Volvo D2-75 manual

OPERA T OR ’S MANU AL D2-55, D2-75[...]

This operator’s manual is also available in the following languages: Diese Betriebsanleitung ist auch auf Deutsch erhältlich. Ein Bestellcoupon ist am Ende der Betriebs- anleitung zu finden. Ce manuel d’instructions peut être commandé en français. Vous trouverez un bon de commande à la fin du manuel d’instructions. Este libro de instrucc[...]

1 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 [...]

2 Safety Information ............................................... 3 – 7 Introduction ......................................................... 8 – 9 Running-in ............................................................ 8 Fuel and oil types ................................................ 8 Certified engines ................................[...]

3 Safety Precautions Read this chapter carefully. It concerns your safety. This chapter describes how safety information is presented in the Operator's Manual and on the engine itself. It also gives a general account of basic safety precautions to be taken when operating the boat and maintaining the engine. Check that you have the correct Oper[...]

4 Safety precautions to be taken when operating the boat Your new boat Read Operator's Manuals and other information supplied with your new boat. Learn to operate the engine, controls and other equipment safely and correctly. If this is your first boat, or is a boat type with which you are not familiar, we recommend that you practice controlli[...]

5 Carbon monoxide poisoning When a boat is moving forward backwash is caused behind the boat. Sometimes this backwash can be so powerful that exhaust gases can be sucked into the cabin or seating well on the boat with the resulting risk of carbon monoxide poisoning for those on boar d. The backwash problem is greatest with high, broad boats with a [...]

6 Safety precautions for maintenance and service operations Preparations Knowledge The Operator's Manual contains instructions on how to carry out general maintenance and service operations safely and correctly. Read the instructions carefully before starting work. Service literature covering more complicated opera- tions is available from you[...]

7 Hot surfaces and fluids There is always a risk of burns when working with a hot engine. Beware of hot surfaces. For example: the exhaust pipe, turbocharger (TC), oil pan, charge air pipe, starter element, hot coolant and hot oil in oil lines and hoses. Carbon monoxide poisoning Start the engine only in a well-ventilated area. If operating the eng[...]

8 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. Alw[...]

9 Certified engines It is important to be aware of the following information if you own or run an engine that is exhaust emission certified: Certification means that an engine type is inspected and approved by the authorities. The engine manufac- turer guarantees that all engines manufactured of that type correspond to the certified engine. This pl[...]

10 Presentation D2-55 with reverse gear HS25A 1 5 7 D2-55 with reverse gear HS25A 15 14 9 2 3 13 10 6 4 8 11 12 D2-55 with reverse gear MS25L 5 3 2 D2-55 with reverse gear MS25L 13 12 15 6 11 1 14 7 8 10 9 4 7742957 - www.volvopenta.com 22/09/2008 11:33:23[...]

11 1. Coolant filler cap 2. Heat exchanger 3. Relay box with fuses 4. Generator 5. Starter motor 6. Oil cooler, reverse gear 7. Dipstick, reverse gear/S-drive 8 . Air cleaner (ACL)/Air intake 9 . Dipstick, engine 10. Oil filler cap, engine 11. Fuel pump 12. Oil filter 13. Fuel filter 14. Injection pump 15. Seawater pump 16. Cooling water intake, S-[...]

12 D2-75 with reverse gear HS25A D2-75 with reverse gear HS25A D2-75 with reverse gear MS25L 7 23 D2-75 with reverse gear MS25L 6 1 8 5 4 15 14 17 13 16 9 10 12 11 7 23 9 1 8 5 4 17 16 11 15 12 6 10 13 14 Presentation 7742957 - www.volvopenta.com 22/09/2008 11:33:23[...]

13 1. Coolant filler cap 2. Relay box with fuses 3. Heat exchanger 4. Charge air cooler 5. Turbo 6. Oil cooler, reverse gear 7. Starter motor 8. Generator 9. Dipstick, reverse gear/S-drive 10. Air cleaner (ACL)/Air intake 11. Dipstick, engine 12. Oil filler cap, engine 13. Fuel pump 14. Oil filter 15. Fuel filter 16. Injection pump 17. Seawater pum[...]

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

15 Instrumentation 67 3 8 15 2 4 9 39 4 15 2 This chapter only describes the instrument panels available as standard alternatives for your engine from Volvo Penta. Note that in certain boats instruments, alarm panels, key switches etc. may be installed separately without the instrument panels shown here. If you want to install additional instrument[...]

16 12 14 13 10 15 11 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. I I = Glow plug position. The glow plugs are connected and pre-heating the engine. I I I = Start position. The starter motor is engaged. IMPORTANT! Read the s[...]

17 18 20 19 16 21 17 Instrument panel with electrical start/stop function The instrument panel does not have an ignition switch. To stop unauthorized persons starting the engine the wheelhouse should have a lock or a lockable main switch should be used. 16 . Tachometer and hour counter (accessory). Displays engine speed. Multiply this value by 100 [...]

18 26 27 28 29 23 24 22 25 Warning display If the acoustic alarm sounds, one of the three warning lamps (16-18) on the instrument panel starts to flash to indicate the source of the alarm. 22 . Engine coolant temperature too high. IMPORTANT! If the alarm sounds: Reduce engine speed to idle (neutral). Stop the engine if the temperature does not drop[...]

19 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. A neutral position switch is available as an accessory, this will only permit the engine to be started wi[...]

20 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. Before starting ● Open the co[...]

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. WARNING! Make sure that the gear shift function is disconnec- ted. If the engine i[...]

22 Starting. Instrument panel without ignition switch WARNING! Never use start spray or similar to start the engine. Danger of explosion! 1. If the engine is cold: Disconnect the gear shift function and move the control lever forwards to half throttle. WARNING! Make sure that the gear shift function is disconnec- ted. If the engine is warm: Move th[...]

23 Starting using auxiliary batteries WARNING! Batteries produce oxyhydrogen. This gas is easily ignited and highly volatile. A short-circuit, naked flame or spark can cause a large explosion. Ensure that the ventilation is good. Never mix up battery positive and negative terminals. This may cause sparks and an explosion. 1. Check the auxiliary bat[...]

24 Operation BAC Avoid violent and unexpected changes in course and gear engagement. There is a risk that someone aboard will fall over or overboard. WARNING! A rotating propeller can cause serious injury. Check that nobody is in the water before engaging ahead or astern. Never drive near bathers or in areas where people could be in the water. Chec[...]

25 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. 2. Move the reverse gear control lever quickly and firmly in[...]

26 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. Stopping If the boat is fitted with a stop control: Pull and hold out the stop control until[...]

27 Maintenance schedule Daily before starting for first time ● Engine and engine room. General inspection .................................................. page 29 ● Engine oil. Checking level .............................................................................. page 32 ● Coolant. Checking level .....................................[...]

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

29 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 [...]

30 Drive belt. Adjusting and replacing WARNING! Always turn the engine off before starting maintenance work. IMPORTANT! Tighten screw (1) to 50 Nm. Check and adjust as necessary after operating the engine when the belts are warm. It should be possible to depress a belt at the correct tension approx. 10 mm between the pulleys using normal thumb pres[...]

31 Idling. Adjustment For engine idling speed: Please refer to the Technical Data chapter. A lower engine speed can cause the engine to stall and a higher engine speeds can cause extra stresses to the drive/reverse when shifting. Adjust with the engine at operating temperature as follows: 1* Set the control lever in the neutral position. Check that[...]

32 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”. Oil level. Checking and topping up The oil lev[...]

33 Coolant. General The freshwater system must be filled with a coolant that protects the engine against internal corrosion and from freezing, if the climate requires it. IMPORTANT! Never use water alone. If the freshwater system is filled with antifreeze mixture it must be changed every other year. If the system is filled with anti-corrosion agent[...]

34 In there is no of risk of freezing When there is never a risk of freezing water may be used as coolant with addition of Volvo Penta anti corrosion agent. Mix according to the instructions on the packaging. Warm up the engine after filling to allow the additive to work as efficiently as possible. If operating hours exceed 600 hours per annum the [...]

35 Coolant. Changing The corrosion-proofing additives become less effec- tive with time and the coolant must be changed. If the freshwater system is filled with antifreeze mixture it must be changed every other year. If the system is filled with anti-corrosion agent mixture it must be changed every year. Drain off the coolant and clean the heat exc[...]

36 Impeller. Checking/Replacing WARNING! Risk for water penetration. Close the sea cock. Close the sea cock. Remove cover (1) on the seawater pump. Remove impeller (2). If there are cracks or other defects the impeller must be re- placed. Lubricate the pump housing and the inside of the cover with a little waterproof grease for rubber . Reinstall t[...]

37 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. Clean all the parts. Turn the cover upside down. Install the membrane first and[...]

38 Seawater system. Flush cleaning and corrosion inhibition When laying up during winter (or out of season), the seawater system must be flushed clean of all depos- its and salt crystals. It must also be treated to pro- tect against internal corrosion. WARNING! Risk of water penetration. This work must be carried out with the boat on dry land. Appr[...]

39 MS25S / 150S 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[...]

40 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 caus[...]

41 Fuel pre-filter. Draining and replacing filter insert Draining The fuel pre-filter is an optional extra. P osition a container under the fuel filter. Drain off water and contaminants using the cock/plug at the bottom of the filter bowl. IMPORTANT! Wait a few hours after the engine has been turned off before draining the filter. Replacing filter [...]

42 Electrical system WARNING! Always stop the engine and break the current using the main switches before working on the electrical system. Isolate shore current to the engine block heater, battery charger, or accessories mounted on the engine. Main switch The main switch must never be turned off before the engine has stopped. If the circuit betwee[...]

43 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. Protect your skin and clothes whe[...]

44 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. WARNING! The battery electrolyte contains extremely corrosive sulfuric acid. [...]

45 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. IMPORTANT! Work on the boat’s[...]

46 5. If an auxiliary battery is in use, a main switch (D) should be connected between its + terminal and the fuse block. The main switch for the auxiliary battery must cut off all power consuming equip- ment connected to that battery and be turned off when power is no longer needed. All equipment connected to the auxiliary battery should have sepa[...]

47 Electrical components diagram 1. Engine coolant temperature sensor D2-55 (optional extra) 2. Coolant temperature switch D2-55 3. Engine coolant temperature sensor D2-75 4. Coolant temperature switch D2-75 5. Fuses 6. Starter relay 7. Glow plug relay 8. Ballast resistor 9. Engine speed sensor 10 . Starter motor 11. Generator 12 . Glow plugs, 4 st[...]

48 S drive and reverse gear The S drive and in certain cases the propeller (reverse gear) is equipped with a sacrificial anode which prevents galvanic corrosion. Faulty electrical installation can also cause the break down of the galvanic protection. Damage due to electrolytic corrosion occurs rapidly and is often extensive. For further information[...]

49 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”. IMPORTANT! Never overfill reverse gear. The oil level should always lie at the recommen[...]

50 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. Remedy any paintwork damage on the d[...]

51 Removing 1. Set the control lever in the ”Ahead” position. 2. Remove the propeller blade by first undoing the locking screws (5) completely and then pressing out the shaft studs (1). 3. Drive: Bend down the tabs of the tab washer (3) and remove the locking screw (4), tab washer and nut (6). Reverse gear: Remove the nut (7), washer (8) and th[...]

52 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. 1 cc water repellent grease into the seal. IMPORTANT! The seal must be replaced every [...]

53 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. It is important this[...]

54 Bringing out of storage ● Check oil level in the engine and drive/reverse gear. Top up if necessary. If there is inhibiting oil in the system drain and fill with new oil, change oil filter. For correct oil grade: See the chapter ”Tech- nical Data”. ● Drain the antifreeze from the seawater system. ● Install the impeller in the seawater [...]

55 P ainting the drive and underwater hull General 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[...]

56 1 . Discharged battery 2 . Loose connection/open-circuit 3 . Fuse tripped 4 . Stop control pulled out 5. Inadequate pre-heating 6 . Lack of fuel 7 . Fouled fuel filter 8 . Air in the fuel injection system 9 . Water/contaminants in the fuel 10 . Boat abnormally loaded 11 . Fouling on underwater hull/drive/ propeller 12 . Limited speed control lev[...]

57 T echnical Data General Engine designation .................................................. D2-55 A D2-75A No. of cylinders ....................................................... 4 4 Cylinder bore ............................................................ 84 mm (3.31 in) 84 mm (3.31 in) Cylinder stroke ......................................[...]

58 Fuel specification Fuel must meet national and international standards at least. For example: EN 590 (with national environmental and cold standards) ASTM D 975 No 1-D and 2-D JIS KK 2204 Sulphur content: According to statutory requirements. Fuels with low density (“urban diesel” in Sweden and “city diesel” in Finland) can cause a drop i[...]

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61 NB! This offer is valid for a period of 12 months from delivery of the boat. Availability after this period will be as far as supplies admit. Post or fax this coupon to: Document & Distribution Center Order Department ARU 2, Dept. 64 620 SE-405 08 Göteborg Sweden Fax: +46 31 545 772 Orders can also be placed via the Internet: http://www.vol[...]

62 Si ricorda che l’offerta è valida per 12 mesi dalla data di consegna dell’imbarcazio- ne; dopo il suddetto periodo l’offerta resta valida solo in base alla disposizione della pubblicazione in oggetto. Spedire il tagliando per posta o per fax a: Document & Distribution Center Order Department ARU 2, Dept. 64 620 SE-405 08 Göteborg Sve[...]

63 Denk eraan dat het aanbod geldt gedurende 12 maanden na de datum waarop de boot werd afgeleverd, daarna alleen indien nog verkrijgbaar. Stuur of fax de coupon naar: Document & Distribution Center Order Department ARU 2, Dept. 64 620 SE-405 08 Göteborg Zweden Fax: +46 31 545 772 U kunt ook bestellen via internet: http://www.volvopenta.com/ m[...]

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7742957 - www.volvopenta.com 22/09/2008 11:33:23[...]

7742957-9 English 06-2003 AB Volvo Penta SE-405 08 Göteborg, Sweden www.volvopenta.com[...]