Volvo Penta D5 Operator's Manual
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Volvo Penta D5 Operator's Manual

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D5/D7

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Summary of Contents for Volvo Penta D5

  • Page 1 Operator’s manual D5/D7...
  • 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 © 2021 AB VOLVO PENTA Volvo reserves the right to make changes Printed on environmentally friendly paper...

  • Page 3: Table Of Contents

    Maintenance and replacement parts ............15 Excessive strain on a product and components ........16 Volvo Penta EVC system, integrity and modification ......16 Installation and use of Volvo Penta External Helm ......... 16 Environmental care ................. 17 Recording engine data ................17 Certified Engines ..................
  • Page 4 Transmission Oil, Change ..............63 Oil Strainer, Cleaning ................64 Storage ....................... 65 Bringing Out of Storage ............... 66 Technical Data ................... 67 Viscosity ....................68 Coolant, Mixing ..................72 Identification Numbers ................. 74 Index ......................75 47713336 03-2021 © 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 Always wear safety glasses if there is a risk of splintering, sparks and spray from the electrolyte (so- called battery acid), or other chemicals. Your eyes are very delicate and damage can result in loss of sight! 47713336 03-2021 © AB VOLVO PENTA...
  • Page 8 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 9 Information on the engine IMPORTANT: Make sure that all warning and information decals on the product are always visible. Replace decals which have been damaged or painted over. 47713336 03-2021 © AB VOLVO PENTA...
  • Page 10 Before welding work IMPORTANT: Before any work with electric weld can begin, the connection to all control units must be disconnected. After finished welding, re-connect the connection to all control units before connecting any battery cable. 47713336 03-2021 © AB VOLVO PENTA...
  • Page 11 There is a risk that hot oil can spray out. Refueling WARNING! There is always a risk of fire and explosion during refueling. Smoking is forbidden and the engine must be stopped. 47713336 03-2021 © AB VOLVO PENTA...
  • Page 12 Safety Information 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. P0024477 WARNING! Risk of personal injury.
  • Page 13 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. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 14: 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. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 15: 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 16: 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 and Emission Control System Warranty Statement.

  • Page 17: Running In The Engine

    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 18: 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 19: 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 20: 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 21: 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 22: 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 23: Warning Display

    Keep the code in a safe place. S = Stop position. 0 = The key can be inserted or removed. = Power on (Running engine). II = Not used. III = Start position. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 24: 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 25: Dual Lever Control

    N = Neutral position. Reverse gear/drive disengaged and engine at idle. F = Reverse gear/drive engaged for forward motion. R = Reverse gear/drive engaged for rearward motion. Red lever (2) Engine rpm control (throttle). Control B 47713336 03-2021 © AB VOLVO PENTA...
  • Page 26 Adjust the friction brake by turning the screw (control A), or by twisting the lever (control B). Turn clockwise (+) for stiffer lever movement, and counterclockwise (–) for easier movement. Control A 47713336 03-2021 © AB VOLVO PENTA...

  • Page 27: Optional

    Optional Trolling Slip Valve All reverse gears that are available for the D5/D7 engines can be fitted with a trolling valve so that the lowest speed of the boat can be variably reduced by 1–80% at engine speeds up to 1100 rpm.

  • Page 28: Starting

    Never use start spray or similar agents to start an engine. This may cause an explosion in the inlet manifold. Risk of personal injury. The engine can be equipped with a temperature switch for start smoke limitation above +5°C, that is available in the Volvo Penta accessory program. Before Starting • Open the fuel cock.

  • Page 29: Starting The Engine

    Turn on the power by putting the starter key in position “I”. Check warning lamps and alarms Press the “Alarm test” button on the instrument panel to make sure the warning lamps come on and the acoustic alarm sounds. 47713336 03-2021 © AB VOLVO PENTA...
  • Page 30 Never race the engine when it is cold. Check the oil level in the reverse gear Check the oil level when the reverse gear has reached operating temperature, please refer to Oil level, checking and topping up, page 62. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 31: Operation

    During operation, the charge voltage gauge should show a reading of 28 V or 14 V for a 24 respectively 12 22 26 V system. The acoustic alarm will sound automatically in case the charge voltage is missing.. P0003025 47713336 03-2021 © AB VOLVO PENTA...

  • Page 32: Alarms

    Stop the engine immediately after an alarm for low P0013822 oil pressure. Investigate the cause, see Fault handling, page 36, and rectify it. 3 No charge voltage. Investigate the cause, see Fault handling, page 36, and rectify it. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 33: Maneuvering

    If the speed of the boat is too high, there is a risk of the propeller torque being so high that the engine will stop and start reversing, causing the engine to break down. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 34: Cruising Speed

    Fault handling, page 36. Select a propeller with greater pitch if actual engine revolutions exceed the full throttle range. Contact your Volvo Penta dealer for advice. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 35: Engine Shutdown

    3 Turn the key to position ”0”. The warning display lamps will turn off. Don’t turn off the engine when under full load. Subsequently allow the engine to idle for approx. 2 min. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 36: After Engine Shutdown

    This will prevent corrosion damage in the engine. If you expect the boat to be unused for two months or more, we recommend you to preserve the engine, please refer to Storage, page 65. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 37: Cold Weather Precautions

    Maintenance, page 49 and Seawater System, Draining, page 54 respectively for more detailed information. Check the charge status of the battery. A poorly- charged battery can freeze and burst. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 38: Fault Handling

    24 Worn or broken impeller in seawater pump 11 Fouled hull/propeller 25 Defective thermostat 12 Engine speed control wrongly adjusted 26 Oil level too high 13 Insufficient air supply 27 Water in the fuel pre-filter 14 Coolant temperature too high 47713336 03-2021 © AB VOLVO PENTA...

  • Page 39: 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. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 40: 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 given preventive maintenance, according to the maintenance schedule, these qualities will be retained and unnecessary malfunctions will be avoided. In order for the warranty to be valid, the owner must make sure that the services in the service intervals are performed.

  • Page 41: Maintenance

    Volvo Penta recommend that all servicing with the engine running should be undertaken by an authorized Volvo Penta workshop. The intervals when maintenance items must be carried are indicated in the Maintenance Schedule.

  • Page 42: Engine, General

    4 Press the button on the service indicator to reset the signal after service. The indicator is now ready to operate again. IMPORTANT! Scrap the old filter. It must not be cleaned. P0013783 47713336 03-2021 © AB VOLVO PENTA...

  • Page 43: Drive Belt, Check And Change

    3 Push the alternator belt pulley (4) to the right until the correct belt tension is achieved. 4 Tighten the screw (5). 5 Replace the belt for the fuel pump and tension the belt as described in Coolant pump / Fuel pump, Adjust”. 47713336 03-2021 © AB VOLVO PENTA...
  • Page 44 2 Push the fuel pump (3) to the right. 3 Remove the belt and replace it with a new one. 4 Push the fuel pump (3) to the left until the belt is correctly tensioned. P0003681 5 Tighten the screws. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 45: Lubrication System

    If you want longer oil change intervals than stated in the table Technical Data, page 68, the oil change interval can under certain conditions be increased. To see if the engine complies, Volvo Penta oil analysis need to be performed. Contact your Volvo Penta dealer for further information.

  • Page 46: Engine Oil, Change

    Watch out for rotating components and hot surfaces. 7 Stop the engine. Wait 15 minutes before checking the oil level. Top up as needed. Hand in the old oil and filters to a recycling station. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 47: Oil Filter, Change

    6 Fill up with oil , refer to Oil level, checking and topping up, page 43. 7 Start the engine (idle) and make sure that no leakages occur. Check the oil level once the engine has stopped. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 48: Fuel System

    Always observe the greatest cleanliness during refueling and work on the fuel system. All work on the injectors of the engine must be carried out by an authorized Volvo Penta workshop. WARNING! Fire hazard. When carrying out work on the fuel system make sure the engine is cold.

  • Page 49: Fuel System, Bleeding

    (1) and then from the pressure maintenance valve (2). 4 Firmly tighten bleeder screw (1) and pressure maintenance valve (2). 5 Start the engine and make sure there are no leaks. P0003058 47713336 03-2021 © AB VOLVO PENTA...

  • Page 50: Fuel Pre-Filter

    5 Place the spring frame on top of the filter element. 6 Check the lid gasket, replace it if necessary. 7 Place the gasket and lid in its right position. 8 Tighten the screws firmly. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 51: 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 52 IMPORTANT! The engine must not be started before the system has been bled and filled. 7 Stop the engine and allow it to cool down. Check the coolant level 8 Top up if needed. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 53: Coolant, Draining

    3 Also drain the heating system, tap water heater etc., if connected to the engine’s freshwater system. 4 Close all drain taps. 5 Collect the old coolant and hand it to a re-cycling station for destruction. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 54: Freshwater System, Flushing

    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, please refer to Maintenance, page 50. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 55: 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. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 56: Seawater System, Draining

    3 Drain the water from the reverse gear oil cooler by opening tap kranen (1). 4 Drain any extra equipment such as the seawater filter. 5 Connect all hoses, close all drain taps and plugs before you leave the boat. P0003678 47713336 03-2021 © AB VOLVO PENTA...

  • Page 57: Anodes, Check And Change

    4 Install the impeller. 5 Fit the cover with a new seal. 6 Open the seawater cock. Always carry a spare impeller and seal. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 58: Seawater Filter, Check And Cleaning

    (1). 2 Allow lubrication / condensation water to drain. 3 Tighten the plug (1) with a new seal. 4 After starting the engine, check for leaks and tighten the screw if necessary. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 59: Electrical System

    Always stop the engine and break the current using the main switches before working on the engine. IMPORTANT: Contact a Volvo Penta dealer for information if any arc welding will be performed on the application. Arc welding can cause damage to the engine and the electronics.

  • Page 60: Battery

    NOTICE! If low starter battery alarm occur, the battery may get drained which might result in loss of functions and engine stopping. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 61: Electrical Installations

    Leakage current can in turn render galvanic protection inadequate in respect of propellers, propeller shafts, rudder posts, the keel etc., and may cause damage through electrochemical corrosion. 47713336 03-2021 © AB VOLVO PENTA...
  • Page 62 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. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 63: Electrical Welding

    The clamp must never be connected to the engine or in such a way that current can pass through a bearing. IMPORTANT! After finished welding, re-connect the alternator terminals before connecting the battery cables. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 64: Reversing Gear

    (2) on the top of the reverse gear, refer to Technical Data, page 73 for oil grade and volume. IMPORTANT! Never over-fill the reversing gear. The oil level must always be within the recommended range. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 65: Transmission Oil, Change

    6 Check the oil level with the engine at low idling speed and the controls in neutral position. The oil level must reach to the upper mark on the dipstick. Top up oil if needed. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 66: Oil Strainer, Cleaning

    2 Clean the strainer and other components in paraffin ZF45 (kerosene). 3 Carefully put the components back again. 4 Tighten the plug/screw. 5 Start the engine and check carefully that no leakage occurs. ZF220, ZF280 P0003683 47713336 03-2021 © AB VOLVO PENTA...

  • Page 67: Storage

    Before the boat is taken out of service for a long period of time, an authorised Volvo Penta workshop should look over the engine and other equipment. Have any faults and deficiencies attended to, so that the equipment is in order, ready for the next start.

  • Page 68: Bringing Out Of Storage

    Start the engine (if the boat is in the water) and warm up at a fast idle before loading the engine. • Check that no oil, fuel or coolant leakage occurs. • Check the oil level in the reversing gear. Top up if necessary. 47713336 03-2021 © AB VOLVO PENTA...

  • Page 69: Technical Data

    R2 103 kW R2 118 kW R1 130 kW R1 148 kW D7A-B TA R2 153 kW R2 174 kW R1 146 kW R1 166 kW D7C-B TA R2 169 kW R2 195 kW 47713336 03-2021 © AB VOLVO PENTA...

  • Page 70: Viscosity

    ACEA = Association des Constructeurs Européenne d'Automobiles API = American Petroleum Institute Global DHD = Global Diesel Heavy Duty TBN = Total Base Number Viscosity Select the viscosity according to the table. The temperature values refer to stable ambient temperatures. 47713336 03-2021 © AB VOLVO PENTA...
  • Page 71 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 72 Penta approves the use of paraffinic diesel fuels that complies with standard EN 15940. The fuel guarantees compliance with emission legislation and fulfills the expected lifetime as long as the service requirements are followed. Volvo Penta also approves the use of fuel blends between these paraffinic fuels and diesel fuels that comply with the quality requirements.
  • Page 73 When shifting from diesel fuel to high FAME diesel fuel - The fuel hoses and sealings shall be replaced - The fuel tank shall be cleaned and the fuel filter shall be replaced after 50h 47713336 03-2021 © AB VOLVO PENTA...

  • Page 74: 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 75 See ZF Operator's Manual See ZF Operator's Manual See ZF Operator's Manual Viscosity See ZF Operator's Manual See ZF Operator's Manual See ZF Operator's Manual Oil pressure during 2,1 MPa 2,5 MPa 2,5 MPa operation Weight 73 kg 70 kg 82 kg 47713336 03-2021 © AB VOLVO PENTA...

  • Page 76: Identification Numbers

    2 Engine Power Kwred VALVE LASH MM IN TIM BTDC FUEL RATE mm / 3 Engine Power DISPL MADE IN GERMANY 01223270 4 Serial number 5 Specification number 19477 6 Engine Speed B Certification label p0020113 47713336 03-2021 © AB VOLVO PENTA...

  • Page 77: Index

    Fuel, oils and coolant..........15 Fuses.................57 Identification Numbers..........74 Ignition switch............21 Impeller, Check and Change........55 Installation and use of Volvo Penta External Helm... 16 Instrument Panel............20 Intake Manifold, Checking the Drain Hole....56 Lubrication System............43 Maintenance and replacement parts......15 Maneuvering............12, 31...
  • Page 79 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 80 AB Volvo Penta SE-405 08 Göteborg, Sweden www.volvopenta.com...

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