Volvo Penta D1-20 Operator's Manual
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- Workshop manual (137 pages) ,
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Table of Contents
Related Manuals for Volvo Penta D1-20
Summary of Contents for Volvo Penta D1-20
- Page 1 OPERATOR’S MANUAL D1-13, D1-20, D1-30, D2-40...
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Page 2: Proposition 65 Warning
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.
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Page 4: Table Of Contents
Stopping the engine ..........24 After stopping the engine ........24 Laying up ............24 Cold weather precautions ........24 © 2005 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
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 Precautions To Be Taken When Operating The Boat
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.
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Page 8: Fire And Explosion
Volvo Penta Using non-original Volvo Penta parts can result in fire recommend that all servicing with the engine running or explosion on board. -
Page 9: Safety Information
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 Declaration of Conformity for Recreational Craft Propulsion Engines with the exhaust emission requirements of Directive 94/25/EC as amended by 2003/44/EC D1-13, D1-20, D1-30, D2-40 Engine manufacturer: Body for exhaust emission assessment: AB Volvo Penta NKIP Gropegårdsgatan Nipkowweg 9 405 08 Göteborg...
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Page 13: Identification Numbers
Product designation (5) ......................Gear ratio (6) ........................Serial number (7) ......................... Product number (8) ......................Propeller designation ......................Engine and transmission decal D2-40 D1-13, D1-20, D1-30 XXXXXX (7) XXX (5) XX (8) XXXXXXXXXX (6) S-drive and reverse gear Engine plate... -
Page 14: Presentation
Presentation D1-20 with reverse gear MS10A D1-20 with reverse gear MS10A D1-30 with reverse gear MS15A D1-30 with reverse gear MS15A... -
Page 15: Presentation
Presentation D2-40 with sailing boat drive 130S D2-40 with sailing boat drive 130S 1. Coolant filler cap 8. Air cleaner (ACL)/Air intake 15. Seawater pump 2. Heat exchanger 9. Dipstick, engine 16. Cooling water intake, S-drive 3. Relay box with fuses 10. -
Page 16: Instrumentation
If you want to install additional instrumentation, or your boat is equipped with instruments not described here, please contact your Volvo Penta dealer. Instrument panel with ignition switch 1. Tachometer and hour counter (accessory). Dis- plays engine speed. -
Page 17: Instrumentation
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 18 Instrumentation Warning display If the acoustic alarm sounds, one of the three warning lamps (13-15) on the instrument panel starts to flash to indicate the source of the alarm. 13. Engine coolant temperature too high. 14 15 IMPORTANT! If the alarm sounds: Reduce engine speed to idle (neutral).
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Page 19: 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 20: 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 21 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.
- Page 22 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.
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Page 23: 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. -
Page 24: Operation
Operating the engine at full speed should be avoided since it is both uneconomical and uncomfortable. Volvo Penta recommends a cruising speed in the range 500–1000 rpm lower than maximum rpm at full speed. Depending on hull type, choice of propeller, load and conditions etc. -
Page 25: 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 26: 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 27: 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 12 months Warranty Period. - Page 28 Every 200 operating hours or at least once a year, included in Extended Protection D1-13, D1-20, D1-30. Engine oil. Replace ............page 30 D1-13, D1-20, D1-30. Oil filter. Replace ............page 30 Reverse gear. Oil change ................page 48 Reverse gear. Lubricate propeller shaft seal...........page 51 S-drive.
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Page 29: Maintenance And Care
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 30 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 31 Maintenance: Engine, general Air Cleaner (ACL). Changing Loosen the hose clamp (1) and screw (2) to remove the old filter. Fit the new filter and tighten the hose clamp. IMPORTANT! Take care that no contaminants enter the engine. Idling. Adjustment For engine idling speed: Please refer to the Technical Data chapter.
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Page 32: 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 33: Freshwater System
The coolant should contain ethylene glycol of a good quality with a suitable chemical consistency for an adequate 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 34: Water Quality
(18°F). (Using 60 % glycol lowers the freezing point to -54 °C (65°F)). Never mix more than 60 % concentrate (Volvo Penta Coolant) in the cooling liquid, this will give reduced cooling effect and increase the risk of overheating, and will give reduced freezing protection. - Page 35 Maintenance: Freshwater system Coolant level. Checking and topping up WARNING! Stop the engine and allow it to cool before opening the filler cap. Steam or hot coo- lant may spurt out. Hot coolant and hot surfaces can cause burns. Turn the filler cap slowly counter clockwise and let any pressure escape from the system before remov- ing the cap.
- Page 36 Let all the water run out. D1-13 3. Close the drain tap and the drain plug. Fill up with coolant to the correct level. Put the filler cap back. D1-20, D1-30 & D2-40...
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Page 37: 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 38 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 39 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 container. 7. Start the engine and let it idle. Stop the engine just before the mixture is finished.
- Page 40 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 (2), vacuum valve (8), exhaust riser with drain cock (9), silencer (7)
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Page 41: 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 42 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.
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Page 43: 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 is fitted with an automatic fuse. The fuse protects the system and cuts power in the event of an overload. - Page 44 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 45 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 46 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 47 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.
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Page 48: Electrical Components Diagram
Maintenance: Electrical components diagram Electrical components diagram 1. Engine oolant temperature switch D1-13, D1-20 2. Engine oolant temperature switch D1-30, D2-40 3. Engine coolant temperature sensor 4. Alternator 5. Starter motor 6. Glow plugs 7. Engine speed sensor 8. Oil pressure switch... -
Page 49: 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 50 Maintenance: S drive and reverse gear Oil change. Reverse gear 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.
- Page 51 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 52 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 53 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.
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Page 54: 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 55: 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 Check the sacrificial anode on the drive. If there is in the system drain and fill with new oil, change oil less than 50% of the anode left it must be re- filter. -
Page 56: 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 57: 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 Information, before starting work. -
Page 58: Technical Data
30–40 Nm * Constant ambient air temperature Oil grade Oil change interval, reached first in operation VDS-3 D1-13, D1-20, D1-30 D2-40 or VDS-2 and ACEA E7 or VDS-2 and Global DHD-1 or VDS-2 and API CH-4 200 hr. or 12 months. -
Page 59: Electrical System
Technical Data Electrical system System voltage ............12 V Fuses ............... 15A Battery capacity (starter battery) ......70 Ah AC generator voltage/max. current ....... 14V/115A output approx........1610 W Starter motor, output approx........2.0 kW Reverse gear Type designation ............MS10A-B ; MS10L-B MS15A-B ;... - Page 60 Notes ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________...
- 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 5857 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 4849 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 4854 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 4855 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 7745857 English 01-2006...
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Questions and answers
What kind ( brand) oil and it viscosity do I use for D1-20 diesel Volvo marine engine
Hei? Har oppdaget at det er litt formye olje på motoren. Hvordan får jeg pumpet ut overflødig olje. ? Hvor gjøres dette? Gjelder en Volvo Penta D1-20. Finner ikke noe sted hvor jeg får dyttet inn avsug slangen. Mvh Harald
Should I tighten the screws to the oil pan with a torque wrench? If so, witch moment?