Volvo penta d2-55 user manual

Comfort Smooth running with low vibration levels is achieved through a dynamically-balanced design incorporating highly efficient rubber isolation. Marine torque This engine delivers high torque at low rpm. Solid and robust engine package With a rigid engine block and a one-piece cylinder head, this Volvo Penta marine diesel engine is designed and built to be immensely strong.

Efficient charging High-capacity charging is standard. Freshwater cooling The engine is fitted with freshwater cooling as standard. Long service life A propulsion system from Volvo Penta is easy to maintain. Close Volvo D2. Product leaflet PDF, Product bulletin D PDF, Bulletin produit D PDF, Produktflyer PDF, Produktbulletin D PDF, Opuscolo prodotto PDF, Check that the start spring is in position in the timing gear cover and is connected to the regula- tor arm link arm.

Page 47 Group 21 Short block 4. Dip them completely even bolt heads in rust pre- ventative and let them run off on a net. The bolts should have stopped dripping when they are installed otherwise oil cold may well up and be regarded as leakage.

Page 48 Connect the battery cables. Open the fuel taps and the sea cock. Start the engine and check carefully that no leakage occurs. Page Valve Lifters, Inspection Group 21 Short block Camshafts and valve lifters, inspection Check, using a steel ruler 1 , that valve lifter contact surface facing the camshaft is convex or flat.

If the surface is concave, change the valve lifter. If the valve lifter is worn all across the lifting surface, the valve lifter should be scrapped. Page 50 Group 21 Short block Acceptable wear. The camshaft does not need to be changed. Unacceptable wear. Camshaft with associated rocker arms must be replaced. The clearances shall never be checked while the engine is running, but on a stationary cold engine.

Valve clearances: Inlet and exhaust: 0. Remove the valve cover. Turn the engine in normal direction of rotation until no. Mark the flywheel position on the crankshaft simplifies installation. Page 54 Group 21 Short block 3.

Inspection of oil pump 1. Page 55 Group 21 Short block Installing the oil pump Gears that are of importance in the timing gear as- sembly are marked as follows: Crankshaft gear 1 and idler gear 2 are marked with a punch mark. Page Oil Channels Group 21 Short block 6. Install a new gasket on the timing cover. Page Oil Pump Bearing, Overhaul Oil pump bearing, overhaul Special tools: In order to remove the oil pump, the timing gear and crankshaft must be removed.

Drive out the oil pump bearing section 1 located in the engine block. Tap it out from inside the crankcase.

Page Setting Injection Timing Group 23 Fuel system Installing the injection pump Check that the pump is free from faults and if neces- sary has been tested and approved before installation. Do not remove the protective plugs before the pipes are to be connected. Page 60 Group 23 Fuel system 4.

Connect a fuel container with stopcock to the inlet of the injection pump. It should hold about 0. Use the hose between the fuel filter and the injection pump to connect the fuel container. If ev- erything is correctly arranged, fuel should start to run out of the drop pipe. Clean around the pump. Close the fuel taps. Loosen the fuel connections from the pump. Remove the feed pump from the cylinder block.

Empty the pump from fuel. Disassembly and inspection of the feed pump 1. The glow plugs are activated at the same time as the starter motor. You can save the batteries if the starter motor is only used for short periods when priming. D A, B Page 64 Tighten the pressure pipe nuts.

To prevent fuel spill, a plastic bag can be pulled over the filter. Unscrew the filter. Wipe a film of oil on the gasket of the new filter. Screw the filter on by hand until it touches the contact surface. Wash around the injectors. Undo the delivery pipes at the injection pump and at the injectors. Lift the fuel delivery pipes away together. Undo the nut at the top of each injector, use the nuts beneath the return fuel line as a counterhold so that the pipes are not bent.

Page Checking Injectors Group 23 Fuel system Opening pressure With the pressure gauge connected, press the injector tester lever down slowly until the injector opens and releases fuel.

Read off the opening pressure at the opening instant. If the value read does not coincide with the specified value, the setting must be changed. Page 68 Group 23 Fuel system Overhauling injectors 1. Clean the injector externally. Fix the injector holder in a vise. Unscrew the in- jector nut and disassemble the injector. Be careful that the injector nozzle does not fall out during disassembly. This concentration protects the engine against corrosion, cavitation damage and freezing conditions Page Draining Coolant Group 26 Cooling system Draining coolant Stop the engine before draining the cooling system.

Do not open the filler cap when the engine is hot, except in emergencies. Steam or hot fluid may spray out 1. Place a suitable collection vessel beneath the en- gine block drain plug 1 and at the heat exchang- er drain tap.

Steam or hot fluid may spray out. Turn the filler cap to the first stop and allow any ex- M I N cess pressure to hiss out before removing the cap completely. Coolant losses during operation can be due to a leak- ing cooling system or air or combustion gases being forced into the cooling system.

Page Circulation Pump Group 26 Cooling system 5. Install the insert in the heat exchanger. Be careful to install the insert in the correct position. Make sure the hole in the insert aligns with the hole in the housing and that the venting hole is upwards. Page Sea Water Pump Check that the thermostat has opened at least 8 mm after minutes. Replace the thermostat if it does not fulfill the requirements.

If the thermostat does not close completely, the engine will run too cold. The system voltage is 12V and the electrical system is single-pole.

The electrical system is shown in two ways. Page 77 When delivered from Volvo Penta, the sensor system is not activated. The connection has probably been done during engine installation, however. Page The Electrical System The charging circuits must never be re-connected with the engine running, for the same reason.

For simulta- neous charging of two independent battery circuits, a Volvo Penta charge splitter can be fitted to the stan- dard alternator accessory. Page Galvanic Corrosion Group 30 Electrical system Electrical wiring Never make holes in the cables insulation to perform measurements with needles. In a corrosive atmo- sphere such as a boat, it only takes 2 years for a small cable with a needle hole to oxidize off.

If it is absolutely necessary to make a hole in the in- sulation, this must be repaired in a suitable way after testing. Remove both battery cables. Remove the power rail between the glow plugs. Measure the resistance of each glow plug to the engine block with an ohmmeter. The resistance shall be 1. Be extremely careful so that the measurement cables, clothes or similar come into contact with the drive beltor pulleys on the engine or alternator when the engine is running.

Check the tension of the alternator belt and the belt condition. Page 82 Group 30 Electrical system Checking charge status Check the charge status with an acid densitometer. Mea- surement shall not be done immediately after charging or filling with battery water. Run the engine at r. Read off and note the voltage across the poles. The alternator delivers approx. If work must be carried out with the engine at operating temperature and the coolant filler cap or a cock open or a coolant hose disconnected, open the coolant 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 that the lubrication system is not under pressure before commencing work on it. Never start or operate the engine with the oil filler cap removed, oil can spray out. 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. Always have the Operator's Manual available. Keep it in a safe place and do not forget to give it to the new owner if you sell your boat. We would all like to live in a clean and healthy environment. Somewhere where we can breathe clean air, see healthy trees, have clean water in our lakes and oceans, and are able to enjoy the sunshine without being worried about our health.

Unfortunately, this cannot be taken for granted nowadays but is something we must work together to achieve. As a manufacturer of marine engines, Volvo Penta has a special responsibility, why care of the environment is a core value in our product development. Today, Volvo Penta has a broad range of engines where progress has been made in reducing exhaust emissions, fuel consumption, engine noise, etc. We hope you will take care in preserving these qualities.

Always follow any advice given in the Operator's Manual concerning fuel grades, operation and maintenance and you will avoid causing unecessary interference to the environment. Get in touch with your Volvo Penta dealer if you notice any changes such as increased fuel consumption exhaust smoke.

Adapt speed and distance to avoid wash and noise disturbing or injuring animal life, moored boats, jetties, etc. Leave islands and harbours in the same condition as you want to find them. Remember to always leave hazardous waste such as waste oil, coolant, paint and wash residue, flat batteries, etc. Operate the engine normally. Do not operate it at full load except for short periods. Never run the engine at a constant engine speed for long periods during the running-inperiod.

The engine can be expected to use more engine oil during the running-in period than would otherwise be normal. Check the oil level more often than is normally recommended. For more information: See the Warranty and Service Book. Only use the fuel and oils recommended in the chapter Technical Data.

Other grades of fuel and oil can cause operating problems, increased fuel consumption and, in the long-term, a shorter engine service life. Volvo Penta marine engines are designed for high operational reliability and long service life. They are constructed to withstand the marine environment while also affecting it as little as possible. Through regular service and the use of Volvo Penta original spare parts, these qualities will be retained.

The Volvo Penta worldwide network of authorized dealers are at your service. They are specialists in Volvo Penta products and have accessories and the original replacement parts, test equipment and special tools necessary for high quality service and repair work. Always follow the maintenance intervals contained in the Operator's Manual.

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 manufacturer guarantees that all engines manufactured of that type correspond to the certified engine. Otherwise the general instructions contained in the Operator's Manual concerning operation, service and maintenance must be followed.

Volvo Penta accepts no responsibility or liability for any damage or costs arising due to the above. Your new Volvo Penta marine engine is covered by a limited warranty according to the conditions and instructions 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. Liability covered in the warranty may otherwise be refused by AB Volvo Penta.

Contact your Volvo Penta dealer if you have not received a Warranty and Service Book and a customer copy of the warranty card. 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 copy should the boat be stolen. The appearance and location of identification plates is shown below.

The figures in brackets refer to the location of the identification numbers on the identification plate. Product designation Serial number Product number Certification number Gear ratio Propeller designation 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. If you want to install additional instrumentation, or your boat is equipped with instruments not described here, please contact your Volvo Penta dealer.

Tachometer and hour counter accessory. Displays engine speed. Multiply this value by for revolutions per minute. The hour counter displays engine operating time in hours and tenths of an hour. Warning display. See pos.

Switch for instrument lighting. To test alarm : Press the switch. All warning lights light and the acoustic alarm sounds. Alarm acknowledgment: Press the switch if there is an alarm. The acoustic alarm stops but the relevant warning lamp continues to flash until the malfunction is corrected. Temperature gauge.

Displays the engine coolant temperature. Oil pressure gauge. Displays the oil pressure in the engine. Displays the charge voltage from the generator. Ignition switch. See description in the next chapter. The starter keys are tagged with a key code. This code must be quoted when ordering extra keys. Keep the code where it is not available to unauthorized persons.

The key springs back automatically to the 0 position. The glow plugs are connected and pre-heating the engine. Read the starting instructions in the chapter: Starting the engine. 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. Switch for connecting and disconnecting instrument panel. Starter button. The starter motor is engaged when this button is pressed.

Glow plugs active: When the rocker switch is in the up position the glow plugs are activated. To test alarm: Move the rocker switch down. Alarm acknowledgment: If there is an alarm the rocker switch is moved down and the alarm is acknowledged. If the acoustic alarm sounds, one of the three warning lamps on the instrument panel starts to flash to indicate the source of the alarm.

Check that the warning lamps are operating before starting the engine according to the description of the relevant instrument panel. If the acoustic alarm sounds, one of the four warning lamps starts to flash to indicate the source of the alarm. The extra warning display is an accessory. 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. Shifting and engine speed are controlled with the same lever 1. The shift function is now disengaged and the lever affects only engine speed. When the lever is moved back to the neutral position it will automatically re-engage. For side-mounted controls the lever must first be removed.

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Bestillingskupon findes i slutningen af instruktionsbogen. Tilauskuponki on ohjekirjan lopussa. Welcome aboard Volvo Penta marine engines are used all over the world today.

Safety Precautions Read this chapter carefully. Safety Information Safety precautions to be taken when operating the boat. Your new boat Read Operator's Manuals and other information supplied with your new boat. Refueling When refueling there is always a danger of fire and explosion. Never overfill the tank. Close the fuel tank filler cap properly. Do not start the engine Do not start or run the engine with a suspected fuel or LPG leak in the boat, when you are close to or in a discharge of explosive media, etc.

Accidents Statistics show that poor maintenance of boats and engines and a lack of safety equipment are often the cause of accidents at sea. Daily checklist Make a habit of checking the engine and engine compartment visually before operating the boat before the engine is started and after operating the boat after the engine has been stopped. Maneuvering Avoid violent and unexpected changes in course and gear engagement. Avoid trimming an outboard drive too much, as steering will be severely reduced.