Operator'S Manual: D25A MS/MT D30A MS/MT

OPERATOR’S MANUAL
D25A MS/MT
D30A MS/MT
Non-classifiable control system
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CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.

Foreword
Thank you for purchasing this Volvo Penta diesel engine.
This manual contains operation instructions and maintenance and inspection information. In or-
der to ensure safety and bring out the maximum performance of the engine, do not operate the
engine until you have read and fully understood the contents of this manual. Do not hesitate to
consult your Volvo Penta dealer.
Failure to follow the instructions and cautions in this manual may result in serious accidents.
* Keep this manual at hand for easy reference.
* If this manual is damaged or misplaced, immediately order a new copy from your dealer.
All information and illustrations in this manual are based on the specifications that were avail-
able at the time of printing. This manual does not cover all available variants of accessories
and options.

Contents
Foreword .................................................................. 3 Fuel system ......................................................... 50
Bleeding the fuel system.................................... 50
Contents .................................................................. 4
Changing fuel filter ............................................. 52
Safety Information ................................................... 5 Changing fuel injector nozzle ............................. 53
Safety regulations during engine operation ............. 6 Fuel injection pressure ....................................... 54
Safety directions for maintenance and service ....... 8 Injection timing inspection .................................. 56
Warning labels ..................................................... 11 Fuel control ........................................................ 57
Introduction ............................................................ 13 Twin fuel pre-filter/water separator ...................... 58
Air inlet and exhaust systems .............................. 60
Presentation ........................................................... 15 Turbocharger inspection ..................................... 60
D25A/D30A MS ................................................... 15 Cleaning the air cooler ........................................ 60
D25A/D30A MT .................................................... 16 Checking the air cooler drain pipe ...................... 60
New engine initial service ....................................... 17 Washing the air inlet silencer filter ...................... 61
Cooling system, general ....................................... 62
Starting .................................................................. 18
Cooling system D25A/D30A MS HE .................. 63
Non-classifiable control system ............................. 19 Cooling system D25A/D30A MS KC .................. 64
Instrument panels ................................................ 19 Cooling system D25A/D30A MT HE ................... 65
Starting procedure ................................................ 21 Freshwater system .............................................. 66
Operation ............................................................. 22 Checking the coolant level ................................. 66
Stopping the engine ............................................. 23 Filling the coolant ............................................... 66
Operation ............................................................... 24 Draining the coolant ........................................... 67
Flushing the freshwater system ......................... 67
Stopping ................................................................ 29 Rawwater system ................................................. 68
Manual stop lever................................................. 29 Draining the rawwater system ............................ 68
After stopping ...................................................... 29 Checking/Changing zinc anodes ........................ 68
Anti-freezing measures ...................................... 30 Checking/Changing the rawwater filter ................ 69
Breaks in operation [not using the genset] ......... 30 Checking/Changing the rawwater pump impeller . 69
Maintenance .......................................................... 31 Cleaning the heat exchanger .............................. 70
Maintenance schedule ......................................... 32 Electrical system ................................................. 71
D25A/D30A MS ................................................. 32 Protective devices inspection ............................ 71
D25A/D30A MT .................................................. 35 Checking the electrical wiring ............................. 71
Overhaul information ............................................ 38 Starter motor inspection ..................................... 71
Recommendation of Daily Operation Records ...... 40 Alternator inspection .......................................... 71
Engine ................................................................. 41 Checking/Adjusting/Changing the drive belts...... 71
Valve clearance ................................................. 41 Inhibiting ................................................................ 72
Firing order ......................................................... 42
Vibration damper inspection ............................... 43 Troubleshooting ..................................................... 74
Re-tighten bolts and nuts ................................... 43 Technical Data ....................................................... 75
Using the turning gear ........................................ 44 D25A MS ............................................................. 75
Lubrication system ............................................... 45 D25A MT ............................................................. 76
Checking oil level ............................................... 45 D30A MS ............................................................. 77
Filling oil ............................................................ 45 D30A MT ............................................................. 78
Changing oil ....................................................... 47 Fuel specification ................................................. 79
Changing oil filter ............................................... 48 Lubrication oil specification .................................. 80
Changing oil by-pass filter .................................. 49 Coolant specification ............................................ 81
Changing hydraulic governor oil filter .................. 49 Tightening torque tables ....................................... 82
Identification numbers .......................................... 88
Sea trial data ....................................................... 89
Notes ..................................................................... 90

Safety Information
Read this chapter thoroughly. It concerns your safety. This section describes how safety information is presented
in this manual and on the product. It also includes a summary of basic safety regulations for operation and main-
tenance of the engine.
Make sure you are in possession of the right operator’s manual before reading on. If this is not the case,
please get in touch with your Volvo Penta dealer.
If operations are performed incorrectly it could result in personal injury or damage to property or the engi-
ne. Read the Operator’s Manual carefully before operating or servicing the engine. If anything is unclear
please contact your Volvo Penta dealer for assistance.
This symbol is used in the book and on the engine to make you aware of safety infor-
mation. Always read these safety precautions very carefully.
In the Operator’s Manual warning texts have the following priority:
WARNING! If these instructions are not followed there is a danger of personal injury,
extensive damage to the product or serious mechanical malfunction.
IMPORTANT! Used to draw your attention to something that can cause damage,
product malfunction or damage to property.
NOTE! Used to draw your attention to important information that will facilitate work or
operations.
This symbol is used in certain cases on our products and refers to important informa-
tion in the Operator’s Manual. Ensure that warning and information symbols on the engine
and transmission are always visible and legible. Replace symbols that have been damaged
or painted over.

5
Safety information
Safety regulations during engine operation

The new engine Filling fuel
Read instruction manuals and other information ac- There is a risk of fire and explosion when filling fuel.
companying the new vessel thoroughly. Accustom Smoking is prohibited and the engine must be turned
yourself with handling the engine, controls and other off. Never overfill the tank. Close the filler cap
equipment in a safe and correct manner. securely. Use only fuel recommended in the operators
manual. The incorrect grade of fuel can disturb opera-
Remember that when operating a vessel, you have a
tion or cause breakdown. This can also lead to the
legal responsibility to be aware of and follow regula-
control rod jamming on diesel engines, which will cau-
tions concerning traffic and safety at sea. Inform your-
se the engine to overspeed and risk damaging machi-
self of the regulations applicable to your vessel and
nery and causing personal injury.
the waters your in by getting in touch with the relevant
authorities or marine safety organization.
Combustible enviroment
Accidents and other incidents Due to the risk of fire and/or explosion, do not start or
continue to run the engine if there is a suspected leak
Sea rescue statistics show that deficient maintenance
or discharge of combustible media, e.g. fuel oil or
of vessels and engines together with defective safety
LPG, in the engine surroundings.
equipment often causes accidents and other incidents
at sea.
Make sure your vessel and engine are maintained in
accordance with directions in the instruction manuals
and that the safety equipment on board is in good
working order.
Daily inspection
Make a habit of visually inspecting the engine and
engine room before starting and after stopping the
engine. This will help you to quickly detect any fuel,
coolant or oil leaks and any other abnormalities that
have occurred or are about to occur.
Maneuvering
Avoid violent and rapid rudder movement and gear
shifting. There is a risk of the passengers falling down
or falling overboard. A rotating propeller can cause se-
rious injury. Make sure there is nobody in the water
before engaging forward/reverse. Never run close to
bathers or in places where you have reason to believe
there are people in the water.

6
Safety information
Carbon monoxide poisoning

When a vessel is moving forward, it will cause a certain vacuum to form behind the vessel. In unfortunate circum-
stances, the suction from this vacuum can be so great that the exhaust gases from the vessel are drawn into the
bridge or cabin and cause carbon monoxide poisoning. This problem is most prevalent on high, wide vessels with
abrupt stern. Other factors that can increase the effect of the suction are wind conditions, load distribution, swells,
trim, open hatches and portholes, etc. Most modern vessels, however, are designed in such a way that this pro-
blem is very rare. If suction should arise anyway, do not open hatches or portholes at the fore of the vessel. Sur-
prisingly, this will otherwise increase the suction. Try changing speed, trim, or load distribution instead. Get in
touch with your Volvo Penta dealer for help in obtaining the best solution for your vessel.
IMPORTANT! Safety equipment: life jackets for everyone on board, communication equipment,
distress rockets, approved fire extinguisher, bandages, life buoy, anchor, paddle, torch, etc.
● Spare parts and tools: Impeller, fuel filter, fuses, adhesive tape, hose clips, engine oil, propeller
and tools for tasks it may be necessary to perform.
● Plan your desired route from the charts. Calculate distance and fuel consumption. Listen to
weather reports.
● Inform relations of your planned route for long trips. Remember to inform of changed plans or
delays.
● Inform the people on board of where the safety equipment is located and how it works. Make
sure there is more than one person on board that knows how to start and maneuver the boat
safely.
This list should be supplemented with necessary safety equipment depending on the type of boat,
where and how it is being used, etc. We recommend you get in touch with a regional boat or marine
safety organization to obtain more detailed marine safety information.

7
Safety information
Safety directions for maintenance and service

Preparations Before starting
Refit all guards and covers that have been removed
Knowledge before starting the engine. Make sure there are no
The operator’s manual contains directions for perfor- tools or other objects left on the engine. A turbochar-
ming normal maintenance and service in a safe and ged engine must never be started without the air filter
correct manner. Read the directions carefully before fitted. The rotating compressor wheel in the turbochar-
starting work. More detailed service literature is avail- ger can cause severe personal injury.
able from your Volvo Penta dealer. Never perform a
task unless you are absolutely sure how it is to be There is also a risk of foreign objects being drawn in
carried out; call your Volvo Penta dealer for assistan- and causing mechanical damage.
ce instead.
Fire and explosion
Stop the engine
Stop the engine before opening or dismantling the Fuel and lubricants
engine hatch/hood. Maintenance and service must be All fuels, most lubricants, and many chemicals are
carried out with the engine stationary unless stated flammable substances. Always read and follow the
otherwise in the instructions. Prevent inadvertent start directions on the packaging. Work performed on the
of the engine by removing the starter key and turning fuel system must be done on a cold engine. Fuel
off the power with the main switch, locking it in the off leaks and spills on hot surfaces or electrical
position. Place warning signs stating that service is in components can cause fires.
progress in every position from which the engine can Keep oil- and fuel drenched rags and other hazardous
be started. Working on or approaching a running engi- materials where they are safe in case of fire. Oil dren-
ne is a safety hazard. Loose clothing, hair, fingers or ched rags can selfignite in certain conditions. Never
a dropped tool can be caught in rotating parts and smoke when refueling, topping up with oil or when in
cause serious bodily injury. Volvo Penta recommend the vicinity of the fuel station or the engine room.
leaving all work requiring the engine to be running to
an authorized Volvo Penta dealer. Non-original parts
Components in fuel, lubrication, ignition and electrical
Lifting the engine
systems on Volvo Penta engines are designed and
Always use the lifting eyes mounted on the engine manufactured to minimize the risk of explosion and
when lifting the engine. Always make sure lifting fire in compliance with existing legislation.
equipment is in good condition and constructed for the
lift (engine weight together with possible reverse gear The use of non-original parts can result in explosion
and extra equipment). Use an adjustable lifting boom or fire.
to ensure safe handling when lifting the engine. All
chains and wires must run parallel with each other and Batteries
as much at right angle as possible to the top of the Batteries contain and generate oxyhydrogen gas,
engine. Note that any extra equipment mounted on the especially when charging. Oxyhydrogen is easily
engine can change the center of gravity. Special lifting ignited and extremely explosive. Smoking, open fla-
devices may be required to obtain the right balance mes and sparks must never occur in, or close to, the
and safe handling. Never perform service on an engi- batteries or battery compartment. A faulty battery con-
ne suspended only from a lifting device. nection or jumper cable can generate sparks that can
cause the battery to explode.
IMPORTANT! Engine must only be lifted
horizontally. Start spray
Never use start spray or similar start help. Explosions
IMPORTANT! Engine lifting eyes are designed can occur in the intake manifold. Risk for personal
only for lifting an engine. Do not use the engine injury.
lifting eyes when lifting an engine with a gearbox
mounted.

8
Safety information
Hot surfaces and fluids Cooling system

At operating temperature, the engine and its compo- There is a risk of water entering when working on the
nents are hot. A hot engine always involves risk for seawater system. Therefore, stop the engine and
burn injuries. Take care with hot surfaces. E.g.: ex- close the seawater cock before starting work.
haust manifold, turbocharger, oil pan, charge air pipe,
Avoid opening the coolant filler cap when the engine is
starting heater, hot coolant and warm lubricant in pi-
warm. Steam or hot coolant may spurt out and cause
pes and hoses.
burn injuries.
WARNING! Do not open the crankcase
If the filler cap, coolant pipe, cock, etc., must
covers while the engine is still hot.
nevertheless be opened or dismantled while the
engine is warm, the filler cap must be opened
Carbon monoxide poisoning carefully to release the pressure before removing it
Start the engine in well-ventilated spaces only. When completely and starting work. Note that the coolant
running in confined spaces, the exhaust gases and can still be hot and cause burn injuries.
crankcase gases must be evacuated.
Lubricating system
Chemicals Hot oil can cause burn injuries. Avoid skin contact
Most chemicals such as glycol, anti-corrosion agent, with warm oil. Make sure the lubricating system is de-
preservatives, degreasing agent, etc., are hazardous pressurized before starting work. Never start or run
to health. Always read and follow the directions on the engine with the oil filler cap removed or there will
the packaging. be a risk of the oil being thrown out.
Certain chemicals such as preservatives are

flammable and harmful to inhale. Provide good Fuel system
ventilation and use breathing protection when Always protect your hands when carrying out leak de-
spraying. Always read and follow the directions on the tection.
packaging. Store chemicals and other hazardous
Escaping fluids under pressure can pierce bodily tis-
materials out of reach of children. Leave left over or
sue and cause serious injury. Risk of blood poisoning.
used chemicals to a destruction plant.
Always cover any electric component if it is located
under the fuel filter. Otherwise it might be damaged by
fuel spills.

9
Safety information
Electrical system
Turn off the power before commencing work on the Handle antifreeze carefully!
electrical system, the engine must be stopped and the Antifreeze contains alkali. Avoid contact with skin
powered turned off with the main switch/switches. and eyes to prevent personal injury. Dispose of
Shore power to the engine heater, battery charger or drained antifreeze coolant according to local
other extra equipment fitted to the engine must be dis- regulations. For disposal, consult your dealer.
connected.
Dress properly for the job!
Batteries Wear protective devices - hard hat, face shield, safety
Batteries contain a highly corrosive electrolyte. Pro- shoes, goggles, heavy gloves, ear protectors, etc. -
tect your eyes, skin and clothing when charging and for your own safety.
handing batteries. Always use protective goggles and
gloves. Recommended fuel, lubrication oil and coolant!
In case of splashes on the skin, wash with soap and Use of any other fuel oil, lurication oil or coolant than
plenty of water. In case of splashes in the eyes, rinse the recommended can cause engine damage and re-
immediately with plenty of water and call a doctor. duce engine service life.
Avoid burns and crushing or cutting! Perform all recommended inspections!

At operating temperature, the engine coolant is hot Perform pre-start inspection and periodic inspection
and under pressure. Steam can cause personal on items listed in this manual. Failure to follow this
injury. Check the coolant level only after the engine recommendation can cause serious engine damage.
has been stopped and the coolant filler cap has coo-
led enough to touch with your hand. Never adjust the
V-belts while the engine is running.
Service batteries carefully!

If you spill electrolyte on yourself, flush skin immedia-
tely with lots of water. Apply baking soda to help neu-
tralize the acid. If electrolyte gets in your eyes, rinse
immediately with large amounts of water then contact
a doctor at once.

10
Safety information
Warning labels
D25A/D30A MS
The engine carries ‘Warning Labels’ at places where you are required to pay special attention. Please read them
carefully and make sure you understand the content of each label and the meaning of their position.
1. Make sure the labels are legible. If you find any letter or picture illegible in a label, remove soil from the label,
or replace it.
2. Clean the label with cloth and water or cleanser. Do not use organic solvent or gasoline, this would dissolve
the label’s adhesive and cause the label to fall off.
3. If any label is damaged, lost or illegible, replace it. When replacing a label, make sure the new label is
identical to the old one. For new labels, please contact your dealer.

11
Safety information
D25A/D30A MT
The engine carries ‘Warning Labels’ at places where you are required to pay special attention. Please read them
carefully and make sure you understand the content of each label and the meaning of their position.
1. Make sure the labels are legible. If you find any letter or picture illegible in a label, remove soil from the label,
or replace it.
2. Clean the label with cloth and water or cleanser. Do not use organic solvent or gasoline, this would dissolve
the label’s adhesive and cause the label to fall off.
3. If any label is damaged, lost or illegible, replace it. When replacing a label, make sure the new label is
identical to the old one. For new labels, please contact your dealer.

12
Introduction
This operator’s manual has been produced to give you the greatest benefit of your Volvo Penta marine engine. It
contains the information necessary to handle and maintain your engine in a safe and correct manner. We would
like you to read this operator’s manual thoroughly and learn how to handle the engine, controls and other equip-
ment in a safe manner before starting to operate the engine.
Keep the operator’s manual within reach at all times.
Care of the environment Fuel and oil

We would all like to live in a clean and healthy envi- Use only fuel and lubrication oil grades recommended
ronment. An environment where we can breathe cle- in the technical data section of this Operator’s Manu-
an air, see healthy trees, have clean water in our la- al. Other grades can cause operational problems, in-
kes and oceans, and are able to enjoy the sunshine crease fuel consumption and have long-range effects
without being worried about our health. Unfortunately, on engine service life.
this cannot be taken for granted nowadays but is so-
mething we must work together to achieve.
Service and spare parts
As a manufacturer of marine engines, Volvo Penta
has a special responsibility, why care of the environ- Volvo Penta marine engines are designed for high
ment is a core value in our product development. To- operational reliability and long service life. They are
day, Volvo Penta has a broad range of engines where constructed to withstand the marine environment whi-
progress has been made in reducing exhaust emis- le affecting it as little as possible. Through regular
sions, fuel consumption, engine noise, etc. We hope service and the use of Volvo Penta original spare
you will take care in preserving these qualities. parts, these qualities will be retained.
Always follow any advice given in the operator’s ma- The worldwide Volvo Penta network of authorized
nual concerning fuel grades, operation and mainte- dealers is at your service. They are specialists in
nance and you will avoid causing unnecessary inter- Volvo Penta products and stock accessories, original
ference to the environment. Get in touch with your spare parts, test equipment and the special tools re-
Volvo Penta dealer if you notice any changes such as quired to perform high-quality service and repairs.
increased fuel consumption exhaust smoke. Always follow the maintenance intervals specified in
Adapt speed and distance to avoid wash and noise the operator’s manual and remember to specify the
disturbing or injuring animal life, moored boats, jetties, engine number when ordering service and spare
etc. Leave islands and harbours in the same condi- parts.
tion as you want to find them. Remember to always
leave hazardous waste such as waste oil, coolant,
paint and wash residue, flat batteries, etc., for dispo-
sal at a destruction plant. Our joint efforts will make a
valuable contribution to our environment.

13
Introduction
Certified engines
It is essential that owners and operators of emission certified engines, used in areas where exhaust emissions
are regulated by law, are aware of the following points:
A certification involves the engine type being checked and approved by applicable authorities. Engine manufac-
turers guarantee that all engines of the same type correspond with the certified engine.
This puts special demands on the maintenance and service of your engine:
* Maintenance and service intervals recommended by Volvo Penta must be followed.
* Only Volvo Penta original spare parts may be used.
* Service of injector pumps, pump settings and injectors must always be performed by an authorized Volvo
Penta service person.
* The engine must not be modified in any way with the exception of accessories and service kits approved by
Volvo Penta for use on the engine.
* Installation modifications must not be made to the engine exhaust pipe or inlet channels.
* Sealed sections must not be broken by anyone other than authorized personnel.
Otherwise, general directions concerning running, care and maintenance given in the operator’s manual apply.
IMPORTANT! Neglected or deficient maintenance/service and the use of non-original spare parts will
entail Volvo Penta renouncing any responsibility for the engine corresponding to the certified version.
Volvo Penta will not compensate for damage and/or costs arising from the above.
Warranty
Your new Volvo Penta marine engine is covered by a limited warranty complying with the conditions and instruc-
tions given in the Warranty and Service Book.
Note that AB Volvo Penta’s responsibility is limited to what is specified in the Warranty and Service Book. Read it
carefully as soon as possible after delivery. It contains important information concerning the warranty card, servi-
ce, maintenance and what the owner is responsible to be aware of, check and perform. AB Volvo Penta will oth-
erwise decline warranty liability completely or fully.
Get in touch with your Volvo Penta dealer if you have not received a Warranty and Service Book or a
copy of the warranty card.

14
Presentation
D25A/D30A MS
The D25A and D30A are in-line, direct injection, 6-cylinder, 4-stroke marine diesel engines. They are equipped
with turbocharger and fitted with either a heat exchanger for thermostat-regulated freshwater cooling or connec-
tions for keel cooling.
An optimal combination of combustion chambers, fuel injection system, effective turbocharger and charge air
cooling, provide excellent fuel consumption over the whole range of engine speeds where the engine is economi-
cal in operation.
1. Fuel filters
2. Oil cooler
3. Fuel injection pump
4. Governor oil filter
5. Manual stop lever
6. Governor
7. Stop solenoid
8. Oil dipstick
9. Fuel feed pump
10. Oil filler cap
11. Freshwater pump
12. Lifting eye
13. Intake air silencer

14. Turbocharger
15. Charge air cooler
16. Alternator
17. By-pass filter for engine oil
18. Oil filters
19. Engine oil drain pipe
20. Starter motor

15
Presentation
D25A/D30A MT
The D25A and D30A are in-line, direct injection, 6-cylinder, 4-stroke marine diesel engines. They are equipped
with turbocharger and fitted with either a heat exchanger for thermostat-regulated freshwater cooling or connec-
tions for keel cooling.
An optimal combination of combustion chambers, fuel injection system, effective turbocharger and charge air coo-
ling, provide excellent fuel consumption over the whole range of engine speeds where the engine is economical in
operation.
1. Fuel filters
2. Oil cooler
3. Fuel injection pump
4. Governor oil filter
5. Manual stop lever
6. Governor
7. Stop solenoid
8. Oil dipstick
9. Fuel feed pump
10. Oil filler cap
11. Freshwater pump
12. Lifting eye
13. Intake air silencer

14. Turbocharger
16. Heat exchanger
17. By-pass filter for engine oil
18. Oil filters
19. Starter motor
20. Engine oil drain pipe
21. Rawwater pump
22. Alternator

16
New engine initial service
General
Before starting a new or reconditioned engine for the first time, give it an initial inspection. This to guarantee your
own safety as well as the maximum service life of the engine.
External inspection Electrical wiring

1. Check the engine control system for loose termin- Check for loose or damaged electrical wiring around
als. the engine and if necessary firmly reconnect to ter-
minals or cable-joint portions. Damaged cables must
2. Check defects of engine parts.
be replaced.
3. Check the following components for loose bolts or
If your engine is reconditioned, make sure the wiring
nuts:
is according to the drawings.
* Plugs and covers of fuel, lubrication and cooling
system
Filling the fuel system
* Coupling of fuel injection pump and shaft
Refer to chapter ”Maintenance: Fuel system”.
* Crankshaft pulley and vibration damper
* Mounting brackets
Filling the lubrication system
* Fuel control linkage
Refer to chapter ”Maintenance: Lubrication system”.
* Turbocharger
* Timing gear case Filling the cooling system
* Exhaust manifolds Refer to chapter ”Maintenance: Cooling system”.
* Cylinder heads
* Air-duct connection-hose clamp
4. Check for fuel, oil, coolant and air leaks and repair
if needed.
5. Make commissioning report for new or overhauled
engine.
IMPORTANT! All covers must be mounted before

attempting to start your engine.
Valves and plugs

Make sure the following valves and plugs are open or
closed properly:
Fuel supply valve Open
Coolant drain cock (engine) Closed
Coolant drain cock (water pump) Closed
Coolant drain cock (heat exchanger) Closed
IMPORTANT! If the coolant drain cocks are not

closed the coolant will drain from the engine and
this may cause severe damage to the engine.

17
Starting
Before starting
WARNING! Before starting the engine make sure that neither people, nor tools, are in contact with
moving parts of the engine. Notify the people in the vicinity of the engine when starting it.
WARNING! Make sure that you know how to stop the engine before you start it (in case of emergency).
If you are starting the engine for the first time, have someone stand-by at the emergency stop lever to
stop the engine in case abnormal noise occurs during start up. Block air intake in case of stop lever
malfunction, this has to be prepared in advance.
WARNING! Make sure that the manual speed control knob is locked in neutral position before starting
the engine (refer to page 26 of this manual).
IMPORTANT! If the starter motor has been engaged for the maximum time (30 seconds), it must be
allowed to cool down for at least one minute before a new attempt is made at starting.
Warming-up
WARNING! Do not conduct warm-up operation for an extended period of time. Prolonged warm-up
operation causes carbon buildup in the cylinders that leads to inperfect combustion.
* Operate at low idle speed for 5 to 10 minutes to warm up the engine.
* The oil pressure will be 0.20 to 0.29 MPa [28 to 43 psi] after the warm-up run. If the engine speed is increased
immediately after start-up, the oil pressure, due to cold lubrication oil and therefore higher viscosity, will ex-
ceed the normal level - 0.49 to 0.64 MPa [71 to 92 psi] (at rated speed) but it will normalize with increasing oil
temperature.
* If the Lubrication oil pressure does not increase when you have started the engine, immediately stop the engi-
ne and do not restart until the problem has been fixed.
* Make sure that the cooling water flow is sufficient.
* Make sure there is enough fuel aboard the vessel for the planned duration of operation.

18
Non-classifiable control system
This chapter describes the non-classifiable control system which is available for your engine. Note that that tacho-
meter, oil gauge, temperature gauge, charge gauge, starting switch, etc., that are shown here as panel mounted,
in some cases may be mounted separately.
If the vessel is equipped with instruments not described here and you are not sure of their function, please get in
touch with the shipyard or the company that installed the installation aboard the vessel.
IMPORTANT! Read the chapter “Starting” before starting your engine.
Instrument panels
Instrumentation for the main control position and auxi-
liary control position.
1. Temperature gauge. Indicates the engine coolant
temperature.
2. Oil pressure gauge. Indicates the pressure of the
engine lubricant.
3. Voltmeter. Indicates the charge voltage from the
generator when the engine is running and the bat-
tery voltage when the engine is stopped.
4. Tachometer. Indicates the speed of the engine in
rpm.
5. Hour counter. Shows the total number of engine
running hours as a decimal number.
6. Press button for testing and acknowledging
alarms (see next page “Warning displays”).
7. Siren for acoustic alarm that sounds if one of the
warning lamps comes on.
8. Warning display (see section “Warning displays”,
pos 1–3).
9. Starting switch (see next page).
10. Press button for instrument illumination.
11. Oil pressure gauge. Indicates the oil pressure in

the reverse gear.
12. Charge air pressure gauge. Indicates the turbo-
charger boost pressure.

19
Standard Control System
Warning displays
If the acoustic alarm sounds, one of the warning dis-
play lamps will immediately start to flash to indicate
the cause of the alarm.
1. High coolant temperature.
2. Low lubricant pressure.
3. Generator not charging
After an alarm
Press the “Alarm test” button to acknowledge and
terminate the acoustic alarm. The relevant warning
lamp will continue to flash until the fault has been rec-
tified.
Alarm test
After pressing the “Alarm test” button, the warning
lamps will come on and the acoustic alarm will start to
sound. Make a habit of always performing an alarm
test before starting.
Starting switch
Together with the starter keys a plate containing the
key code is delivered. This code is required when
ordering additional starter keys. Keep the code in a
safe place.
S = Stop position.
0 = Key can be inserted and removed.
I = Voltage on (drive position).
II = Not used
III = Start position.

20
Starting procedure
1. Disengage the reverse gear and make sure the
turning gear is not engaged. Put the control lever
into neutral and idle on all control positions
WARNING! If the vessel is equipped with
controls that allow starting the engine in
gear, it is essential to check all control
positions to make sure a gear is not
engaged.
2. Turn on the power by putting the starter key in po-
sition “I”.
3. Check warning lamps and alarms. Press the

“Alarm test” button on the instrument panel to
make sure the warning lamps come on and the
acoustic alarm sounds.
4. Start the engine. Start using the starting switch.

Turn the key to position “III”. Release the key so
that it returns to “I” immediately after the engine
has started.
IMPORTANT! If the starter motor has been
engaged for the maximum time (30
seconds), it must be allowed to cool down for
at least one minute before a new attempt is
made at starting.
NOTE! The key must first be turned to “S” before ma-
king a new attempt at starting.
5. Check the instruments and run the engine warm.
Let the engine idle for the first ten seconds and
make sure the instruments and warning display
show normal values. Then run the engine at low
speed and low load so it attains normal operating
temperature before using full power.
IMPORTANT! Do not race the engine when it
is cold.

21
Operation
Learn how to handle the engine, controls and other equip-
ment in a safe and correct manner before taking it into ope-
ration.
Checking the instruments

Check the instruments and warning display directly after
start and regularly during operation.
Oil pressure
During operation, the oil pressure gauge should show a rea-
ding of 0,50 - 0,64 MPa (71 - 93 psi). A lower value is nor-
mal at idling speed. The acoustic alarm will sound automa-
tically in case of low oil pressure.
Coolant temperature
During operation, the temperature gauge should show a rea-
ding of 71–85°C (160–185°F). The acoustic alarm will
sound automatically in case the coolant temperature is too
high.
Charging
During operation, the charge voltage gauge should show a
reading of 28V. The acoustic alarm will sound automatically
in case the charge voltage is missing.

22
Alarms and fault indication

If the acoustic alarm sounds, one of the warning dis-
play lamps will immediately start to flash to indicate
the cause of the alarm: High coolant temperature (1),
low oil pressure (2) and no charge voltage (3).
IMPORTANT! Stop the engine immediately after

an alarm for low oil pressure. Investigate the
cause and rectify it.
IMPORTANT! Slow the engine speed to idle/

disengaged after an alarm for high coolant
temperature. If temperature does not drop, the
engine must be stopped. Investigate the cause
and rectify it.
Stopping the engine

Let the engine run at low idling speed (in neutral) for at
least three minutes before turning it off. This will keep
the engine temperature in balance and prevent it boi-
ling.
IMPORTANT! The procedure described above is

especially important if the engine has been run
hard and/or exerted to heavy loads.
Stop
1. Disengage the marine gear by moving the lever to
neutral position.
2. Turn the key to stop position “S”.
3. Hold the key in position until the engine has stop-
ped (the key will return to “0” automatically when
released and can then be removed).
NOTE! The stop solenoid will be activated for

approximately 40 seconds after stopping the
engine, but the engine can be restarted at any
time.
Emergency stop
If a fault occurs that prevents the engine being stop-
ped by the normal method, it can be stopped manually
using the lever mounted on the engine. Move the lever
in the direction of the arrow and hold it there until the
engine has stopped.
WARNING! Working on or approaching a running

engine is a safety hazard. Beware of rotating
parts and hot surfaces.
WARNING! Never try to increase engine rpm with

the emergency stop lever since this will make
the engine overspeed and this will damage the
engine.

23
Operation
General
Learn how to handle the engine, controls and other equipment in a safe and correct manner before starting the
engine
WARNING! Stay clear of all rotating and moving WARNING! At operating temperature, the engine
parts during operation. and its components are hot. A hot engine always
involves risk for burn injuries. Take care with hot
IMPORTANT! Always keep the engine room well surfaces. E.g.: exhaust manifold, turbocharger,
ventilated. Insufficient airsupply to the engine oil pan, charge air pipe, starting heater, hot
means imperfect combustion and a loss of coolant and warm lubricant in pipes and hoses.
power.
IMPORTANT! Avoid overloading. This can cause
IMPORTANT! During the first 50 hours of opera- incomplete fuel combustion often indicated by
tion, operate the engine under a lighter load and black exhaust, high fuel consumption and carbon
lower speeds than normal for break-in. Proper deposits in combustion chambers, affecting
break-in contributes to maximum service life of engine life.
the engine.
IMPORTANT! Do not turn the starter switch key
IMPORTANT! Do not turn OFF the battery to the START position when the engine is
switch when the engine is running since this may running this may damage the starter.
damage the alternator.

24
Operation
Applying load Manoeuvring

When the engine has reached operation temperature, The marine gear must be engaged at low idling speed.
bring the engine to operating speed and apply the load There must be a brief pause after engaging gear befo-
gradually. re increasing the engine speed. Wait for approximately
two seconds to ensure that the gear clutch has enga-
ged properly.
During load operation make sure that:
1. No engine related alarms occur. IMPORTANT! If the vessel is equipped with two
engines equipped with wed exhaust systems,
2. There are no visible leaks of fuel, lube oil, coolant
they must both be running while in reverse or
or exhaust gas
there will be a risk of water entering the engine
3. No abnormal noise or vibrations occur. (through the exhaust passage).
4. The color of the exhaust gas is normal.
5. The breather mist is of normal quantity and color. Pulling away
6. Instrument readings are the normal.* 1. Move the lever from neutral to the engagement
*Oil pressure: 0,50 to 0,64 Mpa (71 to 92 psi) (at position for the desired direction of travel.
rated speed) 2. Apply load accordingly.
*Coolant temperature: 71 to 85°C (165 to 185 °F)
Forward–Reverse
Running in 1. Slow the engine speed to idling and allow the ves-
sel to loose most of its speed.
The engine must be “run in” during the first 10
hours of operation as follows: 2. Move the lever to neutral.
Run the engine under normal operation. Do not run it 3. Move the lever to reverse. Wait for approximately
at full power except for short periods. Never run the two seconds and then increase the engine speed
engine for long periods at constant rpm during this gradually.
time. A high consumption of lubricant is normal during
the running in period. Therefore, check the oil level IMPORTANT! A direct forward–reverse maneuver
more often than recommended. The prescribed war- can damage the marine gear and engine. It is
ranty inspection “First Service Inspection” must be therefore always necessary to stop with the lever
carried out during this first period of operation. For in neutral for a few seconds and allow the vessel
more information: See Warranty and Service Book. to loose most of its speed before engaging. If the
speed of the vessel is too high, there is a risk of
the propeller windmilling which might cause the
Forced propeller rotation engine to stop and start rotating in the wrong
When the vessel is towed or anchoring in strong cur- direction. This may cause serious engine
rents, the propeller can make the propeller shaft rotate damage.
even though the engine is stationary. This may dama-
ge the marine gear.

25
Operation
Manual speed control

Manual speed adjustment of the engine can be done
using the manual speed control knob.
1. Disconnect the control cable connected to the
remote speed adjustment.
2. Turn the lock counterclockwise to unlock the ma-

nual speed adjustment knob.
3. By pushing the button and pulling the knob

towards you the engine speed will increase. By
bushing the knob towards the engine the engine
speed will decrease.
WARNING! When adjusting engine speed avoid

quick changes since this may harm the engine.

26
Operation
4. Fine-tuning of the engine speed can be done by

turning the control knob:
Turn the knob clockwise to decrease engine
speed. Turn it counterclockwise to increase
engine speed.
5. Bring the manual speed control knob in the neutral

position when ready with the manual speed
adjustment. Turn the lock clockwise to secure the
installation.
6. Connect the control cable for remote speed

adjustment so that the engine can be controlled
from the normal position.

27
Operation
Start using auxiliary batteries

WARNING! Ventilate well. Batteries generate
oxyhydrogen gas, which is extremely flammable
and explosive. A short circuit, naked flame or
spark can cause a powerful explosion.
Never reverse the polarity of the battery. Risk of

sparks and explosion.
1. Make sure the rated voltage of the auxiliary bat-
tery is the same as the system voltage of the
engine.
2. Connect the red auxiliary cable to the discharged
battery’s + terminal and then to the auxiliary
battery’s + terminal.
3. Connect the black jump lead to the auxiliary bat-
tery negative terminal and then to a position
slightly away from the discharged batteries, for
example at the negative cable’s connection to the
starter motor.
WARNING! The black auxiliary cable (–) must not

come in contact with the positive connection on
the starter motor.
4. Start the engine and run at fast idling speed for

about ten minutes to charge the batteries.

WARNING! Do not touch the connections while

attempting to start; Risk of sparks. Do not bend
over the batteries either.
5. Stop the engine. Remove the auxiliary cables in

reverse order to connecting.

28
Stopping
Allow the engine to run at low idling speed (in neutral) for at least 5 to 6 minutes before turning it off. This will keep
the engine temperature in balance and prevent it from boiling.
IMPORTANT! The procedure described above IMPORTANT! If the engine stops abnormally,
is especially important if the engine has been try to locate the problem and make the
run hard and/or exerted to heavy loads. repairs needed before starting again. After
starting the engine, make sure the engine
IMPORTANT! Do not rev up the engine just runs properly.
before stopping it.
Manual stop lever

By pulling the manual stop lever in the “STOP” direc-
tion the engine can be stopped manually. Use this le-
ver only in an emergency when the engine can not be
stopped by the engine control system.
IMPORTANT! When stopping the engine by

pulling the stop lever, continue to pull the le-
ver until the engine stops “rocking.”
Notice: If the engine cannot be stopped with the ma-

nual stop lever, shut off the fuel supply or block air in-
take to turbo.
After stopping
General
* Check the genset and engine room for leaks.
* Close the fuel cock and rawwater cock.
* Read off the hour counter and carry out preventive
maintenance according to the maintenance sche-
dule.
* Turn off the main switch if the genset is not to be
used for a long period.
IMPORTANT! Never turn the power off using
the main switch while the genset is running.
This can damage the alternator.
IMPORTANT! Make sure the generator
heater is working properly to avoid
condensation in the generator

29
Stopping the engine
Anti-freezing measures
If the engine room cannot be protected from frost, the
rawwater system must be drained (if it contains raw-
water) and the coolant in the freshwater system must
contain the right mix of anti-freeze and water. Refer to
chapter Maintenance “Rawwater system” and “Fres-
hwater system” respectively.
WARNING! If the rawwater system bursts
due to freezing, the vessel could sink.
IMPORTANT! If the coolant does not give
sufficient anti-freeze protection, it may cause
costly damage to the engine. Check the
charge of the battery. A poorly charged
battery can freeze and break.
Breaks in operation [not using the

genset]
During periods out of service, the engine must be run
warm once a fortnight. This will prevent it from corro-
ding.
IMPORTANT! The genset must be conser-
ved if it is not to be used for longer than two
months. Refer to chapter Inhibiting.

30
Maintenance
Your Volvo Penta engine and associated equipment is designed to provide high operational reliability and long ser-
vice life. They are constructed to withstand the marine environment while also affecting it as little as possible.
Preventive maintenance in accordance with the maintenance schedule will ensure that it retains these qualities
and avoid unnecessary operational disturbances. The following chapters contain general technical information and
directions for carrying out the prescribed maintenance points. Read the directions carefully before starting work.
The maintenance schedule shows the standard service intervals. When you think the engine should be serviced
more frequently due to particular operating conditions, adjust the intervals accordingly. Appropriate service inter-
vals vary with usage and operating conditions and with fuel, lubricant and coolant used. Due to particular opera-
ting conditions the service intervals may be adjusted accordingly. Consult your Volvo Penta dealer.
NOTE! Dust and foreign particles are the most common cause of excessive wear of parts. When disassembling a
component, take measures to prevent dust and foreign particles from entering it.
Daily operation records

It is recommended to keep daily operation records. Daily recording is a preventive maintenance program and
when comparing values with engine history it will help you recognize conditions, signs or indications of approach-
ing trouble. Daily operation records also make trouble shooting easier and will lessen the down time (to save time
and money for servicing).
Maintenance records
Volvo Penta recommends that accurate maintenance records are kept. With accurate maintenance records your
Volvo Penta Dealer can help in fine tuning the recommended service intervals to meet the specific operating situ-
ation. This should result in a lower engine operation cost.
Fluids
It is also important to keep record of the fluids used in the engine. If brand or type of fuel, lubrication oil or coolant
is changed this should be recorded.
Warranty inspection
The prescribed warranty inspection “First Service Inspection” must be carried out at an authorized Volvo Penta
workshop during this first period of operation. Directions for when and where this is to be carried out can be
found in the Warranty and Service Book.
WARNING! Read the safety directions for maintenance and service in the chapter “Safety information”
before starting work.
WARNING! Read the chapter “Maintenance” thoroughly before starting any maintenance work. It
contains directions for performing maintenance in a safe and correct manner.
WARNING! Working on or approaching a running engine is a safety hazard. Maintenance and service
must be carried out with the engine stationary unless stated otherwise in the instructions. Prevent
inadvertent start of the engine by disabling the start-button and turning off the power with the main
switch, locking it in the off position.
WARNING! Place warning signs stating that service is in progress in every position from which the
engine can be started.
IMPORTANT! Handle parts carefully. Use only original Volvo Penta spare parts.
NOTE! When both operating time and calendar time is given, the one occurring first is to apply.
NOTE! For generator related maintenance information, refer to Generator Manufacturers information.

31
Maintenance schedule
D25A/D30A MS
Daily before first start

General inspection engine and engine room
Check and make sure all valves are in the right position
Check lubrication oil level
Check marine gear oil level
Check coolant level
Drain water from fuel tank
Drain water from fuel pre-filter/water separator
Drain water from air vessel and air filter
Check engine control system (cables, etc.)
Check fuel control linkage
Check aftercooler drain pipe
Inspection of valves and plugs
After start
Check lubrication oil filter differential pressure indicator
Check air-filter differential pressure indicator
Check for leakages
Check if the instrumentation works properly
Weekly
Check starting batteries; electrolyte level/load
Check electrical system for loose terminals/contacts
Check foundation bolts
Check lubrication oil for abnormal smell or waterdilution
Check safety valves of air system
Check air system oiler
Check settings of valves and move valve to keep them operationable
Drain water from the fuel pre-filter/water separator
First 50-250 operating hours of new or recond. engines (First service)

Change lubrication oil
Change full flow and by-pass lubrication oil filters
Change governor lubrication oil filter
Check required lubrication oil change for marine gear
Check/adjust V-belts
Check/adjust valve clearance
Check/retighten bolts and nuts
Drain crankcase ventilation water trap
Drain exhaust silencer (system) water trap

32
Every 250 operating hours or every 12 months

Change lubrication oil. Longer interval requires oil analysis
Check rawwater filter
Check/wash air inlet silencer filter


Change fuel filter elements
Change filter elements of the fuel pre-filter/water separator
Check air filter (if installed)
Check/adjust fuel injection timing
Check/adjust fuel injection pressure and spray pattern
Change fuel injection nozzle o-rings
Check and adjust valve clearance and valve mechanism

Check/adjust valve clearance. Check valve mechanism
Check turbocharger
Check starter motor
Check alternator
Check fuel injection pump flex drive plates
Check fuel injection pump control rack operation
Check fuel rack control ”ball joints”
Check/clean charge air cooler(s)
Check/clean cooling water heat exchanger
Check coolant concentration
Check torsional vibration dampers
Check alarm and shut-down functions
Check engine control panel functions
Change V-belts
Change fuel pre-filter/water separator element
Check/change zinc anodes
Change air inlet silencer filter

33
Every 4000 to 6000 operating hours or every 24 months

Full service inspection(1)
Every 12 months
Check rubber engine mounts
Check rubber hoses and flex connections
Check engine room ventilation fans
Every 10000 operating hours

Check torsional vibration damper temp check
Check rubber of flexible coupling for deformation and cracks
Replace ball-joints in fuel pump control linkage

Every 24 months
Change coolant
(1) Every 4000 to 6000 hours or every 24 months

Have an authorized dealer execute a full service inspection of your engine including:
Endoscopic investigation of cyl heads and liners
Replace all injector nozzles
Change water pump seals
Checking and cleaning of charge air cooler
Check turbo charger
Check battery-charging alternator
Check and test stop solenoid or fuel shut-off valve
(2) Every 15000 hours
As described at 4000 – 6000 hrs
Remove and inspect one piston, piston rings and liner
Inspect crankshaft and one bearing
Inspect camshaft and one bearing

34
D25A/D30A MT
Daily before first start

General inspection engine and engine room.
Check and make sure all valves are in the right position
Check lubrication oil level
Check marine gear oil level
Check coolant level
Drain water from fuel tank
Drain water from fuel pre-filter/water separator48
Drain water from air vessel and air filter
Check engine control system (cables, etc.)
Check fuel control linkage
Check aftercooler drain pipe
Inspection of valves and plugs
After start
Check lubrication oil filter differential pressure indicator
Check air-filter differential pressure indicator
Check for leakages
Check if the instrumentation works properly
Weekly
Check starting batteries; electrolyte level/load
Check electrical system for loose terminals/contacts
Check foundation bolts
Check lubrication oil for abnormal smell or water dilution
Check safety valves of air system
Check air system oiler
Check settings of valves and move valve to keep them operationable
Drain water from the fuel pre-filter/water separator
First 50-250 operating hours of new or recond. engines (First service)

Change lubrication oil
Check required lubrication oil change for marine gear
Check/adjust valve clearance
Drain crankcase ventilation water trap
Drain exhaust silencer (system) water trap

35

Change lubrication oil. Longer interval requires oil analysis
Check rawwater filter
Check/wash air inlet silencer filter


Change fuel filter elements
Change filter elements of the fuel pre-filter/water separator
Check air filter (if installed)
Check/adjust fuel injection timing
Check/adjust fuel injection pressure and spray pattern
Change fuel injection nozzle o-rings
Check and adjust valve clearance and valve mechanism

Check/adjust valve clearance. Check valve mechanism
Check turbocharger
Check starter motor
Check alternator
Check fuel injection pump flex drive plates
Check fuel injection pump control rack operation
Check fuel rack control ”ball joints”
Check/clean charge air cooler(s)
Check/clean cooling water heat exchanger
Check coolant concentration
Check torsional vibration dampers
Check alarm and shut-down functions
Check engine control panel functions
Change V-belts
Change fuel pre-filter/water separator element
Check/change zinc anodes
Change air inlet silencer filter

36
Every 4000 to 6000 operating hours or every 24 months

Every 12 months
Check rubber engine mounts
Check rubber hoses and flex connections
Check engine room ventilation fans

Check torsional vibration damper temp check
Check rubber of flexible coupling for deformation and cracks
Replace ball-joints in fuel pump control linkage

Every 24 months
Change coolant
(1) Every 4000 to 6000 hours or every 24 months

Endoscopic investigation of cyl heads and liners
Replace all injector nozzles
Change water pump seals
Checking and cleaning of charge air cooler
Check turbo charger
Check battery-charging alternator
Check and test stop solenoid or fuel shut-off valve
(2) Every 15000 hours
As described at 4000 – 6000 hrs
Remove and inspect one piston, piston rings and liner
Inspect crankshaft and one bearing
Inspect camshaft and one bearing

37
Overhaul information
Top overhaul
Dependent of your application, working conditions and service level a “top overhaul” might be required
in case of:
Gas leakage through valves
Too much valve clearance
Low compression pressure
Top overhaul includes:

Remove cylinder heads and check liners and com- Change freshwater pump seals
bustion chambers of pistons
Change rawwater pump seals
Disassemble cylinder heads
Overhaul turbo charger
Check inlet and exhaust valves, check valve seats
Check vibration damper on burrs and leaks
(lap if necessary)
Check exhaust pipe joints
Check piston top
Check governor control linkage
Check cylinder liner
Check instruments, alarms and shutdown functions
Check pipe clamp contact
1st major overhaul

Dependent of your application, working conditions and service level a “major overhaul” might be requi-
red in case of:
Gas leakage through valves
Decreased power output
Starting problems
Increased fuel consumption
Increased noise from engine parts
Increased lubrication oil consumption
Abnormal color of exhaust gases from warm engine
Increased blow-by gases
Major overhaul includes:

Disassemble engine, clean, check and change major parts.
Major parts:
Inlet and exhaust valve seats Main bearings
Inlet and exhaust valves Cylinder liners
Valve rotators Main bearing cap bolts and washers
Valve cotters Piston rings
Rocker arm adjusting screws Connecting rod bearings
Valve push rods Vibration damper
Bridge caps Air duct rubber hoses
Camshaft bushings Cooling water rubber hoses
Camshaft expansion plugs Consumable items (gaskets, oil seals, o-rings, etc.)
Lubrication oil pump Change the torsional vibration damper

38
2nd major overhaul

Disassemble engine, clean, check and change major parts.
Major parts:
Inlet and exhaust valve seats Cylinder liners
Inlet and exhaust valves Main bearing cap bolts and washers
Valve rotators Piston rings
Valve cotters Connecting rod bearings
Rocker arm adjusting screws Vibration damper
Valve push rods Air duct rubber hoses
Bridge caps Cooling water rubber hoses
Camshaft bushings Consumable items (gaskets, oil seals, o-rings, etc.)
Camshaft expansion plugs Rocker bushings
Cylinder head bolts Thrust plate crankshaft
Valve guides Pistons and piston pins
Valve bridge guides Connecting rod bolts
Valve bridges Connecting rod bushings etc.
Valve springs Check high-pressure fuel injection pump and fuel
supply pump
Tappets
Change torsional vibration damper
Camshaft thrust plates
Main bearings

39
Maintenance: General
Recommendation of Daily Operation Records

Daily recording is a preventive maintenance program and when comparing values with engine history it will help
you recognize conditions, signs or indications of approaching trouble. Daily operation records also make trouble
shooting easier and will lessen the down time (to save time and money for servicing).
Items to be recorded
The following items are recommended to be recorded
once a day:
1. Operating hours.
2. The amount of lubrication oil and coolant (fresh
water) required for refilling. Fuel consumption.
3. Lubrication oil and coolant (fresh water) changes.
4. Lubrication oil pressure and temperature, engine
rpm, exhaust temperature, coolant temperature,
and charge air temperature and pressure.
5. Rawwater pressure and rawwater temperature
before and after heat exchanger. Ambient
temperature and engine room temperature at turbo
charger inlet.
6. Parts serviced and kinds of service (adjustment,
repairs or replacement).
7. Change in operating conditions (for example,
“Exhaust smoke turned black,” etc.)

40
Maintenance: Engine
Engine
Valve clearance
IMPORTANT! Check and adjust the valve clearance when the engine is cold and not running.
NOTE! Protective plugs should be fitted on the injectors.

Cleanliness should be observed when working on the fuel system
When adjusting the valves the engine should be cold. The engine must under no circumstances be running, since
the valves can knock against the pistons and cause serious damage.
Make sure that the stop lever is pulled out and that the starter key is switched off.
The valves are adjusted when the piston is at top dead center of compression stroke. The valve bridge is adjusted
first, and then the clearance of the rocker arm.
Confirm top dead center on compression stroke

1. Turn the engine in the normal direction to align the
timing mark [1 .6] on the damper with the pointer
as shown.
2. Remove the rocker cover of the cylinder on which
the valve clearance is to be checked and adjus-
ted, and make sure the inlet and exhaust valves
have some clearance. If the timing mark [1 .6] is
aligned with the pointer, either the No. 1 or No. 6
piston is at top dead center on the compression
stroke.
Adjust the valve bridge

IMPORTANT! Make sure the clearance between
the valve bridge and valve rotator is 1.5 mm
[0.059 in.] or more if not, interference will occur
between the bridge and rotator to cause the
valve cones to get out of place. If the clearance
is less than 1.5 mm [0.059 in.] after the height of
valves has been adjusted, consult your dealer.
NOTE! Before inspecting the valve clearance, adjust

the height of the two valves. Bring the bridge into con-
tact with the valves, by means of the valve-bridge ad-
justing screw, so that there is no difference in height
between the two valves. If the valve seats are worn,
one valve will differ from another in height, increasing
the clearance between the valve stem and bridge,
leading to an increased valve clearance.
1. Unscrew the lock nut and adjusting screw on the

pair of valves on the cylinder so that there is clea-
rance between the bridge and the valve stem.
2. Press the valve bridge down.Turn the adjusting
screw so that it makes contact with the valve
stem.
3. Turn an additional 10 degrees. Lock the adjusting
screw with the lock nut.
NOTE! Check if the bridge is properly adjusted, by
putting a little drop of oil the valve stem top.

41
Maintenance: Engine
Valve clearance inspection

1. Check the valve clearance with feeler gauges in-
serted between the rocker arm and yoke cap.
Valve Clearance:
Inlet valve .................................. 0.6 mm [ 0.024 in.]
Exhaust valve ............................ 0.8 mm [ 0.031 in.]
2. The clearance is correct if feeler gauge is slightly

gripped between the rocker arm and the yoke
cap. If the feeler does not fit into the clearance
exactly, perform adjustments as described below.
IMPORTANT! When performing the ”First Ser-

vice”, valves that are checked and deemed not
in need of adjustment must be checked again
within 250 hours.
Adjusting valve clearance

1. Loosen the lock nut of the adjusting screw.
2. Turn in or back off the adjusting screw so that fee-
ler gauge is slightly gripped between the rocker
arm and yoke cap.
3. After adjusting the clearance, tighten the lock nut
of the adjusting screw.
Firing order
Check and adjust the valve clearance in the firing order (injection sequence), turning the engine with each cylinder
piston at top dead center on compression stroke.
Firing order 1 5 3 6 2 4
(Example): After checking and adjusting the cylinder No.1, turn the engine 120° and check and adjust the cylinder
No.5.
Cylinder No. 1 5 3 6 2 4
Timing ( ° ) 0 120 240 360 480 600

42
Maintenance: Engine
Vibration damper inspection

NOTE! When installing a damper protective
cover to the engine, do not use a cover
enclosing the damper.
Visually check for fluid leaks, flaws, distortion, or dis-

coloration or flaking of painted surfaces. Also check
for swelling (by measuring with a scale), and fluid le-
aks past staked portions.
Re-tighten bolts and nuts

Re-tighten the bolts and nuts on the following compo-
nents:
* Timing gear case
* Crankshaft pulley
* Mounting brackets
* Exhaust manifold
* Turbocharger
* Cylinder heads
Check the cylinder head bolts and re-tighten them in
number sequence (1-2-3-4-5-6) if necessary. The tight-
ening torques of the bolts and nuts can be found in
technical data section of this manual.

43
Maintenance: Engine
Using the turning gear

1. Loosen the two bolts securing the shaft lock plate
and remove the plate from the shaft (groove).
2. Push in the shaft all the way to the TURN posi-

tion.
3. Put a socket to the hexagonal end of the shaft

and turn the shaft with a ratchet handle for tur-
ning.
4. After turning the engine, pull the shaft back to the

RUN position, secure the shaft with the locking
device and tighten the plate bolts. Make sure the
plate is secured properly.
WARNING! Before starting the engine, make

sure the turning gear is in the RUN position and
is locked.

44
Maintenance: Lubrication system
Lubrication system
Checking oil level

The oil level must be within the marked range on the
dipstick and must be checked daily.
IMPORTANT! The level must never be allowed

to drop beneath the minimum or rise above the
maximum mark on the dipstick.
Filling oil
Fill the engine with lubrication oil through the filler
pipe. For oil specification refer to ”Technical data:
Lubrication oil specification”. The oil level should be
within the marked area on the dipstick. After filling oil,
secure filler cap.
WARNING! Lubrication oil on hot surfaces or

electrical components may cause fire. Do not
smoke while filling oil or when handling oil con-
tainers.
IMPORTANT! Stop the engine when filling oil.
IMPORTANT! Avoid mixing oils of different

brands, additives used in the oils can cause
chemical reactions that may degrade the oil
performance.
IMPORTANT! The lubrication oil level must

never be allowed to drop beneath the lower, or
rise above the maximum, mark on the dipstick.

45
Filling oil in new or reconditioned engine

If your engine is new or reconditioned you should
besides the actual filling of new lubrication oil also do
the following:
1. Remove the rocker cover. Lubricate the valve
mechanism and fill the camshaft oil bath from the
cylinder head. Repeat the procedure for each cy-
linder.
2. Mount all the rocker covers. Refer to section
Tightening torques for proper torques.
NOTE! Avoid running or cranking the engine without
the rocker covers mounted.
3. Remove the lubrication oil pipe connected to the

turbo.
Fill the turbo through the opening with 2 or 3
pumps of oil from the oil fill can. This has to be
done to secure lubrication of the turbo during the
first start-up.
IMPORTANT! Do not bend the pipe. This can

block the oil supply to the turbo.
4. Reconnect the lubrication oil pipe to the turbo pro-

perly.
5. Crank the engine 3 times for maximum 10 se-
conds with the emergency stop lever in the stop
position and check if the oil pressure rises proper-
ly.
6. Start the engine and operate it for about 10 minu-
tes and check if the oil pressure rises properly.
Check the oil pan and related parts for oil leaks.
IMPORTANT! If oil pressure do not rise

immediately after start, stop the engine and
investigate. Do not restart until problem is fixed.
7. Check the oil level in the oil pan and add oil if ne-
cessary.

46
Changing oil
Always observe the recommended oil change inter-
val.
IMPORTANT! Only use recommended grades of

oil (see chapter technical data).
1. Warm up the engine (this makes it easier to suck

the oil up from the sump). Then stop the engine.
WARNING! Hot oil and hot surfaces may cause

burns.
2. Connect a hose to the outlet pipe of the lubrica-

tion oil scavenging pump. Pump the oil out.
NOTE! Collect the old oil and filters and deposit in ac-
cordance with local regulations. Never dispose of old
oil or oil filters overboard.
3. Change the oil filters and the by-pass filter at eve-
ry oil change (please refer to section oil filters
change).
4. Fill with oil to the correct level trough the oil filling
pipe.
5. Start the engine and allow it to idle. Check the oil
pressure and make sure that there are no leaks
by the filters.
WARNING! Approaching or working with a

running engine is a safety risk. Be careful to
avoid rotating components and hot surfaces.
6. Stop the engine. Wait a few minutes before you

check the oil level. Top up if necessary.

47
Changing oil filter

The oil filters can be changed while the engine is run-
ning as the oil flow can be directed through one filter
at a time.
1. Remove the cover from the filter switch valve by
disconnecting the two bolts.
WARNING! Working on or approaching a

running engine is a safety hazard. Beware of
rotating parts and hot surfaces.
2. Cut off the oil flow through the right filter by tur-
ning the setting valve in position C.
3. Unscrew the oil filter using the special tool. Dis-
card the filter.
NOTE! Place a container beneath the filter when
removing to avoid oil spill.
4. Lightly oil the new filter’s rubber gasket and check
its mating surface on the mounting.
5. Mount the new filter by hand until the gasket is in
contact with the sealing surface. Then tighten the
filter a further approximately 3/4 of a turn using a
filter wrench.
6. Put the filter on-line by turning the valve in posi-
tion A.
7. Replace the left filter as above. Position B is the
left filter change position.
8. Replace both full-flow filters and the by-pass filter
at the same change interval. Refere to next page
for by-pass oil filter change procedure.
NOTE! After a lubrication oil filter change, open the
filter and check for metal parts.

48
Changing oil by-pass filter

1. Stop the engine
2. Unscrew the oil filter using a special filter wrench.
Note! Place a container beneath the filter when remo-
ving to avoid oil spill.
Warning! Hot oil can cause burns.
3. Lightly oil the new filter’s rubber gasket and check
its mating surface on the mounting.
4. Screw on the new filter by hand until the gasket is
in contact with the sealing surface. Then tighten
the filter a further approximately 3/4 of a turn
using a filter wrench.
Changing hydraulic governor oil

filter
1. Stop the engine.
2. Place a drip pan under the governor oil filter.
3. Loosen the screw holding the pipe connecting the
oil filter and the governor (1).
4. Remove the pipe (2).
5. Open the air vent plug (3) so that the rest of the
remaining oil flows into the oil drip pan.
6. Remove the center bolt (4), remove the old filter
and mount a new.
7. Remove the air vent plug and fill the filter housing
with new oil.
8. Tighten the air vent plug.

49
Maintenance: Fuel System
Fuel system
WARNING! Always protect your hands when carrying out leak detection. Escaping fluids under pressure can
pierce bodily tissue and cause serious injury. Risk of blood poisoning. Always cover any electric component
if it is located under the fuel filter. Otherwise it might be damaged by fuel spills.
WARNING! Work performed on the fuel system must be done on a cold engine. Fuel leaks and spills on hot
surfaces or electrical components can cause fires.
Bleeding the fuel system

IMPORTANT! Place a drip pan under the fuel filt-
ers.
Prime the fuel filters and fuel injection pump in the fol-
lowing sequence:
Bleeding the fuel filter

1. Put the fuel filter switching cock in the left filter
bleed position and loosen the left air vent plug.
2. Turn the priming pump plunger counterclockwise

to unlock the mechanism.
3. Move the plunger up and down until the fuel flows

free of bubbles from air and tighten the air vent
plug.
4. Put the fuel filter switching cock in the neutral po-

sition and repeat the above-described procedure
for the other fuel filter.

50
Bleeding the fuel injection pump

1. Loosen the air vent cock on the fuel injection
pump about 1.5 turns.
2. Move the priming pump cap up and down to start

the flow of fuel through the system.
3. When the fuel coming out of the air vent cock

shows no visible bubbles, lock the priming pump
cap while holding it down. Then tighten the air
vent cock.
Be sure to lock the priming pump cap before tight-

ening the air vent plugs and cock. If this is not
done the cap does not return to the original posi-
tion due to the pressure in the priming pump.
4. Tighten the priming pump cap by hand until the

tightening force increases, normally this occurs
after turning it approximately 70 to 90 degrees.
Mark this position on the priming pump cap to
make item 5 work more easily.
5. Tighten the priming pump cap an additional 120
to150 degrees using a wrench.
6. Clean the engine from spoiled fuel to prevent fire
and pollution of the environment.
IMPORTANT! If the priming pump cap is tighte-

ned too much (more than 240 degrees in total),
the top of the priming pump can be damaged.
IMPORTANT! Looseness of the priming pump

cap in combination with engine vibration may
cause engine failure and damage to the installa-
tion.

51
Changing fuel filter

Switchable fuel filters can be changed while the engine is running as the flow of fuel can be cut off to one filter at a
time.
WARNING! Working on or approaching a running engine is a safety hazard. Beware of rotating parts and hot
surfaces.
A. Right Filter bleed position

B. Right Filter change position
C. Neutral position
D. Left Filter change position
E. Left Filter bleed position
1. Place a drip pan under the fuel filter.

2. Put the fuel filter switching cock in the Left filter
change position and unscrew the left-hand fuel fil-
ter. Use a filter wrench if necessary.
3. Coat the gasket of a new filter with clean diesel
fuel.
4. Install the new filter in the filter bracket by hand.
When the gasket contacts the base, tighten 1/2 to
3/4 of a turn more.
5. Put the fuel filter switching cock in the Left filter

bleed position and loosen the left air vent plug un-
til the fuel running out is free from air. Close the
air vent.
6. Put the fuel filter switching cock in the neutral po-

sition and repeat the above described procedure
for the other fuel filter.

52
Changing fuel injector nozzle

IMPORTANT! Cover all open fuel injection pipes,
fuel intake openings and the fuel injectior nozzle
to keep dirt out
Removing the fuel injector

1. Remove the rocker cover.
2. Remove the clamp from the fuel injection pipe.
3. Remove the fuel injection pipe from the fuel injec-
tor.
4. Remove the injector inlet connector.
5. Remove the injector gland nut to take off the
gland.
6. Pull out the fuel injector using the special tool.
Removing the nozzle

IMPORTANT! The injector nozzle is very
delicate, handle with care.
1. Fasten the fuel injector in a vice with protection

plates.
2. Remove the set screw and the cap nut.
3. Loosen the adjusting screw with a screw driver
until it can be loosened by hand.
Note! This operation is required to release spring
pressure applied to the nozzle. When spring pressure
is applied, it is hard to loosen the retaining nut.
3. Remove the retaining nut and remove the nozzle.
Cleaning the nozzle

IMPORTANT! Do not mix up the pairing of needle
valve and body when cleaning more than one at
a time.
1. Dip the nozzle in clean fuel oil, and disassemble

the needle valve.
2. Clean the injection holes.
3. After cleaning, carefully insert the needle valve
into the body in clean oil.

53
Installing the nozzle

1. Install the nozzle according to the pin on the
nozzle.
2. Tighten the retaining nut by applying the specified
torque 177 to 196 Nm (18 to 20kpm) [130 to 145
lbf.ft]. (Apply oil to the nut.)
IMPORTANT! Do not use Moly Disulfide.
3. Adjust the nozzle opening pressure and check
spray conditions.
Fuel injection pressure

WARNING! Do not allow the fuel injected from a
nozzle to contact the skin or body when
inspecting the nozzle using a nozzle tester. The
fuel injected from the nozzle has an extremely
high pressure, strong enough to penetrate skin
and causing serious injury.
1. Attach the fuel injector to the nozzle tester.

2. While watching the pressure gage of the nozzle
tester, push the handle down slowly.
IMPORTANT! If fuel drips from the end of
the nozzle it must be replaced.
3. When the handle is being pressed down, the fuel
is injected, and the pressure on the pressure gage
drops suddenly. The pressure value indicated at
this point is the fuel injection start pressure.
4. Close the valve on the injection pump. If the pres-
sure on the gage drops too fast ( most probably
due to lekage) the nozzle must be replaced.
NOTE! Make sure it isn’t the injection pump itself that
is leaking.
Nozzle opening pressure

34.32 MPa (350 kp/cm2) [4979 psi]

54
Fuel injection nozzle spray pattern

Check spray conditions when checking fuel injection
pressure. Good spray conditions are as follows:
· Fuel is injected from all nozzle holes.
· The fuel is sprayed in a conical shape.
· No big particles but fine ones.
· No oil drip is left after injection.
If the nozzle fails to spray fuel properly, replace with a
new one.
NOTE! Fuel injection pressure and nozzle spray pat-
tern check intervals may be extended in steps of 250
hours if they are ok at 1000 hrs.
Adjusting the fuel injection pressure

1. To adjust injection pressure, remove the set
screw from the nozzle holder, loosen the cap nut,
and then turn the adjusting screw. To increase
the injection pressure, tighten the screw. To de-
crease the injection pressure, loosen the screw.
2. When the pressure meets the standard value,
tighten the cap nut to 69 - 78 Nm (7 - 8 kpm)
[51 - 58 lbf.ft].
3. Tighten the set screw to 34 - 44 Nm
(3.5 - 4.5 kpm) [25 - 33 lbf.ft].
Fuel injector nozzle installation

1 . Remove the nozzle inlet connector from the fuel
injection nozzle.
2. Attach three 0-rings to the nozzle and grease
them.
3. Apply a small amount of grease to a gasket and
attach to the nozzle.
4. Insert the nozzle into the cylinder head aligning its
inlet connector hole to the connector hole in the
head.
5. Attach the nozzle inlet connector to the nozzle by
applying the specified torque, 64 to 74 Nm (6,5
to 7,5 kpm) [47 to 54 lbf].
6. Attach the nozzle gland and tighten the nut at the
specified torque (98 N -m (10 kgf m) [72 lbf]).
7. Attach the injection pipe and fuel leak-off pipe.
8. Before mounting the rocker cover, operate the
engine at approx. 850 rpm and check for any fuel
leakage from each joint. Install the rocker cover
after confirming no fuel leakage.

55
Injection timing inspection

The injection timing is indicated on the caution plate
attached to the No. 1 rocker cover. Check it before
inspection. Bring the piston for No. 1 cylinder to top
dead center on compression stroke as follows:
1. Turn the engine in the normal direction to align
the timing mark [1 .6] on the damper with the
pointer as shown.
2. Remove the No. 1 rocker cover and make sure
the inlet and exhaust valves for No. 1 cylinder
have some clearance. If these valves have no
clearance, turn the engine once again to align the
timing mark [1 .6].
NOTE! Do not confuse the No. 1 cylinder with No. 6.

When the piston for the No. 1 cylinder is in the above-
mentioned position, its inlet and exhaust valve are se-
ated, presenting some clearance.
3. Turn back the engine approximately 60 degrees,

and turn it in the normal direction slowly until the
specified timing (indicated on the caution plate)
aligns with the pointer. To ensure proper injection
timing, make sure that the timing mark on the
coupling flywheel aligns with the pointer on the
fuel injection pump.
a. pointer
b. timing mark
Adjusting fuel injection timing

1. Make sure the timing mark (indicated on the cau-
tion plate) is aligned with the pointer, with the pis-
ton for the cylinder at top dead center on com-
pression stroke.
2. Loosen two bolts for the fuel injection pump coup-
ling.
3. Turn the coupling flywheel until the timing mark
on the coupling flywheel aligns with the pointer on
the fuel injection pump.
4. Tighten the one nut for fuel injection pump coup-
ling. Turn the engine to tighten the other side nut.
5. Turn the engine (two turns) to recheck the injec-
tion timing for verification.

56
Fuel control
Fuel control link joints inspection

Check the ball joints for play. If there is more than
0.1 mm [0.004in.] play, replace the ball joints with
new ones.
WARNING! In case of a control link having ball

joints that is an integral part of the link, change
the link as an assembly.
Injection pump control rack operation

Move the stop lever back and forth a few times and
find out if the control rack can be operated smoothly.
WARNING! If the rack sticks this must be fixed

before starting the engine.
WARNING! Never try to control the engine rpm

by moving the manual stop control leaver in the
opposite direction of the arrow. This casn result
in serius harm of the installation.

57
Twin fuel pre-filter/water separator

The dual filter is equipped with a pressure gauge (1)

indicating when it is time to change the filter insert.
The filter inserts must be changed according to the
maintenance schedule recommendations or earlier if
the pressure gauge indicates a vacuum of 6–10 inHg
at idling speed or 16–20 inHg at full engine speed/
load.
Draining the fuel filter

Place a receptacle under the filter. Drain off water and
contaminants through the plug (1) in the bottom of the
bowl.
IMPORTANT! Do not drain until a few hours after

stopping.
Changing the filter elements

The dual filter inserts can be changed while the engine
is running as the flow of fuel can be cut off to one fil-
ter container at a time.
The flow of the fuel is governed by putting the knob
(1) in the following positions:
A: Normal running (both filters connected).
B: Left filter insert can be changed.
C: Right filter insert can be changed.
D: Both filters turned off.

58
Close the fuel cocks on the tank or cut off the flow of
fuel with the knob (1) for the filter insert to change if
running.
WARNING! Working on or approaching a

running engine is a safety hazard. Beware of
rotating parts and hot surfaces.
1. Place a receptacle under the filter.

2. Undo the T-bolt (2) and remove the cover (3).
3. Take out the insert carefully while turning it.
4. Drain off water and contaminants through the
drain plug (4).
5. Fit a new filter insert and fill the container with cle-
an fuel.
IMPORTANT! Cleanliness! No contaminants

must be allowed in the fuel system.
6. Change the gasket on the cover and the O-ring on

the T-bolt. Moisten the gasket and O-ring with fuel
before assembling.
7. Fit the cover and tighten it by hand.
8. Wipe off any fuel from the heat shield.
9. Dual filter: Change the other filter insert in the
same way.
10. Open the fuel cocks and put the knob (1) in posi-
tion for normal running. Make sure there are no
leaks.

59
Maintenance: Air inlet and exhaust system
Air inlet and exhaust systems
Turbocharger inspection
WARNING! Check the turbocharger only when
the engine is cool and the compressor wheel is
not running.
Check shaft play, take a hold of the compressor

wheel nut and turn the wheel to feel rattle and listen
for abnormal noise. Replace the bearings if the
wheel is noisy or rattles.
NOTE! Also check the turbocharger when the ex-
haust color is abnormal.
Cleaning the air cooler

Remove the air cooler, and blow compressed air in the
direction opposite to normal air flow.
Checking the air cooler drain pipe

Make sure the drain from the air cooler is not clogged.

60
Maintenance: Air inlet and exhaust system
Washing the air inlet silencer filter

Remove dust from air filter on the suction side of the
turbocharger silencer . Be sure to keep the air filter
clean to ensure optimum engine performance.
1. Remove the air filter from the silencer, and hand-

wash with a mild detergent.
2. Rinse the air filter with clean water.
3. After drying thoroughly, reinstall the air filter in the
silencer.
NOTE! If the air filter is damaged it must be replaced.
4. The standard interval for replacement of air filter
is every 2000 servicev hours or at least every 24
months.

61
Maintenance: Cooling system, general
Cooling system, general

The freshwater system is the internal cooling system of the engine. It is a closed system and shall always be fil-
led with coolant that protects the engine from internal corrosion and frost damage if the climate requires it. Anti-
corrosive additives become less efficient with age and the coolant must therefore be changed in accordance with
the recommendations in the maintenance schedule.
The rawwater system can be connected to seawater or a central cooling system.
WARNING! Never open the pressure cap or drain the cooling system when the engine is warm. Steam
or hot fluid may spurt out.
WARNING! The coolant is dangerous to your health and an environmental hazard. Handle coolant with
care and dispose of old coolant in accordance with local regulations.
IMPORTANT! For coolant specification, refer to chapter “Technical Data: Coolant specification” in the
back of this manual.
IMPORTANT! Check the coolant level on a cold stationary engine.
IMPORTANT! Coolant to be added should have the same concentration as the coolant in the engine.
Do not add plain water.
IMPORTANT! Certain parts of the system are made of light alloy. Chemical additives must therefore not
be used when cleaning the system.
62
Cooling system D25A/D30A MS HE

The thermostat regulated freshwater system is cooling the lubrication oil coolers, the engine and the charge air
cooler. An engine driven cooling water pump circulates the coolant through the heat exchanger and through the
engine.
The rawwater system cools the internal cooling system via an engine mounted heat exchanger.
1. Rawwater inlet
4.
2. Rawwater pump (optional)
9.
3. Engine monted
11.
heat exchanger
5.
3.
4. Expansion tank
10.
1. 5. Rawwater outlet
2. 8.
6. Freshwater pump
7. Lubrication oil cooler
8. Engine
7.
9. Exhaust manifold
6. 10. Charge air cooler

Freshwater circuit 11. Thermostat valve
Rawwater circuit
Freshwater drain points (D)
D
D
D
Plus d'informations sur : www.dbmoteurs.fr 63

Cooling system D25A/D30A MS KC

The engine cooling water is cooled by, e.g, a box cooler, a grid cooler, or any other external heat exchanger. The
same coolant (fresh water) is cooling the complete engine.
7. 1. Fresh water inlet

8. 5.
2. Freshwater pump
6. 3. Lubrication oil cooler
4. Engine
4. 5. Exhaust manifold
7. Thermostat valve
8. Fresh water outlet
3.
1.
2.
64
Cooling system D25A/D30A MT HE

The thermostat regulated freshwater system is cooling the engine and the lubrication oil cooler. An engine driven
cooling water pump circulates the coolant through the heat exchanger and through the engine.
The rawwater system is cooling the charge air and the coolant in the freshwater cooling system. The rawwater
circuit is designed for seawater or for connection to a central cooling system.
2.
1.
3.
1. Rawwater inlet
6. 2. Rawwater pump (optional)

11. 4. Heat exchanger
7.
5. 5. Rawwater outlet
4. 6. Expansion tank
7. Thermostat valve
10. 8. Freshwater pump
9. Lubrication oil cooler
10. Engine
9. 11. Exhaust manifold
8.
Freshwater circuit
Rawwater circuit
Plus d'informations sur : www.dbmoteurs.fr 65

Maintenance: Freshwater system
Freshwater system
Checking the coolant level

MS engines
Make sure the level ends between the MIN and MAX
marks. If there are no marks, the coolant level should
be approximately 5 cm below the top of the filler cap.
Fill if necessary with the same type and concentration
of coolant that is already in the system. For coolant
specification refer to chapter “technical data” in the
back of this manual.
NOTE! Coolant to be added should have the same
concentration as the coolant in the engine. Do not add
plain water.
MT engines
The minimum cooling water level on a cold engine is
65 mm [from the bottom of the sight glass and up
(A)].
The cooling water level of a cold engine must never
reach higher than 5 mm below the top of the sight
glass. For coolant specification refer to chapter “tech-
nical data”.
Filling the coolant

Topping up
Fill the freshwater system with coolant to the correct
level through the filler opening in the expansion tank,
for correct level, refer to section “coolant level check”.
Fill slowly so that evacuated air is able to pass the fil-
ler opening.
Filling when the system is empty

1. Open the air ventilation cocks and close the coo-
lant drain cocks.
2. Make sure that systems connected to the cooling
system also are ventilated, e.g. heater, water
heater.
3. Fill the freshwater system with coolant to the cor-
rect level through the filler opening in the expansi-
on tank. For correct level, refer to section “coolant
level check”. Fill slowly letting air ibleed from the
ventilation cocks and the filler opening. When air-
free coolant flows out, close the ventilation cocks.
4. To bleed the system, open all air vent cocks and
crank the engine 10 seconds while holding the
emergency stop lever in stop position. Repeat se-
veral times at one minute intervals.

66
Maintenance: Freshwater system
5. Close air vents. Check the coolant level and top

up if needed.
IMPORTANT! Make sure that the engine is

filled with lubrication oil before starting or
cranking the engine.
IMPORTANT! The engine must not be

started before the system has been bled and
topped up.
6. Start the engine and run it under light load until

the thermostat valve opening temperature is
reached.
7. Check air vents for leaks.
8. Stop the engine and allow it to cool. Check the
coolant level in the expansion tank and top up if
needed.
Draining the coolant

1. Remove the filler cap on the expansion tank.
2. Open the air vent cocks and then drain the coo-
lant from the drain cocks.
IMPORTANT! Check that the coolant really

drains. Deposits may need to be removed inside
the drain plugs/taps.
3. Drain all other systems connected to the freshwa-

ter system, e.g. heater, water heater, etc.
4. Close all drainage points.
Flushing the freshwater system

The system should be flushed before changing coo-
lant to avoid inferior cooling performance due to de-
posits in the cooling system.
1. Drain the coolant as described earlier.
2. Insert a hose into the filler opening in the heat ex-
changer and flush with fresh water.
3. Flush until the water running out of the drainage
points is clean.
4. Close all drainage points when the flushing water
has run out.
5. Fill with coolant. See section coolant filling when
empty.

67
Maintenance: Rawwater system
Rawwater system
The rawwater system is the engine’s external cooling system. It cools the internal cooling system in an engine
mounted or externally mounted heat exchanger. The system is protected against galvanic corrosion by zinc ano-
des located in the heat exchanger.
Keep the engine room heated or use an antifreeze coolant in the rawwater system. Otherwise the rawwater sys-
tem must be drained when there is a risk of freezing in cold weather.
WARNING! The rawwater cocks and/or the cocks of the external cooling system must be closed before
commencing work on the rawwater system. This due to the risk of sea water or water from the central
cooling system entering the vessel.
Draining the rawwater system

1. Close the rawwater in- and outlet cocks.
2. Drain the coolant from the external cooling sys-
tem.
IMPORTANT! Check that the coolant really

drains. Deposits may need to be removed from
inside the drain plugs/taps.
Checking/Changing zinc anodes

Note! Zink anodes are consumed differently, depen-
ding on the marine environment.
1. Drain the external cooling water as described in
the chapter draining the rawwater system.
2. Unscrew the zinc anodes from the heat exchan-
ger.
3. Change the anode if less than 50% remains. If
not, clean the anode with emery cloth to remove
the layer of oxide.
IMPORTANT! Do not use a wire brush or other

metal tool for cleaning as this may decrease the
galvanic protection.
4. Fit the zinc anodes. Make sure there is good con-

tact between the anode and the metal goods.
5. Open the rawwater cocks before starting the engi-
ne
6. Check the installation and make sure there are no
leaks.

68
Checking/Changing the rawwater
filter
If the vessel is equipped with a rawwater filter refer to
the maintenance description supplied by the supplier
of the filter.
NOTE! If the water wherein the vessel operates is se-
verely polluted, contains large amounts of seaweed,
etc., the filter must be checked more often than is
specified. The filter can otherwise become clogged
and the engine overheated.
Checking/Changing the rawwater

pump impeller
IMPORTANT! Always keep a spare impeller and
gasket in store.

2. Remove the pump end cover and the impeller.
3. Inspect the impeller. Change the impeller if there
are any visible cracks or other defects.
4. Clean the inside of the housing. Lubricate the
pump housing and the inside of the cover with
water-resistant grease (non-aggressive on rubber).
5. Push the impeller into position while rotating it in
the normal operating direction.
6. Fit the cover with a new gasket.
7. Close the drain cocks.
7. Open the rawwater cocks.

69
Maintenance: Rawwater system
Cleaning the heat exchanger

Clean if there are signs of clogging, a gradual increase
in engine temperature or high rawwater pressure.
Check/clean the rawwater filter first. Also check for
other damages on the heat exchanger.
2. Detach the pipe connections from the heat ex-
changer.
3. Remove both covers from the heat exchanger
4. Clean the heat exchanger insert pipe using suita-
ble brushes while flushing through the pipe with
water
5. Refit the heat exchanger element and mound the
covers.
6. Connect the pipe connections to the heat exchan-
ger. Check gaskets and change if necessary.
7. Open the rawwater cocks. Fill the freshwater sys-
tem.
8. Start the engine and make sure the rawwater sys-
tem is not leaking.

70
Maintenance: Electrical system
Electrical system
Protective devices inspection

Make sure that the instruments and the alarm func-
tions of the engine control system work properly.
Checking the electrical wiring

Check for loose or damaged electrical cables.
Damaged cables must be replaced.
Starter motor inspection

1. Visually inspect the starter motor for damages
and dirt build-up. Repair and clean if needed.
2. Check the pinion for shifting and meshing action.
If the starter has a defect, consult your dealer.
3. Check if the clutch of the starter motor operates
smoothly.
Alternator inspection
1. Inspect the alternator on functionality and clean it
if needed.
2. Remove the V-belt from the alternator. Turn the
alternator pulley by hand to check the rotation. If
the alternator has a defect, consult your dealer.
Checking/Adjusting/Changing the
drive belts
WARNING! Stop the engine before
commencing maintenance work.
Check belt tension and condition regularly. If the belt
is too tight it can damage bearings and if it is too loo-
se it may slip. Check and adjust after operation when
the belt is warm.
The belt is correctly tensioned when it can be depres-
sed approximately 10 mm between the pulleys. Clean
the belt grooves before fitting a new belt.
IMPORTANT! Always change a belt that
appears worn or is cracked (belts working in
pairs must be replaced together).
IMPORTANT! Always keep the belts clear of
oil or grease. Oil or grease can cause the
belts to slip, which might shorten belt life.

71
Inhibiting
General
To prevent the engine and other equipment from being harmed during long (2 months or more) periods out of servi-
ce, it must be conserved. It is of utmost importance that the conservation is performed correctly. Therefore we
have compiled a checklist of the most important points. Before taking the engine out of service for long periods, it
should be checked by a Volvo Penta dealer for possible needed overhaul or repaire of the engine and other equip-
ment.
WARNING! Read the chapter “Maintenance” thoroughly before starting any maintenance work. It
contains directions for performing maintenance in a safe and correct manner. Certain preservatives are
flammable. Some are also dangerous to inhale. Provide good ventilation. Use a protective mask.
IMPORTANT! The following must be considered when cleaning with a high-pressure water jet: Never
point high-pressure water jets directly at seals, rubber hoses or electrical components. Never use the
high-pressure function when washing the engine.
Preparation Care during storage

1. Drain the lubrication oil from the engine and fill it Recharge the battery at least once a month.
with new lubrication oil or conserving oil.
IMPORTANT! During longer periods out of opera-
IMPORTANT! Post a warning sign on the engine tion, the preparations must be repeated every 12
that the conserving oil must be replaced with the months.
specified lubrication oil before starting the engine
again.
Return the engine to service
2. Run the engine on idling speed on a mixture of
70% fuel and 30% lubrication oil until the 1. Remove the covering from the engine.
complete fuel system is filled with the mixture, 2. Connect well-charged batteries to the engine.
then stop the engine (If possible, top up the fuel
tank to avoid condensation). 3. Remove the covering from the starter and
alternator.
3. When the engine is coming to a stop but is still ro-
tating, spray volatile rust preservative in the air in- 4. Adjust the alternator and water pump drive belts.
take and exhaust system. This to prevent rust on 5. Remove all coverings and tapings.
the intake system.
6. Drain the rust preservative from the engine and fill
4. Apply a coat of rust preservative to the exposed, the engine with recommended engine oil.
machined surfaces of the engine.
7. Fill the fuel tank and prime the fuel system.
5. Cover breather, air inlet and exhaust openings
8. Check under and around the engine for such items
with tape.
as loose or missing bolts, oil, fuel or coolant leaks
6. Loosen the alternator and water pump drive belts. and repair if needed.
7. Tape the starter and alternator terminals and 9. Remove the rocker covers and lubricate the valve
cover the starter and alternator with a mechanism.
polyethylene sheet. Put a desiccant inside the
10. Crank the engine three times, 10 seconds each
covering.
time, at intervals of one minute, with the fuel
IMPORTANT! Never use vinyl sheets for supply shut off, to make sure the oil pressure
covering. This can result in condensation and rises properly.
harm the installation 12. Start the engine.
8. Remove the batteries and charge them. Clean the 13. Allow the engine to warm up at low idle.
terminal posts and coat them with acid free
14. When the engine has run long enough to warm up
Vaseline. Keep the batteries in a dry, cool place.
apply the load and bring it to operating speed.
9. Cover the engine for weather protection.
IMPORTANT! Store the engine in a well-

ventilated room.
IMPORTANT! It is not necessary to drain the

coolant because it contains coolant conditioner.

72
Inhibiting
Storage of engine in operating

condition
Service the engine once a month in the following
manner:
1. Crank the engine two times, for 10 seconds each
time, with the starter at intervals of 30 seconds,
with the fuel supply shut off.
2. Start and run the engine under no-load condition
for 5 to l0 minutes.
IMPORTANT! If the engine is fitted with a wet

exhaust system and the exhaust is situated
below the water line the above has to be perfor-
med twice a week (if the exhaust is situated
above the water line, once a week is enough).

73
Troubleshooting
A number of symptoms and possible causes for engine disturbances are described in the table below. If faults or
hitches arise that you cannot solve alone, you must always get in touch with your Volvo Penta dealer.
NOTE! Dust and foreign particles are the most common cause of excessive wear of parts. When disassembling
a component, take measures to prevent dust and foreign particles from entering it.
WARNING! Read the safety directions for maintenance and service in the chapter “Safety information”
before starting any work.
IMPORTANT! Handle parts carefully. Only use original Volvo Penta spare parts.
Symptoms and possible causes

Starter motor does not rotate when cranking 1,2,3,4,5,6
Starter motor rotates slowly when cranking 1,2,3,22,48,49
Engine does not start ,8,9,10,11,12,13,14,15,20,21,23,24,28,50,58
Engine is difficult to start 8,9,10,11,12,13,14,15,20,21,23,24,28,50,51
Engine starts but stops again 8,9,10,11,12,13,14,15,20,21,23,24,28,50,51

52,53
Engine does not reach correct operating speed 8,9,10,11,12,13,14,15,18,19,20,21,22,

23,24,25,26,27,28,33,36,53,58
Engine runs unevenly 8,9,10,11,12,13,14,15,16,17,23,24,28,29

51,58
Engine knocks 21,29,52
Engine vibrates 9,17,23,33,34
Engine can not be stopped 2,3,4,6,54
High fuel consumption 13,15,17,19,20,21,25,26,28,30,33
Black or dark gray exhaust smoke 13,15,17,18,19,20,21,28,30
Blue or white exhaust smoke 17,19,20,21,22,30,33,43,44,51,59
High lubrication oil consumption 22,32,33,34,44
Lubrication oil pressure too low 22,31,35,45,46
Coolant temperature too high 26,38,39,40,41,42,43,55
Coolant temperature too low 43
No charge or poor charge 2,3,47,56,57
1. Defective starter 21. Improper fuel oil 42. Defective cooling water pump
2. Flat batteries 22. Improper lubrication oil 43. Defective/wrong thermostat
3. Poor contact/broken cables 23. Air in fuel system 44. Too high lubrication oil level
4. Main switch turned off 24. Water/contamination in fuel 45. Defective lubrication oil pump
5. Control lever not in neutral/control 25. Boat abnormally loaded 46. Defective relief valve
position not activated 26. Fouled hull/propeller 47. Alternator drive belt slips
6. A fuse/circuit breaker has blown/tripped 27. Engine speed control wrongly adjusted 48. Clutch is engaged
7. Lack of fuel 28. Insufficient air supply 49. Defective bearings or abnormal cylinder
8. Blocked fuel filter 29. Too high coolant temperature friction
9. Defective fuel filter 30. Too low coolant temperature 50. Fuel supply pump strainer blocked
10. Blocked fuel pipes 31. Too low lubrication oil level 51. Very cold engine and lubrication oil
11. Defective fuel pipes 32. Lubrication oil leakage 52. Heavy initial load
12. Blocked fuel supply pump 33. Worn cylinder liners and/or piston rings 53. Propeller/propeller shaft blocked
13. Defective fuel supply pump 34. Worn valve stem seals 54. Engine consume lubrication oil or combus-
14. Blocked fuel injection pump 35. Blocked lubrication oil filter tible gas
15. Defective fuel injection pump 36. Defective/wrong propeller 55. Cylinder liner have scalings or such that
16. Blocked fuel injection nozzles 37. Faulty engine mounting reduce cooling effect
17. Defective fuel injection nozzles 38. Too low coolant level 56. Alternator/Rectifier broken
18. Incorrect valve clearance 39. Air in fresh water system 57. Faulty governor
19. Incorrect fuel injection timing 40. Blocked sea water inlet/pipe/filter 58. Broken piston
20. Low compression pressure 41. Circulation pump drive belt slips

74
Technical Data
D25A MS
General
Type designation D25A-MS
Number of cylinders .............................................. 6
Displacement ......................................................... 24,51 liters (1496 in3 )
Nominal idling speed ............................................. not available
Low idling speed .................................................... 625 ±25 rpm
High idling speed ................................................... not available [rating 1] not available [rating 2]
Valve clearance* ................................................... 0,6 mm (0,024”) [inlet] 0,8 mm (0,031”) [outlet]
Compression pressure
at starter motor speed (120 rpm) .......................... not available
Dry weight engine, without oil and coolant
without reverse gear or clutch, approx. ................ 2320 kg (5116 lbs)
Exhaust temperatures: 440 kW Rating 1

1008 r/min. ............................................................. 300°C (527°F)
1270 r/min. ............................................................. 380°C (716°F)
1454 r/min. ............................................................. 390°C (734°F)
1600 r/min. ............................................................. 380°C (716°F)
1039 r/min. ............................................................. 348°C (658°F)
1310 r/min. ............................................................. 440°C (824°F)
1500 r/min. ............................................................. 445°C (833°F)
1650 r/min. ............................................................. 450°C (842°F)
* Applies to cold engine.
Lubricating system
Oil capacity, approx. Including oil filters
No engine inclination ............................................. 160 liters (42,3 US gals)
volume difference min. –max. .............................. 30 liters (7,9 US gals)
Oil pressure, hot engine:
at operating speed ................................................. 0,50-0,64 MPa (71-93 psi)
at idling speed ....................................................... min.0,20-0,30 MPa (29-43 psi)
Cooling system
Freshwater system capacity
including heat exchanger, approx. ........................ 50 liters (13,2 US gals)
Electrical system
System voltage ..................................................... 24V
AC generator:
voltage/max. amperage ......................................... 24V/35A
output, approx. ...................................................... 840W
Battery electrolyte density at +25°C (77°F):

fully charged battery .............................................. 1,28 g/cm3 = 0,0462 lb/in3 (1,24 g/cm3 = 0,0448 lb/in3)*
battery recharged at .............................................. 1,24 g/cm3 = 0,0448 lb/in3 (1,20 g/cm3 = 0,0434 lb/in3)*
* Note. Applies to batteries with tropical acid.

75
Technical Data
D25A MT
General
Type designation D25A-MT

1008 r/min. ............................................................. 280°C (536°F)
1270 r/min. ............................................................. 360°C (680°F)
1474 r/min. ............................................................. 376°C (709°F)
1600 r/min. ............................................................. 380°C (716°F)
1039 r/min. ............................................................. 327°C (621°F)
1310 r/min. ............................................................. 395°C (743°F)
1500 r/min. ............................................................. 406°C (763°F)
1650 r/min. ............................................................. 400°C (752°F)
* Applies to cold or warm engine (stopped).
Lubricating system
Oil capacity, approx. including oil filters
Cooling system
Electrical system
System voltage ..................................................... 24V
AC generator:
output, approx. ...................................................... 840W


76
Technical Data
D30A MS
General
Type designation D30A-MS
High idling speed ................................................... not available[rating 1] not available[rating 2]

850 r/min. .............................................................. 309°C (588°F)
1072 r/min. ............................................................. 395°C (743°F)
1227 r/min. ............................................................. 419°C (786°F)
1350 r/min. ............................................................. 395°C (734°F)
882 r/min. .............................................................. 298°C (568°F)
1111 r/min. ............................................................. 378°C (712°F)
1272 r/min. ............................................................. 389°C (732°F)
1400 r/min. ............................................................. 390°C (734°F)
Lubricating system
Cooling system
Electrical system
System voltage ..................................................... 24V
AC generator:
output, approx. ...................................................... 840W


77
Technical Data
D30A MT
General
Type designation D30A-MT

850 r/min. .............................................................. 280°C (536°F)
1072 r/min. ............................................................. 355°C (671°F)
1227 r/min. ............................................................. 375°C (707°F)
1350 r/min. ............................................................. 385°C (725°F)
882 r/min. ............................................................ 290°C (554°F)
1111 r/min. ............................................................. 372°C (702°F)
1272 r/min. ............................................................. 404°C (759°F)
1400 r/min. ............................................................. 412°C (744°F)
Lubricating system
Cooling system
Electrical system
System voltage ..................................................... 24V
AC generator:
output, approx. ...................................................... 840W


78
Technical Data
Fuel specification
Fuel must comply with national and international standards at the least, e.g.:
JIS KK 2204. ...................... Type1, Type2, Type3

ASTM, D975 .................................. No.1-D, No.2-D
BS2869 .................................. Class-A1, Class-A2
DIN51601 ............................................. Diesel-Fuel
ISO8217 ............................................... DMX-Class
Note! It is necessary to use a fuel that has a pour point suitable for ambient temperature during the operation of
the engine. Consult the supplier to select the right type.
Property Use limit

Flash point ............................................................. As stipulated by regulation
First distillation point .............................................. 170°C (338°F) or more
90% distillation point .............................................. 330 to 380°C (626 to 716°F)
Pour point ............................................................... 6°C (10.8°F) below ambient temperature
Cloud point ............................................................. Below ambient temperature
Carbon residue (10% residue oil) ........................... 0.4 weight % or lower
Cetan number ........................................................ 45 or more
Cetan index (new) .................................................. 45 or more
Kinematic viscosity ................................................. 2.0 mm²/S or more [30°C (86°F)]
............................................................................... 8.0 mm²/S or lower [50°C (122°F)]
............................................................................... 10.5 mm²/S or lower [40°C (104°F)]
............................................................................... 16.0 mm²/S or lower [30°C (86°F)]
Sulfur content ......................................................... 0.2 weight % or lower
Water and sediment ............................................... 0.1 volume % or lower
Ash ......................................................................... 0.03 weight % or lower
Copper plate corrosion (100°C)[212°F], 3h ............ No. 3 or lower
Specific gravity (15°C/4°C [59°F/39°F] .................. 0.83 to 0.87
Coking test ............................................................. Not carbonized 100% at 250°C (482°F)
Aromatics content .................................................. 38 weight % or lower
Particulate contaminant .......................................... 5.0 mg/liter or lower
Asphaltene ............................................................. 0.1 weight % or lower

79
Technical Data
Lubrication oil specification

Recommended types of engine oil
Use lubrication oil that meets Class CF standard (recommended engine oil). Class CE and CF-4 engine oils are
designed for diesel fuel with a sulfur content of less than 0,5% and less than 0,2%, respectively. Since the sulfur
content of most Class-A diesel fuel exceeds 0,5%, do not use class CE or CF-4 engine oil when using class-A
diesel fuel
Important! Use of improper or inferior oil can cause excessive wear of bearings and moving parts,
thus shortening the engine life. It can also result in sticking of piston rings and seizing of pistons in the
cylinders, thus causing major damage.
Selection of oil viscosity

Use the following chart to select appropriate oil viscosity according to the ambient temperature. Recommended
oil viscosity is SAE 15W-40 for all seasons.
Important! Excessively high oil viscosity causes power loss and higher oil temperature, while
excessively low oil viscosity results in inadequate lubrication and leakage of combustion gas with
increased wear and reduced output as a result.

80
Technical Data
Coolant specification
Always use Volvo Penta Coolant in the freshwater cooling circuit. Volvo Penta Coolant acts both as anti-freeze
agent and provides corrosion protection for the metal parts of the cooling system. Future claims might be rejec-
ted should Coolant 90 not have been used.
Important! Mixing other types of concentrated coolant with Volvo Penta Coolant, may decrease
corrosion protection and may damage the engine or block the cooling system.
Water
Always use clean water that complies with the requirements in ASTM D4985 X1.1. If these requirements are not
complied with, corrosion may occur, which would result in impaired cooling performance.
Total fixed particle content ..................................... < 340 ppm

Total hardness ....................................................... < 9,5 °dH
Chloride .................................................................. < 40 ppm
Sulphate ................................................................. < 100 ppm
pH value ................................................................. < 5,5 – 9
Silica ....................................................................... < 20 mg SiO2/l
Iron ......................................................................... < 0.10 ppm
Manganese ............................................................ < 0.05 ppm
Conductivity ............................................................ < 500 ìS/cm
Organic content, CODMn ......................................... <15 mg KMnO4/L
Mixing ratio
The mixture of Volvo Penta Coolant and water should contain 40-55% Volvo Penta Coolant. If the coolant con-
tains less than 40% Volvo Penta Coolant, the cooling galleries in the engine or radiator may be blocked by con-
tamination. If the coolant contains more than 60% Volvo Penta Coolant the cooling ability of the coolant mixture
is impaired, this may cause the engine to overheat. Too high concentration of Volvo Penta Coolant also impairs
the frost protection.
Important! The mixture of Volvo Penta Coolant and water may never contain less than 40% Volvo
Penta Coolant.

81
Tightening torque tables
Important bolts and nuts D25

Thread Torque
Description Diam.xPitch Nm kpm lbf.ft Notes
(M-Thread)
Cylinder head 22 x 2,5 539 55 398 (a) (b) (c)
Cylinder head nozzle gland (studs) 14 x 2,0 69-78 7-8 51-58
Rocker case 12 x 1,25 108 11 80
Rocker shaft 14 x 2,0 147 15 108
Rocker arm lock nuts 12 x 1,25 64 6,5 47
Bridge lock nuts 10 x 1,25 55 5,6 40
Camshaft gear 12 x 1,25 127 13 94
Camshaft thrust plate 12 x 1,25 59 6 43
Main bearing caps 22 x 2,5 490 50 362 (a)
Hanger 12 x 1,25 108 11 80
Piston cooling nozzle 12 x 1,75 34 3,5 25 (d)
Timing gear case 16 x 1,5 216 22 159
Rear plate 12 x 1,25 108 11 80
Oil pan 12 x 1,25 59 6 43
Front mounting bracket 12 x 1,25 108 11 80
Rear mounting bracket 16 x 1,5 216 22 159
Connecting rod bearing caps 22 x 1,5 539 55 398 (a) (e)
Flywheel 22 x 1,5 539 55 398 (a)
Viscous damper 22 x 1,5 490 50 362
Rear idler shaft 12 x 1,25 108 11 80
Rear idler shaft thrust plate 10 x 1,25 29 3 22
Exhaust manifold V-clamp nuts 8 x 1,25 19,6 2 14,5

Exhaust manifold mounting bolts 1/4 x 28 9 0,9 6,5 UNF
Exhaust pipe V-clamps 10 x 1,5 98 10 72
Oil pump 12 x 1,25 108 11 80

Oil pump cover 10 x 1,25 26,3-39,7 2,7-4,1 18-32
Freshwater pump 12 x 1,25 59 6 43

Freshwater pump shaft pulley (nuts) 24 x 1,5 245 25 181 For alternator drive.
(a) Wet , apply lubrication oil to the threads of the nut and bolt.
(b) 2-step tightening method.
(c) Tighten cylinder head bolts according to the angle method, tighten to 294 Nm [30 kpm; 217 lbf.ft], then tighten 60° more.
(d) Extremely important to use torque wrench in tightening the piston cooling nozzles. Failure to do so may result in excessive
tightening torque, which may cause valve malfunctions that could lead to seizing of pistons due to insufficient lubrication.
(e) Tighten connecting rod caps according to the angle method, tighten to 245 Nm [25 kpm; 181 lbf.ft], then tighten 60° more.

82
Technical Data
Rawwater pump cam (screw) 10 x 1,25 15,7-21,6 1,6-2,2 11,6-15,9

Rawwater pump casing 8 x 1,25 7,4-9,8 0,75-1,0 5,42-7,23
Rawwater pump cover 8 x 1,25 7,4-9,8 0,75-1,0 5,42-7,23
Rawwater pump drive gear (nut) 24 x 2,0 191-201 19,5-20,5 141-148
Injection pump 12 x 1,25 108 11 80
Injection pump bracket 12 x 1,25 108 11 80
Injection pump drive case 12 x 1,25 108 11 80
Injection pump gear (nuts) 30 x 1,5 392 40 289
Injection pump laminate plate 12 x 1,25 103-113 10,5-11,5 76-83
Injection pump flywheel (nuts) 24 x 1,5 392 40 289
Injection pump coupling shaft 14 x 1,5 167-177 17-18 123-130 Tighten the slit part.
Injection pump plunger assembly 12 x 1,25 78-83 8-8,5 58-61
Injection pump delivery valve holder 30 x 1,5 235-255 24-26 174-188
Injection nozzle gland (nut) 14 x 1,5 98 10 72
Injection nozzle chip (nut) 28 x 1,5 177-196 18-20 130-145
Nozzle holder cap nuts 14 x 1,5 69-78 7-8 51-58
Injection nozzle set screw 10 x 1,5 34-44 3,5-4,5 25-33
Injection nozzle inlet connector 16 x 1,5 64-74 6,5-7,5 47-54
Injection pipes 18 x 1,5 49-69 5-7 36-51
Fuel filter air vent plug – 7,8-9,8 0,8-1,0 5,8-7,2

Fuel rack control lever 8 x 1,25 25 2,5 18 (b)
Governor drivecase 12 x 1,25 108 11 80
Starter 12 x 1,25 59 6 43
Turbocharger compressor wheel (nut) 11 x 1,0 – – – FD13(f)(g)(h)

Turbocharger V-clamp – 7,8-9,8 0,8-1,0 5,8-7,2 FD13 (g)
Turbocharger compressor wheel (nut) 1/2 x 20 – – – FD15UNF(f)(i)
Turbocharger turbine housing 10 x 1,5 25-28 2,6-2,9 19-21 FD15 (g)
(a) Wet, apply lubrication oil to the threads of the nut and bolt.
(f) Left-handed thread.
(g) Apply Moly Disulfide to thread.
(h) Tighten the lock nut to 49 Nm [5 kpm; 36 lbf.ft] firs, then loosen it completely. Retighten to 14,7 Nm [1,5 kpm; 0,8 lbf.ft], then
tighten 80±3° more.
(i) Tighten the lock nut to 69 Nm [7 kpm; 51 lbf.ft] then loosen it completely. Apply Loctite No. 962T to the threads. Retighten to
9,8 Nm [1 kpm; 7,2 lbf.ft], then tighten 90±3° more.

83
Technical Data
Important bolts and nuts D30

Thread Torque
Description Diam.xPitch Nm kpm lbf.ft Notes
(M-Thread)
Cylinder head 22 x 2,5 539 55 398 (a)(b)(c)
Cylinder head nozzle gland (studs) 14 x 2,0 69-78 7-8 51-58
Rocker case 12 x 1,25 108 11 80
Rocker shaft 14 x 2,0 147 15 108
Rocker arm lock nuts 12 x 1,25 64 6,5 47
Bridge lock nuts 10 x 1,25 55 5,6 40
Camshaft gear 12 x 1,25 127 13 94
Camshaft thrust plate 12 x 1,25 59 6 43
Main bearing caps 22 x 2,5 490 50 362 (a)
Hanger 12 x 1,25 108 11 80
Piston cooling nozzle 12 x 1,75 34 3,5 25 (d)
Timing gear case 16 x 1,5 216 22 159
Rear plate 12 x 1,25 108 11 80
Oil pan 12 x 1,25 59 6 43
Front mounting bracket 12 x 1,25 108 11 80
Rear mounting bracket 16 x 1,5 216 22 159
Connecting rod bearing caps 22 x 1,5 539 55 398 (a) (e)
Flywheel 22 x 1,5 539 55 398 (a)
Viscous damper 22 x 1,5 490 50 362
Rear idler shaft 12 x 1,25 108 11 80
Rear idler shaft thrust plate 10 x 1,25 29 3 22
Exhaust manifold V-clamp nuts 8 x 1,25 19,6 2 14,5

Exhaust manifold mounting bolts 1/4 x 28 9 0,9 6,5 UNF
Exhaust pipe V-clamps 10 x 1,5 98 10 72
Oil pump 12 x 1,25 108 11 80

Oil pump cover 10 x 1,25 26,3-39,7 2,7-4,1 18-32
Freshwater pump 12 x 1,25 59 6 43

Freshwater pump shaft pulley (nuts) 24 x 1,5 245 25 181 For alternator drive.
(a) Wet , apply lubrication oil to the threads of the nut and bolt.

84
Technical Data
Rawwater pump cam (screw) 10 x 1,25 15,7-21,6 1,6-2,2 11,6-15,9

Rawwater pump casing 8 x 1,25 7,4-9,8 0,75-1,0 5,42-7,23
Rawwater pump cover 8 x 1,25 7,4-9,8 0,75-1,0 5,42-7,23
Rawwater pump drive gear (nut) 24 x 2,0 191-201 19,5-20,5 141-148
Injection pump 12 x 1,25 108 11 80
Injection pump bracket 12 x 1,25 108 11 80
Injection pump drive case 12 x 1,25 108 11 80
Injection pump gear (nuts) 30 x 1,5 392 40 289
Injection pump laminate plate 12 x 1,25 103-113 10,5-11,5 76-83
Injection pump flywheel (nuts) 24 x 1,5 392 40 289
Injection pump coupling shaft 14 x 1,5 167-177 17-18 123-130 Tighten the slit part.
Injection pump plunger assembly 12 x 1,25 78-83 8-8,5 58-61
Injection pump delivery valve holder 30 x 1,5 235-255 24-26 174-188
Injection nozzle gland (nut) 14 x 1,5 98 10 72
Injection nozzle chip (nut) 28 x 1,5 177-196 18-20 130-145
Nozzle holder cap nuts 14 x 1,5 69-78 7-8 51-58
Injection nozzle set screw 10 x 1,5 34-44 3,5-4,5 25-33
Injection nozzle inlet connector 16 x 1,5 64-74 6,5-7,5 47-54
Injection pipes 18 x 1,5 49-69 5-7 36-51
Fuel filter air vent plug – 7,8-9,8 0,8-1,0 5,8-7,2

Fuel rack control lever 8 x 1,25 25 2,5 18 (b)
Governor drivecase 12 x 1,25 108 11 80
Starter 12 x 1,25 59 6 43
Turbocharger compressor wheel (nut) 11 x 1,0 – – – FD13 (f) (g) (h)

Turbocharger compressor wheel (nut) 1/2 x 20 – – – FD15 UNF (f) (i)
Turbocharger turbine housing 10 x 1,5 25-28 2,6-2,9 19-21 FD15 (g)
(a) Wet, apply lubrication oil to the threads of the nut and bolt.
(f) Left-handed thread.
(g) Apply Moly Disulfide to thread.
(h) Tighten the lock nut to 49 Nm [5 kpm; 36 lbf.ft] firs, then loosen it completely. Retighten to 14,7 Nm [1,5 kpm; 0,8 lbf.ft], then
tighten 80±3° more.
(i) Tighten the lock nut to 69 Nm [7 kpm; 51 lbf.ft] then loosen it completely. Apply Loctite No. 962T to the threads. Retighten to
9,8 Nm [1 kpm; 7,2 lbf.ft], then tighten 90±3° more.

85
Technical Data
Standard bolts and nuts

Fine threads
Thread Strength classification
diameter x pitch 7T 10.9
mm [in.] Nm kpm lbf.ft Nm kpm lbf.ft
M10 x 1,25 [0.39 x 0.049] 33 3,4 25 60 6,1 44
M12 x 1,25 [0.47 x 0.049] 60 6,1 44 108 11,0 80
M14 x 1,5 [0.55 x 0.059] 97 9,9 72 176 17,9 129
M16 x 1,5 [0.63 x 0.059] 145 14,8 107 262 26,7 193
M18 x 1,5 [0.71 x 0.059] 210 21,4 155 378 38,5 278
M20 x 1,5 [0.79 x 0.059] 291 29,7 215 524 53,4 386
M22 x 1,5 [0.87 x 0.059] 385 39,3 284 694 70,8 512
M24 x 1,5 [0.94 x 0.059] 487 49,7 359 878 89,5 647
M27 x 3 [1.06 x 0.12] 738 75,3 544 1328 135,5 980
Coarse threads
M8 x 1,25 [0.31 x 0.049] 17 1,7 12 30 3,1 22
M10 x 1,5 [0.39 x 0.059] 32 3,3 24 58 5,9 43
M12 x 1,75 [0.47 x 0.069] 57 5,8 42 102 10,4 75
M14 x 2 [0.55 x 0.079] 93 9,5 69 167 17,0 123
M16 x 2 [0.63 x 0.079] 139 14,2 103 251 25,6 185
M18 x 2,5 [0.71 x 0.098] 194 19,8 143 350 35,7 258
M20 x 2,5 [0.79 x 0.098] 272 27,7 200 489 49,9 361
M22 x 2,5 [0.87 x 0.098] 363 37,0 268 653 66,6 482
M24 x 3 [0.94 x 0.12] 468 47,7 345 843 86,0 622
M27 x 3 [1.06 x 0.12] 686 70,0 506 1236 126,0 911
Standard eyebolts
Thread Strength classification
diameter x pitch 4T
mm [in.] Nm kpm lbf.ft
M8 x 1,25 [0.31 x 0.049] 8±1 0,8±0,1 5,8±0,72
M10 x 1,25 [0.39 x 0.049] 15±2 1,5±0,2 10,8±1,45
M12 x 1,25 [0.47 x 0.049] 25±3 2,5±0,3 18,1±2,17
M14 x 1,5 [0,55 x 0.059] 34±4 3,5±0,4 25,3±2,89
M16 x 1,5 [0.63 x 0.059] 44±5 4,5±0,5 32,5±3,62
M18 x 1,5 [0.71 x 0.059] 74±5 7,5±0,5 54,2±3,62
M20 x 1,5 [0.79 x 0.059] 98±10 10,0±1,0 72,3±7,23
M24 x1,5 [0.94 x 0.059] 147±15 15,0±1,5 108,5±10,8
M27 x 3 [1.06 x 0.12] 226±20 23,0±2,0 166,3±14,5
(Dry)

86
Technical Data
Standard union nuts

Cap nut size Strength classification Nominal
diameter x pitch diameter
M14 x 1,5 [0.55 x 0.059] 39 4 29 63
M16 x 1,5 [0.63 x 0.059] 49 5 36 80
M20 x 1,5 [0.79 x 0.059] 78 8 58 100
M22 x 1,5 [0.87 x 0.059] 98 10 72 120
M27 x 1,5 [1.06 x 0.059] 157 16 116 150
M30 x 1,5 [1.18 x 0.059] 196 20 145 180
M30 x 1,5 [1.18 x 0.059] 196 20 145 200
M33 x 1,5 [1.30 x 0.059] 245 25 181 220
M36 x 1,5 [1.42 x 0.059] 294 30 217 254
(Dry)
High pressure fuel injection pipes

Cap nut size Strength classification
diameter x pitch
M12 x 1,5 [0.49 x 0.059] 39±5 4±0,5 29±3,6
M14 x 1,5 [0.55 x 0.059] 49±5 5±0,5 36±3,6
M18 x 1,5 [0.71 x 0.059] 59±1 6±1,0 43±7,2
(Dry)

87
Technical Data
Identification numbers
Type plates with identification numbers can be found on the engine and the transmission or generator. This infor-
mation must always be used as a reference when ordering service and spare parts.
Engine .........................................................................................................................................
Product designation .....................................................................................................................
Serial and basic engine number ..................................................................................................
Product number ...........................................................................................................................
Certification, IMO .........................................................................................................................

Decal, part No. ............................................................................................................................
Approval No. ................................................................................................................................
Transmission / Generator ............................................................................................................

Product designation .....................................................................................................................
Serial number ..............................................................................................................................
Product number ...........................................................................................................................

88
Sea trial data
Date .........................................................................
Name .......................................................................
Vessel .....................................................................
Engine no. ...............................................................
Miscellaneuos
Engine speed ................................................................................................................................................... rpm
Vessel speed ................................................................................................................................................... knots
Ambient/eng. room temp. ................................................................................................................................. OC
Sea water temp. ............................................................................................................................................... OC
Eng. cooling water out ...................................................................................................................................... OC
Cooler in ........................................................................................................................................................... OC
Cooler out ......................................................................................................................................................... OC
Eng. cooling water in ........................................................................................................................................ OC
Lubrication oil pressure .................................................................................................................................... Bar
Lubrication oil temp. ......................................................................................................................................... OC
Air intake .......................................................................................................................................................... OC
Charge air temp. .............................................................................................................................................. OC
Charge air press. .............................................................................................................................................. Bar
Exhaust gas temp. ........................................................................................................................................... OC
Exhaust gas temp. common ............................................................................................................................. OC
Fuel temp. engine in ......................................................................................................................................... OC
Fuel press. ....................................................................................................................................................... Bar
Type and brand of lubrication oil ......................................................................................................................
Type and brand of coolant ...............................................................................................................................
Mixture of coolant .............................................................................................................................................
Type of fuel during normal operation ...............................................................................................................
All values to be measured at full load. All values to be measured with approved instrumentation. If
in doubt mount your own equipment.

89
Notes
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English 07-2004
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Operator'S Manual: D25A MS/MT D30A MS/MT

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OPERATOR’S MANUAL

Plus d'informations sur : www.dbmoteurs.fr

Plus d'informations sur : www.dbmoteurs.fr

Plus d'informations sur : www.dbmoteurs.fr

Plus d'informations sur : www.dbmoteurs.fr

Plus d'informations sur : www.dbmoteurs.fr

Safety regulations during engine operation

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Carbon monoxide poisoning

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Safety directions for maintenance and service

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Hot surfaces and fluids Cooling system

Certain chemicals such as preservatives are

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Avoid burns and crushing or cutting! Perform all recommended inspections!

Service batteries carefully!

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Plus d'informations sur : www.dbmoteurs.fr

Plus d'informations sur : www.dbmoteurs.fr

Care of the environment Fuel and oil

Plus d'informations sur : www.dbmoteurs.fr

Plus d'informations sur : www.dbmoteurs.fr

13. Intake air silencer

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13. Intake air silencer

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External inspection Electrical wiring

IMPORTANT! All covers must be mounted before

Valves and plugs

IMPORTANT! If the coolant drain cocks are not

Plus d'informations sur : www.dbmoteurs.fr

Plus d'informations sur : www.dbmoteurs.fr

IMPORTANT! Read the chapter “Starting” before starting your engine.

11. Oil pressure gauge. Indicates the oil pressure in

Plus d'informations sur : www.dbmoteurs.fr

Plus d'informations sur : www.dbmoteurs.fr

3. Check warning lamps and alarms. Press the

4. Start the engine. Start using the starting switch.

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Checking the instruments

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Alarms and fault indication

IMPORTANT! Stop the engine immediately after

IMPORTANT! Slow the engine speed to idle/

Stopping the engine

IMPORTANT! The procedure described above is

NOTE! The stop solenoid will be activated for

WARNING! Working on or approaching a running

WARNING! Never try to increase engine rpm with

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Plus d'informations sur : www.dbmoteurs.fr

Applying load Manoeuvring

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Manual speed control

2. Turn the lock counterclockwise to unlock the ma-

3. By pushing the button and pulling the knob

WARNING! When adjusting engine speed avoid

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