Volvo Penta D25A MS Operator'S Manual Download Page 38

Page: 38 / 87

Maintenance schedule

major overhaul

Disassemble engine, clean, check and change major parts.

Major parts:

Inlet and exhaust valve seats

Inlet and exhaust valves

Valve rotators

Valve cotters

Rocker arm adjusting screws

Valve push rods

Bridge caps

Camshaft bushings

Camshaft expansion plugs

Cylinder head bolts

Valve guides

Valve bridge guides

Valve bridges

Valve springs

Tappets

Camshaft thrust plates

Main bearings

Cylinder liners

Main bearing cap bolts and washers

Piston rings

Connecting rod bearings

Vibration damper

Air duct rubber hoses

Cooling water rubber hoses

Consumable items (gaskets, oil seals, o-rings, etc.)

Rocker bushings

Thrust plate crankshaft

Pistons and piston pins

Connecting rod bolts

Connecting rod bushings etc.

Check high-pressure fuel injection pump and fuel
supply pump

Change torsional vibration damper

Plus d'informations sur : www.dbmoteurs.fr

Summary of Contents for D25A MS

Page 1: ...OPERATOR SMANUAL D25A MS MT D30A MS MT Plus d informations sur www dbmoteurs fr ...

Page 2: ...A Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Plus d informations sur www dbmoteurs fr ...

Page 3: ...the engine do not operate the engine until you have read and fully understood the contents of this manual Do not hesitate to consult your Volvo Penta dealer Failure to follow the instructions and cautions in this manual may result in serious accidents Keep this manual at hand for easy reference If this manual is damaged or misplaced immediately order a new copy from your dealer Plus d informations...

Page 4: ...8 Manual Stop Lever 28 After stopping 29 General 29 Anti freezingmeasures 29 Breaks in operation not using the engine 29 Maintenance 30 MaintnenancescheduleD25A D30AMS 31 MaintnenancescheduleD25A D30AMT 34 Overhaulinformation 37 RecommendationofDailyOperationRecords 39 Engine 40 ValveClearance 40 Firingorder 41 VibrationDamperInspection 42 Re tighten Bolts and Nuts 42 How to use the Turning Gear 4...

Page 5: ...rInspection 66 Drive belts Check Adjust Change 66 Inhibiting 67 General 67 Preparation 67 Careduringstorage 67 Return the engine to service 67 Storage of Engine in operating condition 68 Troubleshooting 69 TechnicalData 70 D25A MS 70 D25A MT 71 D30A MS 72 D30A MT 73 Fuel specification 74 Lubrication oil specification 75 Coolantspecification 76 TighteningTorqueTables 77 Identification numbers D25A ...

Page 6: ...This symbol is used in the book and on the engine to make you aware of safety infor mation 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 extensive damage to the product or serious mechanical malfunction IMPORTANT Used to draw your attention to...

Page 7: ... changing speed trim or load distribution instead Get in touch with your Volvo Penta dealer for help in ob taining the best solution for your vessel The new engine Read instruction manuals and other information ac companying the new vessel thoroughly Accustom yourself with handling the engine controls and other equipment in a safe and correct manner Remember that when operating a vessel you have a...

Page 8: ...s directions for perfor ming normal maintenance and service in a safe and correct manner Read the directions carefully before starting work More detailed service literature is avail able from your Volvo Penta dealer Never perform a task unless you are absolutely sure how it is to be carried out call your Volvo Penta dealer for assistan ce instead Stop the engine Stop the engine before opening or d...

Page 9: ...r pressure can pierce bodily tis sue and cause serious injury Risk of blood poisoning Always cover any electric component if it is located under the fuel filter Otherwise it might be damaged by fuel spills Electrical system Turn off the power before commencing work on the electrical system the engine must be stopped and the powered turned off with the main switch switches Shore power to the engine...

Page 10: ...are legible If you find any letter or picture illegible in a label remove soil from the label or replace it 2 Clean the label with cloth and water or cleanser Do not use organic solvent or gasoline this would dissolve the label s adhesive and cause the label to fall off 3 If any label is damaged lost or illegible replace it When replacing a label make sure the new label is identical to the old one...

Page 11: ...are legible If you find any letter or picture illegible in a label remove soil from the label or replace it 2 Clean the label with cloth and water or cleanser Do not use organic solvent or gasoline this would dissolve the label s adhesive and cause the label to fall off 3 If any label is damaged lost or illegible replace it When replacing a label make sure the new label is identical to the old one...

Page 12: ... 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 condi tion as you want to find them Remember to always leave hazardous waste such as waste oil coolant paint and wash resi...

Page 13: ...must not be broken by anyone other than authorized personnel Otherwise general directions concerning running care and maintenance given in the operator s manual apply IMPORTANT Neglected or deficient maintenance service and the use of non original spare parts will entail Volvo Penta renouncing any responsibility for the engine corresponding to the certified version Volvo Penta will not compensate ...

Page 14: ... and charge air cooling provide excellent fuel consumption over the whole range of engine speeds where the engine is economi cal in operation D25A D30A MS 1 Fuel filters 2 Oil cooler 3 Fuel injection pump 4 Governor oil filter 5 Manual stop lever 6 Governor 7 Stop solenoid 8 Oil dipstick 9 Fuel feed pump 10 Oil filler cap 11 Fresh water pump 12 Lifting eye 13 Intake air silencer 14 Turbocharger 15...

Page 15: ...oling provide excellent fuel consumption over the whole range of engine speeds where the engine is economi cal in operation D25A D30A MT 1 Fuel filters 2 Oil cooler 3 Fuel injection pump 4 Governor oil filter 5 Manual stop lever 6 Governor 7 Stop solenoid 8 Oil dipstick 9 Fuel feed pump 10 Oil filler cap 11 Fresh water pump 12 Lifting eye 13 Intake air silencer 14 Turbocharger 15 Charge air cooler...

Page 16: ...r overhauled engine IMPORTANT All covers must be mounted before attempting to start your engine Valves and Plugs Make sure the following valves and plugs are open or closed properly Fuel supply valve Open Coolant drain cock engine Closed Coolant drain cock water pump Closed Coolant drain cock heat exchanger Closed IMPORTANT If the coolant drain cocks are not closed the coolant will drain from the ...

Page 17: ...l down for at least one minute before a new attempt is made at starting Warming up WARNING Do not conduct warm up operation for an extended period of time Prolonged warm up operation causes carbon buildup in the cylinders that leads to inperfect combustion Operate at low idle speed for 5 to 10 minutes to warm up the engine The oil pressure will be 0 20 to 0 29 MPa 28 to 43 psi after the warm up ru...

Page 18: ... warning lamps comes on 8 Warning display see section Warning displays pos 1 3 9 Starting switch see next page 10 Press button for instrument illumination This chapter describes the standard Volvo Penta instruments that are available for your engine Note that that tachometer oil gauge temperature gauge charge gauge starting switch etc that are shown here as panel mounted in some cases may be mount...

Page 19: ... will continue to flash until the fault has been rec tified Alarm test After pressing the Alarm test button the warning lamps will come on and the acoustic alarm will start to sound Make a habit of always performing an alarm test before starting Starting switch Together with the starter keys a plate containing the key code is delivered This code is required when ordering additional starter keys Ke...

Page 20: ...ed IMPORTANT If the starter motor has been engaged for the maximum time 30 seconds it must be allowed to cool down for at least one minute before a new attempt is made at starting NOTE The key must first be turned to S before ma king a new attempt at starting 5 Check the instruments and run the engine warm Let the engine idle for the first ten seconds and make sure the instruments and warning dis ...

Page 21: ...how a rea ding of 71 85 C 160 185 F The acoustic alarm will sound automatically in case the coolant temperature is too high Charging During operation the charge voltage gauge should show a reading of 28V The acoustic alarm will sound automatically in case the charge voltage is missing Oil pressure During operation the oil pressure gauge should show a rea ding of 0 50 0 64 MPa 71 93 psi A lower val...

Page 22: ...important if the engine has been run hard and or exerted to heavy loads Stop 1 Disengage the marine gear by moving the lever to neutral position 2 Turn the key to stop position S 3 Hold the key in position until the engine has stop ped the key will return to 0 automatically when released and can then be removed NOTE The stop solenoid will be activated for approximately 40 seconds after stopping th...

Page 23: ... and carbon deposits in combustion chambers affecting engine life IMPORTANT Do not turn the starter switch key to the START position when the engine is running this may damage the starter WARNING Stay clear of all rotating and moving partsduringoperation IMPORTANT Always keep the engine room well ventilated Insufficient airsupply to the engine means imperfect combustion and a loss of power IMPORTA...

Page 24: ...ng in the wrong direction This may cause serious engine damage Applying Load When the engine has reached operation temperature bring the engine to operating speed and apply the load gradually During load operation make sure that 1 No engine related alarms occur 2 There are no visible leaks of fuel lube oil coolant or exhaust gas 3 No abnormal noise or vibrations occur 4 The color of the exhaust ga...

Page 25: ...peed adjustment 2 Turn the Lock counterclockwise to unlock the ma nual speed adjustment knob 3 By pushing the button and pulling the knob towards you the engine speed will increase By bushing the knob towards the engine the engine speed will decrease WARNING When adjusting engine speed avoid quick changes since this may harm the engine Plus d informations sur www dbmoteurs fr ...

Page 26: ...rclockwise to increase engine speed 5 Bring the manual speed control knob in the neutral position when ready with the manual speed adjustment Turn the lock clockwise to secure the installation 6 Connect the control cable for remote speed adjustment so that the engine can be controlled from the normal position Plus d informations sur www dbmoteurs fr ...

Page 27: ...lead to the auxiliary bat tery negative terminal and then to a position slightly away from the discharged batteries for example at the negative cable s connection to the starter motor WARNING The black auxiliary cable must not come in contact with the positive connection on the starter motor 4 Start the engine and run at fast idling speed for about ten minutes to charge the batteries WARNING Worki...

Page 28: ... locate the problem and make the repairs needed before starting again After starting the engine make sure the engine runs properly Manual Stop Lever By pulling the manual stop lever in the STOP direc tion the engine can be stopped manually Use this le ver only in an emergency when the engine can not be stopped by the engine control system IMPORTANT When stopping the engine by pulling the stop leve...

Page 29: ...ter system must contain sufficient anti freeze to prevent it from freezing Refer to chapter Maintenance Seawater system and Freshwater system respectively WARNING If the seawater system bursts due to freezing it is possible for the vessel to sink IMPORTANT If the coolant does not give sufficient anti freeze protection it may cause costly damage to the engine Check the charge of the battery A poorl...

Page 30: ...ce records Volvo Penta recommends that accurate maintenance records are kept With accurate maintenance records your Volvo Penta Dealer can help in fine tuning the recommended service intervals to meet the specific operating situ ation This should result in a lower engine operation cost Fluids It is also important to keep record of the fluids used in the engine If brand or type of fuel lubrication ...

Page 31: ...entation works properly Weekly Check starting batteries electrolyte level load Check electrical system for loose terminals contacts Check foundation bolts Check lubrication oil for abnormal smell or waterdilution Check safety valves of air system Check air system oiler Check settings of valves and move valve to keep them operationable Drain water from the fuel pre filter water separator First 50 2...

Page 32: ...just fuel injection pressure and spray pattern Change fuel injection nozzle o rings Check and adjust valve clearance and valve mechanism Every 2000 operating hours or every 12 months Check adjust valve clearance Check valvemechanism Check turbocharger Check starter motor Check alternator Check fuel injection pump flex drive plates Check fuel injection pump control rack operation Check fuel rack co...

Page 33: ...olant 1 Every 4000 to 6000 hours or every 24 months Have an authorized dealer execute a full service inspection of your engine including Endoscopic investigation of cyl heads and liners Replace all injector nozzles Change water pump seals Checking and cleaning of charge air cooler Check turbo charger Check battery charging alternator Check and test stop solenoid or fuel shut off valve 2 Every 1500...

Page 34: ...the instrumentation works properly Weekly Check starting batteries electrolyte level load Check electrical system for loose terminals contacts Check foundation bolts Check lubrication oil for abnormal smell or waterdilution Check safety valves of air system Check air system oiler Check settings of valves and move valve to keep them operationable Drain water from the fuel pre filter water separator...

Page 35: ...just fuel injection pressure and spray pattern Change fuel injection nozzle o rings Check and adjust valve clearance and valve mechanism Every 2000 operating hours or every 12 months Check adjust valve clearance Check valvemechanism Check turbocharger Check starter motor Check alternator Check fuel injection pump flex drive plates Check fuel injection pump control rack operation Check fuel rack co...

Page 36: ...olant 1 Every 4000 to 6000 hours or every 24 months Have an authorized dealer execute a full service inspection of your engine including Endoscopic investigation of cyl heads and liners Replace all injector nozzles Change water pump seals Checking and cleaning of charge air cooler Check turbo charger Check battery charging alternator Check and test stop solenoid or fuel shut off valve 2 Every 1500...

Page 37: ...ul Dependent of your application working conditions and service level a major overhaul might be requi red in case of Decreased power output Increased fuel consumption Increased lubrication oil consumption Increased blow by gases Gas leakage through valves Starting problems Increased noise from engine parts Abnormal color of exhaust gases from warm engine Major parts Inlet and exhaust valve seats I...

Page 38: ...idge guides Valve bridges Valve springs Tappets Camshaft thrust plates Main bearings Cylinder liners Main bearing cap bolts and washers Piston rings Connecting rod bearings Vibration damper Air duct rubber hoses Cooling water rubber hoses Consumable items gaskets oil seals o rings etc Rocker bushings Thrust plate crankshaft Pistons and piston pins Connecting rod bolts Connecting rod bushings etc C...

Page 39: ...ressure 5 Seawater pressure and seawater temperature before and after heat exchanger Ambient temperature and engine room temperature at turbo charger inlet 6 Parts serviced and kinds of service adjustment repairs or replacement 7 Change in operating conditions for example Exhaust smoke turned black etc Daily recording is a preventive maintenance program and when comparing values with engine histor...

Page 40: ... timing mark 1 6 is aligned with the pointer either the No 1 or No 6 piston is at top dead center on the compression stroke Adjust the height of valves IMPORTANT Make sure the clearance between the valve yoke and valve rotator is 1 5 mm 0 059 in or more if not interference will occur between the yoke and rotator to cause the valve cones to get out of place If the clearance is less than 1 5 mm 0 05...

Page 41: ...ent must be checked again within 250 hours Adjust valve clearance 1 Loosen the lock nut of the adjusting screw 2 Turn in or back off the adjusting screw so that feeler gauge is slightly gripped between the rock er arm and yoke cap 3 After adjusting the clearance tighten the lock nut of the adjusting screw Firing order Check and adjust the valve clearance in the firing order injection sequence turn...

Page 42: ...measuring with a scale and fluid le aks past staked portions Re tighten Bolts and Nuts Re tighten the bolts and nuts on the following compo nents Timing gear case Crankshaft pulley Mounting brackets Exhaust manifold Turbocharger Cylinder heads Check the cylinder head bolts and re tighten them in number sequence 1 2 3 4 5 6 if necessary The tightening torques of the bolts and nuts can be found in t...

Page 43: ...socket to the hexagonal end of the shaft and turn the shaft with a ratchet handle for tur ning 4 After turning the engine pull the shaft back to the RUN position secure the shaft with the locking device and tighten the plate bolts Make sure the plate is secured properly WARNING Before starting the engine make sure the turning gear is in the RUN position and is locked Plus d informations sur www db...

Page 44: ...ed position and loosen the left air vent plug 2 Turn the priming pump plunger counterclockwise to unlock the mechanism 3 Move the plunger up and down until the fuel flows free of bubbles from air and tighten the air vent plug 4 Put the fuel filter switching cock in the neutral po sition and repeat the above described procedure for the other fuel filter Fuel system Plus d informations sur www dbmot...

Page 45: ...o the pressure in the priming pump 4 Tighten the priming pump cap by hand until the tightening force increases normally this occurs after turning it approximately 70 to 90 degrees Mark this position on the priming pump cap to make item 5 work more easily 5 Tighten the priming pump cap an additional 120 to150 degrees using a wrench 6 Clean the engine from spoiled fuel to prevent fire and pollution ...

Page 46: ...r 2 Put the fuel filter switching cock in the Left filter change position and unscrew the left hand fuel fil ter Use a filter wrench if necessary 3 Coat the gasket of a new filter with clean diesel fuel 4 Install the new filter in the filter bracket by hand When the gasket contacts the base tighten 1 2 to 3 4 of a turn more 5 Put the fuel filter switching cock in the Left filter bleed position and...

Page 47: ... handle with care 1 Fasten the fuel injector in a vice with protection plates 2 Remove the set screw and the cap nut 3 Loosen the adjusting screw with a screw driver until it can be loosened by hand Note This operation is required to release spring pressure applied to the nozzle tip When spring pres sure is applied it is hard to loosen the retaining nut 3 Remove the retaining nut and remove the no...

Page 48: ... enough to penetrate skin and causing serious injury 1 Attach the fuel injector to the nozzle tester 2 While watching the pressure gage of the nozzle tester push the handle down slowly IMPORTANT If fuel drips from the end of the nozzle tip it must be replaced 3 When the handle is being pressed down the fuel is injected and the pressure on the pressure gage drops suddenly The pressure value indica ...

Page 49: ...replace with a new one NOTE Fuel injection pressure and nozzle spray pat tern check intervals may be extended in steps of 250 hours if they are ok at 1000 hrs Fuel injector nozzle installation 1 Remove the nozzle inlet connector from the fuel injection nozzle 2 Attach three 0 rings to the nozzle and grease them 3 Apply a small amount of grease to a gasket and attach to the nozzle 4 Insert the nozz...

Page 50: ...e clearance 3 Turn back the engine approximately 60 degrees and turn it in the normal direction slowly until the specified timing indicated on the caution plate aligns with the pointer To ensure proper injection timing make sure that the timing mark on the coupling flywheel aligns with the pointer on the fuel injection pump Adjust fuel injection timing 1 Make sure the timing mark indicated on the ...

Page 51: ...he link change the link as an assembly Injection pump control rack operation Move the stop lever back and forth a few times and find out if the control rack can be operated smoothly WARNING If the rack sticks this must be fixed before starting the engine WARNING Never try to control the engine rpm by moving the manual stop control leaver in the opposite direction of the arrow This casn result in s...

Page 52: ...peed or 16 20 inHg at full engine speed load Drainage Place a receptacle under the filter Drain off water and contaminants through the plug 1 in the bottom of the bowl IMPORTANT Do not drain until a few hours after stopping Change the filter elements The dual filter inserts can be changed while the engi ne is running as the flow of fuel can be cut off to one filter container at a time The flow of ...

Page 53: ...n off water and contaminants through the drain plug 4 5 Fit a new filter insert and fill the container with cle an fuel IMPORTANT Cleanliness No contaminants must be allowed in the fuel system 6 Change the gasket on the cover and the O ring on the T bolt Moisten the gasket and O ring with fuel before assembling 7 Fit the cover and tighten it by hand 8 Wipe off any fuel from the heat shield 9 Dual ...

Page 54: ...echnical data The oil level should be within the marked area on the dipstick After filling oil secure filler cap WARNING Lubrication oil on hot surfaces or electrical components may cause fire Do not smoke while filling oil or when handling oil con tainers IMPORTANT Stop the engine when filling oil IMPORTANT Avoid mixing oils of different brands additives used in the oils can cause chemical reacti...

Page 55: ...ing with 2 or 3 pumps of oil from the oil fill can This has to be done to secure lubrication of the turbo during the first start up IMPORTANT Do not bend the pipe This can block the oil supply to the turbo 4 Reconnect the lubrication oil pipe to the turbo pro perly 5 Crank the engine 3 times for maximum 10 se conds with the emergency stop lever in the stop position and check if the oil pressure ri...

Page 56: ...ters and deposit in ac cordance with local regulations Never dispose of old oil or oil filters overboard 3 Change the oil filters and the by pass filter at eve ry oil change please refer to section oil filters change 4 Fill with oil to the correct level trough the oil filling pipe 5 Start the engine and allow it to idle Check the oil pressure and make sure that there are no leaks by the filters WA...

Page 57: ...rface Then tighten the filter a further approximately 3 4 of a turn using a filter wrench 6 Put the filter on line by turning the valve in posi tion A 7 Replace the left filter as above Position B is the left filter change position 8 Replace both full flow filters and the by pass filter at the same change interval Refere to next page for by pass oil filter change procedure NOTE After a lubrication...

Page 58: ...n contact with the sealing surface Then tighten the filter a further approximately 3 4 of a turn using a filter wrench Hydraulic governor oil filter change 1 Place a drip pan under the governor oil filter 2 Loosen the screw holding the pipe connecting the oil filter and the governor 1 3 Remove the pipe 2 4 Open the air vent plug 3 so that the rest of the remaining oil flows into the oil drip pan 5...

Page 59: ... to be added should have the same concentration as the coolant in the engine Do not add plain water IMPORTANT Certain parts of the system are made of light alloy Chemical additives must therefore not be used when cleaning Coolant level check MS engines Make sure the level ends between the MIN and MAX marks If there are no marks the coolant level should be approximately 5 cm below the top of the fi...

Page 60: ...the system crank the engine 10 se conds while holding the emergency stop lever in stop position Repeat several times at one minute intervals 5 Check the coolant level and top up if needed IMPORTANT Make sure that the engine is filled with lubrication oil before starting or cranking the engine IMPORTANT The engine must not be started before the system has been bled and topped up 6 Start the engine ...

Page 61: ...cooling system 1 Drain the coolant as described earlier 2 Insert a hose into the filler opening in the heat ex changer and flush with fresh water 3 Flush until the water running out of the drainage points is clean 4 Close all drainage points when the flushing water has run out 5 Fill with coolant See section coolant filling when empty Plus d informations sur www dbmoteurs fr ...

Page 62: ...s may need to be removed from inside the drain plugs taps Check and Change the zinc anodes 1 Drain the external cooling water as described in the chapter draining the seawater system 2 Unscrew the zinc anodes from the heat exchan ger 3 Change the anode if less than 50 remains If not clean the anode with emery cloth to remove the layer of oxide IMPORTANT Do not use a wire brush or other metal tool ...

Page 63: ... Heat exchanger cleaning Clean if there are signs of clogging a gradual increa se in engine temperature or high seawater pressure Check clean the seawater filter first Check also the seawater pump impeller 1 Drain the external cooling water as described in the chapter draining the seawater system 2 Detach the pipe connections from the heat ex changer 3 Remove both covers from the heat exchanger 4 ...

Page 64: ...ssor wheel nut and turn the wheel to feel rattle and listen for abnormal noise Replace the bearings if the wheel is noisy or rattles NOTE Also check the turbocharger when the ex haust color is abnormal Cleaning the Air Cooler Remove the air cooler and blow compressed air in the direction opposite to normal air flow Check air cooler drain pipe Make sure the drain from the air cooler is not clog ged...

Page 65: ... performance 1 Remove the air filter from the silencer and hand wash with a mild detergent 2 Rinse the air filter with clean water 3 After drying thoroughly reinstall the air filter in the silencer NOTE If the air filter is damaged it must be replaced 4 The standard interval for replacement of air filter is every 2000 servicev hours or at least every 24 months Plus d informations sur www dbmoteurs...

Page 66: ...ed 2 Remove the V belt from the alternator Turn the alternator pulley by hand to check the rotation If the alternator has a defect consult your dealer Drive belts Check Adjust Change WARNING Stop the engine before commencing maintenance work Check belt tension and condition regularly If the belt is too tight it can damage bearings and if it is too loo se it may slip Check and adjust after operatio...

Page 67: ... a coat of rust preservative to the exposed machined surfaces of the engine 5 Cover breather air inlet and exhaust openings with tape 6 Loosen the alternator and water pump drive belts 7 Tape the starter and alternator terminals and cover the starter and alternator with a polyethylene sheet Put a desiccant inside the covering IMPORTANT Never use vinyl sheets for covering This can result in condens...

Page 68: ...ntervals of 30 seconds with the fuel supply shut off 2 Start and run the engine under no load condition for 5 to l0 minutes IMPORTANT If the engine is fitted with a wet exhaust system and the exhaust is situated below the water line the above has to be perfor med twice a week if the exhaust is situated above the water line once a week is enough Plus d informations sur www dbmoteurs fr ...

Page 69: ...Defective starter 2 Flat batteries 3 Poor contact broken cables 4 Main switch turned off 5 Control lever not in neutral control position not activated 6 A fuse circuit breaker has blown tripped 7 Lack of fuel 8 Blocked fuel filter 9 Defective fuel filter 10 Blocked fuel pipes 11 Defective fuel pipes 12 Blocked fuel supply pump 13 Defective fuel supply pump 14 Blocked fuel injection pump 15 Defecti...

Page 70: ...in 348 C 658 F 1310r min 440 C 824 F 1500 r min 445 C 833 F 1650 r min 450 C 842 F Applies to cold engine Lubricating system Oil capacity approx Including oil filters No engine inclination 160 liters 42 3 US gals volume difference min max 30 liters 7 9 US gals Oil pressure hot engine at operating speed 0 50 0 64 MPa 71 93 psi at idling speed min 0 20 0 30 MPa 29 43 psi Cooling system Freshwater sy...

Page 71: ...621 F 1310 r min 395 C 743 F 1500 r min 406 C 763 F 1650 r min 400 C 752 F Applies to cold or warm engine stopped Lubricating system Oil capacity approx including oil filters No engine inclination 160 liters 42 3 US gals volume difference min max 30 liters 7 9 US gals Oil pressure hot engine at operating speed 0 50 0 64 MPa 71 93 psi at idling speed min 0 20 0 30 MPa 29 43 psi Cooling system Fresh...

Page 72: ...568 F 1111 r min 378 C 712 F 1272 r min 389 C 732 F 1400 r min 390 C 734 F Applies to cold or warm engine stopped Lubricating system Oil capacity approx including oil filters No engine inclination 160 liters 42 3 US gals volume difference min max 30 liters 7 9 US gals Oil pressure hot engine at operating speed 0 50 0 64 MPa 71 93 psi at idling speed min 0 20 0 30 MPa 29 43 psi Cooling system Fresh...

Page 73: ...54 F 1111 r min 372 C 702 F 1272 r min 404 C 759 F 1400 r min 412 C 744 F Applies to cold or warm engine stopped Lubricating system Oil capacity approx including oil filters No engine inclination 160 liters 42 3 US gals volume difference min max 30 liters 7 9 US gals Oil pressure hot engine at operating speed 0 50 0 64 MPa 71 93 psi at idling speed min 0 20 0 30 MPa 29 43 psi Cooling system Freshw...

Page 74: ...mm S or lower 40 C 104 F 16 0 mm S or lower 30 C 86 F Sulfur content 0 2 weight or lower Water and sediment 0 1 volume or lower Ash 0 03 weight or lower Copper plate corrosion 100 C 212 F 3h No 3 or lower Specific gravity 15 C 4 C 59 F 39 F 0 83 to 0 87 Coking test Not carbonized 100 at 250 C 482 F Aromatics content 38 weight or lower Particulate contaminant 5 0 mg liter or lower Asphaltene 0 1 we...

Page 75: ...l can cause excessive wear of bearings and moving parts thus shortening the engine life It can also result in sticking of piston rings and seizing of pistons in the cylinders thus causing major damage Selection of oil viscosity Use the following chart to select appropriate oil viscosity according to the ambient temperature Recommended oil viscosity is SAE 15W 40 for all seasons Important Excessive...

Page 76: ...oling performance Total fixed particle content 340 ppm Total hardness 9 5 dH Chloride 40 ppm Sulphate 100 ppm pH value 5 5 9 Silica 20 mg Si02 l Iron 0 10 ppm Manganese 0 05 ppm Conductivity 500 ìS cm Organic content CODMn 15 mg kMnO4 L Mixing ratio The mixture of Volvo Penta Coolant and water should contain 40 55 Volvo Penta Coolant If the coolant con tains less than 40 Volvo Penta Coolant the co...

Page 77: ... 50 362 Rear idler shaft 12 x 1 25 108 11 80 Rear idler shaft thrust plate 10 x 1 25 29 3 22 Exhaust manifold V clamp nuts 8 x 1 25 19 6 2 14 5 Exhaust manifold mounting bolts 1 4 x 28 9 0 9 6 5 UNF Exhaust pipe V clamps 10 x 1 5 98 10 72 Oil pump 12 x 1 25 108 11 80 Oil pump cover 10 x 1 25 26 3 39 7 2 7 4 1 18 32 Fresh water pump 12 x 1 25 59 6 43 Fresh water pump shaft pulley nuts 24 x 1 5 245 ...

Page 78: ... 1 25 25 2 5 18 b Governor drivecase 12 x 1 25 108 11 80 Starter 12 x 1 25 59 6 43 Turbocharger compressor wheel nut 11 x 1 0 FD13 f g h Turbocharger V clamp 7 8 9 8 0 8 1 0 5 8 7 2 FD13 g Turbocharger compressor wheel nut 1 2 x 20 FD15UNF f i Turbocharger turbine housing 10 x 1 5 25 28 2 6 2 9 19 21 FD15 g Turbocharger V clamp 9 8 10 8 1 0 1 1 7 2 8 0 FD15 g a Wet apply lubrication oil to the thr...

Page 79: ...62 Rear idler shaft 12 x 1 25 108 11 80 Rear idler shaft thrust plate 10 x 1 25 29 3 22 Exhaust manifold V clamp nuts 8 x 1 25 19 6 2 14 5 Exhaust manifold mounting bolts 1 4 x 28 9 0 9 6 5 UNF Exhaust pipe V clamps 10 x 1 5 98 10 72 Oil pump 12 x 1 25 108 11 80 Oil pump cover 10 x 1 25 26 3 39 7 2 7 4 1 18 32 Fresh water pump 12 x 1 25 59 6 43 Fresh water pump shaft pulley nuts 24 x 1 5 245 25 18...

Page 80: ... 1 25 25 2 5 18 b Governor drivecase 12 x 1 25 108 11 80 Starter 12 x 1 25 59 6 43 Turbocharger compressor wheel nut 11 x 1 0 FD13 f g h Turbocharger V clamp 7 8 9 8 0 8 1 0 5 8 7 2 FD13 g Turbocharger compressor wheel nut 1 2 x 20 FD15 UNF f i Turbocharger turbine housing 10 x 1 5 25 28 2 6 2 9 19 21 FD15 g Turbocharger V clamp 9 8 10 8 1 0 1 1 7 2 8 0 FD15 g a Wet apply lubrication oil to the th...

Page 81: ...5 8 42 102 10 4 75 M14 x 2 0 55 x 0 079 93 9 5 69 167 17 0 123 M16 x 2 0 63 x 0 079 139 14 2 103 251 25 6 185 M18 x 2 5 0 71 x 0 098 194 19 8 143 350 35 7 258 M20 x 2 5 0 79 x 0 098 272 27 7 200 489 49 9 361 M22 x 2 5 0 87 x 0 098 363 37 0 268 653 66 6 482 M24 x 3 0 94 x 0 12 468 47 7 345 843 86 0 622 M27 x 3 1 06 x 0 12 686 70 0 506 1236 126 0 911 Standard eyebolts Thread Strength classification ...

Page 82: ...M27 x 1 5 1 06 x 0 059 157 16 116 150 M30 x 1 5 1 18 x 0 059 196 20 145 180 M30 x 1 5 1 18 x 0 059 196 20 145 200 M33 x 1 5 1 30 x 0 059 245 25 181 220 M36 x 1 5 1 42 x 0 059 294 30 217 254 Dry High pressure fuel injection pipes Cap nut size Strength classification diameter x pitch mm in Nm kpm lbf ft M12 x 1 5 0 49 x 0 059 39 5 4 0 5 29 3 6 M14 x 1 5 0 55 x 0 059 49 5 5 0 5 36 3 6 M18 x 1 5 0 71 ...

Page 83: ...ion or generator This infor mation must always be used as a reference when ordering service and spare parts Engine Product designation Serial and basic engine number Product number Certification IMO Decal part No Approval No Transmission Generator Product designation Serial number Product number Plus d informations sur www dbmoteurs fr ...

Page 84: ...e air temp O C Charge air press Bar Exhaust gas temp O C Exhaust gas temp common O C Fuel temp engine in O C Fuel press Bar Type and brand of lubrication oil Type and brand of coolant Mixture of coolant Type of fuel during normal operation Sea trial data Date Name Vessel Engine no All values to be measured at full load All values to be measured with approved instrumentation If in doubt mount your ...

Page 85: ...Notes Plus d informations sur www dbmoteurs fr ...

Page 86: ...Notes Plus d informations sur www dbmoteurs fr ...

Page 87: ...7741946 3 English 04 2002 Plus d informations sur www dbmoteurs fr ...

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