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Maintenance: Electrical system

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 between the 
generator and the battery is cut off when the engine 
is running the generator can be seriously damaged. 
For the same reason charging circuits must never be 
switched over while the engine is running.

 

IMPORTANT!  Never break the circuit with the 
main switches while the engine is running.

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).

Summary of Contents for D2 Series

Page 1: ...OPERATOR SMANUAL D2 ...

Page 2: ... può esse re ordinato in lingua italiana Il tagliando per l ordinazione è riportato alla fine del manuale Dit instructieboek kan worden besteld in het Nederlands De bestelcoupon vindt u achter in het instruc tieboek Denne instruktionsbog kan bestilles på dansk Bestillingskupon findes i slutningen af instruk tionsbogen Tämän ohjekirjan voi tilata myös suo menkielisenä Tilauskuponki on ohjekirjan lo...

Page 3: ...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 We also believe that this is what you demand and expect of your Volvo Penta engine We would like you to read this operator s manual thoroughly and consider the advice we give on running and maintenance before you cast off on your maiden voyage so that ...

Page 4: ...ing up 33 Cold weather precautions 33 Maintenance schedule 34 Maintenance 36 Engine general 36 Lubrication system 39 Freshwater system 40 Seawater system 43 Fuel system 47 Electrical system 49 S drive and reverse gear 54 Laying up Launching 59 Inhibiting 59 Bringing out of storage 60 Painting the drive and underwater hull 61 In case of emergency 62 Starting the engine using auxiliary batteries 62 ...

Page 5: ... Penta dealer for assist ance This symbol is used in the book and on the engine to make you aware of safety information Always read these safety precautions very carefully In the Operator s Manual warning texts have the following priority WARNING If these instructions are not followed there is a danger of personal injury exten sive damage to the product or serious mechanical malfunction IMPORTANT ...

Page 6: ...engine and engine compartment visually before operating the boat be fore the engine is started and after operating the boat after the engine has been stopped This will help you to quickly detect fuel coolant and oil leaks and spot anything else unusual that has or is about to happen Maneuvering Avoid violent and unexpected changes in course and gear engagement This could cause someone on the boat ...

Page 7: ... rigged Contact the dealer where the boat was purchased to get more information on how to solve this problem should it occur on your boat Checklist Safety equipment Life jackets for all passengers communication equipment emergency rockets approved fire extinguisher first aid equipment life belt anchor paddle torch etc Replacement parts and tools impeller fuel filters fuses tape hose clamps engine ...

Page 8: ...ay then be required in order to maintain the correct balance and make the engine safe to han dle Never carry out work on an engine suspended on a hoist Before starting the engine Reinstall all guards removed during service opera tions before starting the engine Check that no tools or other items have been left on the engine Never start a turbocharger engine without installing the air cleaner ACL T...

Page 9: ...cause burns If work must be carried out with the engine at operat ing temperature and the coolant filler cap or a cock open or a coolant hose disconnected open the cool ant filler cap carefully and slowly to release pressure before removing the cap completely Note that the coolant may still be hot and can cause burns Lubrication system Hot oil can cause burns Avoid skin contact with hot oil Ensure...

Page 10: ...ays leave hazardous waste such as waste oil coolant paint and wash residue flat batteries etc for disposal at a destruction plant Our joint efforts will make a valuable contribution to our environment Running in The engine must be run in for its first 10 operating hours as follows Operate the engine normally Do not operate it at full load except for short periods Never run the engine at a constant...

Page 11: ...rwise the general instructions contained in the Operator s Manual concerning operation service and maintenance must be followed IMPORTANT Late or inadequate maintenance service or the use of spare parts not approved by Volvo Penta will invalidate AB Volvo Penta s responsibility for the engine specification being in accordance with the certificated variant Volvo Penta accepts no responsibility or l...

Page 12: ...clared in conformity with the relevant provisions of the above mentioned Directives Name and function Sam Behrmann Product Liability Signature and title identification of the person empowered to sign on behalf or an equivalent marking of the engine manufacturer or his authorised representative Date and place of issue yr month day 2006 04 27 Göteborg Body for exhaust emission assessment NKIP Nipkow...

Page 13: ...f identification plates is shown below The figures in brackets refer to the location of the identification numbers on the identification plate Engine plate 1 Product designation 1 Serial number 2 Product number 3 Certification number 4 XXXXXX 7 XXX 5 XXXXXXXXXX 6 XX 8 1 2 3 Engine and transmission decal 2 Product designation 1 Serial number 2 Product number 3 Produktbeteckning 5 Utväxling 6 Serien...

Page 14: ...entation D2 55 with reverse gear MS25L 7 3 2 D2 55 with reverse gear MS25L 15 14 17 6 13 1 16 9 10 12 11 8 D2 75 with reverse gear HS25A D2 75 with reverse gear HS25A 7 2 3 9 1 8 5 4 17 16 11 15 12 6 10 13 14 ...

Page 15: ...ir intake 11 Dipstick engine 12 Oil filler cap engine 13 Fuel pump 14 Oil filter 15 Fuel filter 16 Injection pump 17 Seawater pump 18 Cooling water intake S drive 19 Sea cock S drive 20 Folding propeller 21 Sacrificial anodes 22 Oil drain plug S drive D2 75 with sailing boat drive 150S 20 18 19 14 10 12 9 21 22 11 15 16 17 13 D2 75 with sailing boat drive 150S 7 2 3 1 8 5 4 Presentation ...

Page 16: ... running Start button 4 when this button is pressed the glow function is activated and the starter motor is engaged Multifunction button 2 Alarm acknowledgment If there is an alarm the LCD screen on the tachometer will show a flashing alarm warning and the alarm buzzer sound The alarm is acknowledged by pressing the mul tifunction button The alarm buzzer stops and the alarm warning continues to sh...

Page 17: ...l warning and the alarm buzzer sound Tachometer LCD screen Fuel level Stop Crank Preheat Symbols for operating information The Preheat symbol will show when the glow func tion is activated The Crank symbol will show when the starter motor is engaged The Stop symbol will show when the stop button is pressed The Fuel level symbol will show when 20 or less of usable fuel remains in the tank NOTE The ...

Page 18: ...ater system Oil pressure Voltage Coolant temperature Oil pressure If the oil pressure shows during operation the oil pressure in the engine is too low Stop the engine at once WARNING Continued operation when the oil pressure is too low can cause serious engine damage Check the oil level in the engine Please refer to Maintenance Lubrication system to check and top the oil up Also check that the oil...

Page 19: ...d If a fault occurs the associated lamp on the alarm display will light up the Tachometer LCD screen will show an alarm warning and the alarm buzzer sound NOTE Warning lamps should never light up during operation Alarm display Voltmeter The operating charge volatage is approx 14 V When the engine is stopped battery voltage is approx 12 V Coolant temperature Normal operating temperature is between ...

Page 20: ...s in the tank NOTE The engine has to run at least one minute be fore this function is activated Oil pressure red indication If the oil pressure lamp lights up during operation the oil pressure in the engine is too low Stop the engine at once WARNING Continued operation when the oil pressure is too low can cause serious engine damage Check the oil level in the engine Please refer to Maintenance Lub...

Page 21: ...s up when the coolant temperature is too high 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 Check the coolant level Please refer to Mainte nance Freshwater system WARNING Do not open the coolant filler cap when the engine is warmcould cause serious engine and personal damage Steam or ho...

Page 22: ...just the display contrast and to access the configuration menu It can be used to make display settings amongst other things The configuration menu can also show display mode SYSTEM INFORMATION which is also available via button 2 see diagram below The display mode functions in the same way as the EVC System Tacho meter Before using the display certain display settings must be made To see which set...

Page 23: ... the display does not register the transfer of opera ting information from the electrical system the pop up window CONNECTION LOST flashes When opera ting information has been registered reset the pop up window disappears 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 se...

Page 24: ...S see diagram below NOTE The engine must have the system switched on when you change the display settings or calibrate functions Configuration menu structure System information Language 8 available Click sound ON OFF Engine PORT STARBOARD TWIN SINGLE Engine series D1 D2 D2 Settings GLOBAL LOCAL Display Units Calibration Depth offset Speed Settings System Engine 2500 rpm 9000 rpm in stages of 500 r...

Page 25: ...asurement intervals of the speedometers and tachometers Rpm engine 2500 rpm 9000 rpm in steps of 500 rpm Set to 4000 rpm Speed Change speed display on off Speed 10 KNOT 100 KNOT in steps of 10 in current measurement unit for speed Graph interval 2 MIN 10 MIN 30 MIN 60 MIN 2 H 4 H 8 H Display mode System Information SYSTEM INFORMATION is a display mode that functions in the same way as the EVC Syst...

Page 26: ...ted Perform speed calibration when the boat is moving Compare the sensors speed value SPEED DATA with the GPS speed value or another boat with the same speed and adjust the calibration value CALI BRATION so that the correct speed value is shown on the DISPLAY Calibration value CALIBRATION for the boat s speed sensor can be adjusted upwards or downwards in steps of 0 01 unit or 1 The adjusted value...

Page 27: ...nt temperature instead System The SYSTEM menu is to give necessary functions and information to service technicians Demo Switch between demo mode ON OFF The display is in normal operating mode when demo is OFF Com Viewer Shows the latest messages recei ved on the communication inputs Prog tx Transfers the content of the application program on flash memory to other CANtrak units on the same CANbus ...

Page 28: ...em in the boat and the sensors that the boat is equipped with Optional sen sors include depth sounder water temperature and speed Note The following applies for standard instrument display The maximum engine speed range can be set on the configuration menu The voltage range can be 8V 16V and is changed automatically depending on the latest data value Press button 5 to choose setting mode Buttons 1...

Page 29: ...ion Adjust the friction brake Turning the screw clock wise makes the lever movement stiffer while turning counterclockwise makes it easier to move the lever Reinstall the cover and lever Maneuvering Shifting and engine speed are controlled with the same lever 1 N Neutral position Drive reverse gear disengaged F Drive reverse gear engaged for movement ahead R Drive reverse gear engaged for movement...

Page 30: ...ake sea cock Open fuel valve Carry out the actions in the Daily before the first start up section in the maintenance schedule Switch on the main switch IMPORTANT Never break the circuit with the main switch while the engine is running This could damage the generator Start the engine compartment fan if one is fitted and let it run for at least four minutes Check that there is sufficient fuel Starti...

Page 31: ...ess will only run if the engine tem perature is less than 50 C Read the instruments and warm the engine up Allow the engine to idle for the first ten seconds and check that instruments and warning displays show normal values Check that no warning lamps flash on the alarm display Then warm the engine up at low speed and low load so that reaches normal operating temperature before full power is used...

Page 32: ...then at regular intervals while driving the boat Stop the engine if there is an abnormal reading or any warning lamp comes on and the alarm sounds For engines with measuring instru ments the following standard values apply Cruising speed 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 ra...

Page 33: ...firmly into astern then increase the speed When sailing When sailing the control lever should be in the neutral position if the boat is equipped with HS25 reverse gear If the boat is equipped with S drive or MS25 reverse gear the control lever should be the reverse position if a folding propeller is used and in neutral position if a fixed propeller is used Trolling operation valve HS25 reverse gea...

Page 34: ...ore infor mation about the warning icons and the alarm display indicator lights 1 Reduce engine speed to idling 2 Acknowledged the alarm by pressing the multi function button 1 The alarm buzzer stops and the warning icon continues to show in a steady light until the malfunction is corrected Please refer to the Instrumentation chapter where you will find information about the alarm symbols Tachomet...

Page 35: ...ntenance schedule Switch off the main switch if the boat is not to be used for some time IMPORTANT Never break the circuit with the main switches while the engine is running This could damage the generator Cold weather precautions To prevent freezing damage the seawater system must be drained and the freshwater system coolant must have sufficient antifreeze protection See chap ter Maintenance Cool...

Page 36: ...ational disturbances Warranty inspection The prescribed warranty inspection First Service Inspection must be carried out at an authorised Volvo Penta workshop during this first period of operation Directions for when and how this is to be carried out can be found in the Warranty and Service Book Extended Protection Volvo Penta offers an Extended Protection for your marine diesel engine including t...

Page 37: ...Engine oil Replace page 39 Oil filter Replace page 39 Fuel filter Replace page 48 Fuel pre filter Replace page 48 Idling speed Check page 38 Seawater pump Check impeller page 43 Vacuum valve Cleaning page 44 Every 500 operating hours or at least once every two years Air Cleaner ACL Cleaning page 38 Coolant Replace page 42 Heat exchanger Cleaning page 42 Injectors Test pressure not shown Valve clea...

Page 38: ...visually inspecting the engine and engine room before starting the engine and after stopping when the engine has been turned off This will help you to quickly detect abnormalities that have occurred or are about to occur Look especially carefully for oil fuel and coolant leaks loose bolts worn or slack drive belts loose connections damaged hoses and electric cables This inspection takes only a few...

Page 39: ...screws 1 3 Check the tension To replace the belt slacken off screws 1 and 2 Press the generator in towards the cylinder block so that the belt can be removed Clean off the pulley grooves Install the new belt Adjust as above Check belt tension again after a few hours operation Drive belt Check The belt drives both the circulation pump and the generator A belt that is too loose can result in slip pa...

Page 40: ...osi tions 2 Start engine and allow to idle with gear selector in neutral WARNING Approaching or working on a run ning engine is dangerous Watch out for rotating components and hot surfaces 3 Slacken off locknut D Adjust engine speed with adjustment screw E Tighten the locknut Repeat step 1 Air Cleaner ACL Cleaning Remove the hose clamp 1 and remove the filter Remove the spring inside the filter Cl...

Page 41: ...NT Do not fill the oil above the MAX level Oil and oil filters Changing 1 Run the engine to operating temperature so that the oil is easier to suck out Stop the engine 2 Suck out the oil using an oil drain pump through oil drain pipe WARNING Hot oil and hot surfaces can cause burns 3 Unscrew the old filter To avoid oil spills put a plastic bag over the filter before it is unscrewed 4 Check that th...

Page 42: ...self as coolant IMPORTANT Coolant must be used all year round This applies even if there is never any risk for frost to ensure that the engine has an adequate protection against corrosion Future warranty claims on the engine and additional equipment may be rejected if an unsuitable coolant has been used or if the instructions concerning coolant mixing have not been followed NOTE The anti corrosive...

Page 43: ...increase the risk of overheating and will give reduced freezing protec tion IMPORTANT Coolant must be mixed with pure water use distilled de ionized water The water must fulfill the requirements specified by Volvo Penta see Water quality IMPORTANT It is extremely important that the correct concentration of coolant is added to the system Mix in a separate clean vessel before adding into the cooling...

Page 44: ...er which runs out of the drain tap and the engine block is clean Let all the water run out 3 Close the drain tap and the drain plug Fill up with coolant to the correct level Put the filler cap back 1 2 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 spray out Turn the filler...

Page 45: ... the drive after which the water passes the sea water filter optional extra before it is pumped through the heat exchanger Finally the water is pumped out into the exhaust elbow pipe where it is mixed with the exhaust gases On engines with a reverse gear the sea water pump suck in water via the sea water inlet after which the water passes the sea water filter optional extra and the reverse gear oi...

Page 46: ... membrane first and then the gasket Turn the valve housing upside down as well Screw the cover into position but not too hard 0 2 kpm or the valve may stop working Seawater filter Cleaning The seawater filter is an accessory Screw off cover 1 and remove seal plate 2 Lift out and clean the insert 3 IMPORTANT If the boat is used in water that has a lot of contaminants seaweed etc the filter must be ...

Page 47: ...e is equipped with such a filter 3 Place the free end of the hose in a bucket of fresh water Fill the system IMPORTANT The impeller will be damaged if it runs dry 4 Check that there is nobody close to the propeller and there is nothing that will get splashed behind the exhaust outlet 5 Set the control lever to neutral Start the engine Let the engine run at fast idle for a few minutes Stop the engi...

Page 48: ...cover and sealing plate on the sea water filter 2 3 Remove the cover 3 from the seawater pump Let the water run out 4 Open the drain cock 4 on the rear end of the heat exchanger and drain the water off D2 75 Open the drain cock on the charge air cooler 9 draining the water 5 Disconnect the hoses where indicated by the ar rows 5 Drain the hoses 6 Open the drain plug 6 on the reverse gear oil cooler...

Page 49: ...lling the fuel tank after it has been run dry 1 Open vent screw 1 on the filter mounting approx three turns Avoid fuel spillage Use rags around the venting point 2 Pump the fuel using hand pump 2 until there are no more air bubbles visible in the fuel Continue pumping and at the same time tighten the venting screw There is a strainer 3 in the intake manifold for the pump The strainer does not norm...

Page 50: ...fuel system Deposit the old filter insert at a properly designated dis posal site Start the engine and check for leaks WARNING Approaching or working on a run ning engine is dangerous Watch out for rotating components and hot surfaces 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 r...

Page 51: ... stopped If the circuit between the generator and the battery is cut off when the engine is running the generator can be seriously damaged For the same reason charging circuits must never be switched over while the engine is running IMPORTANT Never break the circuit with the main switches while the engine is running Electrical connections Also check that all electrical connections are dry and free...

Page 52: ...thout delay Connecting and disconnecting First connect the red battery lead to the battery terminal Then connect the black battery lead to the battery terminal When disconnecting the battery disconnect the lead black first and then the lead red Cleaning Keep batteries dry and clean Oxidation or dirt on the battery and battery terminals can cause short circuits voltage drop and discharge especially...

Page 53: ...he battery has discharged it must be charged f the boat has not been used for some time charge the battery and then trickle charge it see manufacturer s recommendations A poorly charged battery will be damaged and may burst in cold weather IMPORTANT Follow the instructions supplied with the battery charger carefully To avoid elec trolytic corrosion when an external charger is connected always disc...

Page 54: ...lt circuit breaker Shore power units transformer rectifier battery chargers etc must be intended for marine usage and the high tension circuit must be galvani cally separated from the low tension circuit 2 Route and clamp electric cables so that they will not be exposed to rubbing damp or bilge water in the keelson 3 The S drive is electrically isolated A from the engine and must never be used as ...

Page 55: ...ch 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 separate switches To simultaneously charge two independent battery circuits fit a Volvo Penta charge distributor ac cessory to the regular generator D ...

Page 56: ... oil as required using the dip stick tube For oil quality and capacity See the chapter Technical Data IMPORTANT Do not overfill under any circum stances The oil level must always be within the recommended level Oil change S drive Remove the oil dipstick Remove the plug on the propeller gear housing and let the oil run out Check that the plug o ring is intact Replace if necessary Install the plug a...

Page 57: ...key Remove lid 2 Replace and oil in the new O rings in the lid 3 Lift up the filter 3 4 Suck up the oil with an oil drain pump via the oil filter housing Connect hose to the suction pipe 4 at the bottom of the housing 5 Measure up the correct quantity of oil and fill the reverse gear with the oil via the oil filter housing Please refer to the Technical Data chapter for oil grades and volume IMPORT...

Page 58: ...ew sacrificial anodes Tighten the ano des so that there is a good metal contact 5 Reinstall the propeller The sacrificial anodes oxidise when they come into contact with air This reduces the galvanic protection There may even be oxidisation on the surface of a completely new anode Always clean the sacrificial anodes before launching the boat IMPORTANT Use emery paper Do not steel tools when cleani...

Page 59: ...he washer 8 and tighten the nut 7 to 220 Nm Apply thread sealant to the locking screws 9 After the locking screws have been tightened apply thread sealant to the screw heads as well 3 Drive Locate the tab washer 3 on the nut Install and tighten the locking screw 4 to 20 Nm and bend one of the tab washer tabs to the screw head IMPORTANT The tab washer 3 must be replaced if necessary Use only Volvo ...

Page 60: ...ress 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 500 running hours or every 5th year Rubber seal S drive Check the rubber seal between the drive and the hull regularly for cracks and wear WARNING The seal must be changed every seven years or earlier if it is defective This work should be carried ...

Page 61: ...the drive Clean the vacuum valve and seawater filter ac cessory Clean and inhibit the seawater system Remove the impeller from the seawater pump Store the impeller in a sealed plastic bag in a cool place Check the condition of the engine coolant anti freeze Top up if required IMPORTANT An anti corrosion mixture in the engine coolant system provides no protection against freezing If there is any po...

Page 62: ...and tighten hose clamps Check engine coolant level and antifreeze protec tion Top up if necessary Connect the fully charged batteries Paint the drive and hull See next page Check the sacrificial anode on the drive If there is less than 50 of the anode left it must be replaced Clean with emery cloth just before the boat is launched IMPORTANT Do not use a wire brush or other steel tools when cleanin...

Page 63: ...and it is therefore important that any paint work damage is remedied Sand down metal surfaces lightly using a 120 grade paper and a finer grade for painted surfaces Wash off using thinners or similar Any pores in the surface should be filled and sanded down Paint using Volvo Penta original primer and topcoat Let the paint dry The drive should be painted with Volvo Penta anti fouling to prevent fou...

Page 64: ... s terminal C and then to a site D where there is good contact with the cylinder block as far away from the discharged battery as possible 4 Start the engine and run it at a fast idle for ap proximately ten minutes to charge the battery WARNING Approaching or working on a run ning engine is dangerous Watch out for rotating components and hot surfaces Do not touch the connections while trying to st...

Page 65: ...tat 25 Lubricating oil level too high 26 Generator drive belt slipping 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 Starter...

Page 66: ...ity at 5 50 C SAE 15W 40 SAE 15W 40 SAE 20W 50 SAE 20W 50 Oil drain plug tightening torque 30 40 Nm 22 30 lbf ft 30 40 Nm 22 30 lbf ft Constant ambient air temperature Oil grade 1 Oil change interval reached first in operation 2 VDS 3 or VDS 2 and ACEA E7 3 or VDS 2 and Global DHD 1 500 hr or 12 months or VDS 2 and API CH 4 or VDS 2 and API CI 4 NOTE Mineral based oil either fully or semi syntheti...

Page 67: ...ent 14 V 115 A output approx 1610 W Starter motor output approx 2 0 kW Reverse gear MS25 Type designation MS25L MS25A Gear ratio Left rotating Position B 2 27 1 2 74 1 2 23 1 2 74 1 Right rotating Position A 2 10 1 2 72 1 2 74 1 Angle output shaft 0 8 Oil volume approx 0 75 liters 0 79 US quarts 0 75 liters 0 79 US quarts Oil grade ATF Dexron II III ATF Dexron II III Weight 25 kg 55 lbs 25 kg 55 l...

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