Volvo Penta D2-75 Operator's Manual
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Volvo Penta D2-75 Operator's Manual

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OPERATOR'S MANUAL
D2-55, D2-75

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Summary of Contents for Volvo Penta D2-75

  • Page 1 OPERATOR’S MANUAL D2-55, D2-75...
  • Page 2 This operator’s manual is also available in the following languages: Diese Betriebsanleitung ist auch auf Dit instructieboek kan worden besteld Deutsch erhältlich. in het Nederlands. Ein Bestellcoupon ist am Ende der Betriebs- De bestelcoupon vindt u achter in het instruc- anleitung zu finden.
  • Page 3 Welcome aboard Volvo Penta marine engines are used all over the world today. They are used in all pos- sible operating conditions for professional as well as leisure purposes. That’s not sur- prising. After more than 90 years as an engine manufacturer and after delivering over 500,000 marine engines, the Volvo Penta name has become a symbol of reliability, technical in- novation, top of the range performance and long service life.

  • Page 4: Table Of Contents

    Stopping the engine ..........26 After stopping the engine ........26 Laying up ............26 Cold weather precautions ........26 © 2003 AB VOLVO PENTA All rights to changes or modifications reserved. Printed on environmentally friendly paper. (Cover: Department of transport (shipping), license 9809095)
  • Page 5 Read the Operator's Manual carefully before operating or servicing the engine. 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 information.

  • Page 6: Safety Information

    Safety Information Safety precautions to be taken when operating the boat Your new boat Refueling Read Operator's Manuals and other information When refueling there is always a danger of fire and supplied with your new boat. Learn to operate the explosion.
  • Page 7 Safety Information Carbon monoxide poisoning When a boat is moving forward backwash is caused Most modern boats are designed in such a way that behind the boat. Sometimes this backwash can be so problems with backwash are extremely unusual. powerful that exhaust gases can be sucked into the Should a backwash problem occur do not open cabin or seating well on the boat with the resulting risk hatches or valves in the forward part of the boat.
  • Page 8 All fuel, most lubricants and many chemicals are Never carry out any work on the engine if you are inflammable. Read and follow the instructions on the unsure of how it should be done, contact your Volvo packaging. Penta dealer who will be glad to offer assistance.
  • Page 9 Safety Information Hot surfaces and fluids Fuel system There is always a risk of burns when working with a Always use protective gloves when tracing leaks. hot engine. Beware of hot surfaces. For example: the Liquids ejected under pressure can penetrate body exhaust pipe, turbocharger (TC), oil pan, charge air tissue and cause serious injury.

  • Page 10: Introduction

    Introduction This Operator's Manual has been compiled to help you get the most from your Volvo Penta engine. It contains all the information you need in order to operate and maintain your engine safely and correctly. Please read the Operator's Manual carefully and learn how to operate the engine, controls and other equipment safely.

  • Page 11: Certified Engines

    Warranty and Service book. Note that AB Volvo Penta’s liability is limited to that contained in the Warranty and Service Book. Read this book as soon as you take delivery of the engine. It contains important information about warranty cards, service and maintenance which you, the owner, must be aware of, check and carry out.

  • Page 12: D2-55

    Presentation D2-55 with reverse gear MS25L D2-55 with reverse gear MS25L D2-55 with reverse gear HS25A D2-55 with reverse gear HS25A...
  • Page 13 Presentation D2-55 with sailing boat drive MS25S D2-55 with sailing boat drive MS25S 1. Coolant filler cap 8. Air cleaner (ACL)/Air intake 15. Seawater pump 9. Dipstick, engine 16. Cooling water intake, S-drive 2. Heat exchanger 10. Oil filler cap, engine 3.

  • Page 14: D2-75

    Presentation D2-75 with reverse gear MS25L D2-75 with reverse gear MS25L D2-75 with reverse gear HS25A D2-75 with reverse gear HS25A...
  • Page 15 Presentation D2-75 with sailing boat drive 150S D2-75 with sailing boat drive 150S 1. Coolant filler cap 15. Fuel filter 8. Generator 2. Relay box with fuses 16. Injection pump 9. Dipstick, reverse gear/S-drive 3. Heat exchanger 17. Seawater pump 10.

  • Page 16: Identification Numbers

    Presentation Identification number Your engine and transmission has identification plates with identification numbers. This information should always be quoted when ordering service and replacement parts. There are probably similar plates on your boat and its equipment. Make a note of the details below, make a copy of the page and keep it so that you have a copy should the boat be stolen.

  • Page 17: Instrumentation

    Instrumentation This chapter only describes the instrument panels available as standard alternatives for your engine from Volvo Penta. Note that in certain boats instruments, alarm panels, key switches etc. may be installed separately without the instrument panels shown here. If you want to install additional instrumentation, or your boat is equipped with instruments not described here, please contact your Volvo Penta dealer.
  • Page 18 Instrumentation S = The mechanical restart inhibitor is disengaged. The key springs back automatically to the 0 position. 0 = The key can be inserted and removed. I = Operating position. II = Glow plug position. The glow plugs are connected and pre-heating the engine.
  • Page 19 Instrumentation Instrument panel with electrical start/stop 21 17 function The instrument panel does not have an ignition switch. To stop unauthorized persons starting the engine the wheelhouse should have a lock or a lockable main switch should be used. 16. Tachometer and hour counter (accessory). Displays engine speed.

  • Page 20: Instrumentation

    Instrumentation Warning display If the acoustic alarm sounds, one of the three warning lamps (16-18) on the instrument panel starts to flash to indicate the source of the alarm. 22. Engine coolant temperature too high. 23 24 IMPORTANT! If the alarm sounds: Reduce engine speed to idle (neutral).

  • Page 21: Controls

    Controls The shift function and engine speed control are combined in one lever. If necessary the shift function can be easily disengaged so that only the engine speed (rpm) is affected by the lever. The control lever has an adjustable friction brake.

  • Page 22: Starting The Engine

    Starting the engine Make a habit of checking the engine and engine compartment visually before operating the boat. This will help you to quickly detect anything unusual that has or is about to happen. Also check that instruments and the warning display are indicating normal values when you have started the engine.
  • Page 23 Starting the engine Starting. Instrument panel with ignition lock WARNING! Never use start spray or similar to start the engine. Danger of explosion! 1. If the engine is cold: Disconnect the gear shift function and move the control lever forwards to half throttle. WARNING! Make sure that the gear shift function is disconnec- ted.
  • Page 24 Starting the engine Starting. Instrument panel without ignition switch WARNING! Never use start spray or similar to start the engine. Danger of explosion! 1. If the engine is cold: Disconnect the gear shift function and move the control lever forwards to half throttle. WARNING! Make sure that the gear shift function is disconnec- ted.

  • Page 25: Starting The Engine Using Auxiliary Batteries

    Starting the engine Starting using auxiliary batteries WARNING! Batteries produce oxyhydrogen. This gas is easily ignited and highly volatile. A short-circuit, naked flame or spark can cause a large explosion. Ensure that the ventilation is good. Never mix up battery positive and negative terminals. This may cause sparks and an explosion.

  • Page 26: Operation

    Cruising speed Operating the engine at wide open throttle (WOT) should be avoided since it is both uneconomical and uncomfortable. Volvo Penta recom- mends a cruising speed in the range 500–1000 rpm lower than maxi- mum rpm at WOT. Depending on hull type, choice of propeller, load and conditions etc.

  • Page 27: Maneuvering

    Operation Maneuvering All shifting between ahead and astern must be done at engine idle speed. Shifting at higher speeds may damage the drive or reverse gear and will also be uncomfortable for those on board. 1. Reduce engine speed to idling and, if possible, let the boat lose most of its speed.

  • Page 28: Stopping The Engine

    Stopping the engine The engine should be run for a few minutes at idle (in neutral) before turning it off. This will avoid boiling and even out the temperature. This is especially important if the engine has been operated at high engine speeds and loads.

  • Page 29: Maintenance Schedule

    Maintenance schedule Your Volvo Penta engine and associated equipment is designed to provide high operational reliability and long service life. They are constructed to withstand the marine environment while also affecting it as little as possi- ble. Preventive maintenance in accordance with the maintenance schedule will ensure that it retains these qualities and avoid unnecessary operational disturbances.

  • Page 30: Maintenance And Care

    Maintenance schedule Every 200 operating hours or at least once a year ● Reverse gear. Oil change ................page 49 ● Reverse gear (HS25) Cleaning the oil filter .............page 49 ● Reverse gear. Lubricate propeller shaft seal...........page 52 ● S-drive.

  • Page 31: Engine, General

    Maintenance This chapter contains instructions regarding how the above maintenance points should be carried out together with general technical information. Read the instructions carefully before starting work. Maintenance intervals are contained in the chapter above. Maintenance schedule WARNING! Read the safety precautions for maintenance and service in the chapter: Safety Precautions, before starting work.

  • Page 32: Drive Belt. Check

    Check that the belt is not cracked or dam- aged. Replace a worn belt. Keep a spare belt on- board. 10 mm D2-75 Drive belt. Adjusting and replacing WARNING! Always turn the engine off before starting maintenance work. IMPORTANT! Tighten screw (1) to 50 Nm.
  • Page 33 3 Slacken off locknut (D). Adjust engine speed with adjustment screw (E). Tighten the locknut. Repeat step 1. Wastegate (D2-75) If the engine is not used for a longer period of time there is a risk that the turbochargeer boost pressure...

  • Page 34: Lubrication System

    Maintenance: Lubrication system Lubrication system IMPORTANT! With a new or reconditioned engine, the oil and oil filters must be changed after 20-50 hours of operation. After that they should be changed every 500 operating hours or at least once a year. Use only the recommended grades of oil: See the chapter ”Technical Data”.

  • Page 35: Freshwater System

    If the system is filled with anti-corrosion agent mixture it must be changed every year. We recommend that a mixture of water and Volvo Penta antifreeze is used all year round, regardless of the climate.

  • Page 36: Coolant. Checking Level

    Maintenance: Freshwater system In there is no of risk of freezing When there is never a risk of freezing water may be used as coolant with addition of Volvo Penta anti corrosion agent. Mix according to the instructions on the packaging.
  • Page 37 Maintenance: Freshwater system Coolant. Changing The corrosion-proofing additives become less effec- tive with time and the coolant must be changed. If the freshwater system is filled with antifreeze mixture it must be changed every other year. If the system is filled with anti-corrosion agent mixture it must be changed every year.

  • Page 38: Seawater System

    Maintenance: Seawater system Seawater system The sea water system is the external cooling system of the engine. On engines with a stern drive, the sea water pump sucks in water via the drive, after which the water passes the sea water filter (optional extra) before it is pumped through the heat exchanger.

  • Page 39: Seawater Filter. Cleaning

    Maintenance: Seawater system Vacuum valve. Cleaning Some engines have a vacuum valve installed in the seawater piping. WARNING! Risk for water penetration. Close the sea cock. Close the sea cock. Disassemble the valve. Unscrew the hexagonal cover. In the cover there is a mem- brane and a gasket.
  • Page 40 Let the engine run at fast idle for a few minutes. Stop the engine. 6. Fill the bucket with an anti-freeze mixture (50% Volvo Penta glycol and 50% fresh water). Collect the mixture from the system in a suitable contai- ner.
  • Page 41 4. Open the drain cock (4) on the rear end of the heat exchanger and drain the water off. D2-75: Open the drain cock on the charge air cooler (9) draining the water. 5. Disconnect the hoses where indicated by the arrows (5).

  • Page 42: Fuel System

    If there is no fuel pre-filter installed, low output may be due to a blocked strainer. D2-75: If any of the two o-rings (4) are damaged they need to be replaced. 3. Start the engine and check for leaks.

  • Page 43: Fuel Pre-Filter. Drain Water

    Maintenance: Fuel system Fuel filter. Changing Clean the filter mounting. To avoid fuel spills put a plastic bag over the filter before it is unscrewed. Unscrew the filter. Moisten the filter rubber gasket with a little oil. Screw on the new filter by hand until it is in contact with the mating surface.

  • Page 44: Electrical System

    Also check that all electrical connections are dry and free of oxidation and that there are no loose connec- tions. If necessary, spray these connections with a water-repellent spray (Volvo Penta Universal oil). Fuses The engine has a fuse holder with four 15 A fuses.

  • Page 45: Battery. Check Electrolyte Level

    Maintenance: Electrical system Battery. Maintenance WARNING! Risk of fire and explosion. Never allow an open flame or electric sparks near the battery or batteries. WARNING! Never mix up battery positive and negative terminals. This may cause sparks and an explosion. WARNING! The battery electrolyte contains extremely corrosive sulfuric acid.
  • Page 46 Maintenance: Electrical system Battery. Charging WARNING! Danger of explosion! The batteries give off hydrogen gas during charging which when mixed with air can form an explosive gas - oxyhydrogen A short-circuit, naked flame or spark can cause a large explosion. Ensure that the ventilation is good.
  • Page 47 Maintenance: Electrical system Electrical installations Leakage current from the electrical system can be caused by incorrect installation of electrical equip- ment. Leakage current can knock out the galvanic protection of components such as the drive, propeller, propeller shaft, rudder stock and keel and cause damage by electrolytic corrosion.
  • Page 48 All equipment connected to the auxiliary battery should have separate switches. To simultaneously charge two independent battery circuits, fit a Volvo Penta charge distributor (ac- cessory) to the regular generator.

  • Page 49: Electrical Components Diagram

    Maintenance: Electrical components diagram Electrical components diagram 1. Engine coolant temperature sensor D2-55 (optional extra) 2. Coolant temperature switch D2-55 3. Engine coolant temperature sensor D2-75 4. Coolant temperature switch D2-75 5. Fuses 6. Starter relay 7. Glow plug relay 8.

  • Page 50: S Drive And Reverse Gear

    Install the plug and o-ring. Top up oil to correct level. For oil quality and capacity: See the chapter ”Techni- cal Data”. IMPORTANT! If oil is colored gray then water has entered the drive. Please contact an author- ised Volvo Penta workshop.
  • Page 51 Maintenance: S drive and reverse gear Oil change. MS25 Remove the dipstick. Suck up oil using an oil pump through the hole for the dipstick. Measure out the correct amount of oil and fill up through the hole for the oil dipstick. For oil quality and capacity: See the chapter ”Technical Data”.

  • Page 52: Folding Propeller. Cleaning

    Maintenance: S drive and reverse gear Corrosion protection. Check Check the sacrificial anode (1) on the drive and the three sacrificial anodes (2) on the propeller. Replace with a new anode if 50% of the material has perished or at least once per season. IMPORTANT! Use zinc sacrificial anodes for salt water and magnesium anodes for freshwa- ter.
  • Page 53 IMPORTANT! The tab washer (3) must be re- placed if necessary. Use only Volvo Penta ori- ginal locking screws (4). 4. Install one propeller blade in the propeller hub and...

  • Page 54: S-Drive. Check Rubber Seal (Hull/Drive)

    Maintenance: S drive and reverse gear Propeller shaft seal. Reverse gear If the boat has a Volvo Penta shaft the shaft seal must be vented and lubricated directly after launching. Vent the bushing by pressing it together while press- ing down on the shaft until water appears. Then press in approx.

  • Page 55: Laying Up/Launching

    Laying up and launching Before taking the boat out of the water for winter/out-of-season storage have an authorized Volvo Penta work- shop inspect the engine and other equipment. Inhibition should be carried out to ensure that the engine and transmission are not damaged while out of commis- sion during the winter/off-season.

  • Page 56: Bringing Out Of Storage

    Maintenance: Laying up and launching Bringing out of storage ● Check oil level in the engine and drive/reverse ● Paint the drive and hull: See next page. gear. Top up if necessary. If there is inhibiting oil ● in the system drain and fill with new oil, change oil Check the sacrificial anode on the drive.

  • Page 57: Painting The Drive And Underwater Hull

    Most countries have introduced legislation controlling the use of anti-fouling agents. In some cases these agents are completely forbidden for use on leisure craft. In these cases ask your Volvo Penta dealer for advice about alternative methods. IMPORTANT! Find out what regulations apply to the use of anti-fouling agents.

  • Page 58: Fault-Tracing

    A number of symptoms and possible reasons for engine problems are described in the table below. In case of faults or mishaps which you cannot solve, always contact the Volvo Penta dealership. WARNING! Read the safety precautions for maintenance and service in the chapter: Safety Precautions, before starting work.

  • Page 59: Technical Data

    Technical Data General Engine designation ..........D2-55 A D2-75A No. of cylinders ............4 Cylinder bore ............84 mm (3.31 in) 84 mm (3.31 in) Cylinder stroke ............100 mm (3.94 in) 100 mm (3.94 in) Overall cylinder displacement ......... 2.2 liters (134 in³) 2.2 liters (134 in³) Power, see sales literature Idling speed .............

  • Page 60: S Drive And Reverse Gear

    Technical Data Reverse gear MS25 Type designation ............MS25L MS25A Gear ratio Left rotating (Position B) ........2.27:1 ; 2.74:1 2.23:1 ; 2.74:1 Right rotating (Position A) ........2.10:1 ; 2.72:1 2.74:1 Angle (output shaft): ..........0 Oil volume, approx........... 0.75 liters (0.2 US gals) 0.75 liters (0.2 US gals) Oil grade ..............
  • Page 61 Notes ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________...
  • Page 62 Notes ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________...
  • Page 63 ✂ Yes please, I would like an operator’s manual in English at no charge. Publication number: 774 2957 Post or fax this coupon to: Document & Distribution Center Name Order Department ARU2, Dept. 64620 Address SE-405 08 Göteborg Sweden Fax: +46 31 545 772 Orders can also be placed via the Internet: http://www.volvopenta.com/...
  • Page 64 ✂ Sí gracias, deseo recibir gratuitamente un libro de instrucciones en español. Número de publicación: 774 2961 Franquear o enviar fax a: Document & Distribution Center Nombre Order Department ARU2, Dept. 64620 Dirección SE-405 08 Göteborg Suecia Fax: +46 31 545 772 El pedido puede hacerse tam- bién por internet: http://www.volvopenta.com/...
  • Page 65 ✂ Ja graag, Ik wil kosteloos een instructieboek in het Nederlands ontvangen. Publicatienummer: 774 2965 Stuur of fax de coupon naar: Document & Distribution Center Naam Order Department ARU2, Dept. 64620 Adres SE-405 08 Göteborg Zweden Fax: +46 31 545 772 U kunt ook bestellen via internet: http://www.volvopenta.com/...
  • Page 66 ✂ Sim, obrigado(a)! Gostaria de receber gratuitamente um manual de instruções em português. Número de publicação: 774 2966 Envie o talão pelo correio ou um fax para: Nome Document & Distribution Center Order Department Endereço ARU2, Dept. 64620 SE-405 08 Göteborg Suécia Fax: +46 31 545 772 A encomenda também pode...
  • Page 68 AB Volvo Penta SE-405 08 Göteborg, Sweden www.volvopenta.com...

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D2-55

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