Volvo Penta D1-13 Instruction manual

Group 30
Workshop Manual
2(0)
A
D1-13, D1-20, D1-30, D2-40

Content
General Information
00-0 General ................................................................................................ 2
Specifications
03-3 Specifications, Electrical ................................................................... 3
Electrical System ........................................................................................ 3
Special tools
08-2 Special Service Tools ......................................................................... 4
General, Complete Vehicle Software
30-0 General ................................................................................................ 5
30-2 Fault Tracing ..................................................................................... 12
General ....................................................................................................... 12
Fault Codes ............................................................................................... 13
Cables and fuses
37-0 Wiring Diagrams ............................................................................... 38
Alphabetical index .................................................................................... 47
References to Service Bulletins .............................................................. 49
47704383 06-2013 © AB VOLVO PENTA 1

00-0 General
About this Workshop manual
General information
This Service Manual contains technical data, descrip-
tions and maintenance and repair instructions for
standard model Volvo Penta products. A list of these
products may be found in the section Specifica-
tions.
The product designation and the serial number and
specification is indicated on the engine decal or type
plate. This information must be included in all corre-
spondence regarding the product.
The service manual is produced primarily for the use
of Volvo Penta workshops and their qualified person-
nel. It is assumed that any person using the Service
Manual has a fundamental knowledge of the product
and is able to carry out mechanical and electrical
work to trade standard.
Volvo Penta continually develops its products; we
therefore reserve the right to make changes. All infor-
mation in this manual is based on product data which
was available up to the date on which the manual was
printed. New working methods and significant
changes introduced to the product after this date are
communicated in the form of Service bulletins.
Spare Parts
Spare parts for the electrical and fuel systems are
subject to various national safety standards. Volvo
Penta Original Spare Parts meet these standards. No
damage of any kind caused by the use of spare parts
not approved by Volvo Penta will be compensated by
any warranty undertaking.
Certified engines
When carrying out service and repair on emis-
sion-certified engines, it is important to be aware
of the following:
Certification means that an engine type has been
inspected and approved by the relevant authority.
The engine manufacturer guarantees that all engines
of the same type are manufactured to correspond to
the certified engine.
This places special demands on service and repair
work, namely:
• Maintenance and service intervals recom-
mended by Volvo Penta must be complied with.
• Only spare parts approved by Volvo Penta may
be used.
• Service on injection pumps, pump settings and
injectors must always be carried out by an
authorized Volvo Penta workshop.
• The engine must not be converted or modified,
except with accessories and service kits which
Volvo Penta has approved for the engine.
• No changes to the exhaust pipe and engine air
inlet duct installations may be made.
• No warranty seals (where present on the prod-
uct) may be broken by unauthorized persons.
The general instructions in the Operator's Manual
concerning operation, service and maintenance
apply.
IMPORTANT!
Neglected or poorly-performed care/service and the
use of spare parts not approved by Volvo Penta, will
mean that AB Volvo Penta no longer guarantees that
the engine conforms to the certified model.
Volvo Penta accepts no responsibility for damage or
costs arising as a result of failure to follow the above
mentioned standards.
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03-3 Specifications, Electrical
Electrical System
Group 30: Electrical System
System voltage 12 V
Battery capacity (starter battery)
D1-13-A/B/F, D1-20-A/B/F, D1-30-A/B/F 70 Ah
D2-40-A/B/F 88 Ah
Glowplugs
rated voltage 11 V
current 11 A
Alternator
Output voltage at +20°C (68°F)
with sense 14.2 ±0.15 V
without sense 14.2 ±0.30 V
Max. current 115 A
Power, approx. 1,630 W
Suppression capacitor 2.2 μF
Starter motor
Power, approx.
D1-13-A/B/F, D1-20-A/B/F 0.8 kW
D1-30-A/B/F 1.1 kW
D2-40-A/B/F 1.4 kW
03-3 Specifications, Electrical
47704383 06-2013 © AB VOLVO PENTA 3

08-2 Special Service Tools
The following special tools are used when working on
the engine. The tools can be ordered from AB Volvo
Penta by specifying the number indicated.
p0005128
p0005125
9998699 Break-out box 88890016 Break-out cable 88890074 Multimeter
08-2 Special Service Tools
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30-0 General
Repair Instructions
General advice
The following advice must be followed to avoid dam-
age to the MDI unit and other electronics.
IMPORTANT!
The system must be disconnected from system volt-
age (by switching off the current at the main switch)
when the MDI connector is removed or reconnected.
Never switch off the current at the main switch when
the engine is running. Never disconnect a battery cable
when the engine is running.
Switch off the main switches or disconnect the battery
cables when fast-charging the batteries.
NOTICE! It is not necessary to switch off the main
switches during normal maintenance charging.
Only batteries may be used for starting. A jumpstart
unit is able to supply very high voltage and damage the
control unit and other electronics.
Take extreme care so that the harness terminals do
not come into contact with oil, water or dirt if a connec-
tor is removed from a sensor.
30-0 General
47704383 06-2013 © AB VOLVO PENTA 5

Fault tracing of cables and connectors
Tools:
88890074 Multimeter
Check all connectors visually
Look for the following:
•Look for oxidation which can impair contact in
connectors.
• Check that terminals are undamaged, that they
are correctly inserted into their connectors, and
that the cable is correctly terminated in the ter-
minal.
• If possible, shake the cables and pull the con-
nectors during measurement to discover
whether the cable 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 occasional recurrent faults can
be difficult to trace and are often caused by oxidation,
vibration or poorly connected cables.
Wear can also cause problems. For this reason, avoid
disconnecting a connector unless necessary.
Other contact problems can be caused by damage to
pins, sleeves and connectors etc.
Shake the cables and pull on the connector during test
measurements to find where the cable is damaged.
Contact resistance and oxidation
The resistance in connectors, wiring and splitters
must be approx 0 Ω. However, there is always a cer-
tain resistance in connectors due to oxidation.
However, if the resistance is too high problems will
occur. The amount of resistance that can be tolerated
before a fault occurs varies depending on circuit load.
Open circuit
Possible fault causes can be defective or chafed
cables or loose connectors.
Use the wiring diagram to check the cables that are
relevant to the function. Begin with the most probable
cable in the circuit.
Look for the following:
• Disconnect the relevant connector at both ends
of the harness.
• Use 88890074 Multimeter to measure the resist-
ance between the cable ends.
Nominal value ~ 0 Ω.
• If possible, shake the cables and pull on the
connectors during test measurements to deter-
mine whether the harness is damaged.
• Check the next cable system in the wiring dia-
gram if no fault is found.
Electrical Welding
Remove the positive and negative cables from the
batteries. Then disconnect all connections to the alter-
nator, starter motor and the MDI.
Connect the welder ground clamp to the component
to be welded, or as close as possible to the weld site.
The clamp must never be connected to the engine or
in such a way that current can pass through a bearing.
IMPORTANT!
When welding is finished the alternator cables must
be reconnected before the battery cables are con-
nected.
Starter motor
Starter motor fault tracing must be assigned to an
authorized marine electrical workshop with the nec-
essary test equipment.
30-0 General
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Check battery voltage
Tools:
88890074 Multimeter
General
If battery voltage falls below 12.4 V*, the starter motor
will not be able to crank the engine at normal speed.
A fully-charged battery has a voltage on an open circuit
of around 12.7 V (depending on ambient temperature).
When open circuit voltage falls to 12.5 V, the battery is
half charged.
NOTICE! * Measured at the batteries.
Voltage measurement, check
1 Check that battery voltage is at least 12.4 V while
the batteries are not under load by using multi-
meter 9812519 to measure between the battery
terminals.
NOTICE! * Measured at the batteries.
2 Turn the main switch on.
3 Check that the voltage between the terminals B+
and B– on the starter motor is the same as the
battery voltage.
P0008397
30-0 General
47704383 06-2013 © AB VOLVO PENTA 7

Check the alternator brushes
Removal of alternator brushes
1 Pull back the black plastic cover.
2 Use a screwdriver to loosen the plastic cover
above the brush holders.
3 Unscrew the two Torx screws that retain the two
brush holders.
P0008398
P0008399
P0008405
30-0 General
8 47704383 06-2013 © AB VOLVO PENTA

4 Pull the brushes out.
5 Measure the length of the brushes. If a brush is
so worn that the 5 mm (0.2") limit has been
exceeded the brush must be changed.
Installation of alternator brushes
1 Make sure that the brushes are placed as illus-
trated when installing.
048
P0008406
5mm
P0008407
P0008408
30-0 General
47704383 06-2013 © AB VOLVO PENTA 9

Check the charging system
Tools:
88890074 Multimeter
General alternator information
Alternator voltage must be limited to prevent battery
electrolyte from evaporating. Alternator output is con-
trolled (limited) by the voltage regulator in the alter-
nator. The maximum current that the alternator can
deliver with a controlled output depends on alternator
rpm. In order for the alternator to charge efficiently a
sensor line may be connected between the alternator
and the battery plus terminal. A voltage drop in the
cable between the alternator and the battery plus ter-
minal is compensated in this way. When the engine is
started a magnetization current is required to excite
the alternator.
NOTICE! It is power consumers (including the batter-
ies) that determine output current from the alternator.
Measurements:
1 Engine switched OFF.
2 Use 88890074 Multimeter to perform a voltage
test across the batteries. The nominal voltage
across a fully-charged battery is around 12.7 V
(depending on ambient temperature).
3 Start the engine. Run at 1,500 rpm.
4 Use 88890074 Multimeter to perform a voltage
test across the batteries. The nominal charge
voltage across the battery should be around
13.8-14.6 V.
Charging system fault tracing
Battery (orange indication):
1 Check that all battery connections are properly
installed.
2 Check the cables to the battery.
3 Check the battery electrolyte level.
4 If possible, check the specific gravity in all cells.
No charge:
1 Check the tension of the alternator drive belts.
2 Check that the alternator and battery connectors
are correctly installed.
3 Check the condition of all charging system
cables.
4 Check that the alternator is receiving the correct
magnetization voltage.
5 Regulator fault; check with another alternator.
Charge too low:
1 Check the tension of the alternator drive belts.
2 Check that the alternator and battery connectors
are correctly installed.
3 Check the condition of all charging system
cables.
4 Regulator fault; check with another alternator.
Over charge:
1 Possible regulator fault; check with another
alternator.
30-0 General
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MDI gauge checks
Tools:
88890074 Multimeter
The gauges are of Easy-Link type and receive their
signals via a serial bus. The instrument cables com-
prise three wires: battery positive, battery negative and
a databus.
If a fault occurs in the instrument Easy Link bus, it can
be detected by the gauge needles stopping in the
same position on the instruments (they “freeze”). If
none of the gauges function, check using
88890074 Multimeter that there is +12 V between the
red (pin 1) and blue (pin 2) wires in the Easy link har-
ness.
Since shared signals from various types of gauges
pass through the same cable, it is difficult to determine
whether information is lacking from the serial bus, or if
an individual gauge is faulty. If an instrument fault is
suspected, use the following procedure to determine
whether the gauges are faulty or not.
1 Start the engine and let it idle with the control lever
in the neutral position.
2 Disconnect the gauge that is suspected of being
faulty.
3 The fault disappears
- Check that there is no oxide or moisture in
the connectors to the gauge concerned.
- Change the disconnected gauge and check
if the fault is still absent when the new gauge
is connected.
The fault remains
Continue to disconnect gauges until gauge dis-
plays are correct. Then attempt to connect the
gauges again. Begin with the gauge that was dis-
connected first and continue to connect the
gauges that were disconnected until the indication
is no longer shown. Change the gauge connected
last.
PREHEAT
START
BATT
P0008396
30-0 General
47704383 06-2013 © AB VOLVO PENTA 11

30-2 Fault Tracing
General
Fault tracing refers only to engine models with MDI.
Function fault
Symptom Action
The alarm cannot be confirmed. Refer to the "Fault on keypad" section.
Charging problems. Refer to the "Battery warning" section, or to the "Check
charging system" section.
Coolant alarm. Refer to the “Warning, coolant temperature” section.
Engine does not start (due to electrical problems). Refer to the “Warning, start / preheat” section.
Warning, fuel level. Refer to the “Warning, fuel level” section.
Glowplug(s) not activated. Refer to the “Warning, start / preheat” section.
No dimmer function. Refer to the "Fault on keypad" section.
No indication of operating hours on the tachometer /
display.
Refer to the “Multilink fault” section.
No indication of engine rpm on the tachometer / display. Refer to the “Multilink fault” section.
No data from the multisensor visible in the EVC display. Refer to the “Multilink fault” section.
Oil pressure alarm. Refer to the ”Oil pressure warning (engine)” section.
If the button does not energize the system. Refer to the "Fault on keypad" section.
The starter motor is not activated. Refer to the "Warning, start / preheat" section, or to the
"Check battery" section.
The stop solenoid is not activated. Refer to the "Stop solenoid" section, or to the "Fault on
keypad" section.
Alarm display
1Lubrication oil pressure: When oil pressure falls
below a given value at a given engine speed, the
alarm lamp is lit.
2Battery voltage: The alarm lamp is lit if the alter-
nator is not charging or if it overcharges.
3Coolant temperature: When coolant temperature
exceeds the alarm limit, the alarm lamp is lit.
4Warning indication: The ”System fault” lamp is lit
if there is a short circuit, wiring break or AUX fault.
In the case of faults that require immediate action
by the helmsman, the alarm buzzer sounds contin-
uously.
5 Not used.
!
12
3
4
5
P0008409
30-2 Fault Tracing
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Fault Codes
Oil pressure (engine) warning
Tachometer
The tachometer LCD screen will show a flashing oil
pressure icon and the alarm buzzer sounds.
Alarm display
The oil pressure indication flashes in the alarm display
+ audible warning.
Circuit description
The oil pressure in the engine is monitored by a pres-
sure switch. The output signal from the pressure switch
can have two distinct positions, high/low, in the same
way as a relay output. A pre-set limit value determines
when the switch switches from one distinct position to
the other one. The switch is closed when the oil pres-
sure is low and when the engine is off. Pin 6 in the
engine interface connector at the MDI provides the
switch with a voltage signal.
Fault tracing
Fault condition
The oil pressure switch closes at a oil pressure lower
than 60 kPa (8.7 PSI).
The alarm is depended of the engine rpm.
<1000 rpm: oil pressure switch closed for more than
30 seconds.
>1000 rpm: oil pressure switch closed for more than
0.5 seconds.
Possible reason
•Oil level too low.
•Short circuit between oil pressure switch supply
cable and battery negative.
•Faulty oil pressure switch.
Suitable action
1 Check the oil level in the engine and the oil quality.
2 Check that the oil filter is not blocked. Change oil
filter and engine oil.
3 Check that no leakage occurs.
P0007945
a
MDI
BL / W 1
SB 2
6
1P
b
P0008410
a Engine connector
bOil pressure switch
30-2 Fault Tracing
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4 Check all wiring and connectors between the oil
pressure switch and the MDI.
5Check the switch by checking the engine oil pres-
sure (see “Checking lubrication oil pressure” in the
mechanical workshop manual for the engine).
30-2 Fault Tracing
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Measurements
Check MDI input for oil pressure switch
Tools:
88890074 Multimeter
9998699 Break-out box
88890016 Break-out cable
1 NOTICE! Cut the current with the main switch.
2 Connect 88890016 Break-out cable with
9998699 Break-out box between the MDI and the
engine connector.
3 Use 88890074 Multimeter 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 negative) - 21
(oil pressure switch sup-
ply)
U ≈ 0 V
(switch closed)
5 Disconnect the oil pressure switch connector at
the oil pressure switch.
Measurement points Nominal value
16 (battery negative) - 21
(oil pressure switch sup-
ply)
U ≈ 3,5 V
6 Reconnect the oil pressure switch connector at
the oil pressure switch.
7 Start the engine. Wait a minute before measuring.
Measurement points Nominal value
16 (battery negative) - 21
(oil pressure switch sup-
ply)
U ≈ 3,5 V
(switch open)
MDI
9998699
8 9 10 11 12 13 14
22 23 24 25 26 27 28
29 30 31 32 33 34 35
36 37 38 39 40 41 42
43 44 45 46 47 48 49
50 51 52 53 54 55 56
16
V
21
P0008411
30-2 Fault Tracing
47704383 06-2013 © AB VOLVO PENTA 15

Coolant temperature warning
Tachometer
The tachometer LCD screen will show a flashing cool-
ant temperature icon and the alarm buzzer sounds.
Alarm display
The coolant temperature indication flashes in the alarm
display + audible warning.
Circuit description
The coolant temperature sensor consists of a thermis-
tor. The property of a thermistor is that its resistance
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 volt-
age 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 reference level. When the cool-
ant heats up, the resistance in the thermistor falls and
the voltage drop across the thermistor changes.
P0007947
5
a
MDI
LBN 1
b
P0008412
a Engine connector
bCoolant Temperature
30-2 Fault Tracing
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Fault tracing
Fault condition
Coolant temperature exceeds +110 °C (+230 °F) for
more than 15 seconds.
Possible reason
•Low coolant level.
•Blocked sea water filter or sea water intake.
•Worn impeller in seawater pump.
•Kinked/leaking/blocked hose on the suction side
(sea water).
•Slipping or broken drive belt for circulation pump.
•Defective thermostat.
•Incorrect pressure cap on expansion tank.
•Fault in the coolant temperature sensor cable
between the MDI and the sensor.
•Faulty coolant temperature sensor.
•Blocked heat exchanger.
•Poor flow through the cooling system due to worn
coolant pump/seawater pump.
Suitable action
1Check the coolant level.
2 Check that the system does not leak.
3 Check the drive belt tension for the coolant pump.
4 Check that the seawater intake 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 the filler cap” in the
mechanical workshop manual for the engine.
8 Check the cables and the connectors between the
engine connector at the MDI and the coolant tem-
perature sensor.
9 Check the sensor.
10 Clean the heat exchanger. See “Clean the heat
exchanger” in the mechanical workshop manual for
the engine.
11 Change coolant pump / seawater pump.
30-2 Fault Tracing
47704383 06-2013 © AB VOLVO PENTA 17

Measurements
Check MDI output for coolant temperature sensor
Tools:
88890074 Multimeter
9998699 Break-out box
88890016 Break-out cable
1 NOTICE! Cut the current with the main switch.
2 Connect 88890016 Break-out cable with
9998699 Break-out box between MDI and the
engine connector.
3 Use 88890074 Multimeter 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 negative) - 20
(coolant temperature)
U ≈ 5 V
6 Reconnect the coolant temperature sensor con-
nector at the coolant temperature sensor.
Measurement points Nominal value
16 (battery negative) - 21
(coolant temperature sen-
sor)
U ≈ 2–3 V at +20°C
(+68°F)
MDI
9998699
8 9 10 11 12 13 14
22 23 24 25 26 27 28
29 30 31 32 33 34 35
36 37 38 39 40 41 42
43 44 45 46 47 48 49
50 51 52 53 54 55 56
16
V
20
P0008413
30-2 Fault Tracing
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