Tamd 165 A

OPERATOR’S MANUAL
TAMD165C/A Marine Genset

Classifiable control system
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.
Foreword
Thank you for purchasing this Volvo Penta Marine Genset.
The Operator’s Manual contains operation instructions and maintenance and inspection informa-
tion. In order to ensure safety and bring out the maximum performance of the genset, do not ope-
rate it until you have read and fully understood the contents of this manual. Also do not operate
the genset unless in compliance with local regulations.
For information on generator specific items refer to generator information supplied 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 manufacturer. Do
not hesitate to consult your Volvo Penta dealer.
Failure to follow the instructions and cautions in this manual may result in serious accidents.
* Keep this manual at hand for easy reference.
* If this manual is damaged or misplaced, immediately order a new one from your dealer.
All information and illustrations in this manual are based on the specifications that were available
at the time of printing. This manual does not cover all available variants of accessories and op-
tions.
3
Contents
Safety Information ................................................... 5 Air inlet and exhaust systems ................................ 44
Safety regulations during engine operation ............. 6 Inspection of turbocharger .................................... 44
Safety directions for maintenance and service ....... 7 Inspecting air filter indicator ................................. 44
Warning labels ..................................................... 10 Changing air filter ................................................. 44
Introduction ............................................................ 11 Cooling system, general ......................................... 46
Certified engines .................................................. 12 Cooling system TAMD165C/A HE ........................ 46
Warranty .............................................................. 12 Cooling system TAMD165A RC ........................... 47
Cooling system TAMD165C KC ........................... 47
Presentation ........................................................... 13
Cooling system TAMD165A KC ........................... 48
TAMD165C HE Marine Genset ............................ 13
TAMD165C KC Marine Genset ............................ 14 Freshwater system ................................................ 49
TAMD165A HE Marine Genset ............................ 15 Filling the coolant ................................................. 49
TAMD165A RC Marine Genset ............................ 16 Checking the coolant level ................................... 49
TAMD165A KC Marine Genset ............................ 17 Draining the coolant ............................................. 51
Flushing the freshwater system ........................... 51
New genset initial service ...................................... 18
Changing the coolant filter .................................... 52
Starting .................................................................. 19 External cleaning of charge air cooler ................... 53
Classifiable control system .................................... 21 Rawwater system ................................................... 54
LCD screen .......................................................... 22 Draining the rawwater system .............................. 54
Views ................................................................... 23 Checking and changing the zinc anodes .............. 55
Starting the genset ............................................... 25 Checking and changing the impeller ..................... 56
Operation ............................................................. 26 Inspection/Cleaning the rawwater filter ................. 56
Stopping the genset ............................................. 27 Inspection/Cleaning of charge air cooler ............... 57
Operation ............................................................... 28 Cleaning the heat exchanger ................................ 58
Stopping ................................................................ 29 Electrical system ................................................... 59

Checking the electrical wiring ............................... 59
Maintenance .......................................................... 30
Main switches ...................................................... 59
Recommendation of Daily Operation Records ...... 31
Fuses .................................................................. 59
Maintenance schedule ......................................... 32
Electric welding .................................................... 59
Engine ................................................................... 34 Batteries. Maintenance ........................................ 60
General inspection ............................................... 34 Battery charging ................................................... 61
Inspecting/Adjusting drive belts ........................... 35
Control system ....................................................... 62
Lubrication system ................................................. 36 System overview ................................................. 62
Checking and filling oil level ................................. 36 Shutdown unit (SDU) ............................................ 63
Changing engine oil .............................................. 37 Broken wire .......................................................... 64
Changing oil filter and bypass filter ....................... 38 Overspeed shutdown test .................................... 64
Changing oil filter under way (switchable filter) ..... 39
Inhibiting ................................................................ 65
Fuel system ........................................................... 40
Troubleshooting ..................................................... 67
Fuel delivery pipes ............................................... 40
Draining the fuel filters ......................................... 40 Technical Data ....................................................... 68
Inspection of the fuel pre-filters ............................ 41 Fuel specification ................................................. 70
Fuel pre-filter. Changing the filter inserts .............. 41 Lubrication oil specification .................................. 71
Changing the fuel fine filters ................................. 42 Coolant specification ............................................ 72
Bleeding the fuel system ...................................... 43 Identification numbers .......................................... 73
Switchable fuel pre-filter ....................................... 43 Notes ..................................................................... 75
Safety Information
Read this chapter thoroughly. It concerns your safety. This section describes how safety information is presented
in this manual and on the product. It also includes a summary of basic safety regulations for operation and main-
tenance of the engine.
This Operator’s Manual is only valid for complete gensets built in the Volvo Penta factory. Make sure you are in
possession of the right operator’s manual before reading on. If this is not the case, please get in touch with your
Volvo Penta dealer.
If operations are performed incorrectly it could result in personal injury or damage to property or the engine. Read
the Operator’s Manual carefully before operating or servicing the engine. For safety information on operation and
maintenance of the generator, 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-
mation. Always read these safety precautions very carefully.
In the Operator’s Manual warning texts have the following priority:
WARNING! If these instructions are not followed there is a danger of personal injury, ex-
tensive damage to the product or serious mechanical malfunction.
IMPORTANT! Used to draw your attention to something that can cause damage, pro-
duct malfunction or damage to property.
NOTE! Used to draw your attention to important information that will facilitate work or ope-
rations.
This symbol is used in certain cases on our products and refers to important informa-
tion in the Operator’s Manual. Ensure that warning and information symbols on the engine
and transmission are always visible and legible. Replace symbols that have been damaged
or painted over.
5
Safety information
Safety regulations during engine operation

The new engine Filling fuel
Read instruction manuals and other information ac- There is a risk of fire and explosion when filling fuel.
companying the new vessel thoroughly. Accustom Smoking is prohibited and the engine must be turned
yourself with handling the engine, controls and other off. Never overfill the tank. Close the filler cap
equipment in a safe and correct manner. securely. Use only fuel recommended in the operators
manual. The incorrect grade of fuel can disturb opera-
Remember that when operating a vessel, you have a
tion or cause breakdown. This can also lead to the
legal responsibility to be aware of and follow regula-
control rod jamming on diesel engines, which will cau-
tions concerning traffic and safety at sea. Inform your-
se the engine to overspeed and risk damaging machi-
self of the regulations applicable to your vessel and
nery and causing personal injury.
the waters your in by getting in touch with the relevant
authorities or marine safety organization.
Combustible enviroment
Accidents and other incidents Due to the risk of fire and/or explosion, do not start or
continue to run the engine if there is a suspected leak
Sea rescue statistics show that deficient maintenance
or discharge of combustible media, e.g. fuel oil or
of vessels and engines together with defective safety
LPG, in the engine surroundings.
equipment often causes accidents and other incidents
at sea.
Make sure your vessel and engine are maintained in Carbon monoxide poisoning
accordance with directions in the instruction manuals When a vessel is moving forward, it will cause a cer-
and that the safety equipment on board is in good tain vacuum to form behind the vessel. In unfortunate
working order. circumstances, the suction from this vacuum can be
so great that the exhaust gases from the vessel are
drawn into the bridge or cabin and cause carbon mon-
Daily inspection oxide poisoning. This problem is most prevalent on
Make a habit of visually inspecting the engine and high, wide vessels with abrupt stern. Other factors
engine room before starting and after stopping the that can increase the effect of the suction are wind
engine. This will help you to quickly detect any fuel, conditions, load distribution, swells, trim, open hat-
coolant or oil leaks and any other abnormalities that ches and portholes, etc. Most modern vessels, howe-
have occurred or are about to occur. ver, are designed in such a way that this problem is
very rare. If suction should arise anyway, do not open
WARNING! Accumulations of fuel, oil and grease hatches or portholes at the fore of the vessel. Surpri-
on the engine or in the engine room is a fire singly, this will otherwise increase the suction. Try
hazard and must be removed immediately they changing speed, trim, or load distribution instead. Get
are detected. in touch with your Volvo Penta dealer for help in ob-
taining the best solution for your vessel.
IMPORTANT! If an oil, fuel or coolant leak is
detected, the cause must be investigated and
the fault rectified before the engine is started.
Maneuvering
Avoid violent and rapid rudder movement and gear
shifting. There is a risk of the passengers falling down
or falling overboard. A rotating propeller can cause se-
rious injury. Make sure there is nobody in the water
before engaging forward/reverse. Never run close to
bathers or in places where you have reason to believe
there are people in the water.
6
Safety information
Safety directions for maintenance and service

Preparations Before starting
Refit all guards and covers that have been removed
before starting the engine. Make sure there are no
Knowledge
tools or other objects left on the engine. A turbochar-
The operator’s manual contains directions for perfor- ged engine must never be started without the air filter
ming normal maintenance and service in a safe and fitted. The rotating compressor wheel in the turbochar-
correct manner. Read the directions carefully before ger can cause severe personal injury.
starting work. More detailed service literature is avail-
able from your Volvo Penta dealer. Never perform a There is also a risk of foreign objects being drawn in
task unless you are absolutely sure how it is to be and causing mechanical damage.
carried out; call your Volvo Penta dealer for assistan-
ce instead.
Fire and explosion
Stop the engine Fuel and lubricants
Stop the engine before opening or dismantling the
All fuels, most lubricants, and many chemicals are
engine hatch/hood. Maintenance and service must be
flammable substances. Always read and follow the
carried out with the engine stationary unless stated
directions on the packaging. Work performed on the
otherwise in the instructions. Prevent inadvertent start
fuel system must be done on a cold engine. Fuel
of the engine by removing the starter key and turning
leaks and spills on hot surfaces or electrical
off the power with the main switch, locking it in the off
components can cause fires.
position. Place warning signs stating that service is in
progress in every position from which the engine can Keep oil- and fuel drenched rags and other hazardous
be started. Working on or approaching a running engi- materials where they are safe in case of fire. Oil dren-
ne is a safety hazard. Loose clothing, hair, fingers or ched rags can selfignite in certain conditions. Never
a dropped tool can be caught in rotating parts and smoke when refueling, topping up with oil or when in
cause serious bodily injury. Volvo Penta recommend the vicinity of the fuel station or the engine room.
leaving all work requiring the engine to be running to
an authorized Volvo Penta dealer.
Non-original parts
Components in fuel, lubrication, ignition and electrical
Lifting the engine systems on Volvo Penta engines are designed and
Always use the lifting eyes mounted on the engine manufactured to minimize the risk of explosion and
when lifting the engine. Always make sure lifting fire in compliance with existing legislation.
equipment is in good condition and constructed for the The use of non-original parts can result in explosion
lift (engine weight together with possible reverse gear or fire.
and extra equipment). Use an adjustable lifting boom
to ensure safe handling when lifting the engine. All
chains and wires must run parallel with each other and Batteries
as much at right angle as possible to the top of the Batteries contain and generate oxyhydrogen gas, es-
engine. Note that any extra equipment mounted on the pecially when charging. Oxyhydrogen is easily ignited
engine can change the center of gravity. Special lifting and extremely explosive. Smoking, open flames and
devices may be required to obtain the right balance sparks must never occur in, or close to, the batteries
and safe handling. Never perform service on an engi- or battery compartment. A faulty battery connection or
ne suspended only from a lifting device. jumper cable can generate sparks that can cause the
battery to explode.
IMPORTANT! Engine must only be lifted
horizontally.
Start spray
IMPORTANT! Engine lifting eyes are designed Never use start spray or similar start help. Explosions
only for lifting an engine. Do not use the engine can occur in the intake manifold. Risk for personal
lifting eyes when lifting a complete genset. injury.
7
Safety information
Hot surfaces and fluids Fuel system

At operating temperature, the engine and its compo- Always protect your hands when carrying out leak de-
nents are hot. A hot engine always involves risk for tection.
burn injuries. Take care with hot surfaces. E.g.: ex-
Escaping fluids under pressure can pierce bodily tis-
haust manifold, turbocharger, oil pan, charge air pipe,
sue and cause serious injury. Risk of blood poisoning.
starting heater, hot coolant and warm lubricant in pi-
Always cover any electric component if it is located
pes and hoses.
under the fuel filter. Otherwise it might be damaged by
WARNING! Do not open the crankcase fuel spills.
covers while the engine is still hot.
Electrical system
Carbon monoxide poisoning Turn off the power before commencing work on the
Start the engine in well-ventilated spaces only. When electrical system, the engine must be stopped and the
running in confined spaces, the exhaust gases and powered turned off with the main switch/switches.
crankcase gases must be evacuated. Shore power to the engine heater, battery charger or
other extra equipment fitted to the engine must be dis-
connected.
Chemicals
Most chemicals such as glycol, anti-corrosion agent,
Batteries
preservatives, degreasing agent, etc., are hazardous
to health. Always read and follow the directions on Batteries contain a highly corrosive electrolyte. Pro-
the packaging. tect your eyes, skin and clothing when charging and
handing batteries. Always use protective goggles and
Certain chemicals such as preservatives are gloves.
flammable and harmful to inhale. Provide good
ventilation and use breathing protection when In case of splashes on the skin, wash with soap and
spraying. Always read and follow the directions on the plenty of water. In case of splashes in the eyes, rinse
packaging. Store chemicals and other hazardous immediately with plenty of water and call a doctor.
materials out of reach of children. Leave left over or
used chemicals to a destruction plant. Avoid burns and crushing or cutting!
At operating temperature, the engine coolant is hot
Cooling system and under pressure. Steam can cause personal
injury. Check the coolant level only after the engine
There is a risk of water entering when working on the has been stopped and the coolant filler cap has coo-
seawater system. Therefore, stop the engine and led enough to touch with your hand. Never adjust the
close the seawater cock before starting work. V-belts while the engine is running.
Avoid opening the coolant filler cap when the engine is
warm. Steam or hot coolant may spurt out and cause
Service batteries carefully!
burn injuries.
If you spill electrolyte on yourself, flush skin immedia-
If the filler cap, coolant pipe, cock, etc., must tely with lots of water. Apply baking soda to help neu-
nevertheless be opened or dismantled while the tralize the acid. If electrolyte gets in your eyes, rinse
engine is warm, the filler cap must be opened immediately with large amounts of water then contact
carefully to release the pressure before removing it a doctor at once.
completely and starting work. Note that the coolant
can still be hot and cause burn injuries.
Handle antifreeze carefully!
Antifreeze contains alkali. Avoid contact with skin
Lubricating system and eyes to prevent personal injury. Dispose of
Hot oil can cause burn injuries. Avoid skin contact drained antifreeze coolant according to local
with warm oil. Make sure the lubricating system is regulations. For disposal, consult your dealer.
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.
8
Safety information
Dress properly for the job!

Wear protective devices - hard hat, face shield, safety
shoes, goggles, heavy gloves, ear protectors, etc. -
for your own safety.
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 inspections!

Perform pre-start inspection and periodic inspection
on items listed in this manual. Failure to follow this
recommendation can cause serious engine damage.
9
Safety information
Warning labels
The engine carries warning labels at places where you are required to pay special attention. Please read them ca-
refully and make sure you understand the content of each label and the meaning of their position.
! Make sure the labels are legible. If you find any letter or picture illegible in a label, remove soil from the label,
or replace it.
! Clean the label with cloth and water or cleanser. Do not use organic solvent or gasoline, this would dissolve
the label’s adhesive and cause the label to fall off.
! If any label is damaged, lost or illegible, replace it. When replacing a label, make sure the new label is
identical to the old one. For new labels, please contact your dealer.
4 5 3 1
4 4
4
3 2
10
Introduction
This operator’s manual has been produced to give you the greatest benefit of your Volvo Penta Marine Genset. It
contains the information necessary to handle and maintain your genset in a safe and correct manner. We would
like you to read this operator’s manual thoroughly and learn how to handle the genset, controls and other equip-
ment in a safe manner before operating the genset.
Keep the operator’s manual within reach at all times.
Care of the environment Fuel and oil

We would all like to live in a clean and healthy envi- Use only fuel and lubrication oil grades recommended
ronment. An environment where we can breathe cle- in the technical data section of this Operator’s Manu-
an air, see healthy trees, have clean water in our la- al. Other grades can cause operational problems, in-
kes and oceans, and enjoy the sunshine without being crease fuel consumption and have long-range effects
worried about our health. Unfortunately, this cannot be on engine service life.
taken for granted nowadays but it is something we
must work together to achieve.
Service and spare parts
As a manufacturer of marine engines Volvo Penta has Volvo Penta marine engines are designed for high
a special responsibility. That is why care of the envi- operational reliability and long service life. They are
ronment is a core value in our product development. constructed to withstand the marine environment whi-
Volvo Penta has a broad range of engines where pro- le affecting it as little as possible. Through regular
gress has been made in reducing exhaust emissions, service and the use of Volvo Penta original spare
fuel consumption, engine noise, etc. We hope you will parts, these qualities will be retained.
take part in preserving these qualities.
The worldwide Volvo Penta network of authorized
Always follow any advice given in the operator’s ma- dealers is at your service. They are specialists in
nual concerning fuel grades, operation and mainte- Volvo Penta products and stock accessories, original
nance and you will avoid causing unnecessary inter- spare parts, test equipment and the special tools re-
ference to the environment. Get in touch with your quired to perform high-quality service and repairs.
Volvo Penta dealer if you notice any changes such as
increased fuel consumption and/or exhaust smoke. Always follow the maintenance intervals specified in
the operator’s manual and remember to specify the
Adapt speed and distance to avoid wash and noise engine number when ordering service and spare
disturbing or injuring animal life, moored boats, jetties, parts.
etc. Leave islands and harbours in the same condi-
tion as you want to find them. Remember to always
leave hazardous waste such as waste oil, coolant,
paint and wash residue, flat batteries, etc., for dispo-
sal at a destruction plant. Our joint efforts will make a
valuable contribution to our environment.
11
Introduction
Certified engines
It is essential that owners and operators of emission certified engines, used in areas where exhaust emissions
are regulated by law, are aware of the following points:
A certification involves the engine type being checked and approved by applicable authorities. Engine manufac-
turers guarantee that all engines of the same type correspond with the certified engine.
This puts special demands on the maintenance and service of your engine:
* Maintenance and service intervals recommended by Volvo Penta must be followed.
* Only Volvo Penta original spare parts may be used.
* Service of injector pumps, pump settings and injectors must always be performed by an authorized Volvo
Penta service person.
* The engine must not be modified in any way with the exception of accessories and service kits approved by
Volvo Penta for use on the engine.
* Installation modifications must not be made to the engine exhaust pipe or inlet channels.
* 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! Neglected or deficient maintenance/service and the use of non-original spare parts will
entail Volvo Penta renouncing any responsibility for the engine corresponding to the certified version.
Volvo Penta will not compensate for damage and/or costs arising from the above.
Warranty
Your new Volvo Penta Marine Genset is covered by a limited warranty complying with the conditions and instruc-
tions given in the Warranty and Service Book.
Note that AB Volvo Penta’s responsibility is limited to what is specified in the Warranty and Service Book. Read it
carefully as soon as possible after delivery. It contains important information concerning the warranty card, servi-
ce, maintenance and what the owner is responsible to be aware of, check and perform. AB Volvo Penta will oth-
erwise decline warranty liability completely or fully.
Get in touch with your Volvo Penta dealer if you have not received a Warranty and Service Book or a
copy of the warranty card.
12
Presentation
TAMD165C HE Marine Genset
TAMD165C HE is an in-line, direct injection, 6-cylinder, 4-stroke marine genset. It has a turbocharger and is
equipped with either a heat exchanger for thermostat regulated freshwater cooling or connections for keel cooling.
An optimal combination of combustion chambers, fuel injection system, effective turbocharger and charge air coo-
ling, provide excellent fuel consumption over the whole range of power output.
The engine is mounted on a frame with a Stamford single or double bearing marine generator. Different starting
and control systems are available.
1 2 3 4 5 6
1. Air inlet generator

2. Conn. box for
generator heating
4. Air inlet filter
5. Switchable fuel filters
6. Pressure cap.
expansion tank
7. Lifting eye
8. Flexible mounting
7 8
9 10 11 12 13 14 15 16 17
9. Expansion tank
10. Electrical connection
unit
11. Coolant filter
12. By-pass oil filter
13. Oil filler
14. Manual oil drain pump
15. Twin oil filter
16. Oil dip stick
17. Crankcase ventilation
connection
13
TAMD165C KC Marine Genset
TAMD165C KC is an in-line, direct injection, 6-cylinder, 4-stroke marine genset. It has a turbocharger and is
equipped with keel cooling.
1 2 3 4 5 6

2. Connection box for
generator heating
4. Air inlet filter
6. Pressure cap.
expansion tank
7. Lifting eye
7 8
9 10 11 12 13 14 15 16 17
9. Expansion tank
unit
11. Coolant filter
12. By-pass oil filter
13. Oil filler
15. Twin oil filter
16. Oil dip stick
connection
14
TAMD165A HE Marine Genset
TAMD165A HE is an in-line, direct injection, 6-cylinder, 4-stroke marine genset. It has a turbocharger and is
equipped with either a heat exchanger for thermostatically controlled fresh water cooling or connections for keel
cooling.
1 2 3 4 5 6

generator heating
4. Air inlet filter
6. Pressure cap.
expansion tank
7. Lifting eye
7 8
9 10 11 12 13 14 15 16 17
9. Expansion tank
unit
11. Coolant filter
12. Oil by-pass filter
13. Oil filler
15. Twin oil filter
16. Oil dip stick
connection
15
TAMD165A RC Marine Genset
TAMD165A RC is an in-line, direct injection, 6-cylinder, 4-stroke marine genset. It has a turbocharger and is
equipped with radiator cooling.
1 2 3 4 5 6

generator heating
4. Air inlet filter
6. Pressure cap.
expansion tank
7. Lifting eye
7 8
9 10 11 12 13 14 15 16 17
9. Expansion tank
unit
11. Coolant filter
12. Oil filler
14. Twin oil filter
15. Oil dip stick
connection
17. Control unit
16
TAMD165A KC Marine Genset
TAMD165A KC is an in-line, direct injection, 6-cylinder, 4-stroke marine genset. It has a turbocharger and is
equipped with keel cooling.
1 2 3 4 5 6

generator heating
4. Air inlet filter
5. Switchable fuel
filters
6. Pressure cap.
expansion tank
7. Lifting eye
7 8
9 10 11 12 13 14 15 16
9. Expansion tank
10. Electrical
connection unit
11. Coolant filter
12. Oil filler
13. Manual oil drain
pump
14. Twin oil filter
15. Oil dip stick
16. Crankcase ventila-
tion connection
17
New genset initial service
General
Before starting a new or reconditioned genset for the first time, give it an initial inspection. This to guarantee your
own safety as well as the maximum service life of the genset.
External inspection Electrical wiring

1. Check the control system for loose terminals. Check for loose or damaged electrical wiring on the
engine and on the generator. If necessary firmly re-
2. Check defects of engine parts.
connect to terminals or cable-joint portions. Damaged
3. Check the following components for loose bolts or cables must be replaced.
nuts:
If your engine is reconditioned, make sure the wiring
* Plugs and covers of fuel, lubrication and cooling is according to the drawings.
system
* Coupling of fuel injection pump and shaft Filling fuel system
* Mounting brackets Refer to chapter ”Maintenance: Fuel system”.
* Fuel control link
* Turbocharger Filling lubrication system
* Timing gear case Refer to chapter ”Maintenance: Lubrication system”.
* Exhaust manifolds
* Cylinder heads Filling cooling system
* Air-duct connection-hose clamp Refer to chapter ”Maintenance: Cooling system”.
* Flexible coupling from engine to generator

4. Check for fuel, oil, coolant and air leaks and repair
Generator
if needed. Refer to manual supplied by generator manufacturer.
5. Make commissioning report for new or overhauled
engine.
IMPORTANT! All covers on engine and generator

must be mounted before attempting to start your
genset.
Valves and plugs

Make sure the following valves and plugs are open or
closed properly:
Fuel supply valve Open
Coolant drain cocks Closed
IMPORTANT! If the coolant drain cocks are not

closed the coolant will drain from the engine and
this may cause severe damage to the engine.
18
Starting
Before starting
WARNING! Before starting the genset make sure that neither people, nor tools, are in contact with
moving parts of the engine or the generator. Notify the people in the vicinity of the genset when starting.
WARNING! Make sure that you know how to stop the genset before you start it (in case of emergency).
If you are starting the genset for the first time, be prepared to stop the engine immediately in case
abnormal noise should occur during start up.
IMPORTANT! 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 conduct warm-up operation for an extended period of time. Prolonged warm-up
operation causes carbon buildup in the cylinders that leads to inperfect combustion.
NOTE! To warm up the engine operate at no load for a short time and then apply a low load.
NOTE! If the lubrication oil pressure does not increase when you have started the engine, immediately stop
the engine and do not restart until the problem has been fixed.
NOTE! Make sure that the cooling water flow is sufficient.
19
Starting
Start using auxiliary batteries

WARNING! Ventilate well. Batteries generate
oxyhydrogen gas, which is extremely flammable
and explosive. A short circuit, naked flame or
spark can cause a powerful explosion.
Never reverse the polarity of the battery. Risk of

sparks and explosion.
1. Make sure the rated voltage of the auxiliary bat-
tery is the same as the system voltage of the
engine.
2. Connect the red auxiliary cable to the discharged
battery’s + 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
example at the negative cable’s connection to the
starter motor.
WARNING! The black auxiliary cable (–) must not

come in contact with the positive connection on
the starter motor.
4. Start the engine and run at no load for about ten

minutes to charge the batteries.
WARNING! Do not touch the connections while

attempting to start; Risk of sparks. Do not bend
over the batteries either.
5. Stop the engine. Remove the auxiliary cables in

reverse order to connecting.
20
Classifiable control system
This chapter describes the functions of the classifiable control system DCU 305 R2. The system control panel is
equipped with eight buttons, an LCD screen and four separate LEDs for indication.
NOTE! For specific information on the control system, please refer to documentation supplied by control system
manufacturer, Auto-Maskin A/S Norway, or contact your Volvo Penta dealer.
1. LCD screen
2. Stop button
3. Start button
4. Acknowledge button and Left button
5. Lamptest button and Right button
6. Buzzer off button and Down button
7. Standby button
8. Log button and Up button
9. Display button
10. LEDs for indication
21
Control System
LCD screen
The control unit is equipped with an LCD screen with
adjustable brightness and contrast. Analogue signals
are displayed graphical, as vertical and horizontal
bars, and as digital values. All actions are displayed
on the screen as text messages. If the control panel
is not used for one hour the screen lighting will be
shut down. By any event or button push the display
lighting will be turned back on.
Lamptest
To make sure the LEDs on the control panel are wor-
king, push the LAMPTEST button (5).
Contrast
Push and hold the LAMPTEST button (5) and adjust
the contrast by pushing the DOWN (6) or UP (8) but-
tons.
Brightness
In the instrument view or the alarm list view, push and
hold the LAMPTEST button (5). Adjust the brightness
in two steps, 1/1 or 1/2, by pushing the ACKNOWLED-
GE button (4).
Standby and manual mode

Push the STANDBY button (7) to toggle between
Standby and Manual mode. Current mode is shown in
the bottom-right corner in the instrument view .
A green LED in the STANDBY button indicates stand-
by mode. If the LED is not lit, the control unit is in Ma-
nual mode.
When the control panel is in Standby mode the engine
will automatically start when a Start Command signal
is received. In Manual mode, automatic start is disab-
led.
Local mode
It is possible to set the control panel in LOCAL mode.
In this mode, none of the start, stop, reset etc. com-
mands will work, neither on communication, nor on
terminal inputs.
There are two exceptions, which are the Remote Start
(terminal 31) and Remote Stop (terminal 32). This is
because the terminals are hardwired directly to the
start- and stop relays.
22
Control System
To access LOCAL mode, first enter INFO-view and

the press and hold BUZZER OFF for two seconds un-
til a ”beep” is heard. The unit is now in LOCAL mode
and the bottom right status field will indicate ”LOCAL”.
To deselect LOCAL mode, repeat the above.
Buzzer off
Push the BUZZER OFF button (6) to turn off the buz-
zer signal when an alarm occurs. The alarm remains
active until acknowledged.
Autostop
Alarms and messages from the control unit are ack-
nowledged by pushing the ACKNOWLEDGE button
(4). This must be done to enable restarting the genset
after autostop.
Views
There are four different screen views:
Instrument view
Sensor/alarm list
Information view
Event Log
Pushing the CHANGE VIEW button (9) will change
from instrument view to alarm list. The information
view is displayed by pushing the CHANGE VIEW but-
ton for one second. To get back to the previous view,
the CHANGE VIEW button is pushed again. The log is
shown when the log button (8) is pushed.
Instrument view
The instrument view is the main view of the control
panel, it shows an upright standing tachometer (2), as
well as a varying number of horisontal gauges (6) sho-
wing the positions of the analogue senders on the
engine.
The status text fields located at the bottom of the in-
strument view (3, 4 and 5) shows current running
mode.
At the top of the instrument view is a field, in which
the first alarm to start will be described with a text
string. The text in the field blinks with inverted text un-
til the alarm is acknowledged. At the upper left corner
of the screen * and + is alternately seen when an
alarm is active.
The */+ blinking will end when the ACKNOWLEDGE
button is pushed to acknowledge the alarm. The inver-
ted text disappears when the alarm stops.
23
Control System
Alarm list
The alarm list shows all alarms that are predefined.
Scroll the alarm list using the UP and DOWN buttons.
When an alarm is active it will be inverted in the alarm
list and an indicating */+ blinking will appear in front of
the text.
When the alarm is acknowledged, using the ACK-
NOWLEDGE button, the blinking will cease, but the
alarm will remain active and the inversion of the text
will remain. When the alarm stops, the text will go
back to normal.
The alarm LED on the control panel is lit when an
alarm is active. If more than one alarm is active at
one time, the LED in the CHANGE VIEW button is lit.
NOTE! In this view the acknowledge-button will ack-
nowledge all alarms simultaneously.
NOTE! Signals from optional relay cards are not dis-
played in the alarm list.
Information view
The information view show information concerning the
engine and generator. The following engine variables
are shown:
- Running mode
- Total engine running hours
- Engine running hours, latest run
- Number of engine starts
- Number of start failures
At the bottom of the screen, current time and date is
displayed, using UTC standard.
NOTE! After 60 seconds in this view, the control unit
automatically returns to the “Instrument view”.
Log list
The log lists all events, specified with the engine run-
ning hours at their occurrence. The log stores up to
250 events in an permanent memory. Log data is sa-
ved even during voltage drop and power failure.
To scroll through the events listed in the log, the UP
and DOWN buttons are used.
24
Control System
Starting the genset

The control unit does not have to be in Manual mode for the genset to be started manually.
1. Press the LAMPTEST button (5) on the control

panel to make sure that the LEDs on the panel are
working. All working LEDs are lit up.
2. Push the START button (3) and hold it until a
green LED in the button indicates that the genset
is running.
When the genset is running the RPM is displayed on
the screen (1) in the instrument view.
NOTE! To enable restart after autostop, alarms and
messages from the control unit must be acknowled-
ged.
IMPORTANT! If the starter motor has been

engaged for the maximum 30 seconds, it must
be allowed to cool down for at least one minute
before a new starting attempt is made.
Check the readings on the LCD screen and run the

genset at low load (if possible) until it reaches normal
operating temperature.
25
Control System
Operation
Learn how to handle the genset, controls and other equipment in a safe and correct manner before taking it into
operation.
Checking the LCD screen

Check the LCD screen regularly during operation to
make sure that all values are normal.
Oil pressure, engine

Refer to chapter Technical data.
Coolant temperature
Exhaust temperature
Charging
Indicating LEDs
The control unit has three main LEDs (10) for indica-
tion:
POWER indicates that the control unit is turned
on. Flashes when low voltage.
WARNING indicates minor technical errors not
related to genset running conditions (e.g. defective
transmitters). Does not need immediate attention.
ALARM indicates one or more active alarm.
Flashes when not acknowledge.
SHUTDOWN indicates that the genset has been
stopped. The LED is lit until the engine has
stopped completely.
Four of the buttons (STOP, START, STANDBY and
CHANGE VIEW) also contain LEDs:
STOP button - lit when the genset is stopping.
START button - lit when the genset is starting.
STANDBY button - lit to indicate standby mode
and not lit when the control unit is in manual
mode.
CHANGE VIEW button - lit if more than one alarm
is active at one time.
26
Control System
Stopping the genset

Let the engine run without load for at least three minutes before turning it off. This will keep the engine temperatu-
re in balance and prevent the engine from overheating.
IMPORTANT! The above procedure is specially important if the engine has been heavily loaded.
Use the red STOP button (2) to manually stop the

genset. The control unit does not have to be in Manu-
al mode to be manually stopped.
The button can be released at once. The stop function
is active for a preset time. A red LED in the STOP
button indicates that the stop function is active.
27
Operation
General
Learn how to handle the engine, controls and other equipment in a safe and correct manner before starting the
engine
WARNING! Stay clear of all rotating and moving WARNING! A hot engine may cause burns.
parts during operation. Beware of hot surfaces. E.g.: exhaust manifold,
turbocharger, oil pan, charge air pipe, starting
IMPORTANT! Always keep the engine room well heater, hot coolant and warm lubricant in pipes
ventilated. Insufficient airsupply to the engine and hoses.
means imperfect combustion and generator
cooling and a loss of power. IMPORTANT! Avoid overloading. This can cause
incomplete fuel combustion often indicated by
IMPORTANT! Do not turn OFF the battery black exhaust, high fuel consumption and carbon
switch when the engine is running since this may deposits in combustion chambers, affecting
damage the alternator. engine life.
IMPORTANT! Do not push the START button

when the engine 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 alarms occur.
2. There are no visible leaks of fuel, lube oil, coolant
or exhaust gas.
3. No abnormal noise or vibrations occur.
4. The color of the exhaust gas is normal.
5. Instrument readings are the normal, refer to chap-
ter Technical Data.
28
Stopping
Allow the genset to run at no load for a couple of minutes before turning it off. This will keep the engine temperatu-
re in balance and prevent it from boiling.
IMPORTANT! The procedure described above is IMPORTANT! If the genset stops abnormally, try
especially important if the genset has been run to locate the problem and make the repairs
at heavy loads. needed before starting again. After starting the
genset, make sure it runs properly.
Emergency stop
If a fault has ocurred. so that the engine can not be stopped in a normal manner, the engine can be emergency
stopped.
The emergency stop is activated by pressing the separate ”STOP” button at the control position, in the engine
compartment or any optional alternative position.
After stopping
General
* Check the genset and engine room for leaks.
* Close the fuel cock and rawwater cock.
* Read off the hour counter and carry out preventive maintenance according to the maintenance schedule.
* Turn off the main switch if the genset is not to be used for a long period.
IMPORTANT! Never turn the power off using the main switch while the genset is running. This can
damage the alternator.
IMPORTANT! Make sure the generator heater is working properly to avoid condensation in the generator
Anti-freezing measures
If the engine room cannot be protected from frost, the raw water system must be drained (if it contains sea water)
and the coolant in the freshwater system must contain the right mix of anti-freeze and water. Refer to chapter
”Maintenance: Rawwater system” and ”Maintenance: Freshwater system” respectively.
WARNING! If the rawwater system bursts due to freezing, the vessel could sink.
IMPORTANT! If the coolant does not give sufficient anti-freeze protection, it may cause costly damage
to the engine. Check the charge of the battery. A poorly charged battery can freeze and break.
Breaks in operation [not using the genset]

During periods out of service, the engine must be run warm once a fortnight. This will prevent it from corroding.
IMPORTANT! The genset must be conserved if it is not to be used for longer than two months. Refer to
chapter Inhibiting.
29
Maintenance
Your Volvo Penta engine and associated equipment is designed to provide high operational reliability and long ser-
vice life. They are constructed to withstand the marine environment while also affecting it as little as possible.
Preventive maintenance in accordance with the maintenance schedule will ensure that it retains these qualities
and avoid unnecessary operational disturbances. The following chapters contain general technical information and
directions for carrying out the prescribed maintenance points. Read the directions carefully before starting work.
The maintenance schedule shows the standard service intervals. When you think the engine should be serviced
more frequently due to particular operating conditions, adjust the intervals accordingly. Appropriate service inter-
vals vary with usage and operating conditions and with fuel, lubricant and coolant used. Due to particular opera-
ting conditions the service intervals may be adjusted accordingly. Consult your Volvo Penta dealer.
NOTE! Dust and foreign particles are the most common cause of excessive wear of parts. When disassembling a
component, take measures to prevent dust and foreign particles from entering it.
Daily operation records

It is recommended to keep daily operation records. Daily recording is a preventive maintenance program and
when comparing values with engine history it will help you recognize conditions, signs or indications of approach-
ing trouble. Daily operation records also make trouble shooting easier and will lessen the down time (to save time
and money 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 recommended service intervals to meet the specific operating situ-
ation. This should result in a lower engine operation cost.
Fluids
It is also important to keep record of the fluids used in the engine. If brand or type of fuel, lubrication oil or coolant
is changed this should be recorded.
Warranty inspection
The prescribed warranty inspection “First Service Inspection” must be carried out at an authorized Volvo Penta
workshop during this first period of operation. Directions for when and where this is to be carried out can be
found in the Warranty and Service Book.
WARNING! Read the safety directions for maintenance and service in the chapter “Safety information”
before starting work.
WARNING! Read the chapter “Maintenance” thoroughly before starting any maintenance work. It
contains directions for performing maintenance in a safe and correct manner.
WARNING! Working on or approaching a running engine is a safety hazard. Maintenance and service
must be carried out with the engine stationary unless stated otherwise in the instructions. Prevent
inadvertent start of the engine by disabling the start-button and turning off the power with the main
switch, locking it in the off position.
WARNING! Place warning signs stating that service is in progress in every position from which the
engine can be started.
IMPORTANT! Handle parts carefully. Use only original Volvo Penta spare parts.
NOTE! When both operating time and calendar time is given, the one occurring first is to apply.
NOTE! For generator related maintenance information, refer to Generator Manufacturers information.
30
Maintenance: General
Recommendation of Daily Operation Records

Daily recording is a preventive maintenance program and when comparing values with engine history it will help
you recognize conditions, signs or indications of approaching trouble. Daily operation records also make trouble
shooting easier and will lessen the down time (to save time and money for servicing).
Items to be recorded
The following items are recommended to be recorded
once a day:
1. Operating hours.
2. The amount of lubrication oil and coolant (fresh
water) required for refilling. Fuel consumption.
3. Lubrication oil and coolant (fresh water) changes.
4. Lubrication oil pressure and temperature, engine
rpm, exhaust temperature, coolant temperature,
and charge air temperature 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 service (adjustment,
repairs or replacement).
7. Change in operating conditions (for example,
“Exhaust smoke turned black,” etc.)
31
Maintenance schedule
Daily before first start
General inspection of engine and engine room
Check air filter indicator
Check lubrication oil level
Check coolant level
Check fuel level
Check/clean radiator (externally)
Drain water from fuel tank
Daily operation records
Weekly
Check electrical system for loose terminals/contacts
Check foundation bolts
Check lubrication oil for abnormal smell or water dilution
Check settings of valves and operate valves to keep them movable
After the first 150 operating hours
Check valve clearances .......................................................................... (refer to note 2)
Every 50 operating hours
Check/drain water from fuel pre-filter/water separator .............................. (refer to note 1)
Check charge conditions of batteries
Every 60–500 operating hours / at least every 12 months
Change lubrication oil .............................................................................. (refer to note 3)
Change lubrication oil filters .................................................................... (refer to note 4)
Every 250 operating hours / at least every 12 months
Check fuel pre-filter (twin filter)
Change crankcase ventilation filter
1)
Check the manometer and change filter if necessary, but change filter at least every 1000 operating hours or at least once a year.
2)
To be carried out at an authorized Volvo Penta workshop.
3)
Refer to chapter ”Technical Data: Lubrication oil specification”
4)
The oil filters are changed in every second oil change.
32
Check/adjust drive belts
Check starting batteries; electrolyte level/load
Check/adjust valve clearances ............................................................... (refer to note 2)
Change coolant filter ............................................................................... (refer to note 6)
Check/change rawwater pump impeller
Check/change zinc anodes
Check/clean rawwater filter
Check/clean charge air cooler ................................................................. (refer to note 2)
Check/clean heat exchanger ................................................................... (refer to note 2)
Change fuel filters
Bleed fuel system
Change filter element fuel pre-filter/water separator
Top up coolant ........................................................................................ (refer to note 5)
Check drainage of charge air cooler
Every 2000 operating hours
Check/adjust fuel injectors pressure ....................................................... (refer to note 2)
Check turbocharger ................................................................................. (refer to note 2)
General inspection of genset ................................................................... (refer to note 2)
Change air filter/air filter insert
Clean and paint the genset
Every 24 months
Change coolant
Flush cooling system
Renovated engine:
After the first 150 operating hours
Check valve clearances .......................................................................... (refer to note 2)
1)
Check the manometer and change filter if necessary, but change filter at least every 1000 operating hours or at least once a year.
2)
To be carried out at an authorized Volvo Penta workshop.
3)
Refer to chapter ”Technical Data: Lubrication oil specification”
4)
The oil filters are changed in every second oil change.
5)
Top up with 1/2 litre corrosion protection fluid. IMPORTANT! This only applies if the cooling system is filled witn a corrosion pro-
tection mixture (not a glycol mixture).
6)
Not at the same time as coolant change.
33
Maintenance: Engine
Engine
General inspection
Make it a habit to give the engine and engine room a
“visual” check before driving before starting the en-
gine and after operation when you have stopped the
engine. This will help you to discover if anything ab-
normal has happened, or is about to happen.
Look especially carefully at oil, fuel and coolant leak-
age, loose screws, worn or poorly tensioned drive
belts, loose connections, damaged hoses and electri-
cal cables. This inspection only takes a few minutes
and can prevent serious malfunctions and expensive
repairs.
WARNING! Deposits of fuel, oils and grease on

the engine or in the engine room are a fire hazard
and must be removed as soon as they are dis-
covered.
IMPORTANT! If you discover a leakage of oil,

fuel or coolant, investigate the cause and fix the
fault before you start the engine.
IMPORTANT! Observe the following when clean-

ing with a high pressure washer: Never aim the
water jet at seals, rubber hoses or electrical
components. Never use a high pressure washer
for engine cleaning.
34
Maintenance: Engine
Inspecting/Adjusting drive belts

WARNING! Stop the engine before doing any
maintenance work.
General information
Check belt tension and condition regularly. A belt
which is to tense can damage the bearings and a belt
which is too loose can slip.
IMPORTANT! Always change a belt which looks

worn or cracked (belts which operate in pairs
must be changed together).
The standard alternator, plus the extra alternator if in-

stalled, are driven by a Poly-Vee belt each, for best
function and service life. The belts are tensioned in
the same way.
1. Remove the protective cover over the drive belts.
2. Undo the screws (A) a couple of turns before
slackening off the belt(s).
3. It should be possible to press the belt(s) down
about 10 mm (3/16") between the pulleys when
the tension is correct.
4. Tighten the screws (A).
5. Install the protective cover over the drive belts.
The flushing and bilge pump etc. are driven by tradi-

tional drive belts. In general, it should be possible to
press these belts down 10 mm (0.4") between the pul-
leys when the tension is correct.
When you change drive belts: Clean the belt grooves
before installing the new drive belts.
35
Maintenance: Lubrication system
Lubrication system
Oil change intervals can vary from 50 to 500 hours, depending on the engine, oil grade and sulphur content of the
fuel. Note that oil change intervals must never exceed a period of 12 months.
For information about oil grade, change volume, change interval and viscosity, please see “Technical data: Lubri-
cation oil specification”.
Checking and filling oil level

The oil level must be inside the marked area on the
dipstick and should be checked daily before the first
start.
Fill up with oil via the filling hole on the side of the
engine.
Check that the correct level has been achieved. But
wait a few minutes to allow the oil to run down into the
sump.
IMPORTANT! Do not fill up above the maximum
oil level. Only use a recommended grade of oil.
36
Changing engine oil

Always observe the recommended oil change interval.
Use a manual or electric (optional) oil drain pump to
suck up the oil from the sump.
1. Warm the engine up (this makes it easier to suck
the oil up from the sump). Then stop the engine.
WARNING! Hot oil and hot surfaces can

cause burns.
Engines with manual oil drain pump:
Set the knob to position (A) to drain the engine,
please refer to the illustration.
Engines with electric oil drain pump (optional
equipment):
Connect the oil drain pump suction pipe (Ø 12
mm) to the dipstick tube.
2. Suck the oil up into a suitable vessel.
The oil can also be drained after the sump drain
plug has been removed.
3. Change the oil filter and bypass filter at each oil
change (please refer to the instructions on the
next page).
4. Fill up with oil to the correct level through the fil-
ling hole on the side of the engine (please refer to
“Technical Data: Lubrication oil specification” for
oil volume).
IMPORTANT! Only use a recommended

grade of oil.
5. Start the engine and let it idle. Check that the low
oil pressure warning lamp goes out and that no
leakage occurs by the filters.
WARNING! Working with, or going close to

a running engine is a safety risk.Watch out
for rotating components and hot surfaces.
6. Stop the engine. Wait a few minutes before
checking the oil level. Top up as necessary.
NOTE! Hand in the old oil to a re-cycling station for
destruction.
37
Changing oil filter and bypass

filter
Change the oil filter and bypass filter during each oil
change.
Remember to hand the old filters in to a re-cycling sta-
tion.
1 WARNING! Hot oil and hot surfaces can cause

burns.
1. Put a suitable vessel underneath the filters to

avoid oil spillage.
2. Clean the filter bracket.
3. Unscrew the bypass filter (1) and the oil filters (2)
with a suitable extractor.
4. Check that the mating surfaces on the filter brack-
ets are clean, and that no residue from the old
seals remains.
5. Moisten the seals on the new filters with engine
oil.
6. Screw the filters on by hand until the rubber seals
just touch the mating surface on the filter brack-
ets. Then tighten a further 1/2 to 3/4 turn.
7. Start the engine (low idle) and check that no leak-
age occurs. Check the oil level once the engine
2 has stopped.
38
Changing oil filter under way

(switchable filter)
The switchable oil filters can be changed while under
way as the flow of oil can be cut off to one filter con-
tainer at a time.
NOTE! Leave the old oil filter to a destruction plant.
WARNING! Working on or approaching a running
engine is a safety hazard. Beware of rotating
parts and hot surfaces.
WARNING! Hot oil and hot surfaces can cause
burns.
1. Place a receptacle under the filters to avoid oil
spill.
3. Shut off the flow of oil through the filter by turning
the lever (1) to the far right.
4. Unscrew the left oil filter and discard it. Use a sui-
table puller.
5. Make sure the contact surface on the filter brack-
et is clean and that none of the old gasket is re-
maining.
6. Moisten the gasket on the new filter with engine
oil.
7. Screw on the filter by hand until the rubber gasket
makes contact with the sealing surface on the fil-
ter bracket. Then screw a further 3/4 turn.
8. Turn the lever to the far left and change the right-
hand fuel filter in the same way.
9. Put the lever back to normal operating position
(straight up).
10. Top up with oil after the first stop. See “Engine oil.
Change” on the previous page.
39
Maintenance: Fuel system
Fuel system
Use only fuel recommended in the fuel specification. Please refer to “Technical Data: Fuel Specification”. Always
observe cleanliness when refuelling and working with the fuel system.
All work concerning the engine injection pump or injectors is to be carried out at an authorized workshop. Breaking
the seal on the injection pump will void the warranty.
WARNING! Fire hazard. Work performed on the fuel system must be done on a cold engine. Fuel spill on hot
surfaces or electrical components can cause fires. Keep fuel-drenched rags where they are safe in case of
fire.
Fuel delivery pipes

The delivery pipes must not be bent, twisted or exert-
ed to any other forces. Change delivery pipes that are
damaged.
WARNING! Fire hazard! The fuel delivery pipes

must not be bent, twisted or exerted to any other
forces.
Draining the fuel filters

The fuel pre-filter supplied by Volvo Penta is a twin fil-
ter with water trap.
Put a suitable vessel underneath the filter. Drain off
water and contamination through the tap/plug (1) be-
neath the filter housing.
IMPORTANT! Do not drain the filter until the en-

gine has been stopped for several hours.
40
1 Inspection of the fuel pre-filters

This filter is equipped with a pressure gauge (1) which
indicates when it is time to change the filter inserts.
Change the filer inserts as recommended in the main-
tenance schedule, or earlier if the pressure gauge
shows a negative pressure of 6–10 (in. Hg) at idle or
16–20 (in. Hg) at full speed/loaded engine.
WARNING! Working with, or going close to a

running engine is a safety risk. Watch out for ro-
tating components and hot surfaces.
1 Fuel pre-filter. Changing the filter

inserts
A The fuel pre-filter/water trap supplied by Volvo Penta
is available in single and twin versions. The twin filter
inserts can be changed with the engine running, by
closing off fuel flow to one filter housing at a time.
C B
Fuel flow is controlled by putting the handle (1) in
the following positions:
A: Normal operation (both filters are connected).
D
B: The left filter insert can be changed.
C: The right filter insert can be changed.
D: Both filters shut off.
Changing the filter inserts:

2 Close the fuel taps at the tank, or shut off the fuel
1 flow with handle (1) for the filter insert to be changed,
3 if changing the insert under way.
A WARNING! Working with, or going close to a
running engine is a safety risk. Watch out for ro-
tating components and hot surfaces.
C B 1. Put a suitable vessel underneath the filter.
2. Undo the T-screw (2) and remove the lid (3).
3. Remove the insert carefully, with a twisting
D movement.
4 4. Drain the water and contamination through the
drain plug (4).
41
5. Install a new filter insert and fill the container with

clean fuel.
6. Change the seal on the lid (3) and the O-ring (2)
on the T-screw. Moisten the seal and the O-ring
with fuel before installing.
7. Install the lid and tighten it by hand.
8. Wipe off fuel from the heat shield, if there is one.
9. Twin filters: Change the other filter insert in the
same way.
10. Open the fuel taps, and put the handle (1) in the
position for normal operation. Check that no leak-
age occurs.
Changing the fuel fine filters

Remember to hand the old filters in to a re-cycling sta-
tion.
1. Put a suitable vessel underneath the filters. Clean
the filter bracket.
2. Unscrew the filters with a suitable extractor.
3. Clean the filter mating surfaces on the filter
bracket.
4. Check that the new filters are absolutely clean
and that the seals are undamaged. Moisten the
seals with engine oil.
NOTE! Do not fill the new fuel filters with fuel be-
fore assembly. There is a risk that contamination
could get into the system and cause damage and
malfunctions.
5. Screw the filters on by hand until the seals just
touch the mating surface. Then tighten a further
1/2 turn, no more!
6. Vent the fuel system.
7. Start the engine and check carefully that no leak-
age occurs.
42
Switchable fuel pre-filter

(Changing when in operation)
Remember to hand the old filters in to a re-cycling
station.
1. Put a suitable vessel underneath the filters. Clean
the filter bracket.
2. Set the lever (1) for the valve in the filter cap to
its right end position.
3. Unscrew the left filter with a suitable extractor.
4. Clean the filter mating surfaces on the filter
bracket.
5. Check that the filter is absolutely clean and that
the seal is undamaged. Moisten the seal with en-
gine oil.
NOTE! Do not fill the new fuel filter with fuel be-
fore assembly. There is a risk that contamination
could get into the system and cause damage and
malfunctions.
6. Screw the filter on by hand until the seal just
touches the mating surface. Then tighten a
further 1/2 turn, no more!
7. Open the left vent screw (2) on the filter bracket.
Move the lever (1) to the operating position,
straight up. Close the vent screw when air-free
fluid streams out.
8. Put the lever in the left end position and change
the right fuel filter in the corresponding manner.
9. Check that no leakage occurs.
Bleeding the fuel system

The fuel system must be bled after the fuel filter is
changed, or after filling the fuel tank when it has been
run dry.
1. Place a receptacle under the fuel filters. Connect a
transparent plastic hose of suitable dimension to
the bleeder nipple (1) on the filter bracket.
2. Open the bleeder nipple and pump fuel using the
hand pump (2) until the fuel running out is free
from air bubbles. Tighten the nipple while fuel is
running out.
3. Pump another 10–20 times with the bleeder nipple
closed to attain a good supply pressure. Further
bleeding is not normally required.
If the injection pump still requires bleeding, undo
the connection for the overflow valve (3) on the
pump and continue pumping by hand until the fuel
flowing out is free from air. Tighten the connection
while fuel is running out. Pump another 10–20 ti-
mes to attain a good supply pressure.
43
Maintenance: Air inlet and exhaust system
Air inlet and exhaust systems
Inspection of turbocharger
WARNING! Check the turbocharger only when
the engine is cool and the compressor wheel is
not running.
Check shaft play, take a hold of the compressor

wheel nut and turn the wheel to feel rattle and listen
for abnormal noise. Replace the bearings if the wheel
is noisy or rattles.
NOTE! Also check the turbocharger when the exhaust
color is abnormal.
Regular cleaning of the compressor housing and com-
pressor wheel is recommended for daily operation in
dusty or oil saturated air. Heavily fouled compressor
parts can result in low boost pressure. The compres-
sor part can be cleaned with the unit dismantled as
follows:
1. Dismantle the compressor housing.
2. Clean the compressor housing, compressor wheel
and the end-head in paraffin or the equivalent.
3. Fit the compressor housing.
Inspecting air filter indicator

The engines have pressure drop indicators (1).
Change air filter when the indicator shows a fully red
field when the engine is stationary. Reinstate the pres-
sure drop indicator by pressing in the indicator button.
Changing air filter
TAMD 165A
1 1. Unscrew the centre screw on the end wall of the
filter. Lift the filter out and scrap it.
2
IMPORTANT! Scrap the old filter. It
must not be cleaned.
2. Clean the inside of the filter housing with a damp
rag.
3. Install a new filter insert. Check that it “bottoms”
in the filter housing. Tighten the central screw.
4. Reinstate the pressure drop indicator by pressing
in the button (2).
5. Check that no air leakage occurs after starting.
44
Maintenance: Air inlet and exhaust system
TAMD 165C
1. Undo the clips holding the filters.
2. Remove the filters.
1 3. Fit new filters and tighten the clips.

4. Reset the pressure drop indicator (1).
45
Maintenance: Cooling system, general
Cooling system, general

The freshwater system is the internal cooling system of the engine. It is a closed system and shall always be fil-
led with coolant that protects the engine from internal corrosion and frost damage if the climate requires it. Anti-
corrosive additives become less efficient with age and the coolant must therefore be changed in accordance with
the recommendations in the maintenance schedule.
The rawwater system is the engine’s external cooling system and it is either a rawwater system or a central coo-
ling system. It cools the internal cooling system in an engine mounted or externally mounted heat exchanger.
The Volvo Penta Genset comes with an internal freshwater system connected to an engine mounted heat exchan-
ger, or prepared for external cooling, e.g. keel cooling or central cooling.
WARNING! Never open the pressure cap or drain the cooling system when the engine is warm. Steam or
hot fluid may spurt out.
WARNING! The coolant is dangerous to your health and an environmental hazard. Handle coolant with
care and dispose of old coolant in accordance with local regulations.
IMPORTANT! For coolant specification, refer to chapter “technical data” in the back of this manual.
IMPORTANT! Check the coolant level on a cold stationary engine.
IMPORTANT! Coolant to be added should have the same concentration as the coolant in the engine. Do
not add plain water.
IMPORTANT! Certain parts of the system are made of light alloy. Chemical additives must therefore not
be used when cleaning the system.
Cooling system TAMD165C/A HE

The system includes two circuits. The freshwater system is cooling the cylinder liners and cylinder heads. An
engine driven cooling water pump circulate the coolant through the heat exchanger and through the engine. The
rawwater system is cooling the charge air and the coolant in the freshwater cooling system. The raw water circuit
is designed for raw water cooling or for connection to a central cooling system.
1. Rawwater inlet
2. Rawwater pump
(optional)
3. Charge air cooler
4. Heat exchanger
5. Rawwater outlet
6. Freshwater pump
7. Engine
8. Lubrication oil cooler
9. Exhaust manifold
10. Expansion tank
46
Cooling system TAMD165A RC

The engine cooling water is cooled by a radiator in a one-circuit cooling system. Air is forced through the radiator
by an engine driven cooling air fan. The charge air is cooled in an air-to-air charge air cooler mounted in front of
the radiator and it make use of the air flow from the engines cooling fan before it enters the radiator.
1. Freshwater pump
2. Engine
4. Exhaust manifold
5. Thermostat valve
6. Radiator fan
8. Heat exchanger
9. Expansion tank
10. Expansion tank
Cooling system TAMD165C KC

The engine cooling water is cooled by, e.g, a box cooler, a grid cooler, or any other external heat exchanger. The
same coolant (fresh water) is cooling the complete engine.
1. Freshwater inlet
3. Freshwater pump
4. Engine
6. Exhaust manifold
7. Thermostat valve
8. Expansion tank
9. Freshwater outlet
47
Cooling system TAMD165A KC

The engine cooling water is cooled by, e.g, a box cooler, a grid cooler, or any other external heat exchanger. The
rawwater system is cooling the charge air.
1. Rawwater inlet
2. Rawwater pump
(optional)
4. Rawwater outlet
5. Freshwater inlet
6. Freshwater pump
7. Engine
9. Exhaust manifold
10. Expansion tank
11. Thermostat valve
12. Freshwater outlet
48
Maintenance: Freshwater system
Freshwater system
The freshwater system is the internal cooling system of the engine. This is a closed system and shall always be
filled with coolant which protects the engine from internal corrosion and from frost damage if the climate requires
it.
The circulation pump is responsible for circulation in the freshwater system. The thermostat begins to open at a
certain temperature and is fully open when the engine has reached its normal operating temperature. When the
thermostat opens, the hot coolant is directed through the heat exchanger, where heat is lead away via the sea-
water system.
Checking the coolant level

WARNING! Never open the pressure cap when
the engine is hot. Steam or hot coolant can
spray out at the same time as the pressure
which has built up is lost.
IMPORTANT! Check the coolant level on a cold

stationary engine.
The level should reach up to the lower edge of the fil-

ler tube.
If a separate expansion tank is installed, the coolant
level must be between the MAX and MIN markings.
Top up the coolant as necessary, following the de-
scription below.
Filling the coolant

WARNING! Do NOT open the pressure cap or
bleeder nipples on a warm engine. Steam or hot
coolant can surge out and pressure will be lost.
Stop the engine and let it cool before filling. Hot
fluids and hot surfaces can cause burns.
IMPORTANT! Top up with the same type of

coolant as already used in the system.
Topping up
Fill up with coolant to the correct level via the filling
hole on the expansion tank. Fill slowly so that evacua-
ted air is able to pass the filler opening.
IMPORTANT! When you fill up an empty sys-
tem, or if the coolant has fallen so low for any
reason that it is no longer visible through the fil-
ling hole, fill up as in the description for “Filling a
completely empty system”.
49
Filling a completely empty system

1. Mix a sufficient quantity of coolant in a vessel be-
fore filling. Please note that a heating system, tap
water heater etc. if connected to the engine cool-
1 ing system, mean that a correspondingly greater
amount of coolant will be needed.
2. Open the venting nipples when filling:
- on the thermostat housing cover (1)
- on the coolant pipe from the turbocharger (2)
3. Also ensure that the heating system, tap water
heater etc. if connected to the engine cooling sys-
tem, are also vented (open the heater control
2 valve).
4. Fill up with coolant via the filling hole on the ex-
pansion tank until the system is completely full.
Fill slowly, to allow the air which is forced out a
chance to flow out of the venting nipples or filling
hole.
5. Close the venting nipples as and when air-free
coolant flows out.
6. Let the engine idle for about two minutes. Check
the coolant level.
Top up with coolant if necessary, until the level
reaches the lower edge of the filling pipe.
7. Start the engine and let it run for about 1 hour at
low loading and about 1500 rpm.
IMPORTANT! Do not start the engine until

the system is vented and completely filled.
8. Stop the engine and let it cool. Check the coolant
level with the engine COLD. Top up if necessary.
50
Draining the coolant

WARNING! Stop the engine and let it cool be-
fore draining. Hot fluids and hot surfaces can
cause burns.
WARNING! Glycol is poisonous (dangerous to

drink). Collect the old coolant and hand it to a re-
cycling station for destruction.
1. Remove the filling cap from the expansion tank.
2. Open the venting taps, as on the previous page.
3. Connect a suitable hose to each drain tap. Open
the tap and allow the coolant to drain off into a su-
itable vessel.
Drain points IMPORTANT! Check that all coolant really

does drain out. Deposits may need to be
cleared away, inside the drain plugs.
4. Continue with all the drain points until all have
been opened and all coolant has been drained off.
5. Also drain the heating system, tap water heater
etc., if connected to the engine’s freshwater sys-
tem.
6. Install the drain plugs.
Flushing the freshwater system

The cooling system should be flushed when the cool-
ant is changed, to avoid loss of cooling performance
due to deposits in the cooling system.
1. Drain the coolant, as in the description on the pre-
vious page.
2. Put a hose into the filling opening in the expansion
tank and flush with fresh water.
3. Flush until the water which runs out of the drain
points is clean.
4. Close all drain points when all coolant has run out.
5. Fill up with coolant, as in the description on the
previous page.
51
Changing the coolant filter

IMPORTANT! Do not change the filter when the
coolant is changed. The concentration of rust-
preventer in the coolant can become too high,
which would cause foaming and impaired cool-
ing.
WARNING! Hot coolant and hot surfaces can

cause burns.
2. Close the filter tap, (position A).
3. Unscrew the filter with a suitable extractor.
4. Clean the filter mating surface on the filter brack-
et.
5. Moisten the seals on the new filter with engine oil
and screw the filter on by hand until the rubber
seal just touches the mating surface on the filter
bracket Then tighten a further 1/2 turn.
6. Open the filter tap, (position B).
age occurs.
52
External cleaning of charge air

cooler
(engine with radiator)
1. Remove the required guards to access the ra-
diator.
2. Clean with water and a mild cleaning agent.
Use a soft brush. Take care not to damage the
cooling vanes.
3. Reinstall the components.
IMPORTANT! Do not use a high pressure
hose.
53
Maintenance: Rawwater system
Rawwater system
The rawwater system is the engine’s external cooling system. The rawwater system sucks in water through the
rawwater inlet and pumps it through the heat exchanger. The system is protected from galvanic corrosion by
means of zinc anodes located in the heat exchanger and in the charge air cooler.
The rawwater system must be drained in cold weather, if there is a risk of frost, to prevent frost damage. An alter-
native to draining is to keep the engine room above freezing temperature, by means of a fan heater which is ap-
proved for outdoor use.
WARNING! There is a risk of water entry when you do any work on the rawwater system (if the boat is in the
water). If any hose, plug etc. located below the waterline is removed, water will flow into the boat.
Always close the rawwater cocks. If the boat does not have rawwater cocks, the water flow must be
blocked in a safe manner. If this is not possible, the boat must be drawn up on land before work starts.
Draining the rawwater system

WARNING! Risk of water entry. Close the raw-
water cocks before doing any work on the rawwa-
ter system.
1. Close the rawwater cock.
2. Connect a hose to each drain point before opening
the plugs (one at a time).
3. Open the drain plugs and allow the water to run
out.
Drain points:
– plug in hose from rear edge of charge air cooler
– taps under heat exchanger end wall
– remove the lid on the rawwater pump with rub-
ber impeller and the flushing/bilge pump, if fit-
ted
– plug under centrifugal rawwater pump
IMPORTANT! Check that all water really

does drain out. Deposits may need to be
cleared away, inside the drain plug.
Check whether the installation has any
further taps or plugs at the lowest points of
the cooling water pipes and exhaust pipe.
4. Also drain any auxiliary equipment such as the
rawwater filter etc.
5. Install the lid on the rawwater pump and flushing/
bilge pump, if fitted.
6. Reinstall all drain plugs before you leave the boat.
54
Checking and changing the zinc

anodes
water cock before doing any work on the rawwa-
ter system.
2. Remove the zinc anodes on:
– Heat exchanger end walls
– Flange by chage air cooler front edge.
3. Check the zinc anodes and replace them if more
than 50% of their original size has been used up.
If not, clean the zinc anodes with emery cloth to
remove the oxide layer before re-installing them.
IMPORTANT! Use an emery cloth for clean-

ing. Do not use steel tools, since this could
impair the galvanic protection.
4. Install the zinc anodes. Make sure that good me-
tallic contact is obtained between the anode and
the casting.
5. Open the rawwater cock before starting the en-
gine.
55
Checking and changing the

impeller
ter system.
1. Remove the rawwater pump lid, and pull the impel-
ler out with water pump pliers.
2. Check the impeller. If any cracks or other defects
are visible, the impeller must be changed.
3. Lubricate the pump housing and the inside of the
lid with water-resistant grease (which is not ag-
gressive to rubber).
4. Press the impeller in with a rotating movement
(anti-clockwise). Install the lid with a new O-ring.
5. Open the rawwater cock.
IMPORTANT! Always carry a spare impeller on

board.
Inspection/Cleaning the rawwater

filter
The rawwater filter is optional equipment.
If the water where the boat is operated contains a lot
of contamination, weed etc., check the filter more fre-
quently than specified in the maintenance schedule.
There is otherwise a risk that the filter would be
blocked, which would make the engine overheat.

ter system.
2. Remove the lid (1) and lift up the insert.
3. Clean the insert and the housing (2).
4. Install the components as in the illustration.
Check the O-ring. Change as necessary.
5. Open the rawwater cock and check carefully that
no leakage occurs.
56
Inspection/Cleaning of charge air

cooler
Water can condense in the intercooler during opera-
tion. Condensate is drained via two hoses from nipp-
les underneath the inlet pipe.
Check that the nipples are not blocked.
WARNING! If a large amount of water flows out
of the drain hoses, from the inlet pipe, the charge
air cooler must be removed and proof tested.
This task must be done by an authorised work-
shop.
WARNING! Risk of water entering. Close the sea
cock and drain off the water in the rawwater sys-
tem before working on the cooling system.
1. Remove the end cover and pipes on the heat ex-
changer and rawwater pump.
2. Connect a hose to the intercooler insert drain cock
on the rear end of the intercooler.
3. Flush out the intercooler insert pipe with high pres-
sure. Clean the pipe using suitable brushes as
well.
If considerable soiling is feared, the charge air
cooler cover must be removed, and the insert
must be lifted out and cleaned separately. This
task must be done by an authorised workshop.
4. Check the end cover gasket and O-rings on the
pipe connections. Change if necessary. Refit the
end cover and pipes on the heat exchanger and
rawwater pump.
57
Cleaning the heat exchanger

This job requires specialist knowledge, and should be
done by an authorised workshop.

water cock and drain off the water in the rawwa-
ter and freshwater systems before doing any
work on the cooling system.
Clean it at the first signs of blockage, slowly increas-
ing engine temperature and increased rawwater pres-
sure.
First check/clean the rawwater filter. Also check the
impeller in the rawwater pump.
It is frequently enough to clean the pipes in the heat
exchanger insert, once the end covers have been re-
moved. This means that the freshwater system does
not need to be drained.
Cleaning the heat exchanger insert

1. Detach the pipe connections from the starboard
side of the heat exchanger.
2. Remove both end covers from the heat exchan-
ger.
3. Clean the whole length of the heat exchanger in-
sert pipe with suitable brushes. Flush out the pipe
and brush it until there are no loose particles co-
ming out with the water.
4. Remove both end walls. Install the end walls with
new seals.
5. Connect the pipe connections to the starboard
side end cover. Check gaskets and change if ne-
cessary.
6. Fill the engine with coolant if the freshwater sys-
tem has been emptied. Open the seawater cock.
7. Fill the centrifugal sea water pump up with water*.
Please refer to “Measures before starting”.
age occurs.
58
Maintenance: Electrical system
Electrical system
The engines have a comprehensive electrical engine management system. This automatic system monitors
engine speed as well as the electrical and fuel systems and the engine cooling and lubrication functions. The sys-
tem consists of a number of switches and sensors which activate an alarm or automatic stop (optional) if a fault is
detected in the engine.
Supply voltage is 24V.
WARNING! Before any work is done on the electrical system, the engine must be stopped and the current
cut by switching off the battery isolator. Shore current for engine heaters, battery chargers or other auxiliary
equipment connected to the engine must be disconnected.
Checking the electrical wiring

Make sure electrical connections are tightened, dry
and free from oxide. If necessary, spray these con-
nections with water-repellant (Volvo Penta all-round
oil).
Main switches
The main switches must never be turned off until the
engine has been 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 engine is running.
IMPORTANT! Never turn the power off using the

main switches while the engine is running.
Fuses
The engine is equipped with two circuit breakers which
cut the current if overloaded.
The circuit breakers are located in the junction box on
the left side of the engine. The circuit breakers are re-
set by pressing the red button on each breaker, once
any faults have been attended to.
NOTE! If the same fuse trips frequently, an authorised
Volvo Penta workshop should be contacted to investi-
gate the cause of the overload.
Electric welding
Remove the positive and negative cables from the
batteries. Then disconnect all the leads to the genera-
tor.
Always connect the welder earth clamp to the compo-
nent to be welded, and as close as possible to the
weld site. The clamp must never be connected to the
engine or in such a way that current can pass through
a bearing.
IMPORTANT! When welding has ceased, con-
nect the leads to the generator before reconnec-
ting the battery cables.
59
Batteries. Maintenance
WARNING! Fire and explosion hazard. Batteries
must never be exposed to open flames or
sparks.
WARNING! Never confuse the positive and neg-

ative poles on the batteries. Risk of arcing and
explosion.
WARNING! Battery electrolyte is highly corro-

sive. Always protect your eyes, skin and clothes
when handling batteries. Always use protective
goggles and gloves. If acid comes into contact
with your skin, wash at once with soap and a lot
of water. If you get battery acid in your eyes,
flush at once with a lot of water, and get medical
assistance at once.
Connection and disconnection

When you connect batteries, first connect the + cable
(red) to the + pole on the battery. Then connect the –
cable (black) to the – pole on the battery.
When you disconnect batteries, disconnect the – ca-
ble (black) first, then the + cable (red).
Cleaning
Keep the batteries dry and clean. Contamination and
oxide on the batteries and battery poles can cause
stray currents, voltage drop and discharge, especially
in wet weather. Clean oxidation from the battery poles
and terminals, using a copper brush. Tighten the ter-
minals securely and grease them with terminal grease
or Vaseline.
Electrolyte level
The electrolyte level should be 5 – 10 mm (0.2 – 0.4")
above the cell plates in the battery. Top up with bat-
tery water as necessary.
After topping up, the batteries should be charged by
connecting them to a battery charger, or by running
the engine at normal speed for 30 minutes.
NOTE! Some maintenance-free batteries have special
instructions, which must be observed.
IMPORTANT! Never confuse the positive and

negative poles on the batteries.
60
Battery charging
WARNING! Explosion risk! Hydrogen is given
off when batteries are charged. This forms an ex-
plosive mixture with air. A short circuit, open
flame or spark could cause a violent explosion.
Ventilate well.
WARNING! Battery electrolyte is highly corro-

sive. Protect your eyes, skin and clothes. Al-
ways use protective goggles and gloves. If acid
comes into contact with your skin, wash at once
with soap and a lot of water. If you get battery
acid in your eyes, flush at once with a lot of wa-
ter, and get medical assistance at once.
Charge batteries if they have become discharged. The
batteries will be damaged by being left discharged,
and can also freeze and crack in cold weather.
IMPORTANT! Observe the instruction manual for

the battery charger carefully. To avoid the risk of
electrochemical corrosion when an external
charger is connected, the battery cables in the
boat should be removed from the batteries before
the charger is connected.
The battery plugs must be unscrewed but left in the
holes while charging is in progress. Ventilate well, es-
pecially if batteries are being charged in confined spa-
ces.
WARNING! Always cut the charging current be-

fore disconnecting the charger cables. Never re-
verse the polarity of the battery. Risk of sparks
and explosion.
Special directions apply for rapid charging. Rapid
charging can impair the service life of the batteries
and should be avoided.
61
Control system
System overview
The control and monitoring system consists of the following components:
- Senders and switches
- Electrical boxes, located on the engine and on a pillar
- Control unit, located on a pillar
All senders and switches are connected to the electrical box. Alarm switches control alarm indications in the con-
trol unit. Shutdown switches, together with the shutdown unit, control emergency stopping of the engine if neces-
sary. The engine is controlled manually by the DCU 305 or by external controls. It can also be connected to a
central alarm system. The control system is classified by all the major classification societies and have at least
protection class IP44. The system requires a 24V DC electrical supply and is 2-pole, i.e. it has an insulated re-
turn. Extra relay cards can be connected to the control unit if necessary.
For more information about the control system components, see ”Senders and switches” and ”Wiring diagrams”.
6
3 5
1 5
8
8
1. Electrical box
1
2. Control unit
2
3. RK-66
4. DCU 305
5. Terminal block
6. GAC-unit
1
7. Shutdown unit (SDU)
8. Shutdown reset button
9. Relays
62
Shutdown unit (SDU)
The shutdown unit (SDU) will shut down the engine by
cutting off the fuel supply. Shutdown functions include
shutdowns for OVERSPEED, COOLANT TEMP, and
OIL PRESSURE, in auxiliary mode and for OVER-
SPEED only, in emergency mode.
Shutdown functions
When above mentioned engine data is not within set
limits the SDU will shut down the engine by cutting off
the fuel supply. This will trigger an alarm indicated by
light and sound on the control panel. The SHUTDOWN
LED indicates that the genset has been stopped. The
LED is lit until the engine has stopped completely.
1. Push the ACKNOWLEDGE button to silence the
buzzer. The cause of the shutdown will be listed
in the alarm list on the LCD screen. A LED on the
SDU in the electrical connection box on the
engine will also indicate the cause of the
shutdown.
2. Rectify the fault.
3. Push the SHUTDOWN RESET button on the
electrical connection box on the engine. The LED
on the SDU and the lamp on the control panel
should go out if the fault no longer exists.
4. Restart the engine.
63
Control System
Broken wire
The broken wire detection will set an alarm (light and
sound) if the shutdown system should somehow mal-
function, e.g. if connection to a switch is lost, or loss
of power supply to the shutdown unit itself (the
POWER LED on the SDU will no longer be lit in case
of power loss).
IMPORTANT! The BROKEN WIRE function only

detect lost connection due to cut off electrical
wires, not faulty or loose contacts.
1. Push the ACKNOWLEDGE button to silence the

alarm.
2. Check the SDU in the electrical connection box on
the engine, a yellow LED corresponding to the
broken wire will be lit:
S1 – Coolant water temperature
S3 – Engine oil pressure
S4 – Coolant water pressure
SS – Engine rpm
FV – Fuel shut-off valve
3. Rectify the fault.
4. Push the BROKEN WIRE RESET button (A) on
the SDU. If the fault is rectified the LED in the
SDU will go out.
Overspeed shutdown test

On a running engine, open the electrical connection
box on the engine and remove the SDU cover. Then
push and hold the OVERSPEED TEST button (A).
This will lower the overspeed setting by 25% and trig-
ger an overspeed shutdown.
Shutdown override
The system can be overridden by activating the OR
input. The Emergency mode lamp, if installed on out-
put SL, will then be activated. Override does not inclu-
de overspeed.
64
Inhibiting
General
To prevent the genset and other equipment from being harmed during long (2 months or more) periods out of servi-
ce, it must be conserved. It is of utmost importance that the conservation is performed correctly. Therefore we
have compiled a checklist of the most important points. Before taking the genset out of service for long periods, it
should be checked by a Volvo Penta dealer for possible need of overhaul or repair.
WARNING! Read the chapter “Maintenance” thoroughly before starting any maintenance work. It
contains directions for performing maintenance in a safe and correct manner. Certain preservatives are
flammable. Some are also dangerous to inhale. Provide good ventilation. Use a protective mask.
IMPORTANT! The following must be considered when cleaning with a high-pressure water jet: Never
point high-pressure water jets directly at seals, rubber hoses or electrical components. Never use the
high-pressure function when washing the engine.
IMPORTANT! For generator specific inhibiting information, refer to generator documentation.
Preparation Care during storage

1. Stop up to eight months: Change oil and oil filter Recharge the battery at least once a month.
on the engine and then run it warm
IMPORTANT! During longer periods out of opera-
Stop over eight months: Treat the lubricating and tion, the preparations must be repeated every 12
fuel systems with preservative. See directions on months.
next page.
2. Make sure there is enough anti-freeze in the coo-
lant. Add more if necessary. An alternative is to Return the engine to service
drain the coolant. 1. Remove any protective covers on the engine, air
3. Drain the rawwater system. intake and exhaust pipe.
4. Remove the impeller from the rawwater pump. 2. Top up with lubricant of the correct grade in the
Keep the impeller in a cool place in a closed plas- engine if necessary.
tic bag. 3. Fit new fuel filters and bleed the fuel system.
5. Drain off any water and contaminant from the fuel 4. Check drive belts.
tank. Fill the tank with fuel to avoid condensation.
5. Check the condition of rubber hoses and check
6. Disconnect the battery cables and clean and char- the tightness of all hose clips.
ge the batteries. Trickle charge during the storage
period. A poorly charged battery can freeze and 6. Close the drain cocks and fit the drain plugs of the
break. rawwater system. Fit the impeller in the rawwater
pump. Fill and bleed the rawwater system.
7. Clean the engine externally. Touch up any paint
damage with Volvo Penta original paint. 7. Check the coolant level and anti-freeze. Top up if
necessary.
8. Spray electric system components with water re-
pellant. 8. Check under and around the engine for such items
as loose or missing bolts, oil, fuel or coolant leaks
9. Inspect all control cables and apply anti-corrosion and repair if needed.
agent.
9. Connect fully charged batteries.
10. Cover the air intake to the engine, the exhaust
aperture and the engine. 10. Start the genset and run it at idling speed until it
reaches operating temperature before loading it.
IMPORTANT! Never use vinyl sheets for 11. Check for oil, fuel or coolant leaks.
covering. This can result in condensation and
harm the installation. 12. When the engine has run long enough to warm up
apply the load and bring it to operating speed.
IMPORTANT! Store the engine in a well-
ventilated room.
IMPORTANT! Affix a label on the engine giving

the date, type of conservation and the
preservative that was used.
65
Inhibiting
Conservation of the lubrication and fuel systems for more than 8

months’ stoppage:
● Drain the oil from the sump and engine and fill
the engine up with conservation oil* to just
above the MIN marking on the dipstick.
● Connect the fuel supply (1) and return fuel pipes
(2) to a jerrican filled with 1/3 conservation oil*
and 2/3 diesel fuel.
● Vent the fuel system.
● Start the engine and run at a fast idle until about
2 litres (0.5 US gal.) have been used. Stop the
engine and connect the ordinary fuel pipes.
1
● Empty the conservation oil out of the engine
● Follow the other instructions on the previous
page.
2
* Conservation oils are sold by oil companies.
66
Troubleshooting
A number of symptoms and possible causes for engine disturbances are described in the table below. For genera-
tor specific troubleshooting, refer to generator documentation. If faults or hitches arise that you cannot solve alo-
ne, you must always get in touch with your Volvo Penta dealer.
Symptoms and possible causes

Starter motor does not rotate when cranking 1,2,3,4,5,
Starter motor rotates slowly when cranking 1,2,3,21,45,46
Engine does not start 7,8,9,10,11,12,13,14,19,20,22,23,25,47,54
Engine is difficult to start 7,8,9,10,11,12,13,14,19,20,22,23,25,47,48
Engine starts but stops again 7,8,9,10,11,12,13,14,19,20,22,23,25,47

48,49
Engine does not reach correct operating speed 7,8,9,10,11,12,13,14,17,18,19,20,21,

22,23,24,25,30,33,54
Engine runs unevenly 7,8,9,10,11,12,13,14,15,16,22,23,25,26

48,54
Engine knocks 20,26,49
Engine vibrates 8,16,22,30,31,34
Engine does not stop 2,3,4,5,50
High fuel consumption 12,14,16,18,19,20,25,27,30
Black or dark gray exhaust smoke 12,14,16,17,18,19,20,25,27
Blue or white exhaust smoke 16,18,19,20,21,27,30,40,41,48,54
High lubrication oil consumption 21,29,30,31,41
Lubrication oil pressure too low 21,28,32,42,43
Coolant temperature too high 33,35,36,37,38,39,40,51
Coolant temperature too low 40
No charge or poor charge 2,3,44,52,53
1. Defective starter 22. Air in fuel system 43. Defective relief valve
2. Flat batteries 23. Water/contamination in fuel 44. Alternator drive belt slips
3. Poor contact/broken cables 24. Engine speed control wrongly adjusted 45. Clutch is engaged
4. Main switch turned off 25. Insufficient air supply 46. Defective bearings or abnormal cylinder
5. A fuse/circuit breaker has blown/tripped 26. Too high coolant temperature friction
6. Lack of fuel 27. Too low coolant temperature 47. Fuel supply pump strainer blocked
7. Blocked fuel filter 28. Too low lubrication oil level 48. Very cold engine and lubrication oil
8. Defective fuel filter 29. Lubrication oil leakage 49. Heavy initial load
9. Blocked fuel pipes 30. Worn cylinder liners and/or piston rings 50. Engine consume lubrication oil or combus-
10. Defective fuel pipes 31. Worn valve stem seals tible gas
11. Blocked fuel supply pump 32. Blocked lubrication oil filter 51. Cylinder liner have scalings or such that
12. Defective fuel supply pump 33. Radiator blocked reduce cooling effect
13. Blocked fuel injection pump 34. Faulty engine mounting 52. Alternator/Rectifier broken
14. Defective fuel injection pump 35. Too low coolant level 53. Faulty governor
15. Blocked fuel injectors 36. Air in fresh water system 54. Broken piston
16. Defective fuel injectors 37. Blocked sea water inlet/pipe/filter
17. Incorrect valve clearance 38. Circulation pump drive belt slips
18. Incorrect fuel injection timing 39. Defective cooling water pump
19. Low compression pressure 40. Defective/wrong thermostat
20. Improper fuel oil 41. Too high lubrication oil level
21. Improper lubrication oil 42. Defective lubrication oil pump
67
Technical Data
TAMD165C
General
Number of cylinders .............................................. 6
Displacement ......................................................... 16,12 liters (984 in3 )
Valve clearance (stationary cold engine):
inlet ........................................................................ 0,30 mm (0,0118 in)
exhaust .................................................................. 0,60 mm (0,0236 in)
Compression pressure
at starter motor speed (180 rpm) .......................... 2760 kPa (400 psi)
Dry weight engine, without oil and coolant
without generator and frame, approx. ................... HE Not available
............................................................................... KC Not available
Exhaust temperatures: 440 kW @ 1500 rpm

HE KC
at 25% of ISO Standard Power ............................ Not available Not available
at 100% of ISO Standard Power .......................... 402°C (756°F) 443°C (829°F)

HE KC
Lubricating system
Oil capacity, approx. Including oil filters
No engine inclination ............................................. 73 litres (19,3 US gals)
volume difference min. –max. .............................. 20 litres (5,3 US gals)
Oil pressure at operating speed ............................ 300-500 kPa (43,5-72,5 psi)
Cooling system
Freshwater system capacity
including heat exchanger, approx. ........................ HE 80 litres (21,1 US gals)
............................................................................... KC Not available
Electrical system
System voltage ..................................................... 24V
AC alternator voltage/max. amperage .................. 28V/60A

AC alternator output, approx. ................................ 1700 W
Battery electrolyte density at +25°C (77°F):

fully charged battery .............................................. 1,28 g/cm3 = 0,0462 lb/in3 (1,24 g/cm3 = 0,0448 lb/in3)*
battery recharged at .............................................. 1,24 g/cm3 = 0,0448 lb/in3 (1,20 g/cm3 = 0,0434 lb/in3)*
68
Technical Data
TAMD165A
General
Number of cylinders .............................................. 6
Displacement ......................................................... 16,123 liters (984 in3 )
Valve clearance (stationary cold engine):
inlet ........................................................................ 0,30 mm (0,0118 in)
exhaust .................................................................. 0,60 mm (0,0236 in)
Compression pressure
at starter motor speed (180 rpm) .......................... 2760 kPa (400 psi)
Dry weight engine, without oil and coolant
without generator and frame, approx. ................... HE Not available
............................................................................... RC Not available
............................................................................... KC Not available

HE RC KC
at 25% of ISO Standard Power ............................ Not available Not available Not available
at 100% of ISO Standard Power .......................... 420°C (788°F) Not available 443°C (829°F)

HE RC KC
Lubricating system
Oil capacity, approx. Including oil filters
No engine inclination ............................................. 73 litres (19,3 US gals)
volume difference min. –max. .............................. 20 litres (5,3 US gals)
Oil pressure at operating speed ............................ 300-500 kPa (43,5-72,5 psi)
Cooling system
Freshwater system capacity
including heat exchanger, approx. ........................ HE 80 litres (21,1 US gals)
............................................................................... RC Not available
............................................................................... KC Not available
Electrical system
System voltage ..................................................... 24V
AC alternator voltage/max. amperage .................. 28V/60A

AC alternator output, approx. ................................ 1700 W
Battery electrolyte density at +25°C (77°F):

fully charged battery .............................................. 1,28 g/cm3 = 0,0462 lb/in3 (1,24 g/cm3 = 0,0448 lb/in3)*
battery recharged at .............................................. 1,24 g/cm3 = 0,0448 lb/in3 (1,20 g/cm3 = 0,0434 lb/in3)*
* Note. Applies to batteries with tropical acid.
69
Standard Control System
Fuel specification
Fuel must comply with national and international standards at the least, e.g.:
JIS KK 2204. ...................... Type1, Type2, Type3

ASTM, D 975 ................................. No.1-D, No.2-D
EN 590 .......................... with national environment
and cold requirements
Note! It is necessary to use a fuel that has a pour point suitable for ambient temperature during the operation of
the engine. Consult the supplier to select the right type.
Sulfur content
Complying with legal requirements in each country. If the sulfur content exceeds 0.5 % by weight, service inter-
vals must be changed, see “Maintenance: Lubricating system”.
Fuels with low density (city diesel) can result in a loss of power by approx. 5% and an increase in fuel consump-
tion of approx. 2–3 %.
70
Technical Data
Lubrication oil specification
Oil change volume

Deep sump Shallow sump*
Oil capacity incl. oil filters, approx:
no engine inclination .................................. 73 liters (19.3 US gals) 51 liters (13.5 US gals)
volume difference min.–max. .................. 20 liters (5.3 US gals) 13 liters (3.4 US gals)
engine inclination 5° ................................... 55 liters (14.5 US gals) 47 liters (12.4 US gals)
volume difference min.–max. .................. 20 liters (5.3 US gals) –
engine inclination 10° ................................. 38 liters (10.0 US gals) 42 liters (11.1US gals)
volume difference min.–max. .................. 14 liters (3.7 US gals) –
Oil pressure, hot engine at operating speed .. 300–500 kPa 300–500 kPa
(43.5–72.5 psi) (43.5–72.5 psi)
*Note. TAMD165A-A and TAMD165C-A in standard versions are equipped with a deep sump.
Engines fitted with shallow oil sump are available as an option.
Oil grade and change interval

1: VDS-2 and ACEA E3 1).
2: API: CE, CF, CF-4, CG-4, CH-4.
Engine Oil Sulphur content

Sulphur content in
in fuel,
fuel, by
by weight
weight
up to 0.5 % 0.5 – 1.0 % more than 1.0 % 2)
Oilchange
Oil changeinterval:
interval:Reached
Reachedfirst
firstininoperation
operation
TAMD165A-A,  1 500 hours eller 12 months 250 hours eller 12 months 125 hours eller 12 months
TAMD165C-A  2 250 hours eller 12 months 125 hours eller 12 months 60 hours eller 12 months
1)
Lubrication oil must comply with both requirements.
2)
If sulphur content is > 1.0% by weight, use oil with TBN > 15 (TBN = Total Base Number).
NOTE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the quality
requirements above.
VDS = Volvo Drain Specification

ACEA = Association des Constructeurs Européenne d’Automobiles
API = American Petroleum Institute
Selection of oil viscosity −30 −20 −10 ±0 +10 20 30 40 o

Use the following chart to select appropriate oil viscosi- C
ty according to the ambient temperature. Recommen- −15oC SAE 15W/40
ded oil viscosity is SAE 15W-40 for all seasons. o
−25 C SAE 10W/30
Important! Excessively high oil viscosity causes ✱✱ SAE 5W/30
power loss and higher oil temperature, while −10oC SAE 20W/30
excessively low oil viscosity results in inadequate
±0oC SAE 30
lubrication and leakage of combustion gas with
increased wear and reduced output as a result.
o
+10 C SAE 40
**Refers to synthetic or semi-synthetic oil. o
F
−22 −4 +14 32 50 68 86 104
Note. Temperature values are stable ambient air Viscosity at different ambient temperatures
temperatures.
71
Technical Data
Coolant specification
Always use Volvo Penta Coolant in the freshwater cooling circuit. Volvo Penta Coolant acts both as anti-freeze
agent and provides corrosion protection for the metal parts of the cooling system. Future claims might be rejec-
ted should Volvo Penta Coolant not have been used.
Important! Mixing other types of concentrated coolant with Volvo Penta Coolant, may decrease
corrosion protection and may damage the engine or block the cooling system.
Water
Always use clean water that complies with the requirements in ASTM D4985. If these requirements are not comp-
lied with, corrosion may occur, which would result in impaired cooling performance.
Total 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 ........................................ <15 mg KMnO4/L
Mixing ratio
The mixture of Volvo Penta Coolant and water should contain 40-55% Volvo Penta Coolant. If the coolant
contains less than 40% Volvo Penta Coolant, the cooling galleries in the engine or radiator may be blocked
by contamination. If the coolant contains more than 60% Volvo Penta Coolant the cooling ability of the
coolant mixture is impaired, this may cause the engine to overheat. Too high concentration of Volvo Penta
Coolant also impairs the frost protection.
Important! The mixture of Volvo Penta Coolant and water may never contain less than 40%
Volvo Penta Coolant.
NOTE! Mix the glycol with water in a separate container before filling the cooling system.
72
Technical Data
Identification numbers
TAMD165C
Type plates with identification numbers and labels with information on certificates and classification, can be found
on the engine and on the generator. This information must always be used as a reference when ordering service
and spare parts.
Engine plate Generator plate
Engine type (1) ......................................................... Generator type (4) ....................................................
Serial and base engine number (2) ........................... Serial number (5) ......................................................
Specification (3) ....................................................... NOTE! The genset shown is mounted with a Stamford generator,
if other generator brand is used refer to generator manufacturers
Engine decal documentation.
Engine type (1) .........................................................

Serial and base engine number (2) ...........................
Specification (3) .......................................................
Generator plate
Engine decal
Engine plate
Engine plate
73
Technical Data
TAMD165A
Type plates with identification numbers and labels with information on certificates and classification, can be found
on the engine and on the generator. This information must always be used as a reference when ordering service
and spare parts.
Engine plate Generator plate

Engine type (1) ......................................................... Generator type (4) ....................................................
Serial and base engine number (2) ........................... Serial number (5) ......................................................
Specification (3) ....................................................... NOTE! The genset shown is mounted with a Stamford generator,
if other generator brand is used refer to generator manufacturers
documentation.
Certification, IMO
Engine type (1) .........................................................
Serial and base engine number (2) ...........................
Specification (3) .......................................................
Generator plate
Certification, IMO
Engine plate
Engine plate
74
Notes
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7744193 English 12-2004

Tamd 165 A

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OPERATOR’S MANUAL

TAMD165C/A Marine Genset

Stopping ................................................................ 29 Electrical system ................................................... 59

Safety regulations during engine operation

Safety directions for maintenance and service

Hot surfaces and fluids Fuel system

Dress properly for the job!

Recommended fuel, lubrication oil and

Perform all recommended inspections!

Care of the environment Fuel and oil

1. Air inlet generator

1. Air inlet generator

1. Air inlet generator

1. Air inlet generator

1. Air inlet generator

External inspection Electrical wiring

* Flexible coupling from engine to generator

IMPORTANT! All covers on engine and generator

Valves and plugs

IMPORTANT! If the coolant drain cocks are not

NOTE! Make sure that the cooling water flow is sufficient.

Start using auxiliary batteries

Never reverse the polarity of the battery. Risk of

WARNING! The black auxiliary cable (–) must not

4. Start the engine and run at no load for about ten

WARNING! Do not touch the connections while

5. Stop the engine. Remove the auxiliary cables in

Standby and manual mode

To access LOCAL mode, first enter INFO-view and

Starting the genset

1. Press the LAMPTEST button (5) on the control

IMPORTANT! If the starter motor has been

Check the readings on the LCD screen and run the

Checking the LCD screen

Oil pressure, engine

Stopping the genset

Use the red STOP button (2) to manually stop the

IMPORTANT! Do not push the START button

During load operation make sure that:

Breaks in operation [not using the genset]

Daily operation records

Recommendation of Daily Operation Records

WARNING! Deposits of fuel, oils and grease on

IMPORTANT! If you discover a leakage of oil,

IMPORTANT! Observe the following when clean-

Inspecting/Adjusting drive belts

IMPORTANT! Always change a belt which looks

The standard alternator, plus the extra alternator if in-

The flushing and bilge pump etc. are driven by tradi-

Checking and filling oil level

Changing engine oil

WARNING! Hot oil and hot surfaces can

IMPORTANT! Only use a recommended

WARNING! Working with, or going close to

Changing oil filter and bypass

1 WARNING! Hot oil and hot surfaces can cause

1. Put a suitable vessel underneath the filters to

Changing oil filter under way