Volvo Penta TAMD 61, 62, 63, 71, 72 Service Workshop Manual

Workshop Service and Repair Manual set for the TAMD 61-72  Volvo Penta engines This full workshop manual set covers every component, service and repair procedure in full Volvo Penta factory specification with clear concise step by step photographs and technical drawings for the engines including fuel, exhaust, lubrication and cooling systems with torque setting values throughout where required for fasteners and reassembly. It also carries a full set of wiring schematics for each model, below is an exhaustive list of the items covered within this set. This is by far the most comprehensive service manual set available as used by marine engineers and boatyards the world over.

The full workshop manual set covering the Volvo Penta TAMD variants below:

TAMD61A
TAMD62A
TAMD63L-A
TAMD63P-A
TAMD71A
TAMD71B
TAMD72A
TAMD72WJ-A
TAMD72P-A

ENGINE WORKSHOP MANUAL
General instructions
Special tools
Other special equipment
Design and function
Engine, generally
Design differences, engine versions
Identification signs
Location of type approval plates
Component description

Repair instructions
General
Engine jig attachment
Condition test, engine
Compression test

Cylinder head, renovation
Cylinder head, removal
Cylinder head, stripping/assembly
Cylinder head, leakage test
Cylinder head, inspection
Valve guides, inspection
Valve guides, replacement
Cylinder head, planing
Cylinder head, milling the seal groove
Valve seat, replacement
Valve seat, grinding
Valves, grinding
Rocker mechanism, renovation
Checking the valve springs
Cylinder head, assembly
Copper injector sleeve, replacement
Cleaning seat for copper sleeve
Copper sleeve, assembly
Valves, adjustment

Cylinder block, renovation
Piston and con rod, removal
Piston and con rod, inspection
Piston removal, gudgeon pin boss
replacement
Piston, assembly
Piston ring inspection and fit
Piston ring assembly
Cylinder liner, inspection and measurement
Cylinder liner, disassembly
Cylinder liner, honing
Cylinder liner position, renovation
Cylinder liner, assembly
Timing gears, disassembly
Timing gears, assembly
Sealant application, timing gear lid
Seal ring, polygon hub, replacement
Polygon hub, assembly
Camshaft, wear check
Camshaft, disassembly
Inspection of valve lifters and camshaft
Camshaft, measurement
Camshaft bearing, replacement
Camshaft, assembly
Crankcase, disassembly
Inspection, crankshaft and bearings
Crankshaft, renovation
Cylinder block, inspection
Cylinder block, planing
Crankshaft, assembly
Big end bearings, replacement
Main bearings, replacement
Flywheel, replacement
Gear ring, replacement
Flywheel, indication
Flywheel housing, indication
Crankshaft seal, rear, replacement
Flange seal, flywheel housing, replacement

FUEL SYSTEM
General instructions
Special tools
Other special equipment
Design and function
General
Injection pump
Regulator
Pressure variable full load stop
Feed pump
Overflow valve
Fuel injector
Fuel shut-off valve (TAMD 63)
Fuel filter
Repair instructions
Injection pump, removal
Injection pump, installation and adjustment (TAMD61, -62*), -71, 72*)
Injection pump, installation and adjustment (TAMD63**) and TAMD72P-A)
Idle speed, adjustment
Feed pump, replacement
Feed pump, renovation
Fuel supply pressure, checking
Fuel shut-off valve, trouble shooting
Fuel shut-off valve, renovation
Seal in pump drive, replacement (TAMD61, -62, -71)
Seal in pump drive, replacement (TAMD63, -72)
Injector, replacement
Injector, renovation
Copper sleeve, cleaning
Recommendations for adjustment of opening
pressure, adjustment pressure and
replacement of fuel injectors
Opening pressure, adjustment
Fuel filter, replacement
Fuel system, venting

WIRING DIAGRAMS
Safety information
Introduction
Important
General information
About the workshop manual
Spare parts
Certified engines
Wiring diagrams, engine
TAMD61A, TAMD71A (12V, 24V)
TAMD61A, TAMD62A, TAMD71A, TAMD71B, TAMD72A, TAMD72WJ-A (12V, 24V)
TAMD63L-A, TAMD63P-A (12V, 24V)
TAMD71B (12V, 24V)
TAMD72WJ-A (12V, 24V)
TAMD72P-A (12V)
TAMD72P-A (24V)
TAMD73P-A (12V)
TAMD73P-A (24V)
TAMD73WJ-A, TAMD74A-A/A-B (12V, 24V)
TAMD74C-A/L-A/P-A (12V)
TAMD74C-B/L-B/P-B, TAMD75P-A (12V)
TAMD74C-A/L-A/P-A/C-B/L-B/P-B, TAMD75P-A (24V)
Block diagram – Instrument panels
Wiring diagram – instrument panel, main control position
Wiring diagrams – instrument panel for alternative control position (flying bridge) and auxiliary control panel
Wiring diagram – instrument kit, main control position
Wiring diagram – instrument kit for alternative control position (flying bridge)
Wiring diagrams – control system (EDC)
Wiring diagrams – general
Wiring diagram – EDC color coding
Wiring diagrams – alternative control system for EDC controls
Wiring diagram – water jet control panel
Reversing bucket operation – water jet

INLET AND EXHAUST SYSTEM
Design and function
General
Turbocharger
Wastegate valve
Aftercooler
By-pass valve for aftercooler
Repair instructions
Turbocharger, removal
Turbocharger, installation
Boost pressure, checking
Actions for low boost pressure
Exhaust back pressure, checking
Exhaust temperature, checking

COOLING SYSTEM
Design and function
General
Hull cooling TAMD61, -62, -71B
Hull cooling TAMD63, -71A, -72
Coolant pump TAMD61, -62, -71, -72
Coolant pump TAMD63
Sea water pump
Heat exchanger/aftercooler
Thermostat
Oil cooler/engine
Oil cooler/reverse gear
Coolant
Repair instructions
Draining coolant
Cleaning the cooling system
Filling coolant
Sea water filter, checking and cleaning
Heat exchanger/aftercooler, cleaning, TAMD61, -62, -71, -72
Aftercooler, proof testing or replacement
Aftercooler/heat exchanger, cleaning or replacement, TAMD63
Oil cooler, reverse gear, cleaning
Zinc anode, inspection/replacement
Coolant pump, replacement, TAMD61, -62, -71, -72
Coolant pump, replacement, TAMD63
Coolant pump, renovation, TAMD61, -62, -71, -72
Coolant pump, renovation, TAMD63
Sea water pump, impeller replacement
Sea water pump, replacement
Sea water pump, renovation, TAMD61, -62, -71, -72
Sea water pump, renovation, TAMD63
Thermostat, replacement
Thermostat, function check

LUBRICATION
General Information
Special Tools
Design and Function General
Control valves
Reduction valves
Pressure relief valve
Piston cooling valve
By-pass valve
Piston cooling
Oil Pump
Oil Cooler
Oil Filter
Crankcase Ventilation
Repair Instructions
General
Engine adaptor, fastening
Lubrication oil pressure, check
Oil filter, replacement
Sump gasket, replacement
Oil pump, replacement
Oil pump, renovation
Oil cooler, replacement
Oil cooler, cleaning
Oil cooler, leakage test
References to Service Bulletins

TECHNICAL DATA
Safety information
General information
Technical data:
General information
Cylinder block
Crank mechanism
Valve mechanism
Timing gears
Lubrication system
Fuel system
Inlet and exhaust system
Cooling system
Electrical system
Tightening torques
Installing seals
References to Service Bulletins