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Volvo Penta D12 User Manual

Volvo Penta D12
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7
Safety information
Hot surfaces and fluids
A hot engine always offers the risk of burns. Be on
your guard against hot surfaces, such as the ex-
haust manifold, turbocharger, sump, charge air pipe,
starting heater, hot coolant and hot lubricating oil in
pipes and hoses.
Carbon monoxide poisoning
Only start the engine in a well-ventilated area. When
operated in a confined space, exhaust fumes and
crankcase gases must be ventilated.
Chemicals
Most chemicals, such as glycol, rust preventer, con-
servation oils, degreasers etc. are hazardous. Always
read and observe the advice on the packages.
Some chemicals, such as conservation oils, are flam-
mable and also hazardous to breathe. Ensure good
ventilation and use a protective mask for spraying. Al-
ways read and observe the advice on the packages.
Store chemicals and other hazardous material out of
the reach of children. Hand in surplus or used chemi-
cals to a recycling station for destruction.
Cooling system
There is always a risk of water entry when any work
is done on the seawater system. For this reason,
stop the engine and close the sea cocks before you start
work.
Avoid opening the coolant filling cap when the engine
is hot. Steam or hot coolant can spray out and cause
scalding.
If the filler cap, coolant hose etc., still has to be ope-
ned or removed when the engine is hot, undo the
filler cap slowly and carefully, to let the pressure out
before removing the filler cap completely and starting
work. Note that the coolant can still be hot and cause
scalding.
Lubrication system
Hot oil can cause burns. Avoid skin contact with hot
oil. Make sure that the oil system is de-pressurised
before starting work. Never start or run the engine with
the oilller cap removed, because of the risk of oil spil-
lage.
Fuel system
Always protect your hands when searching for leaks.
Fluids which leak under pressure can force their way
into body tissue and cause severe injury. Risk of
blood poisoning (septicaemia).
Always cover the alternator if it is located beneath the
fuel filters. Fuel spillage can damage the alternator.
Electrical system
Cut the current
Before any work is done on the electrical system,
the engine must be stopped and the current cut by
switching off the battery isolator. Shore current for
engine heaters, battery chargers or other auxiliary
equipment connected to the engine must be discon-
nected.
Batteries
Batteries contain a highly corrosive electrolyte. Pro-
tect your eyes, skin and clothes during charging and
other handling of batteries. Always use protective
goggles and gloves. If this comes into contact with
your skin, wash at once with soap and a lot of water.
If you get battery acid in your eyes, flush at once with
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Volvo Penta D12 Specifications

General IconGeneral
Displacement12.1 liters
Bore131 mm
Stroke150 mm
Compression Ratio17.5:1
AspirationTurbocharged and aftercooled
Engine TypeDiesel
Fuel SystemElectronic unit injectors
Cooling SystemHeat exchanger
TypeIn-line 6-cylinder

Summary

Safety Information

Safety Advice for Boat Operation

Provides guidance on safe boat operation, including handling, rules, and checks.

Carbon Monoxide Poisoning Risks

Explains the risk of CO poisoning from exhaust fumes due to low-pressure suction.

Safety Advice for Care and Maintenance Work

Provides essential safety guidance for performing maintenance on the engine.

Fire and Explosion Hazards During Maintenance

Addresses risks from fuel, oil, batteries, and starting aids during maintenance work.

Fuel System Leak Safety

Protect hands when checking for leaks; high-pressure fluids can cause severe injury.

Electrical System Maintenance Safety

Disconnect power before electrical work; protect eyes and skin when handling batteries.

Instruments

Instruments

Controls

Single Lever Electronic Control Operation

Explains how the single lever controls shift function and engine speed.

Two Lever Mechanical Control Operation

Describes the operation of separate levers for shifting and speed control.

Starting the Engine

Pre-Start Engine Checks

Lists essential checks before starting the engine, including fuel, sea cocks, and switches.

Engine Starting Method Sequence

Step-by-step guide for starting the engine, including gear neutral, ignition, and warning lamps.

Starting the Engine

Engine Starting Procedure

Details starting the engine using the ignition switch or starter button, and overheating protection.

Operation

Operation

Engine Alarm Indicators and Actions

Describes how alarms are indicated and the immediate steps to take, like reducing speed.

Operation

Stopping the Engine

Engine Stop Procedure

Details the standard procedure for stopping the engine using the ignition key.

Stopping the Engine

Maintenance Schedule

Daily Pre-Start Maintenance Checks

Lists daily checks including engine general inspection, air filter, oil, coolant, fuel filter, and reverse gear oil.

Maintenance Schedule

Maintenance

Engine General Inspection and Care

Emphasizes visual checks for leaks, loose parts, and worn belts, and cleaning procedures.

Maintenance

Maintenance. Engine, general

Maintenance. Lubrication system

Maintenance. Lubrication system

Engine Oil Level Check and Filling

Instructions on checking the oil level using the dipstick and topping up if necessary.

Engine Oil and Filter Change Procedure

Details the process for changing engine oil and filters, including warming the engine and checking for leaks.

Maintenance. Freshwater system

Coolant Mixture Preparation and Safety

Provides instructions for mixing coolant with water and safety warnings regarding glycol.

Coolant Level Inspection

How to check the coolant level via the expansion tank's level glass.

Coolant Draining Procedure

Step-by-step instructions for draining the coolant from the system, including safety warnings.

Coolant Filling Procedure

Details how to top up coolant and fill an empty system, including venting procedures.

Maintenance. Freshwater system

Maintenance. Seawater system

Seawater System Draining Procedure

Instructions for draining the seawater system to prevent frost damage, with safety warnings.

Maintenance. Seawater system

Maintenance. Seawater system

Maintenance. Fuel system

Maintenance. Fuel system

Maintenance. Electrical system

Battery Maintenance and Safety

Covers battery safety hazards (fire, explosion, acid), handling, and cleaning.

Battery Charging Safety and Procedures

Details safety precautions and procedures for charging batteries, including ventilation and cable handling.

Main Switch Safety Precautions

Warns against disconnecting main switches while the engine is running to prevent damage.

Maintenance. Reverse gear

Reverse Gear Oil Level Check and Filling

Instructions for checking and filling the reverse gear oil level at operating temperature.

Reverse Gear Oil Change Procedure

Steps for changing the reverse gear oil, including sucking out old oil and refilling.

Accessories

Laying up/Launching

Engine Inhibiting Procedure for Storage

Comprehensive steps for inhibiting the engine for short (max 8 months) and long (more than 8 months) storage.

Bringing Engine Out of Storage

Steps for preparing the engine after storage, including checks, filter changes, and starting procedures.

In case of emergency

Starting Engine with Auxiliary Batteries

Detailed safety precautions and steps for jump-starting the engine using auxiliary batteries.

In case of emergency

Emergency Shifting Procedure

Describes how to manually shift the revers gear in case of a control lever fault.

Diagnostic Function Overview and Tasks

Explains the diagnostic function's role in monitoring, detecting, and advising on engine malfunctions.

EVC System Malfunction Messages and Alarms

Describes how malfunctions are displayed via pop-ups and buzzers, and how to acknowledge them.

In case of emergency

Engine Malfunction Fault-Tracing Guide

Table listing symptoms, possible causes, and corresponding fault codes for engine malfunctions.

In case of emergency

Fault register

Engine Speed Sensor Faults

Explains faults related to the engine speed sensor and the resulting reaction.

Water in Fuel Faults

Describes faults related to water in fuel filters and the necessary actions.

Air Temperature Faults

Covers faults related to high charge air temperature and engine power reduction.

Coolant Pressure Faults

Details faults related to low coolant pressure and the required checks.

Fuel Pressure Faults

Explains faults related to low fuel pressure and engine power reduction.

Engine Oil Level Faults

Details faults for low engine oil level and the resulting engine power reduction.

Engine Oil Temperature Faults

Covers faults for high engine oil temperature and engine power reduction.

Crankcase Pressure Faults

Explains faults for high crankcase pressure and engine power reduction.

Transmission Oil Pressure Faults

Details faults for low transmission oil pressure and engine power reduction.

Battery Voltage Faults

Explains faults for low battery voltage and necessary checks.

Primary Battery Faults

Details faults related to poor primary battery condition or charging.

EMS Supply Fuse Faults

Covers faults related to a broken EMS supply fuse.

Lever Calibration Faults

Covers faults related to incorrect lever calibration, preventing helm station selection.

Seawater Pressure Faults

Explains faults related to low seawater pressure and the required checks.

Coolant Level Faults

Explains faults for low coolant level and the resulting engine power reduction.

Coolant Temperature Faults

Covers faults for high coolant temperature and the resulting engine power reduction.

Fuel Temperature Faults

Covers faults for high fuel temperature and the resulting engine power reduction.

Engine Oil Pressure Faults

Explains faults for low engine oil pressure and the resulting engine power reduction.

Engine Oil Filter Faults

Details faults related to high oil pressure differential across the filter.

Exhaust Temperature Faults

Covers faults for high exhaust temperature and engine power reduction.

Auxiliary Stop Signal Faults

Covers faults related to external stop signals and engine stopping/non-starting.

Secondary Battery Faults

Covers faults related to poor secondary battery condition or charging.

Extra Supply Fuse Faults

Explains faults when an extra supply fuse is broken.

30V Supply Fuse Faults

Explains faults when the 30V supply fuse is broken.

Control Lever Faults

Details faults in the control lever, leading to emergency mode and neutral gear.

Technical data

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