Volvo Penta TAMD162C Instruction Book Download

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Cooling system

TAMD162C

TAMD163A,
TAMD163P-A

Freshwater system capacity

including head exchanger, approx. .................

88 liters(19.4 Imp. gals/23.2 US gals) 80 liters(17.6 Imp. gals/21.1 US gals)

Thermostats (2)

starts opening at .............................................

82°C (180°F)

73–77°C (163–171°F)

fully opening at ...............................................

95°C (203°F)

86–90°C (187–194°F)

Scavenger pump/bilge pump

TAMD162C, TAMD163A, TAMD163P-A

Type ...................................................................

Impeller

Clutch .................................................................

Electromagnetic

Capacity (liters/minute) at engine speed:

Column pressure 5 m (16.4 ft)

Column pressure 10 m (32.8 ft)

900 rpm. ........................................................

152 liters(33.5 Imp. gals/40.1 US gals) 138 liters(30.3 Imp. gals/36.4 US gals)

1200 rpm. .......................................................

200 liters(44 Imp. gals/52.9 US gals)

185 liters(40.7 Imp. gals/48.8 US gals)

1500 rpm. .......................................................

258 liters(56.8 Imp. gals/68.1 US gals) 243 liters(53.4 Imp. gals/64.1 US gals)

1800 rpm. .......................................................

310 liters(68.2 Imp. gals/81.8 US gals) 295 liters(64.9 Imp. gals/77.9 US gals)

1900 rpm. .......................................................

335 liters(73.7 Imp. gals/88.4 US gals) 318 liters(70 Imp. gals/84 US gals)

Electrical system

TAMD162C

TAMD163A,
TAMD163P-A

System voltage ..................................................

24 V

Battery capacity .................................................

2 x 12 V (in series) max. 220 Ah

Generator for alternating current

voltage/max. amperage ..................................

28 V/60 A

output approx. .................................................

1700 W

1700W

brush length ....................................................

min. 8 mm (0.315")

Extra generator equipment (accessory)

voltage/max. amperage ..................................

28 V/100 A

output approx. .................................................

2800 W

brush length ....................................................

min. 5 mm (0.2")

Battery electrolyte density at +25

C (77

fully charged battery .......................................

1.28 g/cm

(0.046 lb/in

)

1.28 g/cm

(0.046 lb/in

)

battery recharged at .......................................

1.24 g/cm

(0.044 lb/in

)

1.24 g/cm

(0.044 lb/in

)

Reverse gear

MPM

Type designation ...............................................

IRM 350A

Gear ratios .........................................................

1.58:1; 2.07:1; 2.63:1

Angle (output shaft) ............................................

7°

Oil capacity, approx. ..........................................

20 liters (4.4 Imp. gals/5.3 US gals)

Oil grade (in accordance with API system) .......

CC, CD, CE

Viscosity ...........................................................

SAE30*

alternative for operation in hot countries ........

SAE40*

Operating oil pressure at oil temperature
75 ±5°C (167 ±9°F):

min. .................................................................

1.9 MPa (19.3 kp/cm

= 275 psi)

max. ................................................................

2.4 MPa (24.4 kp/cm

= 348 psi)

Max. oil temperature ..........................................

85°C (185°F)

Weight, approx. ..................................................

234 kg (515 lbs)

* Note! Only single grade lubricating oil (only one

viscosity number) may be used in the reverse gear.

Summary of Contents for TAMD162C

Page 1: ...INSTRUCTIONBOOK TAMD162C TAMD163A TAMD163P ...

Page 2: ......

Page 3: ...ngine coolant 16 Operation 17 Before starting 17 Starting the engine 19 Starting using auxiliary batteries 20 Checks during operation 21 Maneuvering during operation 21 After operation 23 Propeller shaft brake 23 When there is a danger of freezing 24 Mechanical safety clutch 25 Maintenance 28 Periodic maintenance 29 Maintenance schedule 30 Technical description 36 Engine 36 Maintenance Engine 40 L...

Page 4: ...e with the oil filler cap removed otherwise oil could be ejected 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 engine Read the book carefully before operating or servic ing the engine If operations are performed incorrectly it could result in personal injury or damage to property o...

Page 5: ...r 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 re...

Page 6: ...l 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 Welcome aboard Thank you for choosing a Volvo Penta marine engine Volvo Penta have been building marine engines since 1907 Quality operating reliability and innov...

Page 7: ...Warranty and Service book Regular maintenance should be carried out after the First Service Inspection in accordance with the mainte nance scheme in this book Any work carried out in addition to maintenance services should be document ed refer to the Warranty and Service book It is an absolute condition for the Volvo Penta Interna tional Limited Warranty to apply that the Pre Delivery Commissionin...

Page 8: ...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 As an owner or operator of a certificated Volvo Penta engine it is important that you are aware of the follow ing The Service Intervals and maintenance operations recommended by Volvo Penta must b...

Page 9: ...cant oil via special jets in the engine block The cylinder liners are of the wet type and are replaceable The cooling system is thermostatically controlled Freshwater in the engine is cooled by seawater in a heat ex changer For a more detailed description of the engine its fuel lubrication and cooling systems etc see under Technical Specification on pages 36 62 Note TAMD162C and TAMD163A can also ...

Page 10: ...cap 5 Oil cooler engine 6 Sender console with switches and senders for monitoring the engine 7 Oil filler engine 8 Exhaust elbow for dry exhaust gases 9 Oil filter reverse gear 10 Twin Disc reverse gear MG516 11 Oil dipstick 12 Lubricating oil filters full flow type 13 Oil scavenging pump 14 Lubricating oil filter part flow type 15 Coolant filter 16 Extra generator 17 Disengageable clutch Fig 3 TA...

Page 11: ...cleaner ACL 3 Filters for crankcase ventilation 4 Intake manifold with charge air cooler CAC 5 Injection pump 6 Fine fuel filters 7 Coolant filler cap 8 Expansion tank 9 Heat exchanger 10 Seawater pump 11 Fuel feed pump 12 Fuel shut off valve 13 Starter motor 14 Starter relay 15 Reverse gear MPM IRM350 16 Oil cooler reverse gear Fig 6 TAMD163P from port 1 Heat exchanger 2 Engine coolant filler cap...

Page 12: ...st been re turned to the stop position S 6 Alarm panel with warning symbols pos 11 14 7 Alarm siren warning for mechanical faults Sounds when lubricating oil pressure is too low engine when coolant temperature is too high or there is a loss of charge 8 Pressure switch for testing alarm functions or acknowledging alarms No alarm Alarm test all warning lights are on and the siren sounds If the alarm...

Page 13: ...utions per minute 20 Hour counter Displays the engine s operating time in hours and tenths of an hour 21 Pressure switch for testing the alarm function 22 Alarm for malfunctions corresponding to alarm on main panel 23 Pressure switch for instrument lighting 24 Key switch start lock with start and stop func tions and a built in restart inhibitor starter motor protection The start lock prevents rest...

Page 14: ...me functions as the panel for the alternative operating position pos 21 23 Note The key switch in the pilot house control panel must be in position I operating position for starting to be carried out from the secondary operating position 29 Start button The starter motor is engaged when this button is pressed Release the button as soon as the engine has started 30 Stop button The stop solenoid or ...

Page 15: ... persons VP single control Lever 1 for reversing maneuvers and controlling engine speed Position N Neutral From N to F reverse gear engaged for forward movement From N to R reverse gear engaged for reverse movement T control of engine speed rpm Disengaging the reverse gear from the control Push the button 2 when the lever is in neutral then push the lever forwards The lever can then be used as a t...

Page 16: ...for controlling a trolling valve if fitted One of these is the type S control VP dual controls 1 Lever for reverse gear maneuvers black handle Position N Neutral From N to F reverse gear engaged for forward movement From N to R reverse gear engaged for reverse movement 2 Lever for controlling engine speed rpm red handle NB dual controls 1 Lever for reverse gear maneuvers black handle Position N Ne...

Page 17: ...ntrol is pri marily intended for engines with fixed engine speeds To change its setting hold the wheel Undo the wing nuts and screw them one way or another until the cor rect engine speed is achieved Tighten wing nuts against each other This locks the engine speed rpm setting Mechanical engine speed rpm control on injection pump ...

Page 18: ... MIL L 2104D standard may also be used For viscosity and capacities see Technical Data on page 76 Oil for servo unit system hydraulic pump accessory ATF oil should be used in the servo unit system ATF Automatic Transmission Fluid oil for automatic gear boxes Coolant The engine s internal cooling system freshwater sys tem is filled with a mixture of freshwater and additives NOTE Never use freshwate...

Page 19: ...he filler pipe See page 55 for topping up instructions Note Do NOT open the pressure cap on a hot engine Steam or hot coolant can spray out and the system pressure will be lost 6 Check the engine oil level This should be within the area marked on the dipstick The oil level must never be below the MIN mark on the stick 7 Check the oil in the reverse gear Note Since the marks on the dipstick apply f...

Page 20: ...18 8 TAMD162C and TAMD163A with centrifugal seawater pump Before starting for first time Fill seawater pump intake side with water 9 Turn on the main switches 10 Check the amount of fuel ...

Page 21: ...n the key switch Turn it to the I position operating position All warning lights will come on and stay on for max 20 seconds The coolant temperature high warning light will then go off 3 Push the Alarm test button and check that the alarm sounds warning lamps come on The alarm stops when the button is released 4 Turn the key to position III to start Release the key as soon as the engine starts The...

Page 22: ...he flywheel may be seriously damaged Warning The batteries auxiliary batteries in particular contain extremely explosive oxyhydrogen gas One spark which may be formed if the auxiliary batteries are con nected incorrectly is sufficient to explode a battery and cause damage and injury 1 Check that the auxiliary batteries are connected in series or in parallel so that their rated voltage is the same ...

Page 23: ...ature too high Reduce the speed to idling in neutral until the temperature drops Investigate the cause of the alarm e g blocked cooling water intake Stop the engine if the temperature does not drop Low lubricating oil pressure Stop the engine immediately and investigate the cause of the alarm Keel cooled engine version High charge air temperature Reduce the speed to idling in neutral until the tem...

Page 24: ...isen gaged position when the valve is not in use Disengageable clutch The clutches have two positions on the control lever Lever towards engine for declutching away from it for neutral When engaging and disengaging the clutch the en gine speed must not exceed 800 rpm Type S controls for maneuvering trolling valve Flushing pump 1 Bilge pump 2 Actuating lever 3 Flushing pump Disengageable scavenging...

Page 25: ...ain operating conditions the propeller may make the propeller shaft rotate when the engine is stopped This rotation may damage the reverse gear since its oil pump which is driven by the integral shaft stops when the engine stops The propeller shaft can be permitted to rotate with the engine stopped for up to 6 8 hours After this time the engine must be started for at least 5 minutes to ensure the ...

Page 26: ...n the system and cause serious damage Check whether the installation has any more cocks or plugs on the cooling water and exhaust pipes lowest points Remove the cover from the seawater pump and the cover on any extra pump Close the cocks fit the plugs and put the cover on the seawater pump and any extra pump fitted Pump out the boat if required Ensure that there are no leaks before you leave the b...

Page 27: ...allen plugs for the Forward clutch 3 Turn the engine the screws in the clutch are opposite both the plug holes Tighten two screws Turn the engine further and tighten the other two screws 4 Reinstall plugs in holes 5 Set the reverse gear lever to Neutral and discon nect the control cable from the lever Run at reduced speed there is no reverse Repair the fault at the earliest possible opportunity Em...

Page 28: ...f Note Applies to classifiable engines Classifiable engines are fitted with a fuel shut off valve for normal stop Emergency start TAMD162C TAMD163A There is an emergency start button at the starter motor The emergency start button functions independent of the key switch being on or off The button has no start interlock function and should therefore never be pressed while the engine is running If t...

Page 29: ... cocks Fill with engine coolant and start pump and engine Emergency operation engine coolant system Certain classification organizations prescribe that it should be possible to replace the seawater and fresh water pumps temporarily This relatively easy to do as follows The scavenger pump can be used as a temporary engine coolant pump in emergencies Otherwise a separate pump mounted by the engine m...

Page 30: ...5 25 Nm 1 Open vent screw 1 Pump with hand pump 2 until fuel containing no air flows out Then pump a further 10 20 times with the hand pump Tighten the venting screw 1 Check for leaks If the engine does not start vent the pressure pipes on the injectors Observe strict cleanliness The fuel in the system must not become contaminated 12 12 12 12 12 12 12 12 12 12 123 123 123 123 123 123 123 123 123 1...

Page 31: ...ration A Engine coolant checking and topping up B Electronics Terminal box with semi auto matic fuses C Freshwater filter D By pass partial flow engine oil filter E Topping up oil engine F Oil dipstick engine G Full flow engine oil filter H Venting cocks I Oil filter reverse gear J Oil cooler reverse gear K Oil dipstick reverse gear L Air Cleaner ACL M Charge air cooler CAC N Feeder pump fuel hand...

Page 32: ...1000 hours 2000 hours 24 months 50 hours 400 hours 800 hours 1200 hours 24 months Use a grease gun and lithium grease Mobilux EP2 Statoil Uniway EP2N Texaco Multifak EP2 Q8 Rembrandt EP2 Engine oil VDS or CD or CE as per API system Drain or pump out oil while engine is hot Use the engine scavenging pump or remove the oil plug Hot oil can cause burns Remove the oil filter using the special tool Lub...

Page 33: ...atoil Uniway EP2N Texaco Multifak EP2 Q8 Rembrandt EP2 Do not lubricate support bearing a grease nipple is fitted main bearings disengaging shaft and moving parts of clutch mechanism Lubricate sparingly 20 30 g for main bearings Quality Use lithium based lubricating grease Mobilux EP2 Statoil Uniway EP2N Texaco Multifak EP2 Q8 Rembrandt EP2 50 hours 500 hours 1000 hours 2000 hours 24 months 50 hou...

Page 34: ...el pre filter 15 Replace fine fuel filters 16 Engine fine fuel filters replacement while engine is running Remove the filter by turning counterclockwise Screw on the new filter by hand Wait a few hours after the engine has been turned off before checking draining the filter Drain off water contaminants through the cock plug 1 Adjustments must be made with the engine stopped Remove the inspection c...

Page 35: ...MD162C TAMD163P Instructions Info pages TAMD163A 17 Venting the fuel system 18 Have authorized personnel check injectors 19 Check and clean seawater filter Note Theseawaterfiltercanrequirecleaning more frequently experience will indicate the best interval after a period of running the engine 20 Replace freshwater filter 21 Check clean heat exchang er charge air cooler CAC and the reverse gear oil ...

Page 36: ...earance 50 hours 500 hours 1000 hours 2000 hours 24 months 50 hours 400 hours 800 hours 1200 hours 24 months No Action TAMD162C TAMD163P Instructions Info pages TAMD163A Close the sea cock and drain the water from the freshwater system Warning Hot engine coolant can cause burns When only 50 of the anodes remains they must be replaced A good electrical contact is vital Also replace the zinc anode o...

Page 37: ...0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 50 hours 500 hours 1000 hours 2000 hours 12 months 50 hours 400 hours 800 hours 1200 hours 24 months No Action TAMD162C TAMD163P Instructions Info pages TAMD163A 29 Check replace air cleaner ACL filter Note ThefiltermustbechangedwhentheACL indicator shows completely red field when engine stopped 30 Have authorized service personnel check charging...

Page 38: ...while avoiding heat stress The vibration damper s is are bolted onto the polygon hub at the front of the crankshaft The polygon provides greater strength at the joint for power take offs that a splined or keyed joint The rear crankshaft seal is a ring with a lip type seal There is no need for a front seal since the front section of the crankshaft is located inside the timing gear cover The gudgeon...

Page 39: ...piston and is returned to the sump The combustion area at the crown of the piston is de signed to provide uniform distribution of the fuel and ef fective combustion The illustration shows the gears for 1 Drive gear crankshaft 2 Intermediate gear oil pump 3 Drive gear oil pump 4 Drive gear engine coolant pump 5 Intermediate gear right 6 Intermediate gear upper 7 Drive gear camshaft 8 Drive gear inj...

Page 40: ... be removed from the engine compartment by a hose in the same way as for the TAMD162C 163A A pipe bend with hose mounting is supplied with the engine for this reason This can be installed on the rear inspection hatch on the right of the engine instead of the standard crankcase ventilation device TAMD163P Crankcase ventilation alternative installation Air Cleaner ACL The TAMD163A and TAMD163P engin...

Page 41: ...ected is greater and the fuel com bustion process is more effective This results in greater engine output lower specific fuel consumption and cleaner emissions The turbocharger is lubricated and cooled by the en gine s lubrication system An external oil line connection supplies and removes the oil required The turbine housing is cooled by freshwater Charge air cooler CAC The intake air enters the ...

Page 42: ... mounting Remove the old air filter 2 Install the new filters Tighten the clamps 3 Reset the pressure drop indicator by pressing in the button 5 Check for air leaks after starting the engine Tensioning drive belts A Locking screws Filter replacement for crankcase ventilation 2 filters TAMD163P 1 Remove the old filters by unscrewing counterclockwise 2 Check the rubber gasket in the mounting replace...

Page 43: ... filter housing TAMD162C Remove the air cleaner ACL and its holder 2 Warning Check that the turbocharger s impeller is stationary before checking 3 Check if the shaft is stiff or if the turbine or com pressor wheels are touching their housings Turn the shaft using light pressure followed by pulling it gently in the axial plane If the rotor is difficult to turn the turbocharger must be replaced or ...

Page 44: ...the oil cooler if the engine is cold C Reducing valve limits oil pressure D Relief valve opens if resistance in the filter is too great E Piston cooling valve releases oil to the piston cooling at RPM greater than idle 1 Oil pump 2 Full flow filters 2 3 Partial flow filter 1 4 Oil cooler Oil valves The oil valve in the lubrication system are used to con trol the oil pressure and volume of oil flow...

Page 45: ...e oil The two full flow oil filters filter all oil before it is passed on to the lubrication system The oil filter insert and housing are one unit and cannot be disasssembled When it is replaced the complete unit must be replaced The old filter cannot be reused and must be scrapped On classifiable engines there is a filter mounting which allows the full flow filters to be replaced while the en gin...

Page 46: ...ne The oil should be changed when the engine is hot Warning Hot oil can cause burns Engines with manual oil scavenger pump Turn the knob to position A for engine pumping see illustration Pump out the oil and collect in a container Engines with power oil scavenging pump accessory Remove the oil dipstick and connect the suction pipe to the dipstick tube Start the pump and collect the oil in a contai...

Page 47: ...the dipstick Top up if required Replacement of full flow oil filters while engine is running switchable filters Note Place a container beneath the filters when re moving to avoid spillage 1 Disconnect oil flow through the filter by turning the control lever counterclockwise to the stop 2 Use the special tool to unscrew the disconnected oil filter Warning Hot oil can cause burns 3 Lightly oil the n...

Page 48: ... 4 turn MPM IRM 350A 1 Oil dipstick 3 Drain plug 2 Oil strainer 4 Oil filler plug 5 Oil filters Twin Disc MG 516 1 Oil dipstick 3 Oil filters 2 Ventilation cap oil filler 4 Oil plug 5 Suction screen Cleaning the reverse gear oil screen Remove and clean the oil screen Check gaskets Rein stall the parts removed and check for leaks Twin Disc MG 5114A 1 Oil dipstick 3 Oil plug 2 Ventilation cap oil fi...

Page 49: ...re disposa ble and the filter insert is made of a spirally wound pa per filter On classifiable engines the fuel fine filters can be re placed with the engine running A double water separating pre filter which is connected in parallel is also available as an accessory The inserts of the double pre filter can be replaced while the engine is running if necessary It is important that the fuel filters ...

Page 50: ...ction pump 1 The injection pump is located on the right side of the en gine and is driven by the timing gears The pump which is of piston type has a centrifugal governor This gov ernor regulates the fuel feed to the engine so that the speed set by the driver using the control is achieved It also limits the engine s max speed if the load should suddenly drop Note Auxiliary engines are fitted with a...

Page 51: ...the nozzle needle 10 which is pressed in its seat by the pressure spring 5 is raised and atomized fuel is sprayed into the engine through carefully calibrated holes in the nozzle body The tension of the pressure spring determines the opening pressure of the injector The injectors should be checked regularly by authorized personnel refer to maintenenance chart An incorrect opening pressure or fault...

Page 52: ...the filter mounting carefully 2 Unsrew the old fuel filters and discard Use special tool to remove filter if necessary 3 Check that the new filters are absolutely clean and that the gaskets are undamaged Lightly moisten the gaskets with oil 4 Screw on the new filters by hand until the gaskets come into contact with the filter mounting Then tighten a further half turn by hand 5 Vent the fuel system...

Page 53: ...fuel filter in the same way Venting the fuel system The fuel system must be vented after the fuel filters have been replaced or after refilling the fuel tank af ter it has been run dry 1 Place a container beneath the fuel filters Open vent screw 1 on the filter mounting 2 Pump fuel using the feed pump s hand pump 2 until no air bubbles are visible in the fuel Tighten the screw while fuel is flowin...

Page 54: ...on to the heat exchanger The reverse gear is also cooled by seawater The freshwater pump and the seawater pump are driven via the timing gears The intake air to the engine is cooled in the charge air cooler CAC A freshwater filter which is connected as a partial flow filter maintains the correct pH value in the coolant and protects the coolant system from clogging and corrosion Note TAMD162C and T...

Page 55: ...ir cooler CAC is supplied with seawater directly from the seawater pump through the lower line connection on the front edge of the CAC The CAC insert is divided into two sections the lower intake section and the upper outlet section Overflow between the sections occurs in the rear edge of the CAC Heat exchanger The seawater passes on through the charge air cooler CAC outlet to the heat exchanger T...

Page 56: ...in the engine and equalizes the temper ature differences within the engine Heat is removed from the lubricating oil in the oil cooler This keeps the oil temperature lower at high engine load and speeds This reduces engine wear as the oil s lubricating prop erties are impaired if the oil temperature gets too high Lubricating oils of lower quality are most sensitive to high temperatures The engine s...

Page 57: ... flow out via the filling opening or venting nipple s 1 Open all venting nipples L during filling The TAMD162C has only one venting nipple 2 Fill with coolant until the system is completely filled up Close the venting nipple s when no bubbles can be seen in the water flowing out of the venting nipple s 3 Run engine at idle speed for approx two minutes 4 Check the coolant level Top up if required I...

Page 58: ... seawater and freshwater systems before working on the cooling system 1 Remove the pipe connections from the heat exchanger end section on the starboard side 2 Remove both ends of the heat exchanger 3 Clean the heat exchanger insert core using a brush and then flush the core through with water 4 Reinstall the heat exchanger s end covers 5 Reinstall the pipe connections to the starboard end cover C...

Page 59: ... Reinstall the zinc anodes Ensure that there is good metallic contact between the anode and the material 6 Close the drain cock Open the sea cock before starting the engine Check for leaks Removing the seawater pump impeller Replacing the seawater pump impeller Rubber impeller Close sea cock before working on cooling system 1 Remove the pump s end cover Pull and twist out the pump impeller counter...

Page 60: ...em also includes senders for monitoring the engine s coolant temperature and oil pressure Keel cooled engine versions are also fitted with a switch for monitoring the charge air temperature For engines that can be subject to certification there is a more comprehensive monitoring system These type of en gines are not dealt with in this section For more information refer to the manual Electrical sys...

Page 61: ...ngine The engine s standard generator can be fitted with a charge distributor as an accessory Two independent battery circuits can then be charged simultaneously The charge distributor separates the two groups from one another so that the engine s storage batteries are kept fully charged even if the accessory batteries are weak or almost discharged Note The charging voltage from the 28V 60A genera...

Page 62: ...ables All separate ground connections should be collected together to form a joint ground connection which is separate from the propul sion package If shore power is connected protector ground should not be connected to the engine or to any other ground on the boat A transformer connected to shore power must be in stalled so that the protective ground terminal on the inlet side 120 220V and the ne...

Page 63: ...ays switch off the charging circuit before removing the battery charger connectors Warning Never allow an open flame or elec tric sparks near the battery compartment Never smoke in proximity to the batteries The batteries give off hydrogen gas during charg ing which when mixed with air can form an ex plosive gas oxyhydrogen This gas is easily ignited and highly volatile Always use protective goggl...

Page 64: ...section entitled Electrical sys tem Important on the previous page Resetting semi automatic fuses Semi automatic fuses The semi automatic fuses are reset by pressing the re spective fuse s button Maintenance Electrical System Check that the batteries are connected properly Also check that all other electrical connections are dry and free of oxidation and that there are no loose con nections If nec...

Page 65: ... Block diagram 1 Key switch 2 Charge warning lamp 3 Resistance 47Ω 25W P N 863400 8 4 Generator GEN Extra generator 28V 100A Oil scavenging pump Suggested connection of oil scanvenger pump pump ing and filling Cable area 1 5mm2 A Fuse 8A A Main panel B Auxiliary panel C Control panel for auxiliary control position Flying Bridge D Alarm panel Used only when there is no main panel A E Y connection F...

Page 66: ...coolant termperature ECT gauge 5 Connector for connecting extra warning display accessory 6 Control module alarm 7 Warning light engine coolant termp ECT 8 Warning light oil pressure 9 Warning light charge 10 Control lamp not used 11 Instrument lighting switch 12 Alarm test acknowledgement switch 13 Tachometer with built in hours run meter 14 Key switch 15 Alarm 16 Connector for connecting neutral...

Page 67: ...wn GN Green VO Violet GR Gray W White OR Orange Y Yellow PU Purple Conversions mm2 AWG American Wiring Gauge mm2 1 0 1 5 2 5 10 16 AWG 16 17 15 16 13 7 5 1 Instrument panel lighting 5 Connector for connecting extra warning display accessory 6 Control module alarm 7 Warning light engine coolant termp ECT 8 Warning light oil pressure 9 Warning light charge 10 Control lamp not used 11 Instrument ligh...

Page 68: ...ge 10 Oil pressure gauge 11 Voltmeter 12 Turbo charging pressure gauge 13 Oil pressure gauge reverse gear 14 Alarm 15 Alarm test acknowledgement switch 16 Instrument lighting switch 17 Key switch 18 Connector for connecting neutral position switch accessory 19 Tachometer with built in hours run meter 20 16 pin connection Cable color BL Blue LBL Light blue BN Brown LBN Light brown GN Green GR Gray ...

Page 69: ...dgement switch 9 Instrument lighting switch 10 Connector cannot be opened 11 Instrument panel lighting 12 Tachometer with built in hours run meter 13 Start button 14 Stop button 15 Connector for connecting neutral position switch accessory 16 16 pin connector Cable color BL Blue LBL Light blue BN Brown LBN Light brown GN Green GR Gray OR Orange R Red SB Black VO Violet W White Y Yellow Cable areas...

Page 70: ...ressure sender engine 14 Oil pressure switch engine 15 Oil pressure sender reverse gear accessory 16 Engine coolant temp ECT sender 40 120o C 17 Engine coolant temperature ECT switch 97 C 207 F normally open closes if fault occurs Located in terminal box Cable color BL Blue R Red LBL Light blue SB Black BN Brown VO Violet LBN Light brown W White GR Gray Y Yellow Cable areas in mm2 are noted after ...

Page 71: ...11 Engine coolant temperature ECT sender 40 120 C 104 248 F 12 Oil pressure switch engine 13 Oil pressure sender engine 14 Joint 15 Connector 16 pin 16 TAMD163A keel cooled engine version Temperature switch charge air temperature 86 C 187 F normally open closes if fault occurs 17 Connector Located in terminal box Cable color BL Blue R Red LBL Light blue SB Black BN Brown VO Violet LBN Light brown ...

Page 72: ...e reverse gear 5 Check the batteries as described on page 62 Connect batteries 6 Fit new fuel filters and vent the fuel system as described on pages 51 7 Open the sea cock Start the engine see Opera tion and warm the engine up at a fast idle before loading the engine 8 Check for any leaks of oil fuel or cooling water Boat unused for up to two months If the boat is not expected to be used for up to...

Page 73: ...personnel Do not try to start the engine if there is a possibility that there is water in the engine The starter motor turns the engine over but it does not start CAUSE Air in fuel system Fuel starvation or no fuel fuel cocks closed fuel tank empty wrong tank on line fuel filters clogged due to contaminants paraffin precipitation in the fuel as a result of low outside temperature Stop solenoid inc...

Page 74: ... air cleaner filter check ventilation to engine compartment Install new pressure line s 4 Engine Coolant Temperature ECT too low CAUSE Defective thermostats REMEDY Install new thermostats 3 Engine Coolant Temperature ECT too high CAUSE Coolant level in engine too low air in system Defective thermostats Seawater pump pump impeller defective Sea cock closed Seawater intake blocked Seawater filter bl...

Page 75: ...s other connections Tighten the hose clips Contact authorized service personnel Check that the ventilation ducts to the engine compart ment are not blocked Adjust the throttle controls Clean the insert as shown on page 56 Check that the exhaust system is not restricted in any way Get authorized service personnel to check the injectors Contact authorized service personnel Contact authorized service...

Page 76: ...00 500 kPa 3 5 kp cm2 43 5 72 5 psi 3 5 kp cm2 43 5 72 5 psi Oil pressure engine hot piston cooling 180 kPa 1 8 kp cm2 26 psi 180 kPa 1 8 kp cm2 26 psi Oil capacity incl oil filters approx Deep oil sump Shallow oil sump engine inclination 0 73 liters 16 1 Imp gals 19 3 US gals 51 liters 11 2 Imp gals 13 5 US gals engine inclination 5 55 liters 12 1 Imp gals 14 5 US gals 47 liters 10 3 Imp gals 12 ...

Page 77: ...load and wide open throttle WOT air temperature approx 25 C 77 F If readings are taken at a different temperature the boost pressure measured must be corrected see Workshop Manual If full power cannot be achieved the pressure is considerably lower TAMD162C TAMD163A TAMD163P A Rating Pleasure Power curve PD Rating 4 Power curve SLD 2100 rpm 155 kPa 1 55 kp cm2 22 5 psi Rating 3 Power curve LD 2100 ...

Page 78: ...D163P A System voltage 24 V 24 V Battery capacity 2 x 12V in series max 220Ah 2 x 12V in series max 220Ah Generator for alternating current voltage max amperage 28V 60A 28V 60A output approx 1700 W 1700W brush length min 8 mm 0 315 min 8 mm 0 315 Extra generator equipment accessory voltage max amperage 28V 100A 28V 100A output approx 2800 W 2800 W brush length min 5 mm 0 2 min 5 mm 0 2 Battery ele...

Page 79: ... kg 564 lbs 720 kg 1586 lbs Note Only single grade lubricating oil only one viscosity number may be used in the reverse gear Clutch Disengageable clutches at front of engine accessory Twin Disc Type Double plate clutch over center type Gear ratios 1 1 Size 292 mm 11 Max output at 1800 r min 256 hk 188 kW Permitted rpm power take off engaged 750 1800 rpm Max permitted torque take off 1000 Nm Weight...

Page 80: ...V 100A 2800W Extra fuel pre filters with water separator Electrical oil scavenging pump Manual oil scavenging pump Shallow oil sump Seawater filter Muffler Bilge scavenging pumps 24V TAMD162C and TAMD163A in commercial operation Capacity at 1800 rpm and 5 m 16 4 ft column pressure 2 310 l min 68 2 Imp gals 81 8 US gals Hydraulic pump Pulley for extra power take off Extra power take off at the fron...

Page 81: ...s Dual lever control The brake is for the engine speed control Adjust the friction by turning the screw at the arrow see figure Turning the screw clockwise makes the lever move ment stiffer while turning counterclockwise conse quently makes it easier to move the lever Disengageable clutch Adjustment Turn off the engine and move the clutch lever to the neutral position Remove the inspection cover a...

Page 82: ...80 Notes ...

Page 83: ......

Page 84: ...7737387 6 English 8 1998 ...

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Volvo Penta TAMD162C, Instruction Book

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