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:0574-26871589 Unit sales : 0574-26871589  

:0574-26886646 Accessories Sales : 0574-26886646

:0574-26871569 Maintenance Hotline : 0574-26871569

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Products
Volvo diesel engine accessories


Detailed Description:

Primary fuel filter drainage
1. Stop the engine and open the fuel valve.
2. Place a suitable container under the filter.
3. Open the drain valve (1) and drain the water / fuel.
4. Unscrew the water tank from the filter box counterclockwise.
5. Clean the water tank and replace it in the filter tank.
6. Close the drain valve and open the fuel valve.
7. Ventilate the system. Test run the engine and check for signs of leakage.
When replacing the primary fuel filter, the filter core rod must be replaced as recommended in the maintenance schedule.
1. Stop the engine and open the fuel valve.
2. Remove the water storage tank and drain the water.
3. Remove the filter box.
4. Check that the filter box is completely clean and the seal is intact.
Apply a layer of oil to the seal.
5. Replace the water tanks into the filter tank and install them on the filter holder.
6. Open the fuel valve to vent the system.
7. Start the engine and check for signs of leakage.
maintenance
42
Vent the fuel system. If the fuel tank is empty, after replacing the filter, or after a long period of outage, vent the fuel system.
1. Place a suitable container at the bottom of the fuel filter.
2. Open the vent (1).
3. Turn the manual counterclockwise and then the pump to start the pump.
4. Run the pump until there are no more air bubbles in the fuel.
5. Tighten the vent (1) and turn off the manual fuel pump.
6. Start the engine and check for signs of leakage.
Replacing the fuel filter Attention! Do not fill a new fuel filter with fuel before assembly; doing so has the risk of causing contaminants to enter the system and cause failure or damage.
Warning! The fuel filter should be replaced while the engine is cooling to avoid fire caused by fuel splashing on hot surfaces.
1. Clean around the fuel filter.
2. Remove the filter with a suitable filter wrench. Collect the leaked fuel in an oil collection container.
3. Clean the mating surface on the filter holder.
4. Coat the seal with diesel and install a new fuel filter. Tighten the fuel filter according to the instructions on the filter.
5. If necessary, vent the air from the fuel system, see "Exhaust the fuel system".
maintenance
43
Electrical system warning! Before working on the electrical system, the engine must be stopped and disconnected from the main power switch. All electrical connections to the battery charger or other auxiliary equipment must be disconnected.
Circuit breaker engine wiring harness provides two circuit breakers. One 10A circuit breaker is connected to the EMS unit, and one 150A is connected to the preheater. The engine only provides these two circuit breakers.
If the electrical system is overloaded, the circuit breaker will cut off the current.
If the engine fails to start or the dashboard does not work while running,
The circuit breaker may be burned out. Check and replace the breaker or reset the breaker.
Important! Please check the cause of the overload.
The main power switch must not be turned off before the engine is stopped. If the circuit between the charging generator and the battery is disconnected while the engine is running, the charging generator and electronic components will be damaged. For the same reason,
Never reconnect the charging circuit while the engine is running.
Important! Never disconnect the power with the main power switch while the engine is running.
Check the electrical connectors. Each circuit connector should be dry, free from oxidation, and fastened reliably.
If necessary, these joints can be sprayed with a moisture-proof agent (Volvo
Penta universal oil).
maintenance
44
Battery maintenance warning! !! Risk of fire and explosion. The battery must not be exposed to open flames or sparks.
Warning! Do not confuse the positive and negative terminals of the battery. Risk of sparks and explosion.
Warning! The battery electrolyte is highly corrosive.
Protect your eyes, skin, and clothing when handling. Always wear protective glasses and gloves. If the electrolyte comes into contact with the skin, immediately wash with soap and plenty of water. In case you touch your eyes,
Rinse immediately with plenty of water and seek medical assistance as soon as possible.
When connecting and disconnecting the battery, first connect the (+) cable (red) to the (+) terminal of the battery. Then connect the (-) cable (black) to the (-) terminal of the battery.
When disconnecting the battery, first remove the (—) cable (black), and then remove the (+) cable (red).
Clean up to keep the battery clean and dry. Dirt and oxides on batteries and battery terminals can cause leakage currents, voltage drops and discharges,
Especially in wet weather. Use a copper wire brush to remove oxides from the battery terminals and cable connectors. Tighten the cable glands and coat them with protective grease or vaseline.
The filling electrolyte surface should be 5-10mm above the battery electrode plate. Fill with distilled water if needed. After filling, the engine should be run at idle for at least 30 minutes to charge the battery. note! Some maintenance-free batteries have special instructions that must be followed.
maintenance
45
Battery charging warning! Risk of explosion. When the battery is charged, it will release hydrogen, and when mixed with air, it will form an explosive gas.
Short circuits, open flames, or sparks can cause strong explosions. Ensure good ventilation.
Warning! !! The battery electrolyte is highly corrosive. Protect your eyes, skin, and clothing. Always wear protective glasses and gloves. If the electrolyte comes into contact with the skin, immediately wash with soap and plenty of water. In case of contact with eyes, rinse immediately with plenty of water and seek medical assistance as soon as possible.
The discharged battery should be charged immediately. If the engine is to be deactivated for a longer period of time, the battery should be fully charged before decommissioning, and regularly maintained for charging afterwards (refer to the battery manufacturer's recommendations). In cold weather, insufficient charging can damage the battery,
It is also prone to freezing and cracking.
Important! Carefully follow the instructions of the battery charger.
To avoid galvanic corrosion when using an external charger,
Before the external charger is connected, the battery cable should be disconnected from the battery.
When charging, unscrew the filler cap on each battery, but do not remove it from the hole. Maintain good ventilation, especially when the battery is charged in an enclosed space.
Warning! Before releasing the charging clip, the charger must be disconnected. Do not confuse the positive (+) and negative (-) terminals of the battery. There is a risk of sparks and explosions.
There are special rules for so-called “fast charging”. Fast charging will shorten the service life of the battery and should be avoided.
46
Storage To prevent damage to engines and other equipment due to outages for 2 months or more, precautions must be taken. It's important to do this without fail in the right way, so we provide a checklist with all the points.
Inspections should be performed by an authorized Volvo Penta service station before the engine is deactivated for an extended period of time.
After handling the faults and defects, the equipment is in good condition for the next startup.
Warning! Before beginning maintenance work, you should read the "Maintenance" chapter carefully, which contains methods for working safely and correctly.
Warning! Some oil seals are flammable, and some are harmful to breathing. Ensure good ventilation and wear a mask when spraying.
Important! When flushing with a water gun, remember not to direct water jets to seals, rubber hoses, or electrical components.
Preparation for archiving
  Storage period does not exceed 8 months:
Replace the engine lubricating oil and lubricating oil filters, and then run to normal operating temperature.
Storage period over 8 months:
Oil seal the lubrication system and fuel system with oil seal oil. See instructions on the next page.
  Check that the coolant has sufficient antifreeze performance. If necessary,
Then add. Another option is to drain the coolant (the coolant filter also needs to be drained).
  Discharge all water and dirt in the fuel filter and fuel tank. Fill the fuel tank with fuel to avoid condensation.
  Disconnect the battery cable, clean and charge the battery. The battery should be regularly charged for maintenance during storage. An undercharged battery will freeze and crack.
  Clean the outside of the engine, but do not use a high-pressure water jet.
Make up paint where paint is damaged.
 Spray parts of electrical system with moisture-proof agent.
 Check each control cable and take anti-rust measures.
  Put a label on the engine, indicating the date, type of storage and oil seal oil used.
 If necessary, cover the air cleaner, exhaust pipe and engine.
maintenance
47
When the storage period exceeds 8 months, the oil seals of the lubrication system and fuel system:
  Drain the lubricating oil in the engine and fill it with oil seal oil to make it slightly higher than the MIN mark on the oil scale.
  Connect the fuel suction pipe and the return pipe to a container containing 1/3 oil seal oil and 2/3 diesel oil.
  Remove air from the fuel system.
  Start the engine and run it at a high idle speed until about 2 liters of oil in the above container is used up. Stop the engine and transfer to the normal fuel line.
 Drain the oil seal oil from the engine.
 Follow the other instructions on the previous page.
* Oil seal oil is placed by oil manufacturers.
Re-enable
  Remove all covers from the engine, air cleaner and exhaust pipe.
  If necessary, add the same quality lubricant to the engine. If the lube filter is not replaced during storage, replace it with a new lube filter.
  Replace the new fuel filter and exhaust the air in the fuel system.
  Check each transmission belt.
  Check all rubber hoses and tighten the hose clamps again.
  Close each drain valve and install all drain plugs.
  Check the coolant level. Add if needed.
  Connect a fully charged battery.
  Start the engine and warm up at idle and high idle speed.
  Check for any leakage of lubricant, fuel or coolant.
48
Fault Tracking The following table describes the symptoms and possible causes of engine failure. If the problem cannot be solved by yourself, please contact your Volvo Penta dealer.
Warning! Before starting work, you should carefully read the safety precautions for maintenance work in "Safety Precautions".
Symptoms and possible causes Diagnostic button light is flashing See chapter "Diagnostic information" Engine cannot be stopped 2, 4
Starter motor does not run 1, 2, 3, 4, 5, 6, 7, 24
Slow starter motor speed 1, 2
Starter motor speed is normal, but engine does not start 8, 9, 10, 11
Engine starts but stops 8, 9, 10, 11, 13
Engine does not reach normal operating speed at full speed 9, 10, 11, 12, 13, 21, 25, 26
Unstable engine operation 10, 11, 27
High fuel consumption 12, 13, 15, 25
Smoky 12, 13
Blue or white smoke 14, 15, 22
Lube oil pressure is too low 16
Coolant temperature is too high 17, 18, 19, 20
Coolant temperature is too low 20
No boost or insufficient boost 2, 23
Battery is not charged
2. Poor contact or open circuit of the cable
3. The main power switch is off
4. Main circuit breaker failure
5. Ignition lock failure
6. Main relay failure
7. Malfunction of starter motor and solenoid
8. Fuel shortage:
-Fuel switch is off-Fuel tank is empty / incorrectly connected fuel tank
9. Fuel fine filter / pre-filter clogged (due to impurities or low-temperature fuel stratification)
10. Air in the fuel system
11. Water / impurities in fuel
12. Fuel injection pump failure
13. Insufficient air supply to the engine:
-Air filter clogged-Air leakage between turbochargers-Fouling of the compressor part in the turbocharger-Turbocharger failure-Poor ventilation in the engine compartment
14. Coolant temperature is too high
15. Coolant temperature is too low
16. Lubricant oil level is too low
17. Coolant level is too low
18. Air in the cooling system
19. Circulating water pump failure
20. Thermostat failure
21. Booster intercooler blocked
22. Lubricant oil level is too high
23. Charging generator drive belt slips
24. Engine water
25. High back pressure in the exhaust system
26. Throttle signal “Pot +” cable is disconnected
27. Engine governor / actuator adjustment failure

Volvo Penta Marine Diesel Engine Maintenance

Overview

Volvo Penta engines and their equipment are designed to achieve high reliability and long service life, and to minimize their environmental impact. Volvo Penta genuine parts are used and advanced maintenance work is performed according to the maintenance plan. These features of the engine are maintained and unnecessary failures are avoided.

Volvo Penta Marine Diesel Engine Maintenance Schedule

Warning! Before starting engine maintenance work, you should read the chapter "Volvo Penta Marine Diesel Engine Maintenance" carefully, which contains methods for working safely and correctly.

Important! When both the operating hours and the operating dates are given, the maintenance work shall be performed on the basis of the expiration date. Items marked with □

This chapter describes how to work with the specified maintenance points. Please read them carefully before starting work. The maintenance cycle of each maintenance point can be found in the previous "Volvo Penta Marine Diesel Engine Maintenance Schedule".

Warning! Before starting work, you should carefully read the safety precautions in the "Safety Precautions" chapter regarding maintenance and service work.

Warning! Unless otherwise stated, maintenance and servicing work must be performed with downtime. Remove the start key and disconnect the system power with the main power switch, making Volvo Penta marine diesel engine unable to start. It is dangerous to work near or on a running engine. Be careful of rotating parts and hot surfaces.

Volvo Penta Marine Diesel Engine General Maintenance

Volvo Penta Marine Diesel Engine General Inspection

Make a habit of making "visual inspections" of the engine and engine room before starting the engine and after running down. This will help you find out in time what has happened and what is going to happen.

Pay particular attention to leaks of lubricant, fuel and coolant, loose bolts, worn or loose belts, loose joints or damaged hoses and cables. This inspection takes only a few minutes, but avoids major failures and costly repairs.

Warning! Fuel, lubricating oil or grease accumulated on the engine or in the engine room are all potential fire hazards. Once found, they must be removed immediately.

Important! If there is a leak of lubricating oil, fuel or coolant, you must find the source and eliminate the problem before starting the engine. .

Important! When rinsing with a water gun, do not point the water jet at the radiator, intercooler, seals, rubber hoses or electrical components.

Check the charge air pipe for leaks Check the charge air pipe, hose connections, and clamps for cracks or other damage. Replace if necessary. Volvo diesel engine accessories

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