Workshop manual A Group 30 2(0) - Plaisance …

1 Workshop manualGroup 30A2(0)D1-13 B D1-20 BD1-30 B D2-40 BD2-55 D D2-55 ED2-75 B D2-75 CGroup 30 Electrical systemMarine Diesel enginesD1-13 B D1-20 BD1-30 B D2-40 BD2-55 D D2-55 ED2-75 B D2-75 C 2007 AB VOLVO PENTAWe reserve the right to make modifications without prior on environmentally compatible 2 General 5 About this Workshop manual .. 5 Spare parts .. 5 Certified 5 Repair 6 Our common responsibility .. 6 Special 7 The MDI system .. 8 Component 9 Component description .. 11 MDI .. 11 Switch, oil pressure, engine .. 11 Sensor, coolant 11 Sensor, engine speed (flywheel) .. 11 Stop 12 Glow 12 Starter motor .. 13 Repair 14 General 14 Fault tracing of cables and connectors .. 14 Starter motor .. 15 Checking battery voltage .. 15 Checking alternator 16 Checking the charging 18 Checking the 20 Oil pressure (engine) warning .. 21 Check MDI output for oil pressure switch .. 22 Coolant temperature warning.

2 23 Check MDI output for coolanttemperature 25 Check coolant temperature sensor .. 26 Multilink 27 Check speed sensor, flywheel .. 29 Check NMEA 2000 Gateway LED .. 30 Fuel level 31 Check fuel level sensor .. 32 Button panel 33 Check button 34 Stop solenoid 35 Check stop solenoid .. 36 Start / preheat warning .. 37 Battery 40 Check altenator excitation voltage .. 41 Wiring 42 Pin configuration, MDI .. 43 Technical 44 Electrical 44 Starter motor .. 44 Safety informationGroup 30: Electrical system2 Safety informationImportantIn this book and on the product you will find the fol-lowing special warning ! Warns for the risk of personal inju-ry, major damage to product or property, or se-rious malfunctions if the instruction is ! Is used to call attention to thingswhich could cause damage or malfunctions toproduct or !Is used to call attention to important informa-tion, to facilitate work processes or give you a overview of the risks which alwaysneed to be observed and precautions which alwayshave to be taken, we have noted them it impossible to start the engine by cuttingsystem current with the main switch(es)and lockit (them) in the off position before starting ser-vice work.

3 Set up a warning notice by the a general rule all service operations must becarried out with the engine stopped. Sometasks, such as adjustments, need the engine tobe running, however. Approaching an enginewhich is operating is a safety hazard. Remem-ber that loose clothing or long hair can getcaught in rotating parts and cause serious per-sonal Workshop manual contains technical data, de-scriptions and repair instructions for the Volvo Pentaproducts or product versions noted in the table ofcontents. Check that you have the correct WorkshopManual for your this safety information and the General Informa-tion and Repair Instructions in the Workshop manualcarefully before starting work is done adjacent to a running engine, a care-less movement or a dropped tool can lead to personalinjury in the worst care to avoid contact with hot surfaces (exhaustpipes, Turbocharger, air intake pipe, starter heateretc.) and fluids in pipes and hoses in an engine whichis running or has just been stopped.

4 Reinstall all pro-tective parts removed during servicework beforestarting the start the engine with the cover from the risk of spilling oil, there is a riskof personal that the warning or information labels onthe product are always clearly visible. Replacelabels which have been damaged or start the engine without installing the aircleaner filter. Foreign objects entering the in-take ducts can cause mechanical use start spray or similar products as astarting aid. They may cause an explosion inthe inlet manifold. Danger of personal opening the coolant filling cap when theengine is hot. Steam or hot coolant can sprayout and the system pressure will be lost. Openthe filler cap slowly, and release the pressure inthe cooling system if the filling cap or tap has tobe opened, or if a plug or coolant hose has tobe removed when the engine is hot. It is difficultto anticipate in which direction steam or hotcoolant can spray oil can cause burns. Avoid skin contact withhot oil.

5 Ensure that the lubrication system is notunder pressure before carrying out any start or operate the engine with the oil fill-er cap removed, otherwise oil could be the engine and close the sea cocks beforedoing any work on the cooling 30: Electrical systemSafety information3 Only start the engine in a well- ventilated operated in a confined space, exhaustfumes and crankcase gases must be ventilatedfrom the engine bay or Workshop use protective glasses or goggles whencarrying out work where there is a risk of splin-ters, grinding sparks, acid splashes or whereother chemicals are used. Your eyes are ex-tremely sensitive, injury could cause blindness!Avoid getting oil on your skin! Repeated expo-sure to oil or exposure over a long period canresult in the skin becoming dry. Irritation, dry-ness and eczema and other skin problems canthen oil is more dangerous than fresh oil from ahealth aspect. Use protective gloves and avoidoilsoaked clothes and rags.

6 Wash regularly, es-pecially before eating. There are special skincreams which counteract drying out of the skinand make it easier to clean off dirt after work chemicals intended for the product ( and transmission oils, glycol, petrol(gasoline) and diesel oil) or chemicals for work-shop use ( degreasers, paints and solvents)are hazardous. Read the instructions on theproduct packaging with care! Always follow thesafety precautions for the product (for exampleuse of protective mask, glasses, gloves etc.).Make sure that other personnel are not inad-vertently exposed to hazardous chemicals, forexample in the air. Ensure good ventilation inthe work place. Follow the instructions providedwhen disposing of used or leftover extreme care when leak detecting onthe fuel system and testing the fuel injector noz-zles. Use eye protection. The jet which comesfrom a fuel injector has very high pressure andconsiderable penetrationability. Fuel can forceits way deep into body tissue and cause severeinjury.

7 Danger of blood poisoning (septicemia).All fuels, and many chemicals, are not allow naked flame or sparks in the vicini-ty. Petrol (gasoline), some thinners and hydro-gen gas from batteries are extremely flammableand explosive when mixed with air in the correctratio. No Smoking! Ensure that the work area iswell ventilated and take the necessary safetyprecautions before starting welding or grindingwork. Always ensure that there are fire extin-guishers at hand when work is being sure that oil and fuel soaked rags, andused fuel and oil filters are stored in a safeplace. Rags soaked in oil can spontaneously ig-nite under certain fuel and oil filters are polluting waste andmust be handed to an approved waste manage-ment facility for destruction, together with usedlubrication oil, contaminated fuel, paint residue,solvents, degreasers and wash must never be exposed to openflames or electric sparks. Never smoke close tothe batteries. The batteries generate hydrogengas when charged, which forms an explosivegas when mixed with air.

8 This gas is easily ignit-ed and highly volatile. A spark, which can becaused by incorrect battery connection, cancause an explosion with resulting damage. Donot move the connections when you attempt tostart the engine (risk of arcing), and do notstand and lean over one of the ensure that the Plus (positive) and Mi-nus (negative) battery cables are correctly in-stalled on the corresponding terminal posts onthe batteries. Incorrect installation can result inserious damage to the electrical equipment. Re-fer to the wiring use protective goggles when chargingand handling the batteries. Battery electrolytecontains sulfuric acid which is highly the battery electrolyte come into contactwith unprotected skin wash off immediately us-ing plenty of water and soap. If you get batteryacid in your eyes, flush at once with a generousamount of water, and get medical assistance the engine off and turn off the power at themain switch(es) before carrying out work on theelectrical adjustments must be carried out with theengine existing lugs on the engine/reversing gearshould be used for lifting the check that the lifting devises are in goodcondition and that they have the correct capaci-ty for the lift (the weight of the engine plus thereversing gear and extra equipment).

9 Safety informationGroup 30: Electrical system4 The engine should be lifted with a customizedor adjustable lifting boom for safe handling andto avoid damaging components on top of theengine. All chains or cables should be parallelto each other and should be as square as pos-sible to the top of the engine. If other equipmentconnected to the engine has altered its centerof gravity, special lifting devises may be neededto obtain the correct balance and safe do any work on an engine which justhangs from a work alone when removing heavy enginecomponents, even when using lifting devicessuch as locking tackle lifts. When using a liftingdevice two people are usually required to do thework, one to take care of the lifting device andanother to ensure that components are liftedclear and not damaged during the lifting you work aboard a boat, always makesure that there is enough space for disassemblywhere you are working, with no risk of personalinjury or material in the electrical and fuel systemson Volvo Penta products have been designedto minimize the risks of explosion and fire.

10 Theengine must not be run in areas where thereare explosive ! Fuel delivery pipes must not bebent or straightened under any pipes must be the following when washing with ahigh pressure washer: Never aim the water jetat seals, rubber hoses or electrical use a high pressure washer for use the fuels recommended by Volvo Pen-ta. Refer to the Instruction Book. Use of fuelsthat are of a lower quality can damage the en-gine. Poor fuel can also lead to higher-maintenance 30: Electrical systemSafety information5 General informationAbout this Workshop ManualThis Workshop manual contains, descriptions and re-pair instructions for the engines equiped with Workshop manual can illustrate tasks done onany of the engines noted above. This means that theillustrations and photographs which clarify certain de-tails might not correspond with other engines in somecases. Repair methods are similar in all important re-spects, however. If this is not the case, this is differences are noted engine designation and number are noted on thenumber plate and engine decal.