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Volvo Penta D2 Series Operator's Manual

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OPERATOR'S MANUAL
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  • Page 1 OPERATOR’S MANUAL...
  • Page 2 This operator’s manual is also available in the following languages: Diese Betriebsanleitung ist auch auf Denne instruktionsbog kan bestilles Deutsch erhältlich. på dansk. Ein Bestellcoupon ist am Ende der Betriebs- Bestillingskupon findes i slutningen af instruk- anleitung zu finden. tionsbogen. Ce manuel d’instructions peut être Tämän ohjekirjan voi tilata myös suo- commandé...
  • 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 ..........33 After stopping the engine ........33 Laying up ............33 Cold weather precautions ........33 © 006 AB VOLVO PENTA All rights to changes or modifications reserved. Printed on environmentally friendly paper. (Cover: Department of transport (shipping), license 9809095)

  • Page 5: Safety Information

    If operations are performed incorrectly this could result in personal injury, or damage to property or the engine. Read the Operator's Manual carefully before operating or servic- ing the engine. If anything is unclear please contact your Volvo Penta dealer for assist- ance.
  • Page 6 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 Most modern boats are designed in such a way that When a boat is moving forward backwash is caused problems with backwash are extremely unusual. behind the boat. Sometimes this backwash can be so Should a backwash problem occur do not open powerful that exhaust gases can be sucked into the hatches or valves in the forward part of the boat.
  • Page 8 Volvo Penta dealer. Fire and explosion Never carry out any work on the engine if you are unsure of how it should be done, contact your Volvo Fuel and lubrication oil Penta dealer who will be glad to offer assistance.

  • Page 9: Fuel System

    Safety Information Hot surfaces and fluids Fuel system There is always a risk of burns when working with Always use protective gloves when tracing leaks. a hot engine. Beware of hot surfaces. For example: Liquids ejected under pressure can penetrate body the exhaust pipe, turbocharger (TC), oil pan, charge 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 Declaration of Conformity for Recreational Craft Propulsion Engines with the exhaust emission requirements of Directive 94/25/EC as amended by 2003/44/EC Engine manufacturer: Body for exhaust emission assessment: AB Volvo Penta NKIP Gropegårdsgatan Nipkowweg 9 405 08 Göteborg Postbus 65 Sweden...

  • Page 13: Identification Numbers

    Identification number Your engine and transmission has identification plates with identification numbers. This information should al- ways be quoted when ordering service and replacement parts. 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. The appearance and location of identification plates is shown below.

  • Page 14: Presentation

    Presentation D-55 with reverse gear MS5L D-55 with reverse gear MS5L D-75 with reverse gear HS5A D-75 with reverse gear HS5A...
  • Page 15 Presentation D-75 with sailing boat drive 50S D-75 with sailing boat drive 50S . Coolant filler cap 8. Generator 5. Fuel filter . Relay box 9. Dipstick, reverse gear/S-drive 6. Injection pump 3. Heat exchanger 0. Air cleaner (ACL)/Air intake 7.

  • Page 16: Instrumentation

    This section describes the instrument panels available as standard alternatives for your engine from Volvo Penta, for Volvo Penta optional extra instruments see next section. Note that in certain boats instruments, alarm panels, key switches etc. may be installed separately without the instrument panels shown here.

  • Page 17: Tachometer

    Instrumentation Tachometer/LCD Gauge The tachometer provides you with the engine RPM on the dial gauge. Multiply this value by 000 for re- volutions per minute. The LCD screen on the tachometer shows engine operating time in hours and tenths of an hour and also symbols for operating information.
  • Page 18 Instrumentation Coolant temperature The coolant temperature symbol shows when the coolant temperature is too high. Coolant temperature Stop the engine if this lamp lights up during opera- tion. WARNING! Continued operation when the coo- lant temperature is too high can cause serious engine damage.
  • Page 19 Instrumentation This section describes the instrument and control panels sold by Volvo Penta as optional extras for your engine. Alarm display Voltmeter Coolant temperature Fuel level Voltmeter The operating charge volatage is approx. 4 V. When the engine is stopped battery voltage is approx.  V.
  • Page 20 Instrumentation System Failure (red indication) The "System Failure lamp" will light up at short circu- it, broken wire and AUX failure. Red: for faults requiring immediate action or attention by the operator. The buzzer will sound constantly. Oil pressure (red indication) If the oil pressure lamp lights up during operation, the oil pressure in the engine is too low.
  • Page 21 Instrumentation Battery (orange indication) The battery lamp lights up if the voltage is too high (>5 V) or the alternator is not charging, this can be due to a fault in the electrical system, or because the alternator drive belt is slack. Stop the engine Check the alternator drive belt.
  • Page 22 Instrumentation Display EVC System Introduction The Volvo Penta EVC System Display is an instru- ment that displays the engine’s operating information and allows communication with the engine electrical system. NOTE! The display is preset for engines larger than D and therefore, before the display can be used with...
  • Page 23 Instrumentation Start image This is the starting image that is shown on the display for a brief period after starting. If the display emits a high pitched sound continuously after starting, the self-test has failed. The display may still function but may act erratically. Symbols for operating information Oil pressure System failure...
  • Page 24 Instrumentation Set display contrast Press button 5 (far right) to set display contrast. Then press the appropriate buttons to adjust the levels and save the settings by pressing EXIT. The display unit has 5 contrast settings. Configuration menu (button 5) (depressed for longer than 3 s) The configuration menu is used to: - reach display mode SYSTEM INFORMATION...
  • Page 25 Instrumentation Display mode System Information SYSTEM INFORMATION is a display mode that functions in the same way as the EVC System Tacho- meter. Control panel Instructions about how the display in the tachometer functions can be found in the section concerning the tachometer in this instruction book.
  • Page 26 Instrumentation Calibration: This is where depth offset and speed calibration are made. See calibration procedure below. Units: (This menu is displayed only if LOCAL is selected in menu SETTINGS.) This is where you select the measurement units to be used to display operating information.
  • Page 27 ID-no: Display serial number Eeprom: No. of writes to the EEPROM Vers: Software version number Chk: Flash memory checksum Part no: Volvo’s part number for the software Source: Shows the source of the received data Label: Label allocated on the bus. Each unit...
  • Page 28 Instrumentation Display mode Multi (button 2) This display mode shows operating information in four different windows (see below). The user can choose which operating information is to be shown in which window. The information can be displayed as figures or as a standard instrument.

  • Page 29: Controls

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

  • Page 30: Starting The Engine

    Check that there is sufficient fuel. ● Starting method Press the on/off button () to activate the control pa- nel. The Volvo Penta logo will show in the LCD screen and two beeps indicate the system is ready.

  • Page 31: Starting The Engine

    Starting the engine Check the warning lamps and LEDs Each time the system is activated all bulbs and LEDs are illumintaed on the alarm display (optional extra). Check that all bulbs and LEDs function! Start the engine To start the engine press the start button () untill the engine starts.

  • Page 32: Operation

    Operating the engine at wide open throttle (WOT) should be avoided since it is both uneconomical and uncomfortable. Volvo Penta recommends a cruising speed in the range 500–000 rpm lower than maxi- mum rpm at WOT. Depending on hull type, choice of propeller, load and conditions etc.

  • Page 33: 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 34: Alarm

    Alarm If there is an alarm the tachometer LCD screen will show a flashing warning icon and the alarm buzzer sound. If the boat is equipped with an alarm display (optional extra) the relevant lamp will start to flash. Please refer to chapter "Instruments" for more infor- mation about the warning icons and the alarm display indicator lights.

  • Page 35: 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 36: Maintenance Schedule

    Extended Protection Volvo Penta offers an Extended Protection for your marine diesel engine, including transmission, if used for plea- sure use only. To be valid a Extended Protection service has to be performed at the owners cost and expense by an authorized Volvo Penta distributor, dealer or workshop before the expiry of the  months Warranty Period.
  • Page 37 Maintenance: Seawater system Every 200 operating hours or at least once a year, included in Extended Protection Reverse gear. Oil change ................page 55 ● ● Reverse gear (HS5) Cleaning the oil filter ........... page 55 Reverse gear. Lubricate propeller shaft seal..........page 58 ●...

  • Page 38: Maintenance

    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 39 Maintenance: Engine, general Drive belt. Check The belt drives both the circulation pump and the generator. A belt that is too loose can result in slip- page, poor cooling and poor charging. A belt that is too tight can damage the bearings in the circulation pump and damage the generator.
  • Page 40 Maintenance: Engine, general Air Cleaner (ACL). Cleaning Remove the hose clamp () and remove the filter. Remove the spring inside the filter. Clean the filter as necessary by washing it in soapy water. Then rinse it in clean water. Squeeze the filter out and leave it to dry.

  • Page 41: Lubrication System

    Maintenance: Lubrication system Lubrication system IMPORTANT! With a new or reconditioned engine, the oil and oil filters must be changed after 0-50 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 42: Freshwater System

    The coolant should contain ethylene glycol of a good quality with a suitable chemical consistency for an ade- quate protection of the engine. Using anti-corrosion aditive exclusively is not permitted in Volvo Penta’s engines. Never use water by itself as coolant.
  • Page 43 (8°F). (Using 60 % glycol lowers the freezing point to -54 °C (65°F)). Never mix more than 60 % concen- trate (Volvo Penta Coolant) in the cooling liquid, this will give reduced cooling effect and increase the risk of overheating, and will give reduced freezing protec- tion.
  • Page 44 Maintenance: Freshwater system Coolant level. Checking and topping up WARNING! Do not open the engine coolant system filler cap when the engine is still hot ex- cept in an emergency. Steam or hot coolant may M I N spray out. Turn the filler cap to the first stop and let any pres- sure escape from the system before removing the cap.

  • Page 45: 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 46 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 47 Let the engine run at fast idle for a few minutes. Stop the engine. 6. Fill the bucket with an anti-freeze mixture (40% Volvo Penta glycol and 60% fresh water). Collect the mixture from the system in a suitable contai- ner.
  • Page 48 Maintenance: Seawater system Seawater system. Draining If it is not possible to keep the engine compartment free of frost, the seawater system must be drained to prevent freezing damage. Note that all the seawater must be drained. The type of drainage must be adapted to the way in which the engine is installed and any additional equipment that is connected, for example sea water filter (), vacuum valve (8), silencer (7) etc.

  • Page 49: Fuel System

    Maintenance: Fuel system Fuel system All work on the engine injection pump or injectors must be carried out at an authorized workshop. Use only the recommended grade of fuel: See the chapter ”Technical Data”. WARNING! Fire risk. When carrying out work on the fuel system make sure the engine is cold. A fuel spill onto a hot surface or an electrical component can cause a fire.
  • Page 50 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. Un- screw 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 51: Electrical System

    Electrical connections 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).
  • Page 52 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 ex- tremely corrosive sulfuric acid.
  • Page 53 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 54 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, propel- ler, propeller shaft, rudder stock and keel and cause damage by electrolytic corrosion.
  • Page 55 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 56: S Drive And Reverse Gear

    S-drive. Top up oil to correct level through the hole for the oil dipstick. For oil quality and capacity: See the chapter ”Technical Data”. IMPORTANT! If oil is colored gray then water has entered the drive. Please contact an author- ised Volvo Penta workshop.
  • Page 57 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 58 Maintenance: S drive and reverse gear Corrosion protection. Check Check the sacrificial anode () on the drive and the three sacrificial anodes () 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 59 IMPORTANT! The tab washer (3) must be replaced if necessary. Use only Volvo Penta original locking screws (4). 4. Install one propeller blade in the propeller hub and push in the stud () in such a position so the groove in the stud is exactly centered in the hole for the locking screw (5).
  • Page 60 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 launch- ing. Vent the bushing by pressing it together while press- ing down on the shaft until water appears.

  • Page 61: 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 com- mission during the winter/off-season.

  • Page 62: 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 63: 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 64: In Case Of Emergency

    In case of emergency Despite regular maintenance according to the maintenance schedule and perfect operation, it may occur faults which must be attended to before the boat can travel further. This chapter contains tips for rectifying some of the possible faults. Starting using auxiliary batteries WARNING! Batteries produce oxyhydrogen.

  • Page 65: 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 66: Technical Data

    When oil quality specifications are joined by ”and” the engine oil must fulfill both requirements. If sulphur content is > .0% by weight, use oil with TBN > 5. ACEA E7 has replaced ACEA E5, but if available ACEA E5 can be used. = Volvo Drain Specification ACEA = Association des Constructeurs Européenne d’Automobiles...

  • Page 67: Electrical System

    Technical Data Cooling system Thermostats, no............ screws The thermostat starts opening at....... 83° ±°C (78-85°F) fully open at .......... 95°C (03°F) Freshwater system capacity, approx......9.5 liters (.5 US gals) Electrical system System voltage ............ V Battery capacity (starter battery) .......
  • Page 68 Notes ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________...
  • Page 69 Notes ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________...
  • Page 70 ✂ Yes please, I would like an operator’s manual in English at no charge. Publication number: 774 7110 Post or fax this coupon to: Document & Distribution Center Name Order Department ARU , Dept. 6460 Address SE-405 08 Göteborg Sweden Fax: +46 3 545 77 Orders can also be placed via the Internet:...
  • Page 71 ✂ Sí gracias, deseo recibir gratuitamente un libro de instrucciones en español. Número de publicación: 774 7114 Franquear o enviar fax a: Document & Distribution Center Nombre Order Department ARU , Dept. 6460 Dirección SE-405 08 Göteborg Suecia Fax: +46 3 545 77 El pedido puede hacerse tam- bién por internet: http://www.volvopenta.com/...
  • Page 72 ✂ Ja graag, Ik wil kosteloos een instructieboek in het Nederlands ontvangen. Publicatienummer: 774 7119 Stuur of fax de coupon naar: Document & Distribution Center Naam Order Department ARU , Dept. 6460 Adres SE-405 08 Göteborg Zweden Fax: +46 3 545 77 U kunt ook bestellen via internet: http://www.volvopenta.com/...
  • Page 73 ✂ Sim, obrigado(a)! Gostaria de receber gratuitamente um manual de instruções em português. Número de publicação: 774 7120 Envie o talão pelo correio ou um fax para: Nome Document & Distribution Center Order Department Endereço ARU , Dept. 6460 SE-405 08 Göteborg Suécia Fax: +46 3 545 77 A encomenda também pode...
  • Page 74 ✂ Evet lütfen, ücretsiz Türkçe kullanım el kitabı istiyorum Yayın numarası: 7747121 Bu kuponu şu adrese postalayın veya fakslayın: Ýsim Dokument & Distribution center Ordermottagningen Adres ARU , Avd. 6460 SE-405 08 Göteborg Ýsveç Faks: +46 3 545 77 Sipariþler Ýnternet üzerinden de Ülke verilebilir: http://www.volvopenta.com/...

This manual is also suitable for:

D2-55D2-75

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