fuel pump 3 to the left until the belt is correctly tensioned Tighten the screws 1 2 3 5 4 P0013630 Maintenance 47713337 03 2021 AB VOLVO PENTA 63 ...

Page 66: ...rs WARNING Working with or approaching a running engine is a safety risk Watch out for rotating components and hot surfaces 1 Place a receptacle beneath the filters and carefully clean the filter bracket 2 Put the lever 2 in its right hand end position 3 Unscrew the left hand fuel filter and discard it Use a filter wrench if necessary 4 Screw on the new filter by hand until the gasket make contact...

Page 67: ... water and contaminants through the drain plug 3 3 Fit a new filter insert and fill the container with clean fuel 4 Change the gasket on the cover and the O ring on the T bolt Moisten the gasket and O ring with fuel before assembling 5 Fit the cover and tighten it by hand Wipe off any fuel from the filter housing 6 Open the fuel cock andmake sure there are no leaks Twin fuel pre filter water separ...

Page 68: ...er itself Place a receptacle under the filters 1 Undo the T bolt 3 remove the cover 4 and take out the filter insert carefully while turning it 2 Drain off water and contaminants through the drain plugs 5 3 Fit a new filter insert and fill the container with clean fuel 4 Change the gasket on the cover and the O ring on the T bolt Moisten the gasket and O ring with fuel before assembling 5 Fit the ...

Page 69: ...ta Genset comes with an internal freshwater system connected to an engine mounted heat exchanger a radiator cooler or prepared for external cooling e g keel cooling or central cooling WARNING Do not open the coolant filler cap when the engine is hot Steam or hot fluid could spray out causing severe burns WARNING All coolant is hazardous and harmful to the environment Do not consume Coolant is flam...

Page 70: ...nd the cylinder heads An engine driven cooling water pump circulates the coolant through the heat exchanger and through the engine The raw water system is cooling the coolant in the freshwater cooling system The raw water system is connected to a seawater inlet or a central cooling system 1 Engine 2 Freshwater pump 3 Thermostat valve 4 Expansion tank 5 Heat exchanger 6 Raw water pump 7 Freshwater ...

Page 71: ...e driven cooling water pump circulates the coolant through the heat exchanger and through the engine The raw water system is cooling the coolant in the freshwater cooling system The raw water system is connected to a seawater inlet or a central cooling system 1 Engine 2 Freshwater pump 3 Thermostat valve 4 Expansion tank 5 Charge air cooler 6 Heat exchanger 7 Raw water pump 8 Freshwater circuit 9 ...

Page 72: ...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 enters the radi ator 1 Freshwater pump 2 Engine 3 Exhaust Manifold 4 Expansion tank 5 Fan 6 Radiator 7 Expansion tank 8 Expansion tank 9 Lubrication oil cooler Maintenance 70 47713337 03 2021 AB VOLVO PEN...

Page 73: ...led by e g a box cooler a grid cooler or any other external heat exchanger The system is cooling the cylinder liners and the cylinder heads An engine driven freshwater pump circulate the coolant through the engine 1 Engine 2 Freshwater pump 3 Thermostat valve 4 Expansion tank Maintenance 47713337 03 2021 AB VOLVO PENTA 71 ...

Page 74: ...pens 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 oil An engine driven HT pump circulates the coolant through the engine The LT circuit is cooling the charge air An engine driven LT pump circulates the coolant through the CAC 1 Engine 2 HT pump 3 Thermostat valve 4 Expansion ...

Page 75: ...ger The HT circuit is cooling 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 pump circulates the coolant through the CAC 1 Engine 2 HT pump 3 Thermostat valve 4 Expansion tank 5 LT pump 6 Charge air cooler 7 HT circuit 8 LT circuit Maintenance 47713337 03 ...

Page 76: ...e cylinder heads An engine driven cooling water pump circulate 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 central cooling system 1 Engine 2 Freshwater pump 3 Thermostat valve 4 Expansion tank 5 Heat exchanger 6 Raw water pump 7 Freshwater circuit ...

Page 77: ...ne driven cooling water pump circulate 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 central cooling system 1 Engine 2 Freshwater pump 3 Thermostat valve 4 Expansion tank 5 Charge air cooler 6 Heat exchanger 7 Raw water pump 8 Freshwater circuit 9 Ra...

Page 78: ...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 enters the radiator 1 Freshwater pump 2 Engine 3 Exhaust Manifold 4 Expansion tank 5 Fan 6 Radiator 7 Expansion tank 8 Expansion tank 9 Lubrication oil cooler Maintenance 76 47713337 03 2021 AB VOLVO PENT...

Page 79: ...oled by e g a box cooler a grid cooler or any other external heat exchanger The system is cooling the cylinder liners and the cylinder heads An engine driven freshwater pump circulate the coolant through the engine 1 Engine 2 Freshwater pump 3 Thermostat valve 4 Expansion tank Maintenance 47713337 03 2021 AB VOLVO PENTA 77 ...

Page 80: ...pens 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 oil An engine driven HT pump circulates the coolant through the engine The LT circuit is cooling the charge air An engine driven LT pump circulates the coolant through the CAC 1 Engine 2 HT pump 3 Thermostat valve 4 Expansion ...

Page 81: ...ger The HT circuit is cooling 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 pump circulates the coolant through the CAC 1 Engine 2 HT pump 3 Thermostat valve 4 Expansion tank 5 LT pump 6 Charge air cooler 7 HT circuit 8 LT circuit Maintenance 47713337 03 ...

Page 82: ...eakages which in the worst case can cause engine breakdown Volvo Penta strongly recommend the use of our own coolants Volvo Penta Coolant VCS Ready Mixed or the concentrate Volvo Penta Coolant VCS which ensure the protection of the cooling system components from corrosion ageing swelling and cracking thereby ensuring optimal engine lifetime Over time the corrosion protection additives become less ...

Page 83: ...reshwater system HT with coolant to the correct level through the filler opening in the expansion tank Fill slowly so that evacuated air is able to pass the filler opening NOTICE For coolant specification refer to section Technical Data page 104 Filling the system when empty Fill the freshwater system HT circuit with coolant to the correct level through the filler opening in the expansion tank Fil...

Page 84: ...to be cleared away inside the drain plug s tap s 3 Drain all other systems connected to the freshwater system e g heater water heater etc 4 Close all drains Freshwater system Flushing The cooling system should be flushed when the coolant is changed to avoid loss of cooling performance due to deposits in the cooling system 1 Drain the coolant please refer to section Coolant Draining page 82 2 Put a...

Page 85: ...ller and gasket in store aboard the ship 1 Close the raw water cocks and drain the external cooling water as described in the chapter draining the raw water system 2 Remove the pump end cover 1 the seal 2 and the impeller 3 3 Inspect the impeller Change the impeller if there are any visible cracks or other defects 4 Clean the inside of the housing Lubricate the pump housing and the inside of the c...

Page 86: ...e hex nut must be flush with the shaft of the raw water pump Assembly IMPORTANT Always use new gaskets and Orings 1 Install the pump with a new gasket 2 Fit the gear with a new hex nut tighten to 80 Nm Pay attention that the key is fitted NOTICE The cones of the gear and shaft must be free from lubricant clean and undamaged 3 Fit the screw cap with a new O ring 4 Fit the connecting socket with a n...

Page 87: ...er 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 Reinsert the raw water bundle 4 and reconnect to the heat exchanger housing 5 6 Fit the reverse cover 2 and the connecting cover 3 with new seals and screws 1 2 3 5 P0013729 Maintenance 47713337 03 2021 AB VOLVO PENTA 85 ...

Page 88: ...engine is stopped 1 Undo the hose clamp below the air filter cartridge 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 ready to operate again P0013783 Maintenance 86 47713337 03 2021 AB VOLVO PENTA ...

Page 89: ... remove it carefully 3 Clean the housing and compressor wheel 4 from soot using a sharp knife NOTICE Be very careful not to damage anything 4 Install the compressor house and tighten the screws equally 5 Check that the compressor wheel can turn easily if not the housing is not in its right position 6 Reinstall the air filter together and the air intake 7 Fit the ventilation pipe to the air intake ...

Page 90: ...hrough the plug 1 on the bottom of the charge air cooler If necessary refit the plug with a new seal Make sure the drain is not blocked IMPORTANT If considerable amounts of water run out of the drain hole the insert must be removed and test pressurized This must be done by an authorized workshop Maintenance 88 47713337 03 2021 AB VOLVO PENTA ...

Page 91: ...ctions with water repellant Volvo Penta all round oil Main switch The main switches must never be turned off until the engine has been stopped Breaking the circuit between 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 engine is running IMPORTANT Never disconnect the current with the main...

Page 92: ...ng and charging batteries Depending on battery type the instructions for maintenance and charging may vary Modern batteries are normally maintenance free but there are some actions that are recommended to increase the battery service life and avoid accidents Keep the batteries clean and dry Contamination and oxide on the batteries and battery poles can result in stray currents voltage drop and dis...

Page 93: ...the battery Connecting B Place the new battery 1 Connect the cable red to the pole on the battery and tighten the nut 2 Connect the cable black to the pole on the battery and tighten the nut NOTICE Hand in the old battery to a re cycling station Electrical Welding Disconnect the positive and negative battery cables Then disconnect all the leads to the generator Always connect the weld clamp to the...

Page 94: ...need of overhaul or repair CAUTION Read the chapter on Maintenance in the Operator s Manual before starting work It contains instructions on how to carry out maintenance and service operations in a safe and technical correct manner IMPORTANT The following must be considered when cleaning with a high pressure water jet Never point high pressure water jets directly at seals rubber hoses or electrica...

Page 95: ...ondensation 6 Disconnect the battery cables and clean and charge the batteries Trickle charge during the storage period A poorly charged battery can freeze and break 7 Clean the engine externally Touch up any paint damage with Volvo Penta original paint 8 Spray electric system components with water repellant 9 Inspect all control cables and apply anti corrosion agent 10 Cover the air intake to the...

Page 96: ... on the dipstick 2 Connect supply 1 and return 2 fuel lines to a fuel can filled with 1 3 conservation oil and 2 3 diesel fuel 3 Bleed the fuel system 4 Start the engine and run it at idling speed until approximately two liters of the fuel conservation oil mixture have been consumed Stop the engine and connect the ordinary fuel lines 5 Drain the conservation oil from the engine 6 Follow the direct...

Page 97: ... system Fit the impeller in the rawwater pump Fill and bleed the rawwater system 7 Check the coolant level and anti freeze Top up if necessary 8 Check under and around the engine for such items as loose or missing bolts oil fuel or coolant leaks and repair if needed 9 Connect fully charged batteries 10 Start the genset and run it at idling speed until it reaches operating temperature before loadin...

Page 98: ... 400 C 752 F 1 Approximated values temperatures varies with ambient temperature and back pressure in the exhaust line General Type Designation D5A TA HE No of cylinders 4 Displacement 4 76 liters 290 in3 Dry weight 1 engine without generator and frame approx 525 kg 1157 lbs Valve clearance setting values cold engine Inlet 0 30 mm 0 0118 Exhaust 0 50 mm 0 0197 1 excl engine oil and coolant Exhaust ...

Page 99: ... varies with ambient temperature and back pressure in the exhaust line General Type Designation D5A T KC 1 circuit No of cylinders 4 Displacement 4 76 liters 290 in3 Dry weight 1 engine without generator and frame approx 510 kg 1124 lbs Valve clearance setting values cold engine Inlet 0 30 mm 0 0118 Exhaust 0 50 mm 0 0197 1 excl engine oil and coolant Exhaust temperatures 1 77 kW 1500 rpm 81 kW 18...

Page 100: ...tures varies with ambient temperature and back pressure in the exhaust line General Type Designation D5A TA KC 2 circuit No of cylinders 4 Displacement 4 76 liters 290 in3 Dry weight 1 engine without generator and frame approx 525 kg 1157 lbs Valve clearance setting values cold engine Inlet 0 30 mm 0 0118 Exhaust 0 50 mm 0 0197 1 excl engine oil and coolant Exhaust temperatures 1 92 kW 1500 rpm 10...

Page 101: ...oximated values temperatures varies with ambient temperature and back pressure in the exhaust line General Type Designation D7A TA HE No of cylinders 6 Displacement 7 15 liters 740 in3 Dry weight 1 engine without generator and frame approx 690 kg 1521 lbs Valve clearance setting values cold engine Inlet 0 30 mm 0 0118 Exhaust 0 50 mm 0 0197 1 excl engine oil and coolant Exhaust temperatures 1 139 ...

Page 102: ... varies with ambient temperature and back pressure in the exhaust line General Type Designation D7A T KC 1 circuit No of cylinders 6 Displacement 7 15 liters 437 in3 Dry weight 1 engine without generator and frame approx 670 kg 1477 lbs Valve clearance setting values cold engine Inlet 0 30 mm 0 0118 Exhaust 0 50 mm 0 0197 1 excl engine oil and coolant Exhaust temperatures 1 116 kW 1500 rpm 122 kW ...

Page 103: ...tures varies with ambient temperature and back pressure in the exhaust line General Type Designation D7A TA KC 2 circuit No of cylinders 6 Displacement 7 15 liters 740 in3 Dry weight 1 engine without generator and frame approx 690 kg 1521 lbs Valve clearance setting values cold engine Inlet 0 30 mm 0 0118 Exhaust 0 50 mm 0 0197 1 excl engine oil and coolant Exhaust temperatures 1 139 kW 1500 rpm 1...

Page 104: ... low oil pressure 150 kPa Oil Grade and Oil Change Interval Oil grade 1 Sulfur content in fuel by weight up to 0 5 0 5 1 0 more than 1 0 2 Oil change interval Reached first in operation VDS 2 ACEA E3 96 E2 96 API CD CE CF CF 4 CG 4 3 500 hr or 12 months 250 hr or 12 months 125 hr or 12 months NOTICE Mineral based oil either fully or semi synthetic may be used on condition that it complies with the...

Page 105: ...for commercially supplied fuels such as EN 590 with nationally adapted environmental and cold weather requirements ASTM D 975 No 1 D och 2 D JIS K 2204 Sulfur content Complying with legal requirements in each country If the sulfur content exceeds 0 5 weight percent the oil change intervals shall be changed refer to Technical Data page 102 Extremely low sulfur content fuel urban diesel in Sweden an...

Page 106: ...03 F Shutdown point High coolant temp 103 C 217 F 103 C 217 F 103 C 217 F D7A T HE D7A T KC D7A T RC D7A TA HE D7A TA KC Cooling system Type Designation D7A T HE D7A TA HE D7A T RC D7A T KC D7A TA KC Freshwater system capacity including heat exchanger approx 22 liters 5 8 US gals 40 litres 8 8 US gals 14 liters 3 7 US gals Coolant temp normal operation 83 95 C 181 203 F 83 95 C 1815 203 F 83 95 C ...

Page 107: ...fied water requirements refer to Water Quality page 105 NOTICE Always use Ready Mixed coolant if water quality cannot be determined or if it does not fulfill ASTM D4985 NOTICE Never mix more than 60 concentrated coolant with water A greater concentration provides reduced cooling effect with the risk for overheating and reduced freeze protection Water Quality ASTM D4985 Total solid particles 340 pp...

Page 108: ...lternator voltage max amperage 28 V 60 A AC alternator output approx 1700 W Battery electrolyte density at 25 C 77 F fully charged battery 1 28 g cm 3 0 0462 lb in3 battery recharged at 1 13 g cm3 0 0408 lb in3 Technical Data 106 47713337 03 2021 AB VOLVO PENTA ...

Page 109: ...e Plate 1 1 P0013801 EP K 1 Engine designationn 2 Product number 3 Serial number 4 Rated power 5 Rated engine speed Engine plate 2 2 P0013802 xxxx 1 xxxxxx 2 xxxxxxxxxxx xxxxx 3 No 1 Product designation 2 Product number 3 Serial base eng No 1 2 P0013804 Technical Data 47713337 03 2021 AB VOLVO PENTA 107 ...

Page 110: ...ne plate 2 2 P0013802 xxxx 1 xxxxxx 2 xxxxxxxxxxx xxxxx 3 No 1 Product designation 2 Product number 3 Serial base eng No Generator plate 3 3 P0013803 1 2 3 1 Generator Type 2 Serial number 3 AVR NOTICE The genset shown is mounted with a Stamford generator if other generator brand is used refer to generator manufacturers documentation P0013800 1 2 3 Technical Data 108 47713337 03 2021 AB VOLVO PENT...

Page 111: ... Serial number 4 Rated power 5 Rated engine speed Engine plate 2 2 P0013802 xxxx 1 xxxxxx 2 xxxxxxxxxxx xxxxx 3 No 1 Product designation 2 Product number 3 Serial base eng No IMO decal 3 Only D7A TA 3 P0013805 THIS ENGINE TYPE IS CERTI FIED ACC TO IMO NOx TECHI CAL CODE ANNEX VI 1 3 2 4 P0013806 Technical Data 47713337 03 2021 AB VOLVO PENTA 109 ...

Page 112: ...xxx 3 No 1 Product designation 2 Product number 3 Serial base eng No IMO decal Only D7A TA 3 3 P0013805 THIS ENGINE TYPE IS CERTI FIED ACC TO IMO NOx TECHI CAL CODE ANNEX VI Generator plate 4 4 P0013803 1 2 3 1 Generator Type 2 Serial number 3 AVR NOTICE The genset shown is mounted with a Stamford generator if other generator brand is used refer to generator manufacturers documentation P0013785 1 ...

Page 113: ...vice Inspection 20 Freshwater System 80 Freshwater system Flushing 82 Fuel filter Change 64 Fuel pre filter draining water contamination 65 Fuel pump 63 Fuel System 62 103 Fuel oils and coolant 14 Fuses 89 G General 67 89 I Identification Numbers 107 Ignition switch 19 Impeller raw water pump 83 Inlet and Exhaust System 86 Instrument Panel 18 L Long Term Storage 94 Lubrication System 60 102 M Main...

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Page 115: ...la ei ole Internet yhteyttä ota yhteys lähimpään Volvo Penta jälleenmyyjään Este Manual do Operador pode ser encomendad em idiomas diferentes isento de custos até 12 meses após entre ga via internet http manual volvopenta com coupon Se não for possível aceder à internet contacte o seu conces sionário Volvo Penta To παρόν Βιβλίο Χρήσης μπορεί να παραγγελθεί δωρεάν σε άλλη γλώσσα μέχρι 12 μήνες μετά...

Page 116: ...AB Volvo Penta SE 405 08 Göteborg Sweden www volvopenta com 47713337 English 03 2021 ...

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