Instruction/ maintenance manual of the product D2-55 Volvo
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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.
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.
2 Safety Information ............................................... 3 – 7 Introduction ......................................................... 8 – 9 Running-in ............................................................ 8 Fuel and oil types ..
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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.
27 Maintenance schedule Daily before starting for first time ● Engine and engine room. General inspection .................................................. page 29 ● Engine oil. 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 ............
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.
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.
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.
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”.
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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”.
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.
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).
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.
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.
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”.
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.
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 .
57 T echnical Data General Engine designation .................................................. D2-55 A D2-75A No. of cylinders ....................................................... 4 4 Cylinder bore ................................................
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.
59 ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ _.
60 ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ _.
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.
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.
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.
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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.
An important point after buying a device Volvo D2-55 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Volvo D2-55 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Volvo D2-55 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Volvo D2-55 you will learn all the available features of the product, as well as information on its operation. The information that you get Volvo D2-55 will certainly help you make a decision on the purchase.
If you already are a holder of Volvo D2-55, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Volvo D2-55.
However, one of the most important roles played by the user manual is to help in solving problems with Volvo D2-55. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Volvo D2-55 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
