Volvo Penta TAMD63L Instruction Book Download Page 101

Page: 101 / 124

2. Engine starts but stops again/runs

unevenly

CAUSE

●

Air in fuel lines

●

Lack of fuel

– fuel taps 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
temp.)

●

TAMD71B: Preheating insufficient

– incorrect starting method

– starter element not in circuit

●

Insufficient air supply to engine

– air cleaner filter clogged

●

Pressure line rupture

3. Engine coolant temperature too high

CAUSE

●

Coolant level in engine too low (air in system)

●

Thermostat malfunction

●

Faulty seawater pump (pump impeller)

●

Sea cock closed

●

Seawater intake blocked

●

Seawater filter blocked

●

Heat exchanger core clogged

●

Faulty circulation pump

REMEDY

Vent the fuel system as shown on page 54

Open the fuel cocks

Fill with fuel/connect the correct fuel tank

Fit new fuel filters (pre-filter and/or fine filters). Vent
the system as shown on page 54

Try starting again as shown on page 23

Check that none of the semi-automatic fuses in the
terminal box has tripped (see page 71 for instructions
on resetting fuses)

Check the electrical leads and key switch, starter
relay and hihg power relay (swap the starter relay
temporarily with stop relay if required). Contact author-
ized service mechanic if the starter element needs to
be replaced

Fit a new air cleaner filter/clean air cleaner filter,
check ventilation to engine compartment

Install new delivery pipe(s)

REMEDY

Fill the engine with coolant and vent the system as
described on pages 59– 60

Install a new thermostat

Replace the seawater pump impeller as shown on
page 64

Open the boat’s sea cock

Clean the seawater intake

Clean the seawater filter as shown on page 60

Clean the insert(s) as shown on pages 60– 62

Contact an authorized Volvo Penta service mechanic

7740156 - Downloaded from www.volvopenta.com 22/07/2009 00:44:08

Summary of Contents for TAMD63L

Page 1: ...INSTRUCTION BOOK TAMD63L P TAMD71B TAMD73P WJ TAMD74C L P ...

Page 2: ...7740156 Downloaded from www volvopenta com 22 07 2009 00 44 08 ...

Page 3: ... 29 Action when there is a risk of freezing 32 The rest of the manual Technical description and maintenance can be read once you have had time to acquaint yourself with your boat This section will give you more information on the design and opera tion of your engine Here you will also find a kind of Do It Yourself description of many aspects of main tenance Maintenance and care Periodic care and m...

Page 4: ...olant line must be removed on a hot engine It is difficult to anticipate in which direction steam or hot coolant can spray out Stop the engine and close the sea cock before carrying out operations on the engine cooling system Only start the engine in a well ventilated area If operating the engine in an enclosed space ensure that exhaust gases and crankcase ven tilation emissions are ventilated out...

Page 5: ...ng the drive unit Always check that the lifting equipment used is in good condition and has the load capacity to lift the engine engine weight including reverse gear and any extra equipment installed To ensure safe handling and to avoid damaging engine components on top of the engine use a lifting beam to raise the engine All chains and cables should run parallel to each other and as perpendicular...

Page 6: ...on The oil and oil filter in the Twin Disc reverse gear should first be changed after a maximum of 50 hours operation Remove and clean the reverse gear s oil screen at the same time In the case of MPM reverse gears the oil screen should be cleaned after 10 and 50 hours of operation and the first oil and filter change should be made after 50 hours of operation The disengageable clutch should be che...

Page 7: ...o minimize the risk of fire and explosion Using non original Volvo Penta parts which do not meet the above standards can result in fire or explosion on board Any type of damage which results from the use of non original Volvo Penta replacement parts for the product will not be covered under any warranty provided by AB Volvo Penta Safety Everyone wants to have a problem free and pleasant time when ...

Page 8: ... tion must be carried out after running the engine for 100 hours TAMD63 TAMD73 and TAMD74 or 150 300 hours TAMD71 or within 180 days from the date of delivery or the end of the first sea son whichever comes first Labor and material costs in connection with the First Service Inspec tion are not covered by the Volvo Penta Interna tional Limited Guarantee for checklist see your Warranty and Service b...

Page 9: ...ve Engine type Serial No Dataset EDC No Reverse gear type Serial No Propeller designation Boat type designation Serial No Disengageable clutch type designation Serial No Other equipment Serial No Identification number Immediately after you have taken delivery of your boat make a note of the serial number and model designation of the engine and reverse gear and the dataset number EDC Refer to next ...

Page 10: ...ifferent combustion chamber and a modified injection sys tem The TAMD73P TAMD73EDC and TAMD74C L P TAMD74EDC are equipped with an electronically controlled governor Electronic Diesel Control EDC This further reduces exhaust emissions The exhaust manifold and turbocharger are fresh water cooled to reduce the radiant heat to the engine compartment For a more detailed description of the engine its fu...

Page 11: ...Oil filler cap 5 Expansion tank 6 Engine coolant filler cap 7 Heat exchanger 8 AC generator 9 Seawater pump 10 By pass filter for lubricating oil 11 Lubricating oil filter engine 12 Starter motor 13 Oil dipstick engine 14 Oil dipstick reverse gear Fig 3 TAMD71B auxiliary engine variant 1 Terminal box with semi automatic fuses 2 Engine coolant filler cap 3 Fine fuel filters interchangeable 4 Oil fi...

Page 12: ... box with semi automatic fuses 7 Turbocharger 8 Water cooled exhaust bend accessory 9 Wastegate valve boost pressure control BPC valve 10 Oil dipstick engine 11 Oil cooler engine 12 Circulation pump 12 11 10 9 1 2 3 4 5 6 7 8 12 11 10 9 8 7 1 2 3 4 5 6 12 11 10 9 8 7 1 2 3 4 5 6 Fig 4 TAMD73P A TAMD73EDC 1 Filter for crankcase ventilation 2 Air Cleaner ACL 3 Charge air cooler CAC 4 Heat exchanger ...

Page 13: ... engine when coolant temperature is too high or there is a loss of charge 8 Pressure switch for testing alarm functions or ac knowledging alarms No alarm Alarm test all warning lights are on and the siren sounds If the alarm sounds Alarm acknowledg ment 9 Operating time meter Displays the engine s op erating time in hours and tenths of an hour 10 Tachometer engine speed Multiply this value by 100 ...

Page 14: ...eutral position For safety reasons the engine can only be started with the control in the neutral posi tion Note When used with the electronic Volvo Penta control unit there is also a function for con trolling the engine speed with the engine disen gaged This function must not be operated dur ing starting Press the button in and hold it down while mov ing the control lever to the shift position Th...

Page 15: ...is always activated when the engines are started the light in the blue Sync button is on The following conditions must be met for opera tion of the engine speed synchronization func tion A The engine speed on both engines must be more than 800 rpm B The controls for both engines must be set so that the difference between the two engines is not more than 50 200 rpm when they are running at 800 1000...

Page 16: ...nel 21 Tachometer engine speed Multiply this value by 100 for revolutions per minute 22 Operating time meter Displays the engine s operating time in hours and tenths of an hour 23 Pressure switch for testing the alarm function 24 Alarm for malfunctions corresponding to alarm on main panel 25 Pressure switch for instrument lighting 26 Key switch start lock with start and stop func tions and a built...

Page 17: ...l pos 11 14 Control panel for pilot house main panel 32 Key switch start lock with start and stop func tions and a built in restart inhibitor starter motor protection The start lock prevents restarting unless the key has first been returned to the stop position S 33 Pressure switch for instrument lighting 34 Alarm siren fault detection warning Sounds when lubricating oil pressure is too low engine...

Page 18: ...or acceleration and reverse gear maneuvers combined in one lever When starting for example the shift function can be easily disengaged so that only the engine speed rpm is affected by the lever When maneuvering the boat astern or ahead the control mechanism in the unit ensures that the engine speed drops to idle speed at the moment shifting occurs The control lever has an adjustable friction brake...

Page 19: ...ou can shift only when the acceleration lever is in the idling posi tion The controls have a neutral switch to prevent starting with the reverse gear engaged Both control levers have separately adjustable friction brakes Electronic controls TAMD73P and TAMD74 The Volvo Penta electronic single lever control com bines the functions of a throttle and reverse gear op eration in one control lever unit ...

Page 20: ...n The yellow lamp starts to flash to confirm that the EDC system is in calibration mode Note Two persons are required for this operation one to turn the key switch key on the main panel while the other calibrates the controls on a Flying Bridge position where the control pan el does not have a key switch VP EDC control electronic Lever 1 for reversing maneuvers and controlling engine speed Positio...

Page 21: ...gle lever control NOTE Certain other makes of control have been shown to have greater travel A with full throttle opening with the reverse gear disengaged than with wide open throttle WOT with the reverse gear engaged Measure the movement A at the potentiometer bracket at wide open throttle WOT and with the reverse gear engaged Note the result NOTE Calibrate first at the Master Control Sta tion fo...

Page 22: ...the lever in this position Acknowledge the position by pressing the green button Hold for at least 3 seconds 4 Move the shift function lever to the position at which the reverse gear is engaged for Ahead forward movement Hold the lever in this posi tion Acknowledge the position by pressing the green button Hold for at least 3 seconds 5 Move the shift function lever to the position where the revers...

Page 23: ...n is not acti vated With mechanical shift the green lamp will not flash 4 Start the engine The engine idle speed can now be adjusted using the control lever throttle lever within the range 550 700 rpm equivalent to the movement of the lever Mechanical single lever control Disengage the reverse gear function before moving the con trol lever 5 Set the engine idle speed required and press in the gree...

Page 24: ...astic expansion tank accessory For filling see page 59 Note Do NOT open the pressure cap when the engine is hot 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 lower than the bot tom mark 7 Check the oil level in the reverse gear Note Since the marks on the dipstic...

Page 25: ...ly to position III to start Starting the engine To keep smoke on starting to a minimum the TAMD71B is fitted with air preheating a starter element This starter element is found in the inlet pipe and its activation time is controlled by a timer relay On the TAMD63 TAMD73 and TAMD74 which all have higher compression different combustion chambers and a modified in jection system a starter element is ...

Page 26: ... F At operating speed the engine s oil pressure gauge should show at least approx 300 kPa 43 psi TAMD63 420 kPa 61 psi TAMD71 73 74 System voltage should be approximately 14V or 28V depending on whether the engine is equipped with a 12V or 24V system The warning lights should be off and the alarm off TAMD71B The preheating indicator light goes off approx 50 secs after starting Check the oil level ...

Page 27: ... coolant levels are too low before starting or if there is water in the extra fuel pre filter An extra alarm function may also be connected Note When running the engine for long periods the engine oil level must be checked at least every 8 hours with the engine stopped check after the engine has been stopped for approx 3 minutes Reverse gear 1 Reduce engine speed to idling and if possible let the ...

Page 28: ...on I and press the red button Active Station in the new control position For a second control station with push but tons Turn the key switch on the Main control station to operating position I and press the red button Active Station in the new control posi tion The indicator lamps in both the red and green buttons light to confirm that the new control posi tion is active NOTE If the red button is ...

Page 29: ... following equipment shown can be obtained only for propulsion engines in working boats Trolling valve Twin Disc MG507 1 and MG507A 1 If the reverse gear has a trolling valve accessory this should be used when the boat is to move very slowly Engage the trolling valve to max slip when the re verse gear control is in neutral After selecting For ward or Reverse the trolling valve can then be set in t...

Page 30: ... automatically into the 0 position The key can then be taken out Safety precautions 3 Close the cooling water intake sea cock and the fuel cocks For anti freeze protection see sec tion Precautions against freezing on page 32 4 Switch off the main switches if the boat is not to be used for some time 5 Inspect the engine and engine compartment for any leaks Emergency stop Pull the stop lever on the ...

Page 31: ...NG The control s for the affect ed engine do not function The engine speed is set to 1000 rpm and the re verse gear is set in Neutral for safety Contact an authorised workshop for corrective action as soon as possible If movement ahead forward is required proceed as follows 1 Stop the engine 2 Engage reverse gear manually for Ahead move ment See the next section Reverse gear emer gency operation 3...

Page 32: ...ear emergency operation On MPM and Twin Disc reverse gears with electroni cally operated shifting there is a safety feature for manual engagement of Ahead forward movement should a malfunction occur on the reverse gear sole noid valve MPM Engagement 1 Stop engine and remove the key from the key switch 2 Note to which solenoid valve P or S the wiring marked Primary is connected Detach the con necto...

Page 33: ...ement the reverse gear is locked for use Ahead and cannot be disengaged with the control Other Twin Disc Manual engagement of reverse gear safety system A Plug P Solenoid valve Primary Used normally for Ahead forward movement S Solenoid valve Secondary Used normally for Astern back ward movement V Valve body Tightening torque Max 27 Nm 2 7 kpm 19 9 lbf ft Back up power supply If the battery voltag...

Page 34: ...he next page Check that all the water runs out There may be deposits by the cock plug which must be removed Otherwise there is a risk that water may remain in 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 NOTE To protect the environment please dispose of used coolant at a properly designated dis p...

Page 35: ...ter pump Also remove the hose between the heat exchanger and the reverse gear s oil cooler then drain off the water while draining the seawater system F Freshwater cocks plugs S Seawater cocks plugs V Venting cocks TAMD63 F V F F F TAMD73 V V TAMD74 7740156 Downloaded from www volvopenta com 22 07 2009 00 44 08 ...

Page 36: ... back of this book In most cases these pages provide a more detailed description 1 Changing the Engine oil Note Refer to table on page 35 for informa tion on oil grade intervals between changes 1 For TAMD63 TAMD73 and TAMD74 2 For TAMD71 engines 2 Replace oil filter 1 and by pass filter if fitted 2 at every other oil ch arings disengaging inspection cover Release the catc g B counterclockwise Rock...

Page 37: ...ways consult an authorized Volvo Penta service dealer who will have the equipment and trained staff to help you A maintenance program well carried out gives better operating economy and fewer unplanned periods of non operation A Filter s for crankcase ventilation B Air Cleaner ACL C Charge air cooler CAC D Engine oil Cap for filling E Coolant Cap for checking and topping up F Heat exchanger G Gene...

Page 38: ...ar Remove and clean re verse gear oil screen 5 Replace oil filter on MPM IRM 301A and 302V re verse gears Note Special recommendations apply for new or reconditioned engines See instructions Running in on page 4 49 49 50 50 Engine oil VDS or CD or CE as per API system Drain or pump out oil while engine is hot Warning Hot oil can cause burns Remove plug and oil screen Clean screen and reinstall com...

Page 39: ...l new filter Check oil level point 3 above Note Every 50 hours applies when clutch operations per day exceed 15 20 op erations Otherwise every 500 hours Use grease sparingly so that it is not pressed out Use lithium based lubricating grease Mobilux EP2 Statoil Uniway EP2N Texaco Multifak EP2 Q8 Rembrandt EP2 Lubricate inner support bearing when a grease nipple is fitted main bearings disengaging s...

Page 40: ...rew on new filters by hand Tighten by 1 2 turn once gasket is tight Cleanli ness The fuel in the system must not become contaminated Vent system see point 15 below Open vent screw 1 Pump with hand pump 2 until fuel containing no air flows out Close screw while fuel is flowing out Then pump a further 10 20 times Check for leaks Lever 2 on right replace left filter Lever up vent left filter Venting ...

Page 41: ...t up insert Clean insert and hous ing 2 Reinstall components Open the sea cock and check for leaks 60 72 96 32 59 32 60 32 64 Use protective goggles Battery fluid approx 10 mm 0 39 over cell plates Warning The batteries contain oxyhydrogen gas and extremely corrosive sulfuric acid Naked flames sparks close to batteries may cause an explo sion Add 1 2 liter anti corrosion agent to the freshwater sy...

Page 42: ...e density should be 1 28 g cm3 1 24 g cm3 with tropical acid Charge the batteries if the density has dropped by 0 04 g cm3 Wash the insert in clean diesel Squeeze it out and place it in the filter housing Fix the insert by pushing the O ring down into the groove around the outer edge of the insert NOTE Replace the filter insert if it is damaged No Operation Instructions Info pge TAMD63 TAMD73 74 T...

Page 43: ...ote Special recommendations apply for new or reconditioned engines See instructions Running in on page 4 46 Undo the clamps x 6 for the covers 1 Remove the covers and replace the filter inserts Check that the rubber hose against the turbocharger is undamaged and that the new filters are scrupulously clean Reinstall components Lift out and remove the filter for disposal Take care that no contaminan...

Page 44: ...f engine and reverse gear No Operation Instructions Info pge 50 Hrs 250 Hrs 500 Hrs 1000 Hrs 2000 Hrs 12 months Have authorized service personnel check the EDC system using a diagnostic tool Improve external corrosion protection by painting over any abraded parts with original paint WARNING Never use high pressure jets when washing the engine Never point the water jet at seals rubber hoses or elec...

Page 45: ...on cooling Valve system The camshaft is journalled in seven bearings and is driven by the timing gears The camshaft actuates the inlet and outlet valves in the cylinder heads via lifters push rods and rockers In the TAMD71 TAMD73 and TAMD74 these valves have double valve springs Cylinder block The cylinder block is made of special alloy cast iron and cast in one piece The cylinder liners are of th...

Page 46: ...gh a replaceable filter cartridge which removes any oil mist before the gases are led out Any oil is returned to the oil sump by a drainage hose on TAMD71 On the filter casing is also a relief valve which opens if the pres sure in the crankcase becomes too high due to a blocked filter Air Cleaner ACL The air cleaner prevents harmful particles from being sucked into the engine TAMD63 engines have a...

Page 47: ...ck the rubber gasket in the mounting replace if necessary Screw on the new filter by hand 3 TAMD71 Check the drain hose is not clogged Checking tensioning drive belt s Check the belt s for wear Replace belt s when necessary Belts which work in pairs should be replaced at the same time Undo screws A before tensioning the belt s TAMD63 TAMD73 and TAMD74 Place the stud of a torque wrench in the squar...

Page 48: ...urbine or compressor 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 reconditioned as soon as possible Note If the turbocharger unit is to function satisfacto rily it is vital that the engine s lubrication system be maintained according to the maintenance s...

Page 49: ...TAMD74 accessory in the TAMD71 before being returned to the oil sump The rest of the oil continues through the oil cooler and out to the piston cooling jets Lubrication TAMD71 1 Main oil channel lubricating oil 15 Filtered oil pressure to lubri 2 Pressure line to turbocharger cation system 3 Main oil channel piston cooling oil 16 Oil pressure from oil pump 4 Rocker mechanism 17 Return oil to oil s...

Page 50: ... way oil can flow into the engine lubrication system even if the filter is clogged But the oil entering the system is unfil tered So it is important that the filter is replaced according to the intervals recommended in the maintenance schedule The piston cooling valve 13 regulates the flow of oil through the oil cooler and on to piston cooling The by pass valve 25 permits increased oil flow throug...

Page 51: ...l filter is of full flow type which means that all the oil is filtered before it enters the lubrication system The filter element is made of folded filter paper In the TAMD63 TAMD73 and TAMD74 the filter is located in front of the starter motor on the right of the engine TAMD71 engines have the filter located at the front of the engine On all marine propulsion engines the filter can alternatively ...

Page 52: ...k the oil level with the engine idling and with the neutral position selected The oil level should reach the upper mark on the dipstick Top up if required Cleaning the reverse gear s oil screen MPM IRM 220 280 MPM IRM 301 302V TD MG5061 MG5062V TD MG507 A 1 MG5075A MG5085 TAMD63 TAMD73 and TAMD74 1 Lubricating oil filter 2 By pass filter 3 Screw on the new filter by hand until the gasket is in con...

Page 53: ...mbustion chambers Return fuel from the injectors returns to the tank via the overflow valve Fuel system 1 Fine fuel filters 2 Venting nipple 3 Pressure pipe from inlet manifold charging pressure 4 Injection pump 5 Pressure pipe 6 Injectors 7 Fuel return line 8 Pressure equalizer 9 Centrifugal governor 10 Overflow valve 11 Return pipe lubricating oil 12 Return line to fuel tank 13 Fuel line intake ...

Page 54: ...integrated in the Electronic Diesel Control EDC system Feed pump Feed pump If the injection pump is to work it requires a supply of fuel at pressure This is provided by the feed pump which is of piston type The feed pump is located on the injection pump and is driven by the injection pump s camshaft The feed pressure is determined by an overflow valve located on the injection pump This valve both ...

Page 55: ... Double filter As a rule the filter inserts should be replaced when the pressure gauge indicates a vacuum of 6 10 in Hg idle or 16 20 in Hg respectively max rpm loaded engine However filters must be replaced after every 1000 operating hours Close the fuel cocks at the tank before dismantling the single filter or replacing the inserts of the double filter with the engine off Double filter If insert...

Page 56: ...ne fuel filters replacement while engine is running 1 Place a container beneath the fuel filters Clean the filter mounting carefully 2 Turn lever 2 for the valve in the filter cover in its right end position 3 Unscrew the left fuel filter and discard it Use special tool to remove filter if necessary 4 Screw on the new filter by hand until the gasket comes into contact with the filter mounting Then...

Page 57: ...jector carefully backwards and for wards using a wrench size 15 mm pulling it up at the same time Note If the injector is stuck you must use a special tool to remove it The copper sleeve around the injector may otherwise be pulled out as well with water in the engine as a conse quence The coolant in the freshwater system can be drained as an extra safety measure before removing the injectors 4 Han...

Page 58: ...freshwater system via the oil cooler The lubricating oil is also used to dissipate heat from the pistons in the engine see Pistons on page 43 The cooling system may operate with a small amount of overpressure The risk of boiling is thereby reduced if the temperature is high If the pressure is higher than normal a pressure valve in the filler cap opens The flow in the seawater system is maintained ...

Page 59: ...wax increases and the thermostat subsequently opens the route to the heat exchanger while the by pass line is closed TAMD63 TAMD73 TAMD74 Flow through heat exchanger 1 Expansion tank 4 Heat exchanger 2 Hot coolant from 5 Seawater inlet from charge engine s thermostat housing air cooler 3 Coolant to coolant 6 Seawater outlet to reverse pump suction side gear oil cooler 1 4 6 5 2 3 2 5 3 4 1 TAMD63 ...

Page 60: ...eat exchanger or charge air for CAC passes between the pipes Note On TAMD71 engines the heat exchanger and charge air cooler are identical so the cooling inserts for example are interchangeable Engine oil cooler 1 Coolant inlet 5 Oil to piston cooling 2 Coolant outlet 6 By pass valve 3 Oil inlet 7 Excess oil return 4 Outlet oil to oil sump Oil cooler engine The lubricating oil transports heat from...

Page 61: ...tem the heater control valve should be opened and the unit vented during filling Fill with coolant to 5 cm 2 beneath the sealing surface of the filler cap or to between the MIN and MAX marks on the separate plastic expansion tank accessory Note Cooling system capacity approx TAMD63 27 liters 7 1 US gals TAMD71 35 liters 9 3 US gals TAMD73 TAMD74 34 liter 9 1 US gals Maintenance Cooling System Anti...

Page 62: ...nd check for leaks Seawater filter Bracket with oil pressure sender and switch TAMD63 Heat exchanger and insert Cleaning the heat exchanger and charge air cooler CAC TAMD63 TAMD73 and TAMD74 Close the sea cock and drain the water from the seawater and freshwater systems before working on the cooling system 1 Remove both battery leads 2 Remove the oil pressure sender and oil pressure switch complet...

Page 63: ...ew turns 10 mm Allen screw 11 Push out the inserts Note The inserts can only be pushed out back wards as they have a flange at the rear 12 Flush and clean them internally and externally Use suitable brushes Also clean the housings and covers Note Ensure that no contaminants enter the engine s inlet manifold via the charge air cooler Check that the drainage hole in screw 1 at the back of the charge...

Page 64: ...over 17 TAMD73 and TAMD74 Lubricate O rings and install coolant pipe between seawater pump and charge air cooler CAC 18 Connect the cooling water hoses to the heat exchanger and charge air cooler CAC Tighten the hose clips 19 Connect the plastic pipe from the thermostat housing to the heat exchanger 20 TAMD73 and TAMD74 Reconnect wiring to charge air temperature sender 21 Reinstall the oil pressur...

Page 65: ... 1 Open the drain cock on the reverse gear s oil cooler 2 Unscrew the zinc anode Z on the oil cooler s right end cover 3 TAMD63 TAMD73 and TAMD74 Unscrew the zinc anode in the heat exchanger s front end cover or in the charge air cooler s rear end cover Note The seawater in the heat exchanger or charge air cooler should be drained at the same time TAMD63 TAMD73 and TAMD74 Zinc anode in CAC rear en...

Page 66: ...MD74 clockwise TAMD71 counterclockwise 4 Reinstall the cover together with a new gasket Always keep a spare pump impeller and gasket on board 5 Open sea cock Start the engine and check for leaks Note In certain installations it is easier to first remove the pump from the engine see next section and then replace the impeller Removing the seawater pump impeller Installing the seawater pump 1 Check t...

Page 67: ...nt is not required The electrical system also includes senders for monitoring the engine s coolant temperature and oil pressure The electrical system is shown in two ways The wiring diagrams pages 73 93 shows the wiring cable areas and cable colors The positions of the respective parts in the engine reverse gear are shown in the figures on pages 65 67 Positions of electrical components in engine a...

Page 68: ...oolant temperature switch 12 Fuse for starter element 21 Engine speed rpm sender Starter element TAMD71B The starter element heats the inlet air to the engine The element consists of three series connected wire elements installed in a connecting pipe It is located between the turbocharger and the engine intake manifold The element is automatically engaged when starting when the starter key is turn...

Page 69: ...ormalize The EDC control module also has a diagnostics system On board diagnostics OBD which assists users service technicians to quickly determine the cause of any malfunctions on the system using the diagnostic lamp or a diagnostic scan tool Diagnostic Key TAMD73 TAMD74 Note The components in the figures are numbered the same as in the engine s wiring diagram on pages 79 81 83 85 and 87 3 Genera...

Page 70: ...jection pump This makes it impossible for the pump element to fill up and the engine stops This valve is located on a bracket beneath the injec tion pump AC generator The generator is belt driven and located at the front of the engine 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 charg...

Page 71: ...gative connection on the output side 12 24V are not connected Warning Electrolytic corrosion as a conse quence of leakage currents may cause serious and expensive damage to your boat s equipment within a short time Work on the boat s low tension circuit should only be carried out by qualified or experienced persons Installation or work on the shore power equipment must only be carried out by elect...

Page 72: ...ent panels togeth er Note For the TAMD73P and TAMD74 max 2A apply Arc welding Remove the positive and negative leads from the batteries Then remove all leads to the generator TAMD73P and TAMD74 Remove the connector from the EDC system control module located behind the fine fuel filters Pull down the red locking catch A below the connector while pulling the connector out at the same time Starting u...

Page 73: ...lways be held tightly see figure Otherwise the wire element may twist inside the starter element and cause a short circuit 4 Fit the new fuse and support as shown in the illustration Reinstall the cover plate over the relay Tightening torque for terminal nuts 11 14 Nm 1 1 1 4 kpm 8 10 lbf ft TAMD71B Removal tightening terminal nuts on starter element terminals Resetting replacing fuses Ensure that...

Page 74: ...cking batteries and electrical connections Read the section entitled Electrical system Important on pages 69 70 The service life of your batteries depends largely on how they are maintained Keep batteries dry and clean Dirt on the batteries may cause tracking and discharge them particularly in damp weather Clean the battery terminals and connections using suitable wire brushes Poor contact may cau...

Page 75: ...gine Block diagram A Main panel D Alarm panel Used only when there is no main B Auxiliary panel panel A C Flying Bridge panel E Y connection F Junction box with fuses Main panel A may also be installed on the Note The picture shows the TAMD63 TAMD73 flying bridge control position and TAMD74 Connecting the charge indicator lamp Extra generator 28V 100A 1 Key switch 2 Charge indicator light 3 Resist...

Page 76: ...erature gauge 5 Connector for extra warning display accessory 6 Electronics module alarm 7 Engine coolant temperature warning lamp 8 Oil pressure warning lamp 9 Charge warning lamp 10 Indicator lamp not used 11 Switch instrument panel lighting 12 Alarm test acknowledgement switch 13 Tachometer with built in hours run meter 14 Key switch 15 Alarm 16 Connector for connecting neutral position switch ...

Page 77: ...ator 5 Starter relay 6 Semi automatic fuses 8A 7 Oil pressure sender reverse gear 0 30 bar 8 Turbo pressure sender 0 3 bar 9 Solenoid valve fuel cut off valve 10 Engine coolant temperature ECT switch 97 C normally open closes if fault occurs 11 Engine coolant temperature ECT sender 40 120 C 104 248 F 12 Oil pressure switch engine 0 7 bar normally open closes if fault occurs 13 Oil pressure sender ...

Page 78: ... gauge 5 Connector for extra warning display accessory 6 Electronics module alarm 7 Engine coolant temperature warning lamp 8 Oil pressure warning lamp 9 Charge warning lamp 10 Control lamp pre heating 11 Switch instrument panel lighting 12 Alarm test acknowledgement switch 13 Tachometer with built in hours run meter 14 Key switch 15 Alarm 16 Connector for connecting neutral position switch if fit...

Page 79: ...round terminal 11 Starter element 12 Fuse 150A for starter element 13 Relay for starter element 14 Time relay for starter element 15 Oil pressure sender reverse gear 16 Pressure sender Turbo boost pressure 17 Oil pressure sender engine 18 Oil pressure switch engine 19 Engine coolant temperature sender 20 Coolant temperature switch 21 Engine speed rpm sender 22 16 pin connector Located in the junct...

Page 80: ...l lighting 12 Alarm test acknowledgement switch 13 Tachometer with built in hours run meter 14 Key switch 15 Alarm 16 Connector for connecting neutral position switch 17 16 pin connector 18 2 pin connector for auxiliary panel where installed 19 Adapter TAMD73P A 12V Cable areas in mm2 are given after the color codes in the wiring diagrams The cable area is 1 0 mm2 unless otherwise stated Conversio...

Page 81: ... Oil pressure switch engine 13 Oil pressure sender engine 14 Engine coolant temperature sender 15 Joint splice 16 16 pin connector instrument cable harness 17 4 pin connector reverse gear 18 Solenoid reverse gear with electronic shifting 19 Charge air temperature sender 20 Engine coolant temperature ECT sender EDC 21 Position sensor control rod 22 Engine speed rpm sender 23 Electro magnetic actuat...

Page 82: ...panel lighting 12 Alarm test acknowledgement switch 13 Tachometer with built in hours run meter 14 Key switch 15 Alarm 16 Connector for connecting neutral position switch 17 16 pin connector 18 2 pin connector for auxiliary panel where installed 19 Adapter Control panel for auxiliary control position Flying Bridge TAMD73P A 24V Cable areas in mm2 are given after the color codes in the wiring diagr...

Page 83: ...nder Turbo boost pressure 12 Oil pressure switch engine 13 Oil pressure sender engine 14 Engine coolant temperature sender 15 Joint splice 16 16 pin connector instrument cable harness 17 4 pin connector reverse gear 18 Solenoid reverse gear with electronic shifting 19 Charge air temperature sender 20 Engine coolant temperature ECT sender EDC 21 Position sensor control rod 22 Engine speed rpm sende...

Page 84: ...ure gauge 5 Connector for extra warning display accessory 6 Electronics module alarm 7 Engine coolant temperature warning lamp 8 Oil pressure warning lamp 9 Charge warning lamp 10 Control lamp not used 11 Switch instrument panel lighting 12 Alarm test acknowledgement switch 13 Tachometer with built in hours run meter 14 Key switch 15 Alarm 16 Connector for connecting neutral position switch if fit...

Page 85: ...umbers as shown in the key diagrams on page 67 1 Battery 2 Main ON OFF power switch 3 Generator 4 Starter motor 5 Starter relay 9 Semi automatic fuses 8A 10 Oil pressure sender reverse gear 11 Pressure sender Turbo boost pressure 12 Oil pressure switch engine 13 Oil pressure sender engine 14 Engine coolant temperature sender 15 Ground terminal 16 Fuel shut off valve 17 Coolant temperature switch 1...

Page 86: ...ting 12 Alarm test acknowledgement switch 13 Tachometer with built in hours run meter 14 Key switch 15 Alarm 16 Connector for connecting neutral position switch 17 16 pin connector 18 2 pin connector for auxiliary panel where installed 19 Adapter Control panel for auxiliary control position Flying Bridge TAMD74C A TAMD74L A TAMD74P A 12V Cable areas in mm2 are given after the color codes in the wi...

Page 87: ...e harness 17 4 pin connector reverse gear 18 Solenoid reverse gear with electronic shifting 19 Charge air temperature sender 20 Engine coolant temperature ECT sender EDC 21 Position sensor control rod 22 Engine speed rpm sender 23 Electro magnetic actuator EDC 24 2 pin connector data link connector 25 16 pin connector male control unit 26 16 pin connector female control unit 27 Fuse 7 5A 28 Connec...

Page 88: ...or for extra warning display accessory 6 Electronics module alarm 7 Engine coolant temperature warning lamp 8 Oil pressure warning lamp 9 Charge warning lamp 10 Control lamp not used 11 Switch instrument panel lighting 12 Alarm test acknowledgement switch 13 Tachometer with built in hours run meter 14 Key switch 15 Alarm 16 Connector for connecting neutral position switch if fitted accessory 17 16...

Page 89: ...connector male instrument cable harness 17 4 pin connector reverse gear 18 Solenoid reverse gear with electronic shifting 19 Charge air temperature sender 20 Engine coolant temperature ECT sender EDC 21 Position sensor control rod 22 Engine speed rpm sender 23 Electro magnetic actuator EDC 24 2 pin connector data link connector 25 16 pin connector male control unit 26 16 pin connector female contr...

Page 90: ...g 8 Connector cannot be opened 9 Engine coolant temperature gauge 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 Switch instrument panel lighting 17 Key switch 18 Connector for connecting neutral position switch if fitted accessory 19 Tachometer with built in hours run meter 20 16 pin connector...

Page 91: ... lighting 10 Connector cannot be opened 11 Instrument lighting 12 Tachometer with built in hours run meter 13 Starter button 14 Stop button 15 Connector for connecting neutral position switch if fitted accessory 16 16 pin connector Cable color BL Blue LBL Light blue BN Brown LBN Light brown GN Green GR Gray OR Orange P Pink R Red SB Black VO Violet W White Y Yellow Cable areas in mm2 are given aft...

Page 92: ...all wiring diagrams 1 Indicator light 2 1 pin switch 3 Position limiter switch 4 Connector 5 Potentiometer 6 16 pin connector 7 2 pin connector data link connector DLC 8 Joint splice Single control position Single or dual lever control with control adapters single installation Multiple control positions Single or dual lever controls with control adapters single installation VP controls Late model ...

Page 93: ... SB Black W White Y Yellow Cable areas 0 75 mm 2 Location diagram both wiring diagrams 1 Indicator light 2 Switch 3 Connector 4 Relay 5 Position limiter switch 6 Potentiometer 7 Connector Port Starboard cable harness 8 2 pin connector data link connector DLC 9 16 pin connector Port engine 10 16 pin connector Starboard engine TAMD73P A VP controls Late model NEUTRAL Early model NEUTRAL 7740156 Down...

Page 94: ...k W White Y Yellow Cable areas 0 75 mm 2 Location diagram 1 Push button with indicator light neutral green 2 Push button with indicator light diagnostic yellow 3 Push button with indicator light active station red 4 Connector 5 Potentiometer throttle shifting 5a Control unit adapter throttle 5b Control unit adapter shifting 6 Neutral switch 7 8 pin connector male 8 8 pin connector female 9 Joint s...

Page 95: ... 2 Push button with indicator light Diagnostic yellow 3 Push button with indicator light Active station red 4 Push button with indicator light Synchro blue 5 Push button with indicator light Neutral green 6 Push button with indicator light Diagnostic yellow 7 Connector 8 Connector Port Starboard cable harness 9 Relay 10 Potentiometer throttle shifting 10a Control unit adapter throttle 10b Control ...

Page 96: ... a protective mask when spraying 9 Stick a label on the engine stating the date of inhibition type of inhibition and the inhibiting oil used 10 Cover the engine s air intake exhaust port and the engine itself if so required Launching procedures Check the condition of the propeller s Damaged propellers should be reconditioned or replaced Boat unused for up to two months If the boat is not expected ...

Page 97: ...For coolant information refer to page 96 4 If necessary fill the engine with lubricating oil of the correct quality Fit a new oil filter if this has not been done when changing the oil during inhibiting Check the oil level in the reverse gear 5 Check the batteries as described on page 72 Reconnect batteries 6 Fit new fuel filters and vent the fuel system as described on pages 53 55 7 Open sea cock...

Page 98: ...ndard may also be used For quality and capacities see Technical Data on pages 110 113 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 system is filled with a mixture of freshwater and additives NOTE Never use freshwater without add...

Page 99: ...as per instructions on pages 18 20 Charge replace the batteries or connect up auxiliary batteries as shown on page 70 Switch on the main switches Reset the fuse by pressing in the button Rectify any open circuits loose connections Check for oxidation on the contacts If required clean and spray connection with damp inhibitor spray See the wiring diagrams on pages 74 89 Replace key switch Replace st...

Page 100: ...s shown on page 54 Check solenoid valve has not been switched on unintentionally Try to start engine again according to instructions on page 23 Check that none of the semi automatic fuses in the terminal box has tripped see page 71 for instructions on resetting fuses Check the electrical leads and key switch starter relay and high power relay swap the starter relay temporarily with stop relay if r...

Page 101: ... fuel filters pre filter and or fine filters Vent the system as shown on page 54 Try starting again as shown on page 23 Check that none of the semi automatic fuses in the terminal box has tripped see page 71 for instructions on resetting fuses Check the electrical leads and key switch starter relay and hihg power relay swap the starter relay temporarily with stop relay if required Contact author i...

Page 102: ...AMD74 engines are not equipped with a smoke limiter REMEDY If possible reduce redistribute the load Clean the bottom of the boat and treat it with anti fouling paint Replace the propeller Fit new fuel filters pre filter and or fine filters Vent the system as shown on page 54 Clean fuel tank Drain water from pre filter if installed Fit new air cleaner filter s clean air cleaner filter Check the rub...

Page 103: ...ve fuel shut off valve TAMD63 and TAMD73WJ have no stop relay TAMD73P and TAMD74 have no fuel shut off valve REMEDY Replace fuse 8A Reset the fuse by pressing in the button Rectify any open circuits loose connections Check for oxidation on the contacts If required clean and spray connection with damp inhibitor spray See the wiring diagrams on pages 74 89 Replace key switch Replace stop relay or sw...

Page 104: ... read out from the system of what the nature of the fault is that is causing the diagnostic trouble code DTC press the yellow Diagnostics button when the light is flashing This results in the system flash ing a two part code The first number of flashes are units of ten followed by a short pause then a series of new flashes single units After the alarm has been acknowledged DTCs have been read off ...

Page 105: ...ed RPM sensor transmits abnormal values to control module System does not enter calibration mode Starter motor cannot be activated Starter motor cannot be activated Engine stopped by system Main relay opens engine stops Engine stopped by system EDC diagnostic Trouble Codes DTC DTC Explanation Cause Reaction Action Check operation of neutral position switch closed in neutral position Erase DTC Reca...

Page 106: ...ion Erase DTC Start the engine If the fault persists shifting can be carried out directly on the reverse gear solenoids Check cabling and connections to starter relay in terminal box Check starter relay Position 5 on the location diagram page 67 Erase DTC Check cabling and connections to main relay in terminal box Check main relay Position 6 on the location diagram page 67 Erase DTC Check bulb in ...

Page 107: ... not start If the engine coolant temperature is too high the system will reduce the volume of fuel injected until temperature has normalized Turn off power completely and wait 3 minutes before reconnecting Contact authorized workshop if fault persists Check the engine coolant system DTC Explanation Cause Reaction Action 7740156 Downloaded from www volvopenta com 22 07 2009 00 44 08 ...

Page 108: ...0 50 mm 0 0197 0 50 mm 0 0197 exhaust 0 65 mm 0 0256 0 65 mm 0 0256 Compression pressure at starter motor speed 300 rpm 2 2 MPa 22 kp cm2 313 psi Weight engine with heat exchanger without reverse gear or clutch approx 880 kg 1940 lbs 860 kg 1896 lbs Note For TAMD73WJ 600 50 rpm applies At delivery the idling speed for the TAMD73P and TAMD74 is adjusted to 600 rpm If needed the speed can be adjuste...

Page 109: ...spring 29 5 0 8 MPa 29 5 0 8 MPa 300 8 kp cm2 4279 psi 300 8 kp cm2 4279 psi Turbocharger Charging pressure min values measured in the engine s inlet manifold at 100 load and wide open throttle WOT air temperature approx 25 C 77 F When measuring at a different temperature the charging pressure measured must be corrected see Workshop Manual If full power cannot be achieved the pressure is considera...

Page 110: ...sed TAMD73P A TAMD74C A TAMD73WJ A TAMD74L A TAMD74P A Oil capacity at oil change without oil filters approx no engine inclination Max 28 liters 7 4 US gals 25 liters 6 6 US gals Min 19 liters 5 0 US gals 18 liters 4 8 US gals engine inclination 5 Max 24 liters 6 3 US gals 20 liters 5 3 US gals Min 16 liters 4 2 US gals 14 liters 3 7 US gals engine inclination 10 Max 18 liters 4 8 US gals 17 liter...

Page 111: ...4V system voltage max amperage 28V 100A 28V 100A output approx 2800W 2800W Battery capacity for 12V system 2 x 12 V connected in parallel 2 x 12 V connected in parallel max 110 Ah total max 220 Ah max 110 Ah tot max 220 Ah for 24V system 2 x 12 V connected in series 2 x 12 V connected in series max 143 Ah max 143 Ah Battery electrolyte density at 25 C 77 F fully charged battery 1 28 g cm3 1 24 g c...

Page 112: ...s 1 4 US gals 1 27 US gals Oil quality as per API system CC CD CE CC CD CE Viscosity SAE30 SAE30 alternative for hot countries SAE40 SAE40 Operating oil pressure 2 5 MPa 2 5 MPa 25 5 kp cm2 25 5 kp cm2 362 psi 362 psi Approx weight 70 kg 154 lbs 82 kg 181 lbs For TAMD74 engines Note Only single grade lubricating oil only one viscosity number may be used in the reverse gears Type designation IRM 22...

Page 113: ...0 1 1 54 1 1 75 1 2 47 1 2 00 1 Angle output shaft 7 7 7 Oil capacity approx 3 2 liters 3 2 liters 3 2 liters 0 85 US gals 0 85 US gals 0 85 US gals Oil quality as per API system CC CD CE CC CD CE CC CD CE Viscosityat oil temp of 66 85 C 151 185 F SAE30 SAE30 SAE30 at oil temperature 85 100 C 185 212 F SAE40 SAE40 SAE40 Working oil pressure at oil temperature of 82 C 180 F engaged 1800 rpm 2 3 MPa...

Page 114: ...perated shifting Note Only single grade lubricating oil only one viscosity number may be used in the reverse gears Type designation MG507 1 MG5075A E Gear ratios 1 10 1 1 51 1 1 53 1 1 77 1 1 77 1 1 98 1 2 05 1 2 54 1 2 99 1 Angle output shaft 0 7 Oil capacity approx 6 7 liters 5 9 liters 1 8 US gals 1 6 US gals Oil quality as per API system CC CD CE CC CD CE Viscosity at oil temp of 66 85 C 151 1...

Page 115: ...p cm 276 psi Approx weight 178 kg 392 lbs 140 kg 309 lbs Reverse gear with electronically operated shifting Note Only single grade lubricating oil only one viscosity number may be used in the reverse gears Type designation MG5085PL Gear ratios 1 2 1 Angle output shaft 0 Oil capacity approx 4 4 liters 1 2 US gals Oil quality as per API system CC CD CE Viscosity at oil temp of 66 85 C 151 185 F SAE3...

Page 116: ... mm 8 or 254 mm 10 Permitted engine speed power take off engaged 900 1800 rpm Approx weight 65 kg 143 lbs Disengageable clutch at rear of engine accessory TAMD71B auxiliary engine Automotive Products Type Double plate clutch over center type Gear ratio 1 1 Size 292 mm 11 1 2 Approx weight 83 kg 183 lbs 7740156 Downloaded from www volvopenta com 22 07 2009 00 44 08 ...

Page 117: ...front of the engine 14V 130A 1800W 28V 100A 2800W Extra fuel pre filter with water separator Single or double Oil filter kit alt location of engine oil filters TAMD71 By pass filter for engine lubricating oil standard on TAMD63 TAMD73 and TAMD74 Electric oil scavenging pump 12V or 24V TAMD71 Auxiliary engine variant Manual oil scavenging pump Seawater filter Separate expansion tank Hot water outle...

Page 118: ...lutches gear ratio 1 1 Rockford BW 203 mm 8 Max output at 1800 rpm 58 hp Max torque 226 Nm 23 kpm 166 7 lbf ft Rockford BW 254 mm 10 Max output at 1800 rpm 80 hp Max torque 314 Nm 32 kpm 231 6 lbf ft Toolkit Exhaust riser Muffler Bilge scavenging pumps 24V TAMD71 in com mercial operation Capacity at 1800 rpm and 3 m 9 8 ft suction height 1 1 4 230 l min 2 300 l min Hydraulic pump only for engine w...

Page 119: ... see fig ure Turning the screw clockwise makes the lever movement stiffer while turning counterclockwise consequently makes it easier to move the le ver 3 Reinstall the cover over the control Dual lever control The brake is for the engine speed control Adjust the friction by turning the screw see figure Turning the screw clockwise makes the lever movement stiffer while turning counterclockwise con...

Page 120: ...118 Notes 7740156 Downloaded from www volvopenta com 22 07 2009 00 44 08 ...

Page 121: ...119 Notes 7740156 Downloaded from www volvopenta com 22 07 2009 00 44 08 ...

Page 122: ...Tel Address Nearest Volvo Penta Service Dealer Name Tel Address Engine information Engine type Serial No Reverse gear type No Disengageable clutch type No 7740156 Downloaded from www volvopenta com 22 07 2009 00 44 08 ...

Page 123: ...7740156 Downloaded from www volvopenta com 22 07 2009 00 44 08 ...

Page 124: ...7740156 0 English 6 2000 AB Volvo Penta SE 405 08 Göteborg Sweden www volvopenta com ...

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