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Workshop manual

Group 30

2(0)

D1-13 B • D1-20 B

D1-30 B • D2-40 B

D2-55 D • D2-55 E

D2-75 B • D2-75 C

https://www.boat-manuals.com/

Содержание D1-13 B

Страница 1: ...Workshop manual Group 30 A 2 0 D1 13 B D1 20 B D1 30 B D2 40 B D2 55 D D2 55 E D2 75 B D2 75 C https www boat manuals com ...

Страница 2: ...https www boat manuals com ...

Страница 3: ...tor 13 Repair instructions 14 General advice 14 Fault tracing of cables and connectors 14 Starter motor 15 Checking battery voltage 15 Checking alternator brushes 16 Checking the charging system 18 Checking the instruments 19 Malfunctions 20 Oil pressure engine warning 21 Check MDI output for oil pressure switch 22 Coolant temperature warning 23 Check MDI output for coolant temperature sensor 25 C...

Страница 4: ...refully before starting work If work is done adjacent to a running engine a care less movement or a dropped tool can lead to personal injury in the worst case Take care to avoid contact with hot surfaces exhaust pipes Turbocharger air intake pipe starter heater etc and fluids in pipes and hoses in an engine which is running or has just been stopped Reinstall all pro tective parts removed during se...

Страница 5: ...with air in the correct ratio No Smoking Ensure that the work area is well ventilated and take the necessary safety precautions before starting welding or grinding work Always ensure that there are fire extin guishers at hand when work is being carried out Make sure that oil and fuel soaked rags and used fuel and oil filters are stored in a safe place Rags soaked in oil can spontaneously ig nite u...

Страница 6: ...er to ensure that components are lifted clear and not damaged during the lifting opera tions When you work aboard a boat always make sure that there is enough space for disassembly where you are working with no risk of personal injury or material damage Components in the electrical and fuel systems on Volvo Penta products have been designed to minimize the risks of explosion and fire The engine mu...

Страница 7: ...ystems are sub ject to various national safety requirements such as U S Coast Guard Safety Regulations Volvo Penta Original Spare Parts meet these specifications Any damage occasioned by use of non original Volvo Penta spares for the product will be not be compen sated by the warranty offered by Volvo Penta Certified engines When doing service and repair on emission certi fied engines it is import...

Страница 8: ...fe Our common responsibility Each engine consists of a large number of collaborat ing systems and components Any deviation of a component from its technical specification can dra matically increase the environmental impact of an otherwise good engine For this reason it is important that the specified wear tolerances are observed that systems which are adjustable are correctly adjusted and that Vol...

Страница 9: ...Group 30 Electrical system Repair instructions 7 Special tools 9812519 Multimeter 88890016 Adapter cable 9998699 Measurebox 9812519 88890016 9998699 https www boat manuals com ...

Страница 10: ...complement or replace ment for the EVC system tachometer and optional in struments The display shows operation information information messages and alarms The user selects what operation information to display with the buttons on the display The EVC system display can show more than one operation information at one and the same time The display also has access to the same display mode and calibrat...

Страница 11: ...Group 30 Electrical system Design and function 9 Component location Basic instrumentation De luxe instrumentation https www boat manuals com ...

Страница 12: ... 4 MDI 5 Starter relay 6 Glowplug relay 7 Charge sensing resistor 8 Starter motor 9 Alternator 10 Oil pressure switch 11 Engine speed sensor 2 9 8 11 10 1 5 6 7 3 4 NOTE The engine on these pictures is a D1 13 but the component location is the same on D1 20 D1 30 D2 40 D2 55 D2 75 https www boat manuals com ...

Страница 13: ... is connected that controls the start and stop function of the engine MDI Mechanical diesel interface Switch oil pressure engine Oil pressure is observed by a pressure switch in stalled in the engine block on the right side of the en gine The switch is normally open in normal opera tion If the oil pressure is too low the switch closes When the engine is not running the switch is closed Sensor cool...

Страница 14: ... operated by a control solenoid and can be slid axially on the rotorshaft The starter motor has a reduction gear which makes it possible to obtain greater torque The starter motor power depends on the engine it is fitted to please refer to the table below D1 13 D1 20 0 8 kW D1 30 1 1 kW D2 40 1 4 kW D2 55 D2 27 2 0kW Glow plugs One glowplug per cylinder is installed in the cylinder head All glowpl...

Страница 15: ...se system The sense system compares the charge voltage be tween the alternator terminals B and B with the voltage across the battery positive and negative ter minals The voltage regulator then compensates for any voltage drop in the cables between the alternator and the batteries by increasing the charge voltage supplied by the alternator as necessary https www boat manuals com ...

Страница 16: ... harness is damaged Check that the cables are not damaged Avoid clamping cables in tight bends close to the con nector Contact problems Intermittent contact or temporary recurring faults can be difficult to fault trace and are frequently caused by oxidation vibration or poorly terminated cables Wear can also cause faults For this reason avoid disconnecting a connector unless it is necessary Other ...

Страница 17: ...on the batteries 2 Turn the main switch on 3 Check that the voltage between terminals B and B on the starter motor are the same as the battery voltage Electric welding Remove the positive and negative cables from the batteries Then disconnect all cables connected to the alternator starter motor MDI Always connect the welder earth clamp to the compo nent to be welded and as close as possible to the...

Страница 18: ...sh dismounting Pull out the black plastic lid Use a screwdriver to snap of the plastic lid over the brush holders Disassemble the two torx screws that holds the two brush holders Pull out the brushes Checking alternator brushes https www boat manuals com ...

Страница 19: ...ir instructions 17 Measure the brush length If the brush is worn be yond the wear limit line 5mm it must be replaced Brush mounting When mounting the brush be sure to positioning it as shown in the picture https www boat manuals com ...

Страница 20: ...oltage over a full loaded battery is approx 12 7V depended of ambient temperature 3 Engine on Run at 1500 rpm 4 Use multimeter 9812519 to do a voltage measure ment over the battery The nominal charging volt age over the battery should be approx 13 8 14 6V Fault tracing charging system Battery 1 Check that all connectors at the battery is correct assembled 2 Check the conditions of the cables to th...

Страница 21: ...ne whether information is missing from the se rial bus or if an individual instrument is faulty If you suspect an instrument fault you can use the following procedure to determine whether the instrument is faulty or not 1 Start the engine and let it idle with the control lever in the neutral position 2 Disconnect the instrument that is suspected of being faulty 3 The fault disappears Check that th...

Страница 22: ...or see section Checking the charging system Coolant alarm see section Coolant temperature warning Engine does not start see section Start preheat warning due to electrical conditions Fuel level warning see section Fuel level warning Glowing not activated see section Start preheat warning No dimmer function see section Button panel fault No engine hours in the tachometer display see section Multi l...

Страница 23: ...value de termines when the switch switches from one distinct position to the other one The switch is closed when the oil pressure is low and when the engine is off Pin 6 in the engine interface connector at the MDI pro vides the switch with a voltage signal Fault tracing Fault conditions The oil pressure switch closes at a oil pressure lower than 60kPa 0 6bar The alarm is depended of the engine rp...

Страница 24: ...699 1 NOTE Cut the current with the main switch 2 Connect adapter cable 88890016 with measure box 9998699 between the MDI and the engine connector 3 Use multimeter 9812519 for voltage measure ment 4 Turn the main switch on and press the on button on the button panel Measurement points Nominal value 16 battery neg U 0V 21 oil pressure switch supply switch closed 5 Disconnect the oil pressure switch...

Страница 25: ...r The property of a thermistor is that its resis tance changes non linearly with temperature in the medium it measures Pin 5 in the engine interface connector at the MDI supplies the thermistor with a reference voltage of 5 Volt The sensor is connected to battery negative via the engine When the engine coolant is cold the sensor resistance is high and the MDI senses a voltage close to the referenc...

Страница 26: ...rough the cooling system due to worn coolant pump seawater pump Suitable action 1 Check the coolant level 2 Check that the system does not leak 3 Check the drive belt tension for the circulation pump 4 Check that the sea water filter is not blocked 5 Check the impeller in the sea water pump 6 Change the thermostat 7 Check the pressure cap on the expansion tank see checking the pressure valve in th...

Страница 27: ...e engine connector 3 Use multimeter 9812519 for voltage measure ment 4 Disconnect the coolant temperature sensor con nector at the coolant temperature sensor 5 Turn the main switch on and press the on button on the button panel Measurement points Nominal value 16 battery neg U 5V 20 coolant temp sensor 6 Reconnect the coolant temperature sensor con nector at the coolant temperature sensor Measurem...

Страница 28: ...se multimeter 9812519 for resistance measure ment NOTE All resistance values shall be seen as guidline values Measurement points Nominal value 16 20 R 1743 Ω at 0 C 32F 16 20 R 1076 Ω at 10 C 50F 16 20 R 677 Ω at 20 C 68F 16 20 R 439 Ω at 30 C 86F 16 20 R 291 Ω at 40 C 104F 16 20 R 197 Ω at 50 C 122F 16 20 R 134 Ω at 60 C 140F 16 20 R 97 Ω at 70 C 158F 16 20 R 70 Ω at 80 C 176F 16 20 R 51 Ω at 90 ...

Страница 29: ...Connected to the multilink is also if they are used the multisensor and the NMEA interface The multilink contains of two pairs of CAN communiction wires and supply voltage To be able to present engine revolution a flywheel sensor is used The flywheel sensor is an inductive sensor The MDI uses the sensor signal to calculate the flywheel speed which presents in the tachometer The flywheel input in t...

Страница 30: ... is correctly installed and that no swarf has collected on the sensor 3 Check the funtion of the flywheel sensor Fault conditions 2 The tachometer and or the display shows neither en gine hours nor engine revolution and easy link instru ments does not work If fault in multilink CAN communication the display shows Connection lost Possible reason Open circuit in multilink bus or multilink supply Sho...

Страница 31: ...ctor Do not connect the MDI 3 Use multimeter 9812519 to measure resistance Measurement points Nominal value 17 18 R 0 9 kΩ 4 Remove the sensor from the flywheel casing Check that the sensor has no external damage and that no metal chips are stuck on the sensor 5 Use multimeter 9812519 for a AC voltage mea surement 6 Move a metal object rapidly back and forwards not more than 1 mm in front of the s...

Страница 32: ... each pin If the resistance is less than infinite there is a fault 2 Do a resistance check through each of the con ductors in the cable to detect if there is any open circuit Connect one probe to pin1 in one connec tor and connect the other probe to pin1 in the con nector in the other end of the cable this does not apply to the Y split which has a different pin con figuration The resistance should...

Страница 33: ... description A fuel level sensor can be connected to the MDI 3 180 ohm The MDI supplies the fuel level sensor with a reference voltage of 5 Volt Fault tracing Fault conditions The fuel level is 20 or less for more than 60 sec onds Possible reason The fuel level is too low Fault in the fuel level sensor wiring Suitable action 1 Check the fuel level 2 Check all wiring and connectors between the fuel...

Страница 34: ...9 to measure the resistance between the two terminal pins on the level sensor Nominal values Empty tank A R 3 2 Ω Full tank B R 180 15 Ω 4 Turn the main switch on and turn the ignition on 5 Use multimeter 9812519 to measure the voltage be tween the two fuel level conductors from the MDI The fuel level sensor shall not be connected Measurement points Nominal value MDI fuel level output U 5 V https ...

Страница 35: ...ch must be closed before the engine can be started Fault tracing Fault conditions The button panel does not function properly Possible reason The power switch is disconnected The multi link connector and the button panel con nector at the MDI have been switched Open circuit in the wiring between the button panel and the MDI Short circuit in the wiring between the button panel and the MDI Defective...

Страница 36: ...0 OL button not pushed Battery neg Stop 13 10 leads button pushed Battery neg Stop 13 11 OL button not pushed Battery neg On off 13 11 leads button pushed Battery neg On off 13 12 OL button not pushed Battery neg Ack dim 13 12 leads button pushed Battery neg Ack dim 13 14 OL button not pushed Battery neg Start Preh 13 14 leads button pushed Battery neg Start Preh OL Open line NOTE When testing a b...

Страница 37: ...ectromagnetic relay When the stop button is pushed the stop solenoid is activat ed by the MDI output pin 4 The stop solenoid shuts off the fuel supply at the injection pump Fault tracing Fault conditions The stop solenoid does not function properly Possible reason Open circuit in the wiring between the stop sole noid and the MDI Short circuit in the wiring between the stop sole noid and the MDI Fa...

Страница 38: ...id pos U 0 9 x battery voltage 16 battery neg solenoid activated 5 Disconnect the solenoid connector at the stop so lenoid Measurement points Nominal value solenoid disconnected 19 solenoid pos U battery voltage 16 battery neg Check stop solenoid Special tools Adapter cable 88890016 Measurebox 9998699 1 NOTE Cut the current with the main switch 2 Disconnect the solenoid connector at the stop so le...

Страница 39: ...e relay is used to activate the preheat function The other relay is used to activate the starter solenoid at the starter motor The preheat function will be activated when the start preheat button is pushed if the coolant temperature is below 50 C The MDI preheat output will change its potential from 0 volt to nearly battery voltage across the glowing plugs when the preheat function is acti vated W...

Страница 40: ...s activated switch closed 2 Preheating is activated due to too cold coolant temperature Repress the start preheat button within 10 seconds to activate the starter motor 3 Check wiring and the connections between the MDI start output and the starter solenoid at the starter motor 4 Check the starter solenoid at the starter motor 5 Try with another MDI unit Fault conditions 2 The preheat symbol is no...

Страница 41: ...ery negative start crank button activated MDI starter relay output U battery voltage Battery negative Check MDI output for preheat function Special tools Multimeter 9812519 1 NOTE Cut the current with the main switch 2 Loosen the rubber protection hood over the pre heat output at the MDI to be able to do a measure ment 3 Use multimeter 9812519 for voltage measure ment 4 Turn the main switch on and...

Страница 42: ...at tery icon and the alarm buzzer sound Alarm display The battery indication flashes in the alarm display audible warning Fault tracing Fault condition 1 The voltage input at the MDI is 15V or higher for more than 30 seconds Possible reason Faulty alternator regulator Suitable action 1 Try another alternator https www boat manuals com ...

Страница 43: ...itions of all cables in the charging system 4 Check that the alternator recieves correct excita tion voltage current 5 Check the brushes length and condition 6 Try another alternator Measurements When the engine is started an excitation voltage cur rent is needed to wake up the alternator Check altenator excitation voltage Special tools Multimeter 9812519 Adapter cable 88890016 Measurebox 9998699 ...

Страница 44: ...stem 1 Battery 2 Main switch 3 Starter motor 4 Alternator 5 Glow plugs 6 Flywheel sensor 7 Stop solenoid 8 Coolant temperature sensor 9 Oil pressure switch 10 Fuel level sensor 11 Auxiliary switch Wiring diagram https www boat manuals com ...

Страница 45: ...tive supply 5 CAN H 6 Multi link power supply Engine harness 1 Battery negative 2 Flywheel sensor 3 Flywheel sensor 4 Stop solenoid 5 Coolant temperature sensor 6 Oil pressure switch 7 Excitation 8 Not used Button panel 1 Stop 2 On Off 3 Ack Dim 4 Battery negative 5 Start Preheat 6 Buzzer https www boat manuals com ...

Страница 46: ...0 B D1 30 B 70 Ah D2 40 B D2 55 B D2 75 B 88 Ah Alternator Voltage output at 20 C 68 F with sense 14 2 0 15 V without sense 14 2 0 3 V Max current 115 A Power approx 1630W Suppressor capacitor 2 2μF Starter motor Starter motor power approx D1 13 B D1 20 B 0 8 kW D1 30 B 1 1 kW D2 40 B 1 4 kW D2 55 B D2 75 B 2 0 kW https www boat manuals com ...

Страница 47: ...omments on it and send it to us The address is at the bottom We would appreciate it if you were to write in English or Swedish From Refers to publication Publication no Date of issue Suggestion Motivation Date Name AB Volvo Penta Technical Information Dept 42200 SE 405 08 Göteborg Sweden https www boat manuals com ...

Страница 48: ...7748428 English 09 2007 https www boat manuals com ...

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