Volvo Penta D49A MS Operator'S Manual Download Page 1

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OPERATOR’S MANUAL

D49A MS/MT

Non-classifiable control system

Plus d'informations sur : www.dbmoteurs.fr

Summary of Contents for D49A MS

Page 1: ...OPERATOR SMANUAL D49A MS MT Non classifiable control system 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: ...nual 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 All information and illustrations in this manual are based on the specifications that were avail able at the time of pri...

Page 4: ...3 Injection timing inspection 55 Fuel control 56 Twin fuel pre filter water separator 57 Air inlet and exhaust systems 59 Turbocharger inspection 59 Cleaning the air cooler 59 Checking air cooler drain pipe 59 Washing the air inlet silencer filter 60 Cooling system general 61 Cooling system D49A D65A MS HE 62 Cooling system D49A D65A MS KC 1 circuit 63 Cooling system D49A D65A MT HE 64 Cooling sys...

Page 5: ...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 6: ...regula tions concerning traffic and safety at sea Inform your self of the regulations applicable to your vessel and the waters your in by getting in touch with the relevant authorities or marine safety organization Accidents and other incidents Sea rescue statistics show that deficient maintenance of vessels and engines together with defective safety equipment often causes accidents and other inci...

Page 7: ...We recommend you get in touch with a regional boat or marine safety organization to obtain more detailed marine safety information Carbon monoxide poisoning When a vessel is moving forward it will cause a certain vacuum to form behind the vessel In unfortunate circum stances the suction from this vacuum can be so great that the exhaust gases from the vessel are drawn into the bridge or cabin and c...

Page 8: ...al contains 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 op...

Page 9: ...or used chemicals to a destruction plant Cooling system There is a risk of water entering when working on the seawater system Therefore stop the engine and close the seawater cock before starting work Avoid opening the coolant filler cap when the engine is warm Steam or hot coolant may spurt out and cause burn injuries If the filler cap coolant pipe cock etc must nevertheless be opened or dismantl...

Page 10: ...th your hand Never adjust the V belts while the engine is running Service batteries carefully If you spill electrolyte on yourself flush skin immedia tely with lots of water Apply baking soda to help neu tralize the acid If electrolyte gets in your eyes rinse immediately with large amounts of water then contact a doctor at once Handle antifreeze carefully Antifreeze contains alkali Avoid contact w...

Page 11: ... 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 Fo...

Page 12: ...e 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 For new l...

Page 13: ... 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 14: ...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 15: ...bocharger and charge air cooling provide excellent fuel consumption over the whole range of speeds where the engine is economical in operation 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 Freshwater pump 12 Lifting eye 13 Intake air silencer 14 Turbocharger 15 Alternator 1...

Page 16: ...e air coo ling provide excellent fuel consumption over the whole range of speeds where the engine is economical in opera tion 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 Freshwater pump 12 Lifting eye 13 Intake air silencer 14 Turbocharger 15 Heat exchanger 16 Oil filters...

Page 17: ...d 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 engine and ...

Page 18: ...ds it must be allowed to cool 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...

Page 19: ... the 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 non classifiable control system which is available for your engine Note that that tacho meter oil gauge temperature gauge charge gauge starting switch etc that are shown here as panel mounted in some cases may be m...

Page 20: ...l 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 Keep t...

Page 21: ...ted 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 22: ... show 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 v...

Page 23: ...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 24: ... 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 25: ...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 26: ...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 27: ...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 28: ...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 29: ...is 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 lever continue to pull the le ver until the engine stops rocking Notice If the engine cannot be stopped with the ma nual stop lever shut off the fuel supply or block air in take to turbo After stopping General Check the genset and engine room for lea...

Page 30: ...system bursts due to freezing the vessel could 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 poorly charged battery can freeze and break Breaks in operation not using the genset During periods out of service the engine must be run warm once a fortnight This will prevent it from corro ding IMP...

Page 31: ...Maintenance 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 lub...

Page 32: ...trumentation works properly Check for leakages Weekly Check starting batteries electrolyte level load Check electrical system for loose terminals contacts Check foundation bolts Check lubrication oil for abnormal smell or water dilution 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 wa...

Page 33: ...djust 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 valve mechanism Check turbocharger Check starter motor Check alternator Check fuel injection pump flex drive plates Check fuel injection pump control rack operation Check fuel rack ...

Page 34: ...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 35: ...trumentation works properly Check for leakages Weekly Check starting batteries electrolyte level load Check electrical system for loose terminals contacts Check foundation bolts Check lubrication oil for abnormal smell or water dilution 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 wa...

Page 36: ...djust 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 valve mechanism Check turbocharger Check starter motor Check alternator Check fuel injection pump flex drive plates Check fuel injection pump control rack operation Check fuel rack ...

Page 37: ...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 38: ...l 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 In...

Page 39: ...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 40: ...re 5 Rawwater pressure and rawwater 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 history it ...

Page 41: ...idge IMPORTANT Make sure the clearance between the valve bridge and valve rotator is 1 5 mm 0 059 in or more if not interference will occur between the bridge and rotator to cause the valve cones to get out of place If the clearance is less than 1 5 mm 0 059 in after the height of valves has been adjusted consult your dealer NOTE Before inspecting the valve clearance adjust the height of the two v...

Page 42: ...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 fee ler gauge is slightly gripped between the rocker 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 turning the engine with each c...

Page 43: ...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 44: ...ket 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 dbmot...

Page 45: ...PORTANT The level must never be allowed to drop beneath the minimum or rise above the maximum mark on the dipstick Filling oil Fill the engine with lubrication oil through the filler pipe For oil specification refer to chapter technical 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 compo...

Page 46: ...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 WARNING...

Page 47: ... new filter by hand until the gasket is in contact with the sealing surface 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 filter switch cover at its original posi tion and retighten the two connection bolts 8 Repeat the described procedure for the other oil filters NOTE After a lubricat...

Page 48: ...the pipe connecting the oil filter and the governor 1 4 Remove the pipe 2 5 Open the air vent plug 3 so that the rest of the remaining oil flows into the oil drip pan 6 Remove the center bolt 4 remove the old filter and mount a new 7 Remove the air vent plug and fill the filter housing with new oil 8 Tighten the air vent plug Plus d informations sur www dbmoteurs fr ...

Page 49: ...r 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 WARNING Always protect your hands when carrying out leak detection Escaping fluids under pressure can pierce bodily tissue and cause serious injury Risk of blood poisoning Always cover any electric component if it is located un...

Page 50: ... 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 NOTE Be sure to bleed both injection pumps 6 Clean the engine from spoiled fuel to preve...

Page 51: ...lter 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 ...

Page 52: ...cate 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 When spring pressure is applied it is hard to loosen the retaining nut 3 Remove the retaining nut and remove the noz...

Page 53: ...er The fuel injected from the nozzle has an extremely high pressure strong 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 it must be replaced 3 When the handle is being pressed down the fuel is injected and the p...

Page 54: ...aligning its connector hole with the rocker case hole 4 Attach the nozzle inlet connector to the nozzle by applying the specified torque 64 to 74 Nm 6 5 to 7 5 kpm 47 to 54 lbf 5 Attach the nozzle gland and tighten the nut at the specified torque 98 N m 10 kgf m 72 lbf 6 Attach the injection pipe and fuel leak off pipe 7 Before mounting the rocker cover operate the engine at approx 850 rpm and che...

Page 55: ...er have some clearance If these valves have no clearance turn the engine once again to align the timing mark 1 6 NOTE Do not confuse the No 1 cylinder with No 6 When the piston for the No 1 cylinder is in the above mentioned position its inlet and exhaust valve are se ated presenting some clearance 3 Turn back the engine approximately 60 degrees and turn it in the normal direction slowly until the...

Page 56: ... the engine rpm by moving the manual stop control leaver in the opposite direction of the arrow This casn result in serius harm of the installation Adjusting fuel injection timing 1 Make sure the timing mark indicated on the cau tion plate is aligned with the pointer with the pis ton for the cylinder at top dead center on com pression stroke 2 Loosen the bolts C for the fuel injection pump couplin...

Page 57: ... contaminants through the plug 1 in the bottom of the bowl IMPORTANT Do not drain until a few hours after stopping Changing the filter elements The dual filter inserts can be changed while the engine is running as the flow of fuel can be cut off to one fil ter container at a time The flow of the fuel is governed by putting the knob 1 in the following positions A Normal running both filters connect...

Page 58: ...uel 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 filter Change the other filter insert in the same way 10 Open the fuel cocks and put the knob 1 in posi tion for nor...

Page 59: ...sor 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 Checking air cooler drain pipe Make sure the drain from the air cooler is not clogge...

Page 60: ...he air filters clean to ensure optimum engine 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 4 Repeat the procedure on the other airfilter NOTE If the air filter is damaged it must be replaced Plus d informations sur www dbmoteurs fr ...

Page 61: ...open the pressure cap or drain the cooling system when the engine is warm Steam or hot fluid may spurt out WARNING The coolant is dangerous to your health and an environmental hazard Handle coolant with care and dispose of old coolant in accordance with local regulations IMPORTANT For coolant specification refer to chapter Technical data Coolant specification in the back of this manual IMPORTANT C...

Page 62: ... the coolant through the heat exchanger and through the engine The rawwater system cools the internal cooling system in an engine mounted heat exchanger 1 Rawwater inlet 2 Rawwater pump optional 3 Engine mounted heat exchanger 4 Expansion tank 5 Rawwater outlet 6 Fresh water pump 7 Lubrication oil cooler 8 Engine 9 Charge air cooler 10 Thermostat valve Freshwater circuit Rawwater circuit Freshwate...

Page 63: ...a grid cooler or any other external heat exchanger The same coolant fresh water is cooling the complete engine 1 Freshwater inlet 2 Freshwater pump 3 Lubrication oil cooler 4 Engine 5 Charge air cooler 6 Thermostat valve 7 Freshwater outlet 1 2 3 4 5 3 4 6 6 7 Freshwater drain points D D D Plus d informations sur www dbmoteurs fr ...

Page 64: ...g the charge air and the coolant in the freshwater cooling system The rawwater cir cuit is designed for seawater or for connection to a central cooling system 1 Rawwater inlet 2 Rawwater pump optional 3 Charge air cooler 4 Fresh water pump 5 Lubrication oil cooler 6 Engine 7 Thermostat valve 8 Engine mounted heat exchanger 9 Expansion tank 10 Raw water outlet 1 3 3 4 5 6 5 6 7 7 2 8 9 10 Freshwate...

Page 65: ...ed by e g a box cooler a grid cooler or any other external heat exchanger The rawwater system is cooling the charge air 1 Rawwater inlet 2 Rawwater pump optional 3 Charge air cooler 4 Rawwater outlet 5 Freshwater inlet 6 Freshwater pump 7 Lubrication oil cooler 8 Engine 9 Thermostat valve 10 Expansion tank 11 Freshwater outlet Freshwater circuit Rawwater circuit Freshwater drain points D D D D Plu...

Page 66: ...le to pass the filler opening Filling when the system is empty 1 Open the air ventilation cocks and close the coo lant drain cocks 2 Make sure that systems connected to the cooling system also are ventilated e g heater water heater 3 Fill the freshwater system with coolant to the cor rect level through the filler opening in the expansi on tank For correct level refer to section Check ing the coola...

Page 67: ...as been bled and toppedup 6 Start the engine and run it under light load until the thermostat valve opening temperature is reached 7 Check air vents for leaks 8 Stop the engine and allow it to cool Check the coolant level in the expansion tank and top up if needed Flushing the freshwater system The system should be flushed before changing coo lant to avoid inferior cooling performance due to depo ...

Page 68: ...drain plugs taps Checking Changing zinc anodes Note Zink anodes are consumed differently depen ding on the marine environment 1 Drain the external cooling water as described in the chapter draining the rawwater 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 us...

Page 69: ...ks 8 Open the rawwater cocks Cleaning the heat exchanger Clean if there are signs of clogging a gradual increase in engine temperature or high rawwater pressure Check clean the rawwater filter first Also check for other damages on the heat exchanger 1 Drain the external cooling water as described in the chapter draining the rawwater system 2 Detach the pipe connections from the heat ex changer 3 R...

Page 70: ...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 Checking Adjusting Changing the drive belts 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...

Page 71: ... 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 72: ...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 73: ...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 74: ...F 1310 r min 490 C 914 F 1500 r min 500 C 932 F 1650 r min 490 C 914 F Applies to cold engine Lubricating system Oil capacity approx Including oil filters No engine inclination 230 liters 60 8 US gals volume difference min max 42 liters 11 1 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 system capaci...

Page 75: ... F 1310 r min 410 C 770 F 1500 r min 420 C 788 F 1650 r min 412 C 774 F Applies to cold engine Lubricating system Oil capacity approx Including oil filters No engine inclination 230 liters 60 8 US gals volume difference min max 42 liters 11 1 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 system capac...

Page 76: ... 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 weight...

Page 77: ...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 78: ...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 SiO2 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 79: ...Flywheel 22 x 1 5 539 55 398 a Balance weight 22 x 1 5 490 50 362 Viscous damper 22 x 1 5 490 50 362 Ring gears 10 x 1 25 59 6 43 Rear idler shaft 20 x 1 25 392 40 289 Rear idler shaft nuts 18 x 1 5 196 20 145 Front gear case 12 x 1 25 59 6 43 Front gear case 16 x 1 5 216 22 159 Front plate 12 x 1 25 59 6 43 Front idler shaft 12 x 1 25 108 11 80 Front idler gear thrust plate 10 x 1 25 29 3 22 Exha...

Page 80: ...rack control lever 8 x 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 TD13 f g h Turbocharger V clamp 7 8 9 8 0 8 1 0 5 8 7 2 TD13 g Turbocharger compressor wheel nut 1 2 x 20 TD15UNF f i Turbocharger turbine housing 10 x 1 5 25 28 2 6 2 9 19 21 TD15 g Turbocharger V clamp 9 8 10 8 1 0 1 1 7 2 8 0 TD15 g a Wet apply lubr...

Page 81: ...amper 22 x 1 5 490 50 362 Ring gears 10 x 1 25 59 6 43 Rear plate 12 x 1 25 108 11 80 Rear plate 16 x 1 5 216 22 159 Rear idler shaft 20 x 1 25 392 40 289 Rear idler shaft nuts 18 x 1 5 196 20 145 Front gear case 12 x 1 25 59 6 43 Front gear case 16 x 1 5 216 22 159 Front plate 12 x 1 25 59 6 43 Front idler shaft 12 x 1 25 108 11 80 Front idler gear thrust plate 10 x 1 25 29 3 22 Exhaust manifold ...

Page 82: ...4 5 25 33 Injection nozzle inlet connector 16 x 1 5 64 74 6 5 7 5 47 54 Injection pipes 18 x 1 5 49 69 5 7 36 51 Fuel filter air vent plug 7 8 9 8 0 8 1 0 5 8 7 2 Fuel rack control lever 8 x 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 1 2 x 20 TD15UNF f i Turbocharger turbine housing 10 x 1 5 25 28 2 6 2 9 19 21 TD15 g Turboch...

Page 83: ... 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 d...

Page 84: ...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 85: ...r 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 86: ...O C Charge air temp Right bank O C Charge air press Left bank Bar Charge air press Right bank Bar Exhaust gas temp Left bank O C Exhaust gas temp Right bank 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 ...

Page 87: ... Notes Plus d informations sur www dbmoteurs fr ...

Page 88: ... Plus d informations sur www dbmoteurs fr ...

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Page 91: ...Plus d informations sur www dbmoteurs fr ...

Page 92: ...7744281 English 07 2004 Plus d informations sur www dbmoteurs fr ...

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