Volvo Penta D1 Series Operator's Manual
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Volvo Penta D1 Series Operator's Manual

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D1/D2

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  • Page 1 Operator’s manual D1/D2...
  • Page 2 Do not modify or tamper with the exhaust system. • Do not idle the engine except as necessary. For more information www.P65warnings.ca.gov/marine www.p65warnings.ca.gov/products/diesel © 2019 AB VOLVO PENTA Volvo reserves the right to make changes Printed on environmentally friendly paper...

  • Page 3: Table Of Contents

    Fuel, oils and coolant ................17 Maintenance and replacement parts ............17 Excessive strain on a product and components ........18 Volvo Penta EVC system, integrity and modification ......18 Environmental care ................. 19 Recording engine data ................19 Certified Engines ..................20 Volvo Penta Dealer Network ..............
  • Page 4 Painting the Drive and Underwater Hull ..........78 Technical Data ................... 79 Coolant, Mixing ..................82 Identification Numbers ................. 84 Declaration of Conformity ..............85 Declaration of Conformity ..............85 Declaration of Conformity ..............86 Index ......................87 47711262 01-2019 © AB VOLVO PENTA...

  • Page 5: Foreword

    Pay careful attention to the safety instructions included in the manual. As the owner of a Volvo Penta marine engine, you become part of a worldwide network of dealers and service workshops that assist you with technical advice, service requirements and replacement parts.

  • Page 6: Safety Information

    This chapter describes how safety precautions are If anything remains unclear or if you are unsure of presented in the manual and on the product. Read the something, contact your Volvo Penta dealer for chapter through very carefully before you start the assistance.
  • Page 7 WARNING! Ensure that all machine guards and safety devices are in place and are functional. P0024482 CAUTION! Never use tools or products that show signs of damage. 47711262 01-2019 © AB VOLVO PENTA...
  • Page 8 Ensure that the workplace is well ventilated and take the necessary precautions before welding or grinding begins. Always ensure that there is a fire extinguisher close at hand in the work area. P0024470 47711262 01-2019 © AB VOLVO PENTA...
  • Page 9 Spare parts — safety WARNING! Always use spare parts with the same quality as genuine Volvo Penta parts to minimize the risk of an explosion or fire. Components in fuel systems and electrical systems on Volvo Penta engines are designed and manufactured to minimize the risk of explosions and fire, in accordance with applicable legal requirements.
  • Page 10 Prohibition on use of start spray WARNING! Never use start spray or similar agents to start an engine. This may cause an explosion in the inlet manifold. Risk of personal injury. P0024483 47711262 01-2019 © AB VOLVO PENTA...
  • Page 11 Before any work on the cooling system WARNING! Stop the engine and let it cool before starting work on the cooling system. Hot fluids and hot surfaces can cause burns. 47711262 01-2019 © AB VOLVO PENTA...
  • Page 12 Smoking is forbidden and the engine must be stopped. Proper fuel quality IMPORTANT: Always use the fuel recommended by Volvo Penta. See Technical Data in Operator’s Manual. Other fuel can damage the engine. Wrong fuel quality can also lead to higher service costs.
  • Page 13 Correct polarity of the batteries IMPORTANT: Make sure that the positive (+) and negative (–) battery cables are correctly connected to the corresponding battery terminals. Wrong connection may cause severe damage to electrical equipment. P0024468 47711262 01-2019 © AB VOLVO PENTA...
  • Page 14 Cleanliness for sensitive components IMPORTANT: Observe meticulous cleanliness when handling system components. Even minimal amounts of dirt could cause a breakdown. Adjustment of the clutch CAUTION! Clutch adjustments must be carried out with the engine stopped. 47711262 01-2019 © AB VOLVO PENTA...

  • Page 15: Maneuvering

    Instead, try to change the speed, trim or load distribution. If possible, take down or open the cockpit awning. Contact your boat dealer for the best solution for your boat. 47711262 01-2019 © AB VOLVO PENTA...
  • Page 16 • anchor • paddle • flashlights Spare Parts and Tools: • impeller • fuel filters • fuses • tape • hose clamps • engine oil • other tools that may be required 47711262 01-2019 © AB VOLVO PENTA...

  • Page 17: Introduction

    Introduction Check that you heave received the correct operator’s manual before continuing reading. If not, please contact your Volvo Penta dealer. Read the Operator’s Manual carefully and learn to handle the engine, controls and other equipment in a safe manner before you start the engine.

  • Page 18: Warranty

    Introduction Warranty Your new Volvo Penta marine engine is covered by a limited warranty, subject to the conditions compiled in the Warranty Information. Note that AB Volvo Penta’s liability is limited to the specification in the Warranty Information (included CD) and Emission Control System Warranty Statement.

  • Page 19: Fuel, Oils And Coolant

    These qualities will be maintained through regular servicing and the use of spare parts with the same quality as genuine Volvo Penta parts. If reliable and purpose-built parts are not used, your safety, health, and the machine’s function may be compromised.

  • Page 20: Excessive Strain On A Product And Components

    Modifying the EVC system or connecting spare parts or systems that do not comply with the quality of genuine Volvo Penta parts may adversely affect the system performance, safety, and warranty coverage.

  • Page 21: Environmental Care

    Introduction Environmental care Environmental care is a core value at Volvo Penta. Energy efficiency and low emissions are among the most important product related aspects and priority focus areas for Volvo Penta business. Several of the global challenges the world faces are directly or indirectly related to power industries and transports.

  • Page 22: Certified Engines

    NOTICE! Neglects or failure to follow the points listed here may invalidate the engine emission certificate. This means AB Volvo Penta can no longer guarantee engine conformity with the certified model. Volvo Penta is not responsible for damages or costs arising as a result of this.

  • Page 23: Volvo Penta Dealer Network

    The Volvo Penta global network of authorized dealers is at your service. We strongly recommend that you take your product to an authorized Volvo Penta dealer for service and repair. They are specialists in Volvo Penta products and have the accessories, genuine...

  • Page 24: Instruments And Controls

    Instruments and Controls This chapter describes the instruments, panels and controls Volvo Penta sells for your engine. If you would like to complement your instrumentation, or if your boat is equipped with instruments not described here, we ask that you contact your Volvo Penta dealer.

  • Page 25: Gauges

    8 Oil pressure If the oil pressure lamp lights up during operations, the engine oil pressure is too low. 9 Charging The charging lamp lights up if the alternator stops charging. P0007517 47711262 01-2019 © AB VOLVO PENTA...
  • Page 26 75-95°C (167-203°F). 3 Fuel level gauge The fuel level gauge shows the quantity of remaining fuel. 4 Alarm monitor The alarm monitor gives a visual warning to call attention to any alarms that occur. P0007518 47711262 01-2019 © AB VOLVO PENTA...

  • Page 27: Evc System Display

    The display has five contrast settings. Depress button 5 (far right) and change the contrast by depressing + (button 4) or – (button 3). Store the setting by depressing EXIT (button 5). ENGINE HOURS HOURS P0003010 47711262 01-2019 © AB VOLVO PENTA...
  • Page 28 Then repeatedly depress the button that corresponds to the window to be set until the desired information is shown. The type of information accessible depends on the type of electrical system and sensors the boat is equipped with. P0003011 47711262 01-2019 © AB VOLVO PENTA...
  • Page 29 Instruments and Controls, page 23 for further information. Alarm When the system detects a fault, the display automatically switches to the System Information screen. For further information, refer to Fault handling, page 41. 47711262 01-2019 © AB VOLVO PENTA...
  • Page 30 Calibration: the engine must be switched on during calibration. Depth compensation Setting the Volvo Penta echo sounder. The echo- sounder can be installed anywhere between the waterline and the boat's deepest point. Set the deviation – off set – so that the display value shows one of these points.
  • Page 31 The speed sensor calibration value can be adjusted upwards (+) or downwards (-) in stages of 0.01 units (+ or - 1%). Store the adjusted value by depressing BACK (button 5). P0003005 47711262 01-2019 © AB VOLVO PENTA...

  • Page 32: Controls

    Instruments and Controls Controls This section describes the controls Volvo Penta sells for your engine. Contact your dealer if your boat is equipped with controls other than those described here, and you feel uncertain about their function. Maneuvering A single-lever control operates both gearshift and throttle functions from the same lever.
  • Page 33 2 Move the lever to the half throttle/astern position. 3 Adjust the friction brake by turning the screw clockwise (+) for stiffer lever movement, and counterclockwise (-) for easier movement. 4 Replace the cover and the lever. 47711262 01-2019 © AB VOLVO PENTA...

  • Page 34: Starting

    The alternator and electronics could be damaged. • Start the engine bay fan, where fitted, and allow it to run for at least four minutes. • Check that there is sufficient fuel for the planned trip. 47711262 01-2019 © AB VOLVO PENTA...

  • Page 35: Starting The Engine

    Starting the Engine Activate the control panel by depressing the on/off button (1). The Volvo Penta logo is displayed in the window. Two audible signals are sounded to indicate the system is ready and that the engine may be started.
  • Page 36 Fault handling, page 41 chapter for more detailed information and recommended actions. Warm up the engine at low speed and low load, so that normal working temperature is reached before full power is applied. 47711262 01-2019 © AB VOLVO PENTA...

  • Page 37: Operation

    2 Cancel the alarm by depressing the multi-function button (2). The audible alarm will be silenced. The symbol will be lit continuously until the fault is remedied 3 Take the necessary action: refer to the Fault handling, page 41 section. 47711262 01-2019 © AB VOLVO PENTA...

  • Page 38: Maneuvering

    2 Move the control lever to the neutral position with a quick, firm movement. Pause a moment. 3 Move the control lever back with a quick, firm movement and increase revolutions. P0005856 47711262 01-2019 © AB VOLVO PENTA...

  • Page 39: Cruising Speed

    Depending on the type of hull, choice of propeller, load and sea state etc., maximum revolutions at top speed may vary, but should be within the full throttle range; refer to the Engines section. 47711262 01-2019 © AB VOLVO PENTA...

  • Page 40: Engine Shutdown

    Auxiliary stop If the engine cannot be stopped in a normal procedure, it is possible to stop the engine via the auxiliary stop (A) mounted on the side of the engine. 47711262 01-2019 © AB VOLVO PENTA...

  • Page 41: After Engine Shutdown

    NOTICE! Do not turn off the main switch within 30 seconds after turning off the ignition. This in order to save engine data to the engine control unit. 47711262 01-2019 © AB VOLVO PENTA...

  • Page 42: Cold Weather Precautions

    Maintenance, page 58 and Seawater System, Draining, page 61 respectively for more detailed information. Check the charge status of the battery. A poorly- charged battery can freeze and burst. 47711262 01-2019 © AB VOLVO PENTA...

  • Page 43: Fault Handling

    Note that the content of this chapter does not provide full coverage of the possible fault messages and alarms. Contact a Volvo Penta workshop for assistance with diagnostic readouts and unresolved faults. If an operational fault arises an audible alarm will...
  • Page 44 Check that the oil filter is not blocked. Change the oil filter as necessary; refer to Engine oil and engine oil filter, changing. • Contact a Volvo Penta workshop if the fault remains. Battery The charging lamp lights up when the alternator stops...
  • Page 45 • Check to see if there are any chafed wires or wires with loose connections. • Contact a Volvo Penta workshop if the fault remains. Fuel Level The fuel level symbol is displayed when less than 20% fuel remains in the tank if a fuel level sensor is installed (optional equipment).

  • Page 46: Fault Tracing

    A number of symptoms and possible causes of engine malfunctions are described in the table below. Always contact your Volvo Penta dealer if any problems occur which you cannot solve by yourself. NOTICE! Read the safety regulations for care and maintenance in the Safety precautions for maintenance and service operations chapter before work you start work.

  • Page 47: In Case Of Emergency

    Do not touch the connections during the start attempt: Risk of arcing. Do not bend over any of the batteries either. 5 Turn off the engine. Remove the start cables in the exact opposite order to their connection. 47711262 01-2019 © AB VOLVO PENTA...

  • Page 48: Maintenance Schedule

    Maintenance Schedule Your Volvo Penta engine and its equipment are designed for high reliability and long life. The engines are built to have the smallest possible environmental impact. If preventive maintenance is carried out, according to the maintenance schedule, these qualities will be retained and unnecessary malfunctions will be avoided. It is the owner's responsibility to make sure that the services in the service intervals are performed in order for the warranty to be valid.

  • Page 49: Maintenance

    Read through the safety precautions for maintenance and service in the Safety precautions for maintenance and service operations chapter before work on the engine is begun. Volvo Penta recommend that all servicing with the engine running should be undertaken by an authorized Volvo Penta workshop.
  • Page 50 Relay box Alternator Starter motor Oil dipstick, reverse gear D1-13 with MS10A reverse gear Air filter/air intake Fuel hand pump Oil filler, engine Oil dipstick, engine Fuel filter Oil filter Injection pump Raw water pump 47711262 01-2019 © AB VOLVO PENTA...
  • Page 51 D1-20 with 130S sailboat drive Oil dipstick, S-drive Air filter/air intake Fuel hand pump Oil filler, engine Oil dipstick, engine Sacrificial anodes Oil drain, S-drive Fuel filter Oil filter Injection pump Raw water pump 47711262 01-2019 © AB VOLVO PENTA...
  • Page 52 Oil cooler, reverse gear Oil dipstick, reverse gear D1-30 with MS15A reverse gear Air filter/air intake Fuel hand pump Oil dipstick, engine Oil filler, engine Fuel filter Oil filter Injection pump Raw water pump 47711262 01-2019 © AB VOLVO PENTA...
  • Page 53 D2-40 with 130S sailboat drive Oil dipstick, S-drive Air filter/air intake Fuel hand pump Oil dipstick, engine Oil filler, engine Sacrificial anodes Oil drain, S-drive Fuel filter Oil filter Injection pump Raw water pump 47711262 01-2019 © AB VOLVO PENTA...

  • Page 54: Engine, General

    Never direct the jet from a high-pressure washer at seals, rubber hoses or electrical components. Never use the high pressure setting for engine cleaning. 47711262 01-2019 © AB VOLVO PENTA...

  • Page 55: Drive Belt, Check And Change

    3 Install the new belt. Adjust. 4 Check the belt tension again after a few hours' operations. IMPORTANT! P0007520 D1-30, D2-40: Ensure that the alternator belt is placed D1-30 and D2-40 in the groove closest to the alternator. 47711262 01-2019 © AB VOLVO PENTA...

  • Page 56: Idling

    3 Undo the locknut (D). Adjust to the correct revolutions using the adjuster screw (E). Tighten the lock nut. 4 Repeat item 1. 1. This item does not apply to boats with twin helm stations. 47711262 01-2019 © AB VOLVO PENTA...

  • Page 57: Lubrication System

    (1) or at the side (2). 2 Wait 5 minutes so that the oil has time to run down into the engine. 3 Check the oil level again when the engine has cooled. P0007522 47711262 01-2019 © AB VOLVO PENTA...

  • Page 58: Fuel System

    5 Purge the fuel system, refer to the Fuel system, bleeding, page 57 section. 6 Start the engine and check for leaks. 7 Hand in the old filter to a re-cycling station. P0003731 47711262 01-2019 © AB VOLVO PENTA...

  • Page 59: Fuel System, Bleeding

    5 Vent the fuel system, please refer to section Fuel system, bleeding, page 57. 6 Start the engine and check for leaks. 7 Deposit the old filter insert at a properly designated disposal site. 47711262 01-2019 © AB VOLVO PENTA...

  • Page 60: Freshwater System

    - in the worst case - can cause engine breakdown. Volvo Penta strongly recommend the use of our own coolants, ”Volvo Penta Coolant VCS Ready Mixed” or the concentrate ”Volvo Penta Coolant VCS”, which...

  • Page 61: Coolant Level, Checking And Topping Up

    When filling a completely empty system the coolant level must be checked after the engine has been run for an hour or so, as the system is self purging. Top up with coolant as necessary. 47711262 01-2019 © AB VOLVO PENTA...

  • Page 62: Seawater System

    If the boat does not have sea 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. 47711262 01-2019 © AB VOLVO PENTA...

  • Page 63: Seawater System, Draining

    Close the heat exchanger drain tap. 10 Open the raw water tap when the boat is returned to operations. Check that no leakage exists in the raw water system. 47711262 01-2019 © AB VOLVO PENTA...

  • Page 64: Impeller, Check And Change

    4 Reinstall the impeller using a clockwise rotating movement. 5 Install the cover together with a new gasket. Open the sea cock. P0007527 Always carry a spare impeller on board. 47711262 01-2019 © AB VOLVO PENTA...

  • Page 65: Seawater System, Cleaning And Inhibiting

    Let it run at fast idle for a few minutes. Stop the engine. 6 Fill the bucket with an antifreeze solution (40% Volvo Penta Coolant and 60% freshwater) and arrange for the collection of the solution throughput. 7 Start the engine and let it idle. Stop the engine just before the mixture is depleted.

  • Page 66: Seawater Filter, Check And Cleaning

    WARNING! Risk of water entry. Close the seawater cocks before doing any work on the seawater system. 1 Close the sea cock. 2 Remove the valve. 3 Clean all components. 4 Install the valve. 47711262 01-2019 © AB VOLVO PENTA...

  • Page 67: Electrical System

    Always investigate the cause of the overload. If the fuse trips frequently, contact an authorized Volvo Penta workshop. p0013054 Electrical Connections Check that electrical connections are dry, free from oxide, and that they are securely tightened. 47711262 01-2019 © AB VOLVO PENTA...

  • Page 68: Battery

    • Charge the battery regularly. A battery that is kept fully loaded has a maximum service life. The easiest way to check if a battery needs charging is to use a voltmeter. 47711262 01-2019 © AB VOLVO PENTA...
  • Page 69 1 Connect the + cable (red) to the + pole on the battery and tighten the nut. 2 Connect the – cable (black) to the – pole on the battery and tighten the nut. NOTICE! Hand in the old battery to a re-cycling station. 47711262 01-2019 © AB VOLVO PENTA...

  • Page 70: Electrical Installations

    The S-drive is insulated electrically (A) from the P0007534 engine and may never be used as the ground or be connected electrically to other equipment such as radios, navigation equipment, rudder, and boarding ladders. 47711262 01-2019 © AB VOLVO PENTA...
  • Page 71 All equipment connected to the auxiliary battery must have separate main switches. For simultaneous charging of two independent battery circuits a separate charging distributor (accessory) should be installed on the standard alternator. 47711262 01-2019 © AB VOLVO PENTA...

  • Page 72: Reverse Gear

    Never over-fill the reverse gear. The oil level must always be within the recommended range. Propeller Shaft Sealing, Check If the boat is fitted with a Volvo Penta propeller shaft, the propeller shaft seals must be lubricated before launch and purged directly after launching.

  • Page 73: Drive

    If required, top up oil through the oil dipstick hole. For oil grade and quantity, refer to the Technical Data, page 83 section IMPORTANT: Never over-fill the drive. The oil level must always be within the recommended range. 47711262 01-2019 © AB VOLVO PENTA...

  • Page 74: Corrosion Protection, Checking And Changing

    Check the rubber seal between the drive and the hull regularly for cracks and wear. IMPORTANT: The seal must be changed every seven years or earlier if it is defective. This work should be carried out by an authorized workshop. P0003085 47711262 01-2019 © AB VOLVO PENTA...

  • Page 75: Propeller

    (8). 4 Pull off the propeller hub and spacer sleeve (stern drive). Clean and grease the propeller. 3-bladed folding propeller (drive) 2-bladed folding propeller (drive) C 3-bladed folding propeller (reverse gear) 47711262 01-2019 © AB VOLVO PENTA...
  • Page 76 The tab washer (3) must be replaced if necessary. Only Volvo Penta original lock screws (2) or screws with the same quality may be used. 4 Install one propeller blade to the hub and press in the cotter pin (1) so that the groove in the pin is aligned with the lock screw hole (2).

  • Page 77: Storage

    Storage Have an authorized Volvo Penta workshop carry out checks on the engine and other equipment before the boat is put into winter storage. Make sure all necessary repairs and service are completed so that the boat is in top condition before the next season.
  • Page 78 • Clean the outside of the engine. Do not use a high pressure washer to clean the engine. Touch up any paint damage with Volvo Penta original paint. • Check all control cables and treat with conservation agent.

  • Page 79: Bringing Out Of Storage

    Launch the boat. Check for leaks. • Vent and grease the propeller shaft packing box (reverse gear). • Start the engine. Check that there are no fuel, coolant or exhaust leaks and that all controls function. 47711262 01-2019 © AB VOLVO PENTA...

  • Page 80: Painting The Drive And Underwater Hull

    2 Wash with cellulose thinners or an equivalent. 3 Spackle and sand smooth any pores in the surface. 4 Paint with Volvo Penta original primer and paint. Allow to dry. 5 Paint the stern drive with anti-fouling agent for aluminum drives according to the manufacturer's recommendations.

  • Page 81: Technical Data

    Max. permissible rearward inclination in 20° 20° 20° 20° operation Max. side inclination in operation 30° 30° 30° 30° Weight, engine less oil and water 96 kg 118 kg 127 kg 148 kg * According to ISO 8665 47711262 01-2019 © AB VOLVO PENTA...
  • Page 82 = Total Base Number Global DHD = Global Diesel Heavy Duty Viscosity Select the viscosity according to the table. The temperature values refer to stable ambient temperatures. * SAE 5W/30 refers to synthetic or semi-synthetic oils. 47711262 01-2019 © AB VOLVO PENTA...
  • Page 83 Sufficient fuel lubricity is essential to protect the fuel injection system against excessive wear. Restrictions for other diesel fuels Volvo Penta also approves the use of other diesel fuels as long as the here specified restrictions are followed. However Volvo Penta does not guarantee compliance with emission legislation or fulfillment of expected lifetime with these other diesel fuels.

  • Page 84: Coolant, Mixing

    Follow the mixing recommendation on the product. The coolant should be mixed with distilled, deionized water. For Volvo Penta specified water requirements; refer to Water Quality. NOTICE! Always use “Ready Mixed” coolant if water quality cannot be determined or if it does not fulfill ASTM D4985.
  • Page 85 Type designation 130S-B, 130SR-B 130S-C, 130SR-C Gear ratio 2.19:1 2.19:1 Oil capacity 2.9 liters 3.3 liters Oil quality SAE 15W–40 SAE 15W–40 Weight 26.5 kg 32 kg Tightening torques 10 ±5 Nm 10 ±5 Nm 47711262 01-2019 © AB VOLVO PENTA...

  • Page 86: Identification Numbers

    Serial number (3): ........Transmission Product designation (4): ........Gear ratio (5): ........Serial number (6): ........Product number (7): ........P0007541 A Engine and transmission decal B Engine plate C Transmission plate p0007825 47711262 01-2019 © AB VOLVO PENTA...

  • Page 87: Declaration Of Conformity

    Declaration of Conformity for Recreational Craft Propulsion Engines with the exhaust emission requirements of Directive 2013/53/EU Engine manufacturer Body for exhaust emission assessment TÜV SÜD Product Service GmbH AB Volvo Penta Gropegårdsgatan Ridlerstrasse 65 405 08 Göteborg 80339 München Sweden...

  • Page 88: Declaration Of Conformity

    Declaration of Conformity for Recreational Craft Propulsion Engines with the exhaust emission requirements of Directive 2013/53/EU D1, D2 Engine manufacturer Body for exhaust emission assessment TÜV SÜD Product Service GmbH AB Volvo Penta Ridlerstrasse 65 Gropegårdsgatan 405 08 Göteborg 80339 München Sweden...

  • Page 89: Index

    Vacuum Valve............64 Drive belt, check and change........53 Volvo Penta Action Service........21 Volvo Penta Dealer Network........21 Electrical Connections..........65 Volvo Penta EVC system, integrity and modification 18 Electrical Installations..........68 Electrical System............65 Warranty..............16 Engine Fuel Filter Replacement........ 56 Engine, General............52 Environmental care...........
  • Page 91 παράδοση,μέσω διαδικτύου. http://manual.volvopenta.com/coupon/ http://manual.volvopenta.com/coupon/ Veuillez contacter votre Distributeur Volvo Penta si vous avez Εάν δεν είναι δυνατή η πρόσβαση στο ιαδίκτυο,παρακαλούμε un problème d‘accès à l‘Internet. επικοινωνήστε με το δικό σας αντιπρόσωπο της Volvo Penta.
  • Page 92 AB Volvo Penta SE-405 08 Göteborg, Sweden www.volvopenta.com...

This manual is also suitable for:

D1-13D1-20D1-30D2-40D2 series

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