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Maintenance: Cooling system general

Cooling system D5A TA KC (2-circuit)

The engine cooling water is cooled by, e.g, a box cooler, a grid cooler, or any other external heat exchanger.

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

Drain points HT-circuit

Drain points LT-circuit

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Содержание D5A T

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

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

Страница 3: ...upplied by generator manufacturer In case of contradictions the information in this Volvo Penta Operator s Manual overrules any information given in the documentation provided by the generator manufac...

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

Страница 5: ...r refer to the generator documentation If anything is unclear please contact your Volvo Penta dealer for assistance This symbol is used in the book and on the engine to make you aware of safety infor...

Страница 6: ...solution for your vessel The new engine Read instruction manuals and other information ac companying the new vessel thoroughly Accustom yourself with handling the engine controls and other equipment...

Страница 7: ...owledge The operator s manual contains directions for perfor ming normal maintenance and service in a safe and correct manner Read the directions carefully before starting work More detailed service l...

Страница 8: ...e sure the lubricating system is depressurized before starting work Never start or run the engine with the oil filler cap removed or there will be a risk of the oil being thrown out Fuel system Always...

Страница 9: ...Recommended fuel lubrication oil and coolant Use of any other fuel oil lurication oil or coolant than the recommended can cause engine damage and re duce engine service life Perform all recommended i...

Страница 10: ...to the environment Get in touch with your Volvo Penta dealer if you notice any changes such as increased fuel consumption and or exhaust smoke Adapt speed and distance to avoid wash and noise disturb...

Страница 11: ...ls Sealed sections must not be broken by anyone other than authorized personnel Otherwise general directions concerning running care and maintenance given in the operator s manual apply IMPORTANT Negl...

Страница 12: ...e with a Stamford single or double bearing marine generator Different starting and control systems are available 1 Air outlet generator 2 Governor Stop solenoid 3 Electrical connection box 4 Fuel retu...

Страница 13: ...frame with a Stamford single or double bearing marine generator Different starting and control systems are available 1 Air outlet generator 2 Governor Stop solenoid 3 Electrical connection box 4 Fuel...

Страница 14: ...uel consumption over the whole range of power output The engine is mounted on a frame with a Stamford single or double bearing marine generator Different starting and control systems are available 1 M...

Страница 15: ...Stamford single or double bearing marine generator Different starting and control systems are available 1 Air outlet generator 2 Governor Stop solenoid 3 Electrical connection box 4 Fuel return 5 Oil...

Страница 16: ...gle or double bearing marine generator Different starting and control systems are available 1 Air outlet generator 2 Governor Stop solenoid 3 Electrical connection box 4 Fuel return 5 Oil cooler 6 HT...

Страница 17: ...erator Different starting and control systems are available D5A TA Genset 1 Air outlet generator 2 Governor Stop solenoid 3 Electrical connection box 4 Fuel return 5 Oil cooler 6 HT pump 7 Fuel pump F...

Страница 18: ...ew or overhauled engine IMPORTANT All covers on engine and generator must be mounted before attempting to start your genset Valves and plugs Make sure the following valves and plugs are open or closed...

Страница 19: ...ORTANT If the starter motor has been engaged for the maximum time 30 seconds it must be allowed to cool down for at least one minute before a new attempt is made at starting Warming up WARNING Do not...

Страница 20: ...terminal and then to the auxiliary battery s terminal 3 Connect the black jump lead to the auxiliary bat tery negative terminal and then to a position slightly away from the discharged batteries for...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 68: ...Notes...

Страница 69: ......

Страница 70: ...7744195 English 07 2004...

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