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Safety Precaution to Operate Volvo Engine

Oct. 18, 2019

Volvo is one of the best well-known and most respected brands around the world. Volvo Penta, as one member of Volvo Group, has the privilege to use the trademark, entailing a responsibility to foster, develop the brand and its values and to protect them.

Founded in 1907, Volvo Penta offers complete power systems and services for industrial applications (such as diesel-powered generating equipment), leisure boats, and workboats. Volvo Penta operates in three areas of activity: Industrial, Marine, Commercial and Marine Leisure.

In this article, we mainly talk about Volvo diesel engine safety precaution.

Volvo diesel engine.jpg

WARNING! Possible danger of personal injury, extensive damage to property or serious mechanical malfunction if the instructions are not followed.

Safety Precaution

Below is a summary of the risks involved and safety precautions you should always observe or carry out when operating or servicing the engine.

Immobilize the engine by turning off the power  supply to the engine at the main switch (switches) before starting work. Put a warning notice at the engine control panel.

Generally, all service operations must be carried out with the engine stopped.

However, some work, for example certain adjustments requires that the engine is running when they are carried out. Approaching an engine, which is operating, is a safety risk. Loose clothing or long hair can fasten in rotating parts and cause severe personal injury.

Take care to avoid contact with hot surfaces (exhaust pipes, turbocharger, air intake pipe, starter element etc.) and hot liquids in lines and hoses on an engine that is running or has just been stopped. Reinstall all protective parts removed during service operations before starting the engine.

Check that the warning or information labels on the product are always clearly visible. Replace labels that have been damaged or painted over.

Never start the engine without installing the air cleaner filter. Foreign objects entering the in[1]take ducts can also cause mechanical damage.

Never use ether or similar products when starting the engine. They may cause an explosion in the inlet manifold and causing personal injuries.

Only start the engine in a well-ventilated area. If operating the engine in an enclosed area make sure that the exhaust is leading out of the engine compartment and working area.

Avoid opening the coolant filler cap when the engine is hot, when hot steam or coolant might spray out. If the filler cap must be open, slowly release the pressure in the system. Be very careful, it is difficult to anticipate in which direction hot steam or coolant can spray out.

Stop the engine before carrying out operations on the engine cooling system.

Always use protective glasses or goggles, when carrying out work where there is a risk of splinters, grinding sparks and acid splashes or when other chemicals are in use. The eyes are extremely sensitive and an injury could result in blindness!

Avoid getting hot oil on your skin, it might cause severe burns. Ensure that the lubrication system is not under pressure before carrying out any work. Never start or operate the engine with the oil filler cap removed, otherwise oil could be ejected.

Exposure to oil over a long period or repeatedly will cause problems such as skin drying out, irritation and toxic eczema. Used oil is in a health aspect even more dangerous than new oil. Use protective gloves. Use protection creams, which will ease up cleaning of the skin and counteract drying out.

Many chemicals such as oils, glycol, diesel oil and other chemicals, for example decreasing agents, paint and solvents are dangerous to your health.

Always follow the safety precautions for the product, for example using protective mask, glasses, gloves etc. Make sure of good ventilation is provided in the working area. Follow the instructions on the product, when disposing used chemicals

Follow extreme care when working with/or checking the fuel system. Use eye protection. The jet from a fuel injector nozzle is under extremely high pressure and can cause severe personal injury.

 WARNING! Use new delivery pipes every time. Be careful, delivery pipes should under no circumstances be bent.

All fuels and many chemical substances are flammable. Do not allow naked flame or sparks in the working area!

Make sure that the working area is well ventilated and take the necessary safety precautions before starting welding or grinding work.

Make sure that there always are fire extinguishers in the working area.


Ensure that rags soaked in oil or fuel are stored safely. Rags soaked in oil can spontaneously ignite. Used fuel filters, oil filters, lubricating oil, contaminated fuel, solvent and decreasing agents are environmentally dangerous waste and must be deposited at an approved site for destruction.

Never expose a battery to naked flame or electrical sparks. Batteries always produce hydrogen gas, which mixed with air form an explosive gas  oxyhydrogengas.

This gas is highly volatile and easily ignited. Incorrect connection of the battery can cause a single spark that is sufficient to cause an explosion. Be very careful when attempting to jump start the engine and do not at any time lean over the batteries.

Always ensure that the Plus (positive) and Minus (negative) battery leads are correctly installed. Incorrect installation can result in severe damage to the electrical equipment. Refer to the wiring diagrams.

Always use protective goggles when charging and handling the batteries. Battery electrolyte contains sulfuric acid, which is highly caustic. Should the battery electrolyte come into contact with unprotected skin wash off immediately using plenty of water and soap and if it is exposed to the eyes, immediately flush with plenty of water and obtain medical assistance at once.

Turn the engine off and turn off the power at the main switch/switches before carrying out work on the electrical system.

Clutch adjustments must be carried out with the engine stopped.

Use the lifting eyes fitted on the engine when lifting the drive unit. Always check that the lifting equipment is in good condition and has the correct load capacity to lift the engine (engine weight including gearbox, if fitted, and any extra equipment installed).

To make sure of safe handling and to avoid damage, use a lifting beam to raise the engine. This lifting beam is installed on the top of the engine, make sure that all chains and cables should run parallel to each other.

If extra equipment is installed on the engine that would alter its center of gravity, it is required that the lifting device has to be altered for obtaining the correct balance for safe handling. Never carry out work on an engine suspended on a hoist without other supporting equipment attached.

Never work alone when removing heavy engine components, even when using lifting devices such as locking tackle lifts. When using a lifting device two people are usually required to do the work, one to take care of the lifting device and another to ensure that components are lifted clear and not damaged during the lifting operations. Check before starting work if there is enough room to carry out removal work without risking personal injury or damage to the engine or parts.

WARNING! The components in the electrical system and in the fuel system on Volvo Penta products are designed and manufactured to minimize the risk of fire and explosion. The engine must not be run in areas where there are explosive materials.

Always use the fuels recommended by AB Volvo Penta. Refer to the Instruction Book. Use of fuels that are of a lower quality can damage the engine. On a diesel engine, poor quality fuel can cause the control rod to seize, which can result in an over revving of the engine, risking of damaging to the engine and of personal in[1]juries. Poor fuel quality can also lead to higher maintenance costs.

Observe the following rules when cleaning with  high-pressure water jets. Never direct the water jet at seals, rubber hoses, or electrical components. Never use a high-pressure jet when washing the engine.

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