OPERATOR’S MANUAL
D2-55, D2-75
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This operator’s manual is also available in the following languages:
Diese Betriebsanleitung ist auch auf
Deutsch erhältlich.
Dit instructieboek kan worden besteld
in het Nederlands.
Ein Bestellcoupon ist am Ende der Betriebsanleitung zu finden.
De bestelcoupon vindt u achter in het instructieboek.
Ce manuel d’instructions peut être
commandé en français.
Denne instruktionsbog kan bestilles på
dansk.
Vous trouverez un bon de commande à la fin
du manuel d’instructions.
Bestillingskupon findes i slutningen af instruktionsbogen.
Este libro de instrucciones puede solicitarse en español.
Tämän ohjekirjan voi tilata myös suomenkielisenä.
El cupón de pedido se encuentra al final del
libro.
Tilauskuponki on ohjekirjan lopussa.
Den här instruktionsboken kan beställas på svenska.
Este manual de instruções pode ser
encomendado em português.
Beställningskupong finns i slutet av instruktionsboken.
O talão de requerimento encontra-se no fim
do manual.
Questo manuale d’istruzioni può essere ordinato in lingua italiana.
Áõôü ôï åã÷åéñßäéï ÷ñÞóçò äéáôßèåôáé
óôçí áããëéêÞ ãëþóóá.
Il tagliando per l’ordinazione è riportato alla
fine del manuale.
Ãéá íá ðáñáããåßëåôå Ýíá áíôßôõðï,
óõìðëçñþóôå ôç öüñìá ðïõ âñßóêåôáé óôï
ôÝëïò áõôïý ôïõ åã÷åéñéäßïõ ÷ñÞóçò.
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.
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Welcome aboard
Volvo Penta marine engines are used all over the world today. They are used in all possible operating conditions for professional as well as leisure purposes. That’s not surprising.
After more than 90 years as an engine manufacturer and after delivering over 500,000
marine engines, the Volvo Penta name has become a symbol of reliability, technical innovation, top of the range performance and long service life. We also believe that this is
what you demand and expect of your Volvo Penta engine.
We would like you to read this operator’s manual thoroughly and consider the advice we
give on running and maintenance before you cast off on your maiden voyage so that
you will be ensured of fulfilling your expectations.
Best regards
AB VOLVO PENTA
1
Contents
Safety Information ............................................... 3–7
Maintenance schedule .................................... 26–27
Introduction ......................................................... 8–9
Running-in ............................................................ 8
Fuel and oil types ................................................ 8
Certified engines .................................................. 9
Warranty information ............................................ 9
Maintenance and care ..................................... 28–53
Engine, general .................................................. 28
Lubrication system ............................................. 32
Freshwater system ............................................ 33
Seawater system ............................................... 36
Fuel system ....................................................... 40
Electrical system ............................................... 42
Electrical components diagram .......................... 47
S drive and reverse gear .................................... 48
Introduction ..................................................... 10–14
D2-55 ................................................................. 12
D2-75 ................................................................. 12
Identification numbers ........................................ 14
Instrumentation ............................................... 15–18
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Controls ................................................................ 19
Starting the engine. ........................................ 20–23
Preparations and starting ................................... 20
Starting the engine using auxiliary batteries ....... 23
Operation ......................................................... 24–25
Checking instruments ........................................ 24
Cruising speed ................................................... 24
Maneuvering ...................................................... 25
When sailing ...................................................... 25
Stopping the engine ............................................
After stopping the engine ...................................
Laying up ...........................................................
Cold weather precautions ...................................
2
Laying up/Launching ...................................... 52–55
Inhibiting ............................................................ 52
Bringing out of storage ....................................... 54
Painting the drive and underwater hull ................ 55
Fault-tracing ......................................................... 56
Technical Data ................................................. 57–58
General .............................................................. 57
Lubrication, cooling and electrical systems ........ 57
S drive and reverse gear .................................... 58
Fuel specification ............................................... 58
26
26
26
26
© 2003 AB VOLVO PENTA
All rights to changes or modifications reserved. Printed on environmentally friendly paper.
(Cover: Department of transport (shipping), license 9809095)
Safety Precautions
Read this chapter carefully. It concerns your safety. This chapter describes how safety information is presented
in the Operator's Manual and on the engine itself. It also gives a general account of basic safety precautions to
be taken when operating the boat and maintaining the engine.
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Check that you have the correct Operator's Manual before you read on. If this is not the case please contact your Volvo Penta dealer.
If operations are performed incorrectly this could result in personal injury, or damage to
property or the engine. 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 information.
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 information 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.
3
Safety Information
Safety precautions to be taken when operating the boat
Your new boat
Read Operator's Manuals and other information
supplied with your new boat. Learn to operate the
engine, controls and other equipment safely and
correctly.
If this is your first boat, or is a boat type with which
you are not familiar, we recommend that you practice
controlling the boat in peace and quiet. Learn how the
boat behaves at different speeds, weather conditions
and loads before casting off for your “real” maiden
voyage.
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Remember that the person driving a boat is legally
required to know and follow the current rules regarding
traffic and safety at sea. Make sure you know the
rules that apply to you and the waters you are sailing
in by contacting the relevant authorities or organization.
A good piece of advice is to take a course in seamanship. We recommend that you contact your local
boating organization to find a suitable course.
Accidents
Statistics show that poor maintenance of boats and
engines and a lack of safety equipment are often the
cause of accidents at sea.
Ensure that your boat is maintained in accordance
with the relevant Operator's Manual and that the
necessary safety equipment is on-board and is
serviceable.
Daily checklist
Make a habit of checking the engine and engine
compartment visually before operating the boat
(before the engine is started) and after operating the
boat (after the engine has been stopped). This will
help you to quickly detect fuel, coolant and oil leaks
and spot anything else unusual that has, or is about to
happen.
Maneuvering
Avoid violent and unexpected changes in course and
gear engagement. This could cause someone on the
boat to lose their balance and fall over or overboard.
A rotating propeller can cause serious injury. Check
that nobody is in the water before engaging ahead or
astern. Never drive near bathers or in areas where
people could be in the water.
Avoid trimming an outboard drive too much, as
steering will be severely reduced.
4
Refueling
When refueling there is always a danger of fire and
explosion. Smoking is forbidden and the engine must
be switched off.
Never overfill the tank. Close the fuel tank filler cap
properly.
Only use the fuel recommended in the Operator's
Manual. The wrong grade of fuel can cause operating
problems or cause the engine to stop. On a diesel
engine poor quality fuel can cause the control rod to
seize and the engine to overrev with a resultant risk of
damage to the engine and personal injury.
Do not start the engine
Do not start or run the engine with a suspected fuel or
LPG leak in the boat, when you are close to or in a
discharge of explosive media, etc. There is a risk for
fire and/or explosion in explosive surroundings.
Safety Information
Carbon monoxide poisoning
When a boat is moving forward backwash is caused
behind the boat. Sometimes this backwash can be so
powerful that exhaust gases can be sucked into the
cabin or seating well on the boat with the resulting risk
of carbon monoxide poisoning for those on boar d.
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The backwash problem is greatest with high, broad
boats with a squared stern. But other types of boat
can also have backwash problems under certain
conditions, for example when running with an awning
rigged. Among other factors that can increase the
backwash effect are wind conditions, load distribution,
the sea running, trim, open hatches and valves.
Most modern boats are designed in such a way that
problems with backwash are extremely unusual.
Should a backwash problem occur do not open
hatches or valves in the forward part of the boat. This
will only increase backwash. Try changing speed, trim
or load distribution in the boat instead. In addition take
down, open or change the rigging of the awning in
some other way if an awning is rigged. Contact the
dealer where the boat was purchased to get more
information on how to solve this problem should it
occur on your boat.
Checklist
●
●
●
●
●
Safety equipment: Life jackets for all passengers, communication equipment, emergency rockets,
approved fire extinguisher, first-aid equipment, life belt, anchor, paddle, torch etc.
Replacement parts and tools: impeller, fuel filters, fuses, tape, hose clamps, engine oil, propeller
and tools for any repairs that might have to be carried out.
Get out your charts and go over the planned route. Calculate distance and fuel consumption.
Listen to the weather reports
Make sure that relations or contact persons are informed when planning a longer voyage. Remember to inform them if your plans have changed or been delayed.
Tell your passengers and crew where the safety equipment is stored and how to operate it. Make
sure you are not the only person on board who knows how to start the boat and operate it safely.
The list should be supplemented because the requirement for safety equipment varies depending on
the boat type and how it is used etc. We recommend that you contact a local boating or maritime
safety organization for more detailed marine safety information.
5
Safety Information
Safety precautions for maintenance and service operations
Preparations
Knowledge
The Operator's Manual contains instructions on how to
carry out general maintenance and service operations
safely and correctly. Read the instructions carefully
before starting work.
Service literature covering more complicated operations is available from your Volvo Penta dealer.
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Never carry out any work on the engine if you are
unsure of how it should be done, contact your Volvo
Penta dealer who will be glad to offer assistance.
Stop the engine
Stop the engine before opening or removing engine
hatches. Unless otherwise specified all maintenance
and service must be carried out with the engine
stopped.
To prevent accidental start of the boat engine remove
the ignition key, turn off the power supply to the
engine at the main switch and lock it in the OFF
position before starting work. Put up a warning sign in
the control position that work on the engine is being
carried out.
Approaching or working on an engine that is running is
a safety risk. Loose clothing, hair, fingers or a
dropped tool can be caught in the rotating parts of the
engine and cause serious personal injury. Volvo Penta
recommend that all servicing with the engine running
be undertaken by an authorized Volvo Penta workshop.
Lifting the engine
When lifting the engine use the lifting eyes installed
on the engine (reverse gear where installed). Always
check that lifting equipment is in good condition and is
strong enough for the lift (engine weight with any extra
equipment). For safety’s sake lift the engine using an
adjustable lifting beam. All chains and cables should
run parallel to each other and as perpendicular as
possible in relation to the top of the engine. Bear in
mind that extra equipment installed on the engine may
alter its center of gravity. Special lifting equipment
may then be required in order to maintain the correct
balance and make the engine safe to handle. Never
carry out work on an engine suspended on a hoist.
Before starting the engine
Reinstall all guards removed during service operations
before starting the engine. Check that no tools or
other items have been left on the engine.
6
Never start a turbocharger engine without installing the
air cleaner (ACL). The rotating compressor in the
turbocharger can cause serious personal injury.
Foreign objects can also be sucked in and cause
mechanical damage to the unit.
Fire and explosion
Fuel and lubrication oil
All fuel, most lubricants and many chemicals are
inflammable. Read and follow the instructions on the
packaging.
When carrying out work on the fuel system make sure
the engine is cold. A fuel spill onto a hot surface or
electrical components can cause a fire.
Store fuel soaked rags and other flammable material
so that there is no danger of them catching fire. In
certain conditions oil-soaked rags can spontaneously
ignite.
Do not smoke when filling fuel, oil or in proximity of a
filling station or in the engine room.
Non-original components
Components used in the fuel and ignition system
(gasoline engines) and electrical systems on Volvo
Penta products are designed and constructed to
minimize the risk of fire and explosion.
Using non-original Volvo Penta parts can result in fire
or explosion on board.
Batteries
The batteries contain and give off oxyhydrogen gas,
especially during charging. This gas is easily ignited
and highly flammable.
Do not under any circumstances smoke or use naked
flame or allow sparks in the vicinity of the batteries or
battery compartment.
Incorrectly connecting a battery terminal cable or
jump-start cable can cause a spark which in turn can
be sufficient to cause an explosion.
Start spray
Never use start spray or similar agents to start an
engine equipped with air pre-heating (glow plugs/
starter element). The starter element may cause an
explosion in the inlet manifold. Danger of personal
injury.
Safety Information
Hot surfaces and fluids
There is always a risk of burns when working with a
hot engine. Beware of hot surfaces. For example: the
exhaust pipe, turbocharger (TC), oil pan, charge air
pipe, starter element, hot coolant and hot oil in oil
lines and hoses.
Carbon monoxide poisoning
Start the engine only in a well-ventilated area. If
operating the engine in an enclosed space, ensure
that there is proper ventilation in order to remove
exhaust gases and crankcase ventilation emissions
from the working area.
Chemicals
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Most chemicals such as anti-freeze, rustproofing
agent, inhibiting oil, degreasing agent etc. are hazardous to health. Read and follow the instructions on the
packaging.
Some chemicals such as inhibiting oil are inflammable
and dangerous if breathed in as well. Ensure good
ventilation and use a protective mask when spraying.
Read and follow the instructions on the packaging.
Store chemicals and other hazardous materials out of
the reach of children. To protect the environment
please dispose of used or leftover chemicals at a
properly designated disposal site for destruction.
Fuel system
Always use protective gloves when tracing leaks.
Liquids ejected under pressure can penetrate body
tissue and cause serious injury. There is a danger of
blood poisoning.
Always cover the generator if it is located under the
fuel filter. The generator can be damaged by spilled
fuel.
Electrical system
Cutting off power
Always stop the engine and break the current using
the main switches before working on the electrical
system. Isolate shore current to the engine block
heater, battery charger, or accessories mounted on
the engine.
Batteries
The batteries contain an extremely corrosive electrolyte. Protect your skin and clothes when charging or
handling batteries. Always use protective goggles and
gloves.
If battery electrolyte comes into contact with unprotected skin wash off immediately using plenty of water
and soap. If battery acid comes into contact with the
eyes, flush immediately with plenty of water and
obtain medical assistance without delay.
Cooling system
There is a risk of water penetration when working on
the seawater system. Turn off the engine and close
the sea cock before starting work on the system.
Avoid opening the coolant filler cap when the engine is
hot. Steam or hot coolant can spray out and cause
burns.
If work must be carried out with the engine at operating temperature and the coolant filler cap or a cock
open or a coolant hose disconnected, open the
coolant filler cap carefully and slowly to release
pressure before removing the cap completely. Note
that the coolant may still be hot and can cause burns.
Lubrication system
Hot oil can cause burns. Avoid skin contact with hot
oil. Ensure that the lubrication system is not under
pressure before commencing work on it. Never start or
operate the engine with the oil filler cap removed, oil
can spray out.
7
Introduction
This Operator's Manual has been compiled to help you get the most from your Volvo Penta engine. It contains all
the information you need in order to operate and maintain your engine safely and correctly. Please read the
Operator's Manual carefully and learn how to operate the engine, controls and other equipment safely.
Always have the Operator's Manual available. Keep it in a safe place and do not forget to give it to the new owner
if you sell your boat.
Care of the environment
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We would all like to live in a clean and healthy environment. Somewhere where we can breathe clean
air, see healthy trees, have clean water in our lakes
and oceans, and are able to enjoy the sunshine without being worried about our health. Unfortunately,
this cannot be taken for granted nowadays but is
something we must work together to achieve.
As a manufacturer of marine engines, Volvo Penta
has a special responsibility, why care of the environment is a core value in our product development.
Today, Volvo Penta has a broad range of engines
where progress has been made in reducing exhaust
emissions, fuel consumption, engine noise, etc.
We hope you will take care in preserving these qualities. Always follow any advice given in the Operator's
Manual concerning fuel grades, operation and maintenance and you will avoid causing unecessary interference to the environment. Get in touch with your
Volvo Penta dealer if you notice any changes such as
increased fuel consumption exhaust smoke.
Adapt speed and distance to avoid wash and noise
disturbing or injuring animal life, moored boats, jetties, etc. Leave islands and harbours in the same
condition 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 disposal at a destruction plant.
Our joint efforts will make a valuable contribution to
our environment.
The engine can be expected to use more engine oil
during the running-in period than would otherwise be
normal. Check the oil level more often than is
normally recommended.
The prescribed warranty inspection “First Service
Inspection“ must be carried out during this first period
of operation. For more information: See the Warranty
and Service Book.
Fuel and oils
Only use the fuel and oils recommended in the chapter Technical Data. Other grades of fuel and oil can
cause operating problems, increased fuel consumption and, in the long-term, a shorter engine service
life.
Always change oil, oil filters and fuel filters at the
recommended intervals.
Service and replacement parts
Volvo Penta marine engines are designed for high
operational reliability and long service life. They are
constructed to withstand the marine environment while
also affecting it as little as possible. Through regular
service and the use of Volvo Penta original spare
parts, these qualities will be retained.
The engine must be run in for its first 10 operating
hours as follows:
The Volvo Penta worldwide network of authorized
dealers are at your service. They are specialists in
Volvo Penta products and have accessories and the
original replacement parts, test equipment and special
tools necessary for high quality service and repair
work.
Operate the engine normally. Do not operate it at full
load except for short periods. Never run the engine at
a constant engine speed for long periods during the
running-in period.
Always follow the maintenance intervals contained in
the Operator's Manual. Remember to state the engine/
transmission identification number when ordering
service and replacement parts.
Running-in
8
Introduction
Certified engines
It is important to be aware of the following information
if you own or run an engine that is exhaust emission
certified:
●
The engine must not be modified in any way
except with accessories and service kits approved
by Volvo Penta.
Certification means that an engine type is inspected
and approved by the authorities. The engine manufacturer guarantees that all engines manufactured of that
type correspond to the certified engine.
●
No modifications to the exhaust pipes and air
supply ducts for the engine may be undertaken.
●
Seals may only be broken by authorized personnel.
This places special requirements for maintenance
and service as follows:
●
The maintenance and service intervals recommended by Volvo Penta must be observed.
●
Only genuine Volvo Penta replacement parts may
be used.
●
The service of injection pumps and injectors or
pump settings must always be carried out by an
authorized Volvo Penta workshop.
Otherwise the general instructions contained in the
Operator's Manual concerning operation, service and
maintenance must be followed.
IMPORTANT! Late or inadequate maintenance/
service or the use of spare parts other than
Volvo Penta original spare parts will invalidate
AB Volvo Penta’s responsibility for the engine
specification being in accordance with the
certificated variant.
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Volvo Penta accepts no responsibility or liability
for any damage or costs arising due to the
above.
Warranty
Your new Volvo Penta marine engine is covered by a limited warranty according to the conditions and
instructions contained in the Warranty and Service book.
Note that AB Volvo Penta’s liability is limited to that contained in the Warranty and Service Book. Read this
book as soon as you take delivery of the engine. It contains important information about warranty cards,
service and maintenance which you, the owner, must be aware of, check and carry out. Liability covered in
the warranty may otherwise be refused by AB Volvo Penta.
Contact your Volvo Penta dealer if you have not received a Warranty and Service Book and a
customer copy of the warranty card.
9
Presentation
1
2
3
9
10
8
7
6
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4
11
15
12
5
D2-55 with reverse gear MS25L
1
2
9
6
7
5
D2-55 with reverse gear HS25A
10
14
D2-55 with reverse gear MS25L
3
4
13
10
8
15
11
12
13
14
D2-55 with reverse gear HS25A
Presentation
9 10
1
2
3
8
7
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4
15
17
5
11 12 13
14
16
18
19
D2-55 with sailing boat drive MS25S
1.
2.
3.
4.
5.
6.
7.
Coolant filler cap
Heat exchanger
Relay box with fuses
Generator
Starter motor
Oil cooler, reverse gear
Dipstick, reverse gear/S-drive
8.
9.
10.
11.
12.
13.
14.
Air cleaner (ACL)/Air intake
Dipstick, engine
Oil filler cap, engine
Fuel pump
Oil filter
Fuel filter
Injection pump
20
D2-55 with sailing boat drive MS25S
15.
16.
17.
18.
19.
20.
Seawater pump
Cooling water intake, S-drive
Sea cock, S-drive
Folding propeller
Sacrificial anodes
Oil drain plug, S-drive
11
Presentation
2
1
3
5
4
11 12
10
9
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8
6
17
13
14
7
D2-75 with reverse gear MS25L
1
2
3
4
15
16
D2-75 with reverse gear MS25L
5
11 12
10
6
8
7
D2-75 with reverse gear HS25A
12
9
13
14
15
16
D2-75 with reverse gear HS25A
17
Presentation
1
2
3
4
5
11 12
10
9
8
19
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7
13
14
15
16
17
18
20
21
D2-75 with sailing boat drive 150S
22
D2-75 with sailing boat drive 150S
1. Coolant filler cap
8. Generator
15. Fuel filter
2. Relay box with fuses
9. Dipstick, reverse gear/S-drive
16. Injection pump
3. Heat exchanger
10. Air cleaner (ACL)/Air intake
17. Seawater pump
4. Charge air cooler
11. Dipstick, engine
18. Cooling water intake, S-drive
5. Turbo
12. Oil filler cap, engine
19. Sea cock, S-drive
6. Oil cooler, reverse gear
13. Fuel pump
20. Folding propeller
7. Starter motor
14. Oil filter
21. Sacrificial anodes
22. Oil drain plug, S-drive
13
Presentation
Identification number
Your engine and transmission has identification plates with identification numbers. This information should always
be quoted when ordering service and replacement parts. There are probably similar plates on your boat and its
equipment. Make a note of the details below, make a copy of the page and keep it so that you have a copy
should the boat be stolen.
The appearance and location of identification plates is shown below. The figures in brackets refer to the location
of the identification numbers on the identification plate.
Engine
Product designation (1) .......................................................................................................
Serial number (2) .................................................................................................................
Product number (3) .............................................................................................................
Certification number (4) .......................................................................................................
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S-drive/Reverse gear
Product designation (5) ........................................................................................................
Serial number (6) ..................................................................................................................
Product number (7) ..............................................................................................................
Gear ratio (8) ........................................................................................................................
Propeller designation ............................................................................................................
Engine and transmission decal
XXXXXX (7)
XXX (5)
XX (8)
XXXXXXXXXX (6)
S-drive and reverse gear
Engine plate
14
Instrumentation
This chapter only describes the instrument panels available as standard alternatives for your engine from Volvo
Penta. Note that in certain boats instruments, alarm panels, key switches etc. may be installed separately
without the instrument panels shown here.
If you want to install additional instrumentation, or your boat is equipped with instruments not described here,
please contact your Volvo Penta dealer.
6
7
3
8
Instrument panel with ignition switch
1. Tachometer and hour counter (accessory). Displays engine speed. Multiply this value by 100 for
revolutions per minute. The hour counter displays
engine operating time in hours and tenths of an
hour.
2. Siren for acoustic alarm.
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3. Warning display. See pos. 22-25.
4. Switch for instrument lighting.
5. Alarm test/acknowledgment switch.
To test alarm: Press the switch. All warning lights
light and the acoustic alarm sounds.
1
5 2
4
9
Alarm acknowledgment: Press the switch if there
is an alarm. The acoustic alarm stops but the
relevant warning lamp continues to flash until the
malfunction is corrected.
6. Temperature gauge. Displays the engine coolant
temperature.
1
5 2
7. Oil pressure gauge. Displays the oil pressure in the
engine.
8. Voltmeter. Displays the charge voltage from the
generator.
9. Ignition switch. See description in the next chapter.
3
9
4
Ignition switch
The starter keys are tagged with a key code. This
code must be quoted when ordering extra keys. Keep
the code where it is not available to unauthorized
persons.
15
Instrumentation
S = The mechanical restart inhibitor is disengaged.
The key springs back automatically to the 0
position.
0 = The key can be inserted and removed.
I = Operating position.
II = Glow plug position. The glow plugs are connected
and pre-heating the engine.
III = Start position. The starter motor is engaged.
IMPORTANT! Read the starting instructions in
the chapter: Starting the engine.
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10
Instrument panel without ignition switch
15 11
The instrument panel does not have an ignition
switch. To stop unauthorized persons starting the
engine the wheelhouse should have a lock or a
lockable main switch should be used.
10. Tachometer and hour counter (accessory).
Displays engine speed. Multiply this value by 100
for revolutions per minute. The hour counter
displays engine operating time in hours and
tenths of an hour.
11. Siren for acoustic alarm.
12. Warning display. See pos. 22-25.
12
14
13
13. Switch for connecting and disconnecting instrument panel.
14. Starter button. The starter motor is engaged when
this button is pressed.
15. Alarm test/acknowledgment and glow plug rocker
switch.
Glow plugs active: When the rocker switch is in
the up position the glow plugs are activated.
To test alarm: Move the rocker switch down. All
warning lights light and the acoustic alarm
sounds.
Alarm acknowledgment: If there is an alarm the
rocker switch is moved down and the alarm is
acknowledged. The acoustic alarm stops but the
relevant warning lamp continues to flash until the
malfunction is corrected.
16
Instrumentation
16
Instrument panel with electrical start/stop
function
21 17
The instrument panel does not have an ignition
switch. To stop unauthorized persons starting the
engine the wheelhouse should have a lock or a
lockable main switch should be used.
16. Tachometer and hour counter (accessory).
Displays engine speed. Multiply this value by 100
for revolutions per minute. The hour counter
displays engine operating time in hours and
tenths of an hour.
17. Siren for acoustic alarm.
18
20
19
18. Warning display. See pos. 22-25.
19. Rocker switch for connecting/disconnecting the
instrument panel and stop function.
20. Starter button. The starter motor is engaged when
this button is pressed.
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21. Alarm test/acknowledgment and glow plug rocker
switch.
Glow plugs active: When the rocker switch is in
the up position the glow plugs are activated.
To test alarm: Move the rocker switch down. All
warning lights light and the acoustic alarm
sounds.
Alarm acknowledgment: If there is an alarm the
rocker switch is moved down and the alarm is
acknowledged. The acoustic alarm stops but the
relevant warning lamp continues to flash until the
malfunction is corrected.
17
Instrumentation
Warning display
If the acoustic alarm sounds, one of the three warning
lamps (16-18) on the instrument panel starts to flash
to indicate the source of the alarm.
22. Engine coolant temperature too high.
23 24
22
25
IMPORTANT! If the alarm sounds: Reduce engine
speed to idle (neutral). Stop the engine if the
temperature does not drop. Investigate and correct
the malfunction.
23. Low oil pressure.
IMPORTANT! If the alarm sounds: Stop the
engine immediately and investigate.
24. Generator not charging.
25. Indicator lamp Comes on when the glow plugs are
activated.
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Check that the warning lamps are operating before
starting the engine according to the description of the
relevant instrument panel.
Extra warning display
If the acoustic alarm sounds, one of the four warning
lamps starts to flash to indicate the source of the
alarm. The extra warning display is an accessory.
26. Not used.
27. Low coolant level. Top up to correct level before
starting.
26 27 28 29
28. Water in extra fuel pre-filter. Drain off water in
filter. See instructions in the chapter Maintenance.
29. Extra alarm for an optional function.
18
Controls
The shift function and engine speed control are combined in one lever. If necessary the shift function can be
easily disengaged so that only the engine speed (rpm) is affected by the lever. The control lever has an adjustable
friction brake. A neutral position switch is available as an accessory, this will only permit the engine to be started
with the drive/reverse gear disengaged.
Maneuvering
Shifting and engine speed are controlled with the same lever (1).
T
T
N = Neutral position. Drive/reverse gear disengaged.
F = Drive/reverse gear engaged for movement ahead.
1
R = Drive/reverse gear engaged for movement astern.
T = Engine speed control
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2
For top-mounted controls
Disengaging the shift function
T
T
●
Move lever (1) to the neutral position (N).
●
Press in button (2), move the lever slightly forward and release
the button.
1
The shift function is now disengaged and the lever affects only
engine speed. When the lever is moved back to the neutral
position it will automatically re-engage.
IMPORTANT! Take care not to engage the drive/reverse gear
by mistake.
2
For side-mounted controls
Adjusting the friction brake
The friction brake only affects the engine speed control movements.
●
Lift the cover over the control. For side-mounted controls the
lever must first be removed.
●
Set the lever to the half-open throttle/reverse position.
●
Adjust the friction brake. Turning the screw clockwise (+) makes
the lever movement stiffer, while turning counterclockwise (–)
makes it easier to move the lever.
●
Reinstall the cover and lever.
19
Starting the engine
Make a habit of checking the engine and engine compartment visually before operating the boat. This will help you
to quickly detect anything unusual that has or is about to happen. Also check that instruments and the warning
display are indicating normal values when you have started the engine.
Before starting
●
Open the cooling water intake sea cock.
●
Open fuel cock.
●
Carry out the actions in the “Daily before the first start-up” section in
the maintenance schedule
●
Switch on the main switch.
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IMPORTANT! Never break the circuit with the main switch while
the engine is running. This could damage the generator.
20
●
Start the engine compartment fan if one is fitted and let it run for at
least four minutes.
●
Check that there is sufficient fuel.
●
Push in the stop control, if the boat is fitted with one.
Starting the engine
Starting. Instrument panel with ignition lock
WARNING! Never use start spray or similar to start the engine.
Danger of explosion!
1. If the engine is cold: Disconnect the gear shift function and move
the control lever forwards to half throttle.
WARNING! Make sure that the gear shift function is disconnected.
If the engine is warm: Move the control lever to the neutral/idling
position.
2. Insert the key in the ignition switch. Turn key to the ”I” position. The
three warning lamps come on and can be tested.
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Check that the acoustic alarm is operating by pressing the ”Alarm
Test” button.
3. Turn key to the ”II” position. The indicator light comes on and the
glow plugs are connected to pre-heat the engine. Let the glow plugs
remain activated for 10 seconds (max. 30 seconds).
IMPORTANT! Always pre-heat the engine (even when it is
warm).
4.
Turn the key to position ”III” to start. Release the key as soon
as the engine has started, the key will automatically spring
back to the ”I” position. If the engine did not start the key must
first be turned to the ”0” position before trying again.
IMPORTANT! If the starter motor is engaged for its maximum
engagement time (20-30 seconds) let it cool down for five
minutes before trying to start the engine again.
5. Warm up the engine at low speed and low load.
IMPORTANT! Do not race the engine while it is cold.
21
Starting the engine
Starting. Instrument panel without ignition
switch
WARNING! Never use start spray or similar to start the engine.
Danger of explosion!
1. If the engine is cold: Disconnect the gear shift function and move
the control lever forwards to half throttle.
WARNING! Make sure that the gear shift function is disconnected.
If the engine is warm: Move the control lever to the neutral/idling
position.
2. Instrument panel without ignition switch:
Activate the instrument panel by pressing the ”Power ON/OFF”
switch. The three warning lamps come on and can be tested.
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Check that the acoustic alarm is operating by pushing the rocker
switch to the ”Alarm Test” position.
Instrument panel with electrical start/stop function:
Activate the instrument panel by pressing the rocker switch downwards to ”Power ON/OFF”. The three warning lamps come on and
can be tested.
Check that the acoustic alarm is operating by pushing the rocker
switch to the ”Alarm Test” position.
3. Push the rocker switch to the “Glow” position. The indicator light
comes on and the glow plugs are connected to pre-heat the engine.
Let the glow plugs remain activated for 10 seconds (max. 30 seconds).
IMPORTANT! Always pre-heat the engine (even when it is
warm).
4. Press the starter button. Release the starter button as soon as the
engine starts.
IMPORTANT! If the starter motor is engaged for its maximum
engagement time (20-30 seconds) let it cool down for five
minutes before trying to start the engine again.
5. Warm up the engine at low speed and low load.
IMPORTANT! Do not race the engine while it is cold.
22
Starting the engine
Starting using auxiliary batteries
WARNING! Batteries produce oxyhydrogen. This gas is easily
ignited and highly volatile. A short-circuit, naked flame or spark
can cause a large explosion. Ensure that the ventilation is good.
Never mix up battery positive and negative terminals. This may
cause sparks and an explosion.
C B
1. Check the auxiliary batteries have the same rated voltage as the
engine’s system voltage.
2. First connect the red jump lead to the discharged battery’s + terminal (A) and then to the auxiliary battery’s + terminal (B).
A
D
3. First connect the black jump lead to the auxiliary battery’s - terminal (C) and then to a site (D) where there is good contact with the
cylinder block as far away from the discharged battery as possible.
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4. Start the engine and run it at a fast idle for approximately ten minutes to charge the battery.
WARNING! Approaching or working on a running engine is dangerous. Watch out for rotating components and hot surfaces.
Do not touch the connections while trying to start the engine: This
may cause sparks. Do not lean over the batteries.
5. Stop the engine. Remove the jump leads in exactly the opposite
order to which you put them on.
23
Operation
Avoid violent and unexpected changes in course and gear engagement. There is a risk that someone aboard will
fall over or overboard.
WARNING! A rotating propeller can cause serious injury. Check that nobody is in the water before engaging
ahead or astern. Never drive near bathers or in areas where people could be in the water.
B
A
C
Checking instruments
Check the instruments and warning display directly after starting the
engine and then at regular intervals while driving the boat. Stop the
engine if there is an abnormal reading or any warning lamp comes on
and the alarm sounds. For engines with measuring instruments the
following standard values apply:
Oil pressure (A)
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Normal operating oil pressure is between 150–500 kPa (21–71 psi). At
engine idle this is normally lower. The acoustic alarm will automatically
go off if the oil pressure is too low.
IMPORTANT! If the alarm sounds: Stop the engine immediately.
Investigate and correct the malfunction.
Engine coolant temperature (ECT) (B)
Normal operating temperature is between 75–90°C. The acoustic alarm
will automatically go off if the engine coolant temperature (ECT) is too
high.
IMPORTANT! If the alarm sounds: Reduce engine speed to idle
(neutral). Stop the engine if the temperature does not drop.
Investigate and correct the malfunction.
Charging (C)
The operating charge current is approx. 14 V. When the engine is
stopped battery voltage is approx. 12 V.
Cruising speed
Operating the engine at wide open throttle (WOT) should be avoided
since it is both uneconomical and uncomfortable. Volvo Penta recommends a cruising speed in the range 500–1000 rpm lower than maximum rpm at WOT. Depending on hull type, choice of propeller, load and
conditions etc. the maximum engine speed at top speed can vary, but
it should be within the WOT range.
Wide Open Throttle (WOT) range: ................. 2,700–3,000 rpm
24
Operation
1.
Maneuvering
All shifting between ahead and astern must be done at engine idle
speed. Shifting at higher speeds may damage the drive or reverse
gear and will also be uncomfortable for those on board.
2.
1. Reduce engine speed to idling and, if possible, let the boat lose
most of its speed.
2. Move the reverse gear control lever quickly and firmly into the
neutral position. Wait for a moment.
3.
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3. Move the gear control lever quickly and firmly into astern, then
increase the speed.
Trolling operation valve
HS25 reverse gear can be equipped with a trolling operation valve
which makes it possible to steplessly reduce the boats lowest speed
by 20-80% at engine speeds up to 1200 rpm.
IMPORTANT! At engine speeds above 1200 rpm, the reversing
gear can overheat.
When sailing
When sailing the control lever should be in the neutral position if the
boat is equipped with HS25 reverse gear. If the boat is equipped with
S-drive or MS25 reverse gear the control lever should be the reverse
position if a folding propeller is used and in neutral position if a fixed
propeller is used.
25
Stopping the engine
The engine should be run for a few minutes at idle (in neutral) before turning it off. This will avoid boiling and even
out the temperature. This is especially important if the engine has been operated at high engine speeds and
loads.
Stopping
If the boat is fitted with a stop control: Pull and hold out the stop
control until the engine has stopped. Push in the stop control. If the
instrument panel has an ignition switch the key should turned to the stop
position ”S”. The key will automatically spring back to the ”0” position
when it is released and can then be removed.
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If the boat is fitted with an electric start/stop function: Push the rocker switch to the ”Stop” position until the engine stops. Release the rocker
switch and it returns automatically to the ”Power OFF” position.
After stopping the engine
●
Inspect the engine and engine compartment for any leaks.
●
Close the fuel cock and sea cock for the cooling water intake.
IMPORTANT! Do not forget to open the cocks before the engine is
started again.
●
Read off the hours counter and do preventive maintenance as in the
maintenance schedule.
●
Switch off the main switch if the boat is not to be used for some time.
IMPORTANT! Never break the circuit with the main switches while
the engine is running. This could damage the generator.
Laying up
If the boat is not going to be used for some time but is being left in the
water, the engine must be run to operating temperature at least once
every 14 days. This prevents corrosion in the engine. If the boat will not
be used for more than two months then inhibiting should be carried out:
See chapter “Laying up/Launching”.
Cold weather precautions
To prevent freezing damage, the seawater system must be drained and
the freshwater system coolant must have sufficient antifreeze protection. See chapter Maintenance ”Cooling systems”.
IMPORTANT! A poorly charged battery may burst as a result of
freezing.
26
Maintenance schedule
Your Volvo Penta engine and associated equipment is designed to provide high operational reliability and long
service 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.
Warranty inspection
The prescribed warranty inspection “First Service Inspection” must be carried out at an authorised Volvo Penta workshop during this first period of operation. Directions for when and how this is to be carried out can be
found in the Warranty and Service Book.
MAINTENANCE SCHEDULE
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WARNING! Read the chapter “Maintenance” thoroughly before starting any maintenance work. It contains directions for performing maintenance in a safe and correct
manner.
IMPORTANT! When both operating time and calendar time is given, the one occurring first is to apply. Maintenance points marked with are to be carried out at an
authorised Volvo Penta workshop.
Daily before starting for first time
● Engine and engine room. General inspection..................................................page 29
● Engine oil. Checking level ..............................................................................page 32
● Coolant. Checking level .................................................................................page 34
Every 14 days
● Fuel pre-filter. Drain water ..............................................................................page 41
● Drive belt. Check ...........................................................................................page 30
● Seawater filter. Cleaning ................................................................................page 37
● Battery. Check electrolyte level .....................................................................page 43
● Reverse gear. Check oil level .........................................................................page 48
● S-drive. Check oil level .................................................................................. page 48
Least once a year
● Folding propeller. Cleaning .............................................................................page 50
● S-drive. Check rubber seal (hull/drive) ............................................................page 52
27
Maintenance schedule
Every 200 operating hours or at least once a year
● Reverse gear. Oil change ............................................................................... page 49
● Reverse gear (HS25) Cleaning the oil filter .....................................................page 49
● Reverse gear. Lubricate propeller shaft seal. ..................................................page 52
● S-drive. Oil change ........................................................................................ page 48
● S-drive/Reverse gear. Checking corrosion protection ..................................... page 50
Every 500 operating hours or at least once a year
● Engine oil. Replace ........................................................................................ page 32
● Oil filter. Replace ........................................................................................... page 32
● Fuel filter. Replace .........................................................................................page 41
● Fuel pre-filter. Replace ...................................................................................page 41
● Idling speed. Check ....................................................................................... page 31
● Coolant 1). Replace .........................................................................................page 35
● Seawater pump. Check impeller ..................................................................... page 36
● Vacuum valve. Cleaning ................................................................................page 37
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1)
If the freshwater system is filled with an anti-corrosion agent mixture it must be changed every year.
If the freshwater system is filled with an antifreeze (glycol) mixture it must be changed every other year.
Every 500 operating hours or at least once every two years
● Air Cleaner (ACL). Cleaning ........................................................................... page 31
● Coolant 1). Replace .........................................................................................page 35
● Heat exchanger. Cleaning .............................................................................. page 35
Injectors. Test pressure ............................................................................. not shown
Valve clearance. Adjustment ..................................................................... not shown
1)
If the freshwater system is filled with an anti-corrosion agent mixture it must be changed every year.
If the freshwater system is filled with an antifreeze (glycol) mixture it must be changed every other year.
Every 500 operating hours or at least every fifth year
Reverse gear. Replacing propeller shaft seal .............................................. not shown
Every seventh year
S-drive. Replacing rubber seal between drive and hull ................................ not shown
28
Maintenance
This chapter contains instructions regarding how the above maintenance points should be carried out together
with general technical information. Read the instructions carefully before starting work. Maintenance intervals are
contained in the chapter above. Maintenance schedule
WARNING! Read the safety precautions for maintenance and service in the chapter: Safety Precautions,
before starting work.
WARNING! Unless otherwise specified all maintenance and service must be carried out with the engine
stopped. Stop the engine before opening or removing engine hatches. Immobilize the engine by removing
the ignition key, turning off the power supply with the main switch.
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Engine, general
General inspection
Make a habit of “visually” inspecting the engine and
engine room before starting the engine and after
stopping when the engine has been turned off. This
will help you to quickly detect abnormalities that have
occurred or are about to occur.
Look especially carefully for oil, fuel and coolant
leaks, loose bolts, worn or slack drive belts, loose
connections, damaged hoses and electric cables.
This inspection takes only a few minutes but can prevent serious operating diesturbances and costly repairs.
WARNING! Accumulations of fuel, oil and grease
on the engine or in the engine room is a fire hazard and must be removed immediately they are
detected.
IMPORTANT! If an oil, fuel or coolant leak is detected, the cause must be investigated and the
fault rectified before the engine is started.
IMPORTANT! Never point high-pressure water
jets directly at seals, rubber hoses or electrical
components. Never use the high-pressure function when washing the engine.
29
Maintenance: Engine, general
Drive belt. Check
The belt drives both the circulation pump and the
generator. A belt that is too loose can result in slippage, poor cooling and poor charging. A belt that is
too tight can damage the bearings in the circulation
pump and damage the generator.
Check the tension of the belt regularly. Adjust as
required. Check that the belt is not cracked or damaged. Replace a worn belt. Keep a spare belt onboard.
3
2
10 mm
4
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1
D2-75
Drive belt. Adjusting and replacing
WARNING! Always turn the engine off before
starting maintenance work.
IMPORTANT! Tighten screw (1) to 50 Nm.
2
Check and adjust as necessary after operating the
engine when the belts are warm. It should be possible
to depress a belt at the correct tension approx. 10 mm
between the pulleys using normal thumb pressure.
D2-55:
To adjust slacken off the screws (1 and 2). Tension
the belt, adjust to the correct tension and tighten the
screws. Check the tension.
D2-75:
Loosen the alternator fixing screws (1-3). Tension the
belt with the adjustment screw (4), to the correct
tension. Tighten the screws (1-3). Check the tension.
1
D2-55
30
To replace the belt slacken off screws (1 and 2).
Press the generator in towards the cylinder block so
that the belt can be removed. Clean off the pulley
grooves. Install the new belt. Adjust as above. Check
belt tension again after a few hours’ operation.
Maintenance: Engine, general
Air Cleaner (ACL). Cleaning
Remove the hose clamp (1) and remove the filter.
Remove the spring inside the filter. Clean the filter as
necessary by washing it in soapy water. Then rinse it
in clean water. Squeeze the filter out and leave it to
dry.
IMPORTANT! Take care that no contaminants
enter the engine.
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1
Idling. Adjustment
For engine idling speed: Please refer to the Technical
Data chapter. A lower engine speed can cause the
engine to stall and a higher engine speeds can cause
extra stresses to the drive/reverse when shifting.
A
B
C
Adjust with the engine at operating temperature as
follows:
1* Set the control lever in the neutral position. Check
that gap (A) is approx. 3 mm. Adjustment: Slacken
off the locknut (B) and adjust until the correct gap
is obtained with screw (C). Tighten the locknut.
*This point does not apply to boats with double control
positions.
2 Start engine and allow to idle with gear selector in
neutral.
D
E
WARNING! Approaching or working on a running
engine is dangerous. Watch out for rotating
components and hot surfaces.
3 Slacken off locknut (D). Adjust engine speed with
adjustment screw (E). Tighten the locknut. Repeat
step 1.
Wastegate (D2-75)
If the engine is not used for a longer period of time
there is a risk that the turbochargeer boost pressure
valve may stick. Check that the shaft turns.
31
Maintenance: Lubrication system
Lubrication system
IMPORTANT! With a new or reconditioned engine, the oil and oil filters must be changed after 20-50 hours of
operation. After that they should be changed every 500 operating hours or at least once a year. Use only the
recommended grades of oil: See the chapter ”Technical Data”.
2
Oil level. Checking and topping up
1
The oil level should be within the marked area on the
dipstick (1). It should be checked every day before
the engine is started. Topping up is done through the
valve cover (2). Top up oil slowly. Wait a few minutes
before checking the oil level again to give the oil time
to run down to the oil pan. Then check the level again.
Use only the recommended grades of oil: See the
chapter ”Technical Data”.
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IMPORTANT! Do not fill the oil above the MAX
level.
Oil and oil filters. Changing
1. Run the engine to operating temperature so that
the oil is easier to suck out. Stop the engine.
2. Suck out the oil using an oil drain pump through oil
drain pipe.
WARNING! Hot oil and hot surfaces can
cause burns.
3. Unscrew the old filter. (To avoid oil spills put a
plastic bag over the filter before it is unscrewed).
4. Check that the engine mating surface is clean.
5. Moisten the filter rubber gasket with a little oil.
Screw on the new filter by hand until it is in contact
with the mating surface. And then a further half
turn but no more!
6. Top up oil to correct level. Start the engine and let
it idle. Check that the warning lamp for low oil
pressure goes out.
7. Stop the engine. Wait for approx. 10 minutes
before checking the oil level. Top up if required.
Check that there are no leaks round the oil filter.
NOTE! Collect up the old oil and filter for deposit at
a proper disposal site.
32
Maintenance: Freshwater system
Freshwater system
The freshwater system is the engine's internal cooling system. It is a closed system and must always be filled
with a coolant that protects it against internal corrosion and freezing when the climate demands.
The circulation pump ensures sufficient circulation in the system. The thermostat will start to open at a certain
temperature and will be fully open when the engine has attained normal operating temperature. When the thermostat opens, the warm coolant passes through the heat exchanger where it is cooled by the water in the engine’s
seawater system.
Coolant. General
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The freshwater system must be filled with a coolant
that protects the engine against internal corrosion and
from freezing, if the climate requires it.
IMPORTANT! Never use water alone.
If the freshwater system is filled with antifreeze
mixture it must be changed every other year. If the
system is filled with anti-corrosion agent mixture it
must be changed every year.
We recommend that a mixture of water and Volvo
Penta antifreeze is used all year round, regardless
of the climate.
Water quality
To avoid the risk of blocking the cooling system the
coolant should be mixed with clean water. If there is
any doubt over the water quality distilled water or
premixed coolant should be used.
In event of risk of freezing
Use a mixture of 50% Volvo Penta antifreeze (glycol)
and 50% pure water. This mixture will protect against
freezing to a temperature of approx. -40ºC (-40ºF) and
should be used all year round.
Mix the coolant in a separate container before filling.
IMPORTANT! There should be at least 40%
antifreeze in the system for complete protection
against corrosion.
WARNING! Glycol is harmful to health (dangerous if ingested).
33
Maintenance: Freshwater system
In there is no of risk of freezing
When there is never a risk of freezing water may be
used as coolant with addition of Volvo Penta anti
corrosion agent.
Mix according to the instructions on the packaging.
Warm up the engine after filling to allow the additive to
work as efficiently as possible.
If operating hours exceed 600 hours per annum the
coolant anti corrosion must be complemented with ½
liter anti corrosion agent every 600 hours.
WARNING! Anti-corrosive agents are harmful to
health (dangerous if ingested).
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IMPORTANT! Never mix antifreeze (glycol) and
anti-corrosive agents. The two combined can
produce foam and drastically reduce the coolant’s effectiveness.
Coolant level. Checking and topping up
WARNING! Do not open the engine coolant
system filler cap when the engine is still hot
except in an emergency. Steam or hot coolant
may spray out.
MAX
MIN
1
Turn the filler cap to the first stop and let any pressure
escape from the system before removing the cap. Top
up coolant if necessary. The level should lie between
the filler neck lower edge and the level spur (1).
Reinstall the filler cap.
If a separate expansion tank is installed (optional
extra), the coolant level should be between the MAX
and MIN levels on the extra expansion tank.
IMPORTANT! When filling a completely drained
system the coolant level must be checked after
an hours use because the system is self bleeding. Top up if required.
34
Maintenance: Freshwater system
Coolant. Changing
The corrosion-proofing additives become less effective with time and the coolant must be changed. If the
freshwater system is filled with antifreeze mixture it
must be changed every other year. If the system is
filled with anti-corrosion agent mixture it must be
changed every year.
Drain off the coolant and clean the heat exchanger as
in the following paragraphs. Close the drain tap and
the drain plug, and fill up with new coolant.
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Coolant. Draining
1
Put a suitable collection vessel underneath the engine
drain plug (1) and underneath the heat exchanger drain
tap (2). Remove the filler cap on the heat exchanger
to let the coolant run out faster. Open the drain plug
(1) and the drain tap (2) and drain off all coolant.
Before new coolant is put in, clean the heat exchanger
as in the following paragraphs.
NOTE! Deposit old coolant at a properly designated
disposal site.
Heat exchanger. Cleaning
Cooling performance is reduced by scaling in the heat
exchanger. It should therefore be flushed when the
coolant is changed.
1. Drain the coolant as above.
2. Insert a hose into the filling pipe on the heat exchanger. Rinse with fresh water until the water
which runs out of the drain tap and the engine
block is clean. Let all the water run out.
2
3. Close the drain tap and the drain plug. Fill up with
coolant to the correct level. Put the filler cap back.
35
Maintenance: Seawater system
Seawater system
The sea water system is the external cooling system of the engine. On engines with a stern drive, the sea water
pump sucks in water via the drive, after which the water passes the sea water filter (optional extra) before it is
pumped through the heat exchanger. Finally, the water is pumped out into the exhaust elbow pipe, where it is
mixed with the exhaust gases.
On engines with a reverse gear, the sea water pump suck in water via the sea water inlet, after which the water
passes the sea water filter (optional extra) and the reverse gear oil cooler before it is pumped through the heat
exchanger. Finally, the water is pumped out into the exhaust bend, where it is mixed with the exhaust gases.
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WARNING! There is a risk that water will enter while working on the seawater system (if the boat is in the
water). Water may flow into the boat if a hose, plug or similar object located below the waterline is removed.
So always close the seawater cock. If the boat does not have a seawater cock, the flow of water must be
stopped in a safe manner. The boat must be brought up on land if this is not possible.
Impeller. Checking/Replacing
WARNING! Risk for water penetration. Close the
sea cock.
Close the sea cock. Remove cover (1) on the
seawater pump. Remove impeller (2). If there are
cracks or other defects the impeller must be replaced. Lubricate the pump housing and the inside of
the cover with a little waterproof grease for rubber.
Reinstall the impeller using a clockwise rotating
movement. Install the cover together with a new
gasket. Open the sea cock.
2
1
36
IMPORTANT! Always carry a spare impeller on
board.
Maintenance: Seawater system
Vacuum valve. Cleaning
Some engines have a vacuum valve installed in the
seawater piping.
WARNING! Risk for water penetration. Close the
sea cock.
Close the sea cock. Disassemble the valve. Unscrew
the hexagonal cover. In the cover there is a membrane and a gasket. Clean all the parts. Turn the
cover upside down. Install the membrane first and
then the gasket. Turn the valve housing upside down
as well. Screw the cover into position, but not too hard
(0.2 kpm), or the valve may stop working.
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Seawater filter. Cleaning
The seawater filter is an accessory. Screw off cover
(1) and remove seal plate (2). Lift out and clean the
insert (3).
1
2
3
IMPORTANT! If the boat is used in water that
has a lot of contaminants, seaweed etc. the filter
must be checked more frequently than indicated
in the maintenance schedule. Otherwise there is
a risk the filter will clog and the engine will
overheat.
37
Maintenance: Seawater system
Seawater system. Flush cleaning and
corrosion inhibition
When laying up during winter (or out of season), the
seawater system must be flushed clean of all deposits and salt crystals. It must also be treated to protect against internal corrosion.
2
1
WARNING! Risk of water penetration. This
work must be carried out with the boat on dry
land.
Approaching or working on a running engine is
dangerous. Watch out for rotating components
and hot surfaces.
Glycol is harmful to health (dangerous if
ingested). Collect used and drained glycol and
take it to a proper disposal site.
1. Open the seawater cock (1).
2. Disconnect the hose at the seawater cock (1) or
on the outlet side of the sea water filter (2) (if the
engine is equipped with such a filter).
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3. Place the free end of the hose in a bucket of
fresh water. Fill the system.
IMPORTANT! The impeller will be damaged if
it runs dry.
4. Check that there is nobody close to the propeller
and there is nothing that will get splashed behind
the exhaust outlet.
5. Set the control lever to neutral. Start the engine.
Let the engine run at fast idle for a few minutes.
Stop the engine.
6. Fill the bucket with an anti-freeze mixture (50%
Volvo Penta glycol and 50% fresh water). Collect
the mixture from the system in a suitable container.
7. Start the engine and let it idle. Stop the engine just
before the mixture is finished.
Repeat as necessary until the entire system has
been flushed with the mixture.
8. Reconnect the hose.
This mixture prevents corrosion and protects against
freezing. It must be left in the seawater system
throughout the laying-up period. Drain the mixture just
before the boat is launched.
38
Maintenance: Seawater system
Seawater system. Draining
8
If it is not possible to keep the engine compartment
free of frost, the seawater system must be drained to
prevent freezing damage.
2
Note that all the seawater must be drained. The type
of drainage must be adapted to the way in which the
engine is installed and any additional equipment that
is connected, for example sea water filter (2),
vacuum valve (8), silencer (7) etc.
9
4
5
7
3
WARNING! Risk of water penetration. Close the
sea cock before starting work.
5
IMPORTANT! If the boat is laid-up for winter or
the off season, the seawater system must be
instead flushed clean and protect against
corrosion according to the instructions in the
previous section.
1
MS25S / 150S
Draining:
1. Close the seawater cock (1).
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8
4
2. Remove the cover and sealing plate on the sea
water filter (2).
2
9
3. Remove the cover (3) from the seawater pump. Let
the water run out.
7
4. Open the drain cock (4) on the rear end of the heat
exchanger and drain the water off.
3
D2-75:
Open the drain cock on the charge air cooler (9)
draining the water.
6
5
1
5. Disconnect the hoses where indicated by the
arrows (5). Drain the hoses.
6. Open the drain plug (6) on the reverse gear oil
cooler and drain the water off. Close the drain plug.
MS25 / HS25
7. Drain the silencer (7), the exhaust system and any
other additional equipment connected to the
seawater and exhaust systems.
8. Reinstall all hoses, the cover on the seawater
pump and the cover and sealing plate on the
seawater filter. Close the drain cock on the heat
exchanger.
6
D2-75:
Close the draincock on the charge air cooler.
9. Opened the seawater cock the next time the boat
is used.
6
HS25
MS25
WARNING! Check that there is no leakage in
the seawater system.
39
Maintenance: Fuel system
Fuel system
All work on the engine injection pump or injectors must be carried out at an authorized workshop. Use only the
recommended grade of fuel: See the chapter ”Technical Data”.
WARNING! Fire risk. When carrying out work on the fuel system make sure the engine is cold. A fuel spill
onto a hot surface or an electrical component can cause a fire. Store fuel soaked rags and other flammable
material in fireproof conditions.
1
Venting the fuel system
The fuel system must be vented after fuel filters have
been replaced or after refilling the fuel tank after it has
been run dry.
1. Open vent screw (1) on the filter mounting approx.
three turns. Avoid fuel spillage. Use rags around the
venting point.
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3
2. Pump the fuel using hand pump (2) until there are no
more air bubbles visible in the fuel. Continue pumping and at the same time tighten the venting screw.
D2-55: If the pump output is low, turn the engine
so that the marking on the pulley is at “TOP”
(see the illustration). If the pump output is still
low, turn the engine one more revolution to “TOP”.
2
D2-55
There is a strainer (3) in the intake manifold for the
pump. The strainer does not normally need to be cleaned since the engine should be installed with a fuel
pre-filter. If there is no fuel pre-filter installed, low
output may be due to a blocked strainer.
D2-75: If any of the two o-rings (4) are damaged
they need to be replaced.
3. Start the engine and check for leaks.
WARNING! Approaching or working on a running
engine is dangerous. Watch out for rotating components and hot surfaces.
D2-55
1
3
4
D2-75
40
2
Maintenance: Fuel system
Fuel filter. Changing
Clean the filter mounting. To avoid fuel spills put a
plastic bag over the filter before it is unscrewed.
Unscrew the filter. Moisten the filter rubber gasket
with a little oil. Screw on the new filter by hand until it
is in contact with the mating surface. And then a
further half turn but no more! Vent fuel system.
Deposit the old filter at a properly designated
disposal site.
Start the engine and check for leaks.
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WARNING! Approaching or working on a running
engine is dangerous. Watch out for rotating
components and hot surfaces.
Fuel pre-filter. Draining and replacing
filter insert
1
Draining
The fuel pre-filter is an optional extra.
Position a container under the fuel filter. Drain off
water and contaminants using the cock/plug at the
bottom of the filter bowl.
IMPORTANT! Wait a few hours after the engine
has been turned off before draining the filter.
Replacing filter insert
Close fuel cock at the fuel tank. Position a container
under the fuel filter.
Remove the filter bowl by undoing screw (1). Empty
and clean the filter bowl. Replace insert and reinstall
the bowl. Open fuel cock. Vent fuel system. Deposit
the old filter insert at a properly designated disposal site.
Start the engine and check for leaks.
WARNING! Approaching or working on a running
engine is dangerous. Watch out for rotating
components and hot surfaces.
41
Maintenance: Electrical system
Electrical system
WARNING! Always stop the engine and break the current using the main switches before working on the
electrical system. Isolate shore current to the engine block heater, battery charger, or accessories mounted
on the engine.
Main switch
The main switch must never be turned off before the
engine has stopped. If the circuit between the generator and the battery is cut off when the engine is
running the generator can be seriously damaged. For
the same reason charging circuits must never be
switched over while the engine is running.
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IMPORTANT! Never break the circuit with the
main switches while the engine is running.
Electrical connections
Also check that all electrical connections are dry and
free of oxidation and that there are no loose connections. If necessary, spray these connections with a
water-repellent spray (Volvo Penta Universal oil).
Fuses
The engine has a fuse holder with four 15 A fuses.
This is located on the relay box to the left of the
engine. One fuse protects the system and cuts power
in the event of an overload, the others are spares.
If a fuse blows the system can be reconnected by
moving the cable to the next fuse. Always investigate
the cause of an overload before resetting the fuse!
IMPORTANT! Make sure that you always have
spare fuses on board.
42
Maintenance: Electrical system
Battery. Maintenance
WARNING! Risk of fire and explosion. Never
allow an open flame or electric sparks near the
battery or batteries.
WARNING! Never mix up battery positive and
negative terminals. This may cause sparks and
an explosion.
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WARNING! The battery electrolyte contains
extremely corrosive sulfuric acid. Protect your
skin and clothes when charging or handling
batteries. Always use protective goggles and
gloves. If battery electrolyte comes into contact
with unprotected skin wash off immediately
using plenty of water and soap. If battery acid
comes into contact with the eyes, flush immediately with plenty of water and obtain medical
assistance without delay.
Connecting and disconnecting
First connect the red battery lead + to the battery +
terminal. Then connect the black battery lead - to the
battery - terminal.
When disconnecting the battery, disconnect the -lead
(black) first and then the + lead (red).
Cleaning
Keep batteries dry and clean. Oxidation or dirt on the
battery and battery terminals can cause short-circuits,
voltage drop and discharge especially in damp
weather. Clean the battery terminals and leads to
remove oxidation using a brass brush. Tighten the
cable terminals well and grease them with terminal
grease or petroleum jelly.
Topping up
The electrolyte should be 5 - 10 mm over the plates in
the battery. Top up using distilled water if necessary.
Charge the battery after topping up for at least 30
minutes by running the engine at fast idle. NOTE!
Certain maintenance-free batteries have special
instructions which must be followed.
43
Maintenance: Electrical system
Battery. Charging
WARNING! Danger of explosion! The batteries
give off hydrogen gas during charging which
when mixed with air can form an explosive gas oxyhydrogen A short-circuit, naked flame or
spark can cause a large explosion. Ensure that
the ventilation is good.
WARNING! The battery electrolyte contains
extremely corrosive sulfuric acid. Protect your
skin and clothes when charging or handling
batteries. Always use protective goggles and
gloves. If battery electrolyte comes into contact
with unprotected skin wash off immediately
using plenty of water and soap. If battery acid
comes into contact with the eyes, flush immediately with plenty of water and obtain medical
assistance without delay.
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If the battery has discharged it must be charged. f the
boat has not been used for some time charge the
battery and then trickle charge it (see manufacturer’s
recommendations). A poorly charged battery will be
damaged and may burst in cold weather.
IMPORTANT! Follow the instructions supplied
with the battery charger carefully. To avoid
electrolytic corrosion when an external charger is
connected, always disconnect the battery leads
before connecting the charger.
When charging, unscrew filler plugs but leave them in
their holes. Ventilation should be good, particularly if
the batteries are being charged in an enclosed area.
WARNING! Always switch off the charging
circuit before removing the battery charger
connectors. Never mix up battery positive and
negative terminals. This may cause sparks and
an explosion.
Special instructions apply when boost charging the
batteries. Avoid boost charging the batteries as it will
shorten their service life.
44
Maintenance: Electrical system
Electrical installations
Leakage current from the electrical system can be
caused by incorrect installation of electrical equipment. Leakage current can knock out the galvanic
protection of components such as the drive, propeller,
propeller shaft, rudder stock and keel and cause
damage by electrolytic corrosion.
IMPORTANT! Work on the boat’s low tension
circuit should only be carried out by qualified or
experienced persons. Installation or work on the
shore power equipment must only be carried out
by electricians authorized to work with highvoltage installations.
The following should always be observed:
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1. If shore power is connected, the protector ground
should be ashore, never in the boat. Shore power
should always have a ground fault circuit breaker.
Shore power units (transformer, rectifier, battery
chargers etc.) must be intended for marine usage
and the high tension circuit must be galvanically separated from the low tension circuit.
2. Route and clamp electric cables so that they will
not be exposed to rubbing, damp or bilge water in
the keelson.
3. The S-drive is electrically isolated (A) from the
engine and must never be used as a ground.
C
A
B
IMPORTANT! The S-drive must never be
used as a ground or be electrically connected
to other equipment such as the radio, navigational equipment, the rudder, bathing steps
etc.
Protective grounds for the radio, navigational
equipment, rudder, bathing steps or other equipment with separate ground leads must be connected to a common ground terminal (B).
4. There must be a main switch (C) connected to the
starter battery positive (+) terminal. The main
switch should cut off power to all power consuming equipment and should be switched off when
the boat is not in use.
45
Maintenance: Electrical system
5. If an auxiliary battery is in use, a main switch (D)
should be connected between its + terminal and
the fuse block. The main switch for the auxiliary
battery must cut off all power consuming equipment connected to that battery and be turned off
when power is no longer needed.
All equipment connected to the auxiliary battery
should have separate switches.
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D
46
To simultaneously charge two independent battery
circuits, fit a Volvo Penta charge distributor (accessory) to the regular generator.
Maintenance: Electrical components diagram
Electrical components diagram
5
6
7
4
3
1. Engine coolant temperature sensor D2-55
(optional extra)
1
2
2. Coolant temperature switch D2-55
8
3. Engine coolant temperature sensor D2-75
4. Coolant temperature switch D2-75
5. Fuses
6. Starter relay
9
7. Glow plug relay
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8. Ballast resistor
9. Engine speed sensor
10. Starter motor
11. Generator
12. Glow plugs, 4 st
13. Oil pressure sensor D2-55 (optional extra)
14. Oil pressure switch D2-55
15. Combined oil pressure switch/sensor D2-75
10
11
12
13
14
15
47
Maintenance: S drive and reverse gear
S drive and reverse gear
The S drive and in certain cases the propeller (reverse gear) is equipped with a sacrificial anode which prevents
galvanic corrosion. Faulty electrical installation can also cause the break down of the galvanic protection. Damage
due to electrolytic corrosion occurs rapidly and is often extensive. For further information see the chapter: ”Electrical system”
IMPORTANT! Improperly applied paint or the wrong type of paint on the keel can put the corrosion
protection system out of action. For further information on painting see the chapter: Laying up/Launching
Oil level. Check
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Remove the dipstick by turning counter-clockwise.
Wipe the dipstick and reinsert it in the drive / reverse gear without screwing it in. Remove the dipstick and check the oil level. The correct oil level is
between the MAX and MIN markings.
MAX
MAX
MIN
MIN
MS25
Top up the oil as required using the dip stick tube. For
oil quality and capacity: See the chapter ”Technical
Data”.
HS25 / MS25S
IMPORTANT! Do not overfill under any circumstances. The oil level must always be within the
recommended level.
Oil change. S-drive
Remove the oil dipstick. Remove the plug on the
propeller gear housing and let the oil run out. Check
that the plug o-ring is intact. Replace if necessary.
Install the plug and o-ring. Top up oil to correct level.
For oil quality and capacity: See the chapter ”Technical Data”.
IMPORTANT! If oil is colored gray then water
has entered the drive. Please contact an authorised Volvo Penta workshop.
48
Maintenance: S drive and reverse gear
Oil change. MS25
Remove the dipstick. Suck up oil using an oil pump
through the hole for the dipstick. Measure out the
correct amount of oil and fill up through the hole for
the oil dipstick. For oil quality and capacity: See the
chapter ”Technical Data”.
IMPORTANT! Never overfill reverse gear. The oil
level should always lie at the recommended
level.
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Oil change and filter cleaning. HS25
5
1
1. Clean around the cover (2) so that there is no risk
of the dirt falling into the filter housing.
2
3
4
2. Undo the screws (1). Remove the cover (2) and
gasket (3).
3. Carefully remove the filter (4). Clean the filter in
kerosene (leave the gasket (5) in place). Clean the
filter housing.
4. Suck up oil using an oil pump through the hole for
the dipstick.
5. Measure out the correct amount of oil and fill up
through the hole for the oil dipstick or filter housing.
For oil quality and capacity: See the chapter
”Technical Data”.
IMPORTANT! Never overfill reverse gear.
6. Reinstall the filter (4) with gasket (5) in the filter
housing. Check that the filter bottoms correctly.
IMPORTANT! If the filter does not sit flat
there is a risk of breaking it when the cover
(2) is installed.
7. Center the gasket (3) above the filter. Install the
cover.
8. Move the control lever to the neutral position. Start
engine and run at 1500 rpm for a few minutes so
the reverse gear oil cooler is filled with oil.
9. Stop engine and check oil level. Top up if required.
49
Maintenance: S drive and reverse gear
Corrosion protection. Check
Check the sacrificial anode (1) on the drive and the
three sacrificial anodes (2) on the propeller. Replace
with a new anode if 50% of the material has perished
or at least once per season.
IMPORTANT! Use zinc sacrificial anodes for
salt water and magnesium anodes for freshwater.
Remedy any paintwork damage on the drive according to the instruction in the chapter: Laying up /
Launching.
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2
1
Replacing sacrificial anodes
1. Remove the propeller (see the next section).
2. Remove the sacrificial anodes. Thoroughly
scrape clean the mating surfaces on the drive
and propeller.
3. Apply thread sealant to the screws for the
sacrificial anodes on the propeller.
4. Install the new sacrificial anodes. Tighten the
anodes so that there is a good metal contact.
5. Reinstall the propeller.
The sacrificial anodes oxidise when they come into
contact with air. This reduces the galvanic protection. There may even be oxidisation on the surface
of a completely new anode. Always clean the sacrificial anodes before launching the boat.
IMPORTANT! Use emery paper. Do not steel
tools when cleaning, as these may damage the
galvanic protection.
Folding propeller. Cleaning
The propeller must be cleaned and lubricated once a
year. Remove the propeller and clean all components thoroughly. Apply waterproof grease to the
propeller blade teeth and bearing surfaces so that
the propeller folds easily. Also apply waterproof
grease to the studs, spacing sleeve (drive), propeller
shaft and hub.
WARNING! Prevent accidental starting. Remove the ignition key and turn off the power at
the main switch before working on the propeller.
50
Maintenance: S drive and reverse gear
Removing
1. Set the control lever in the ”Ahead” position.
A
2. Remove the propeller blade by first undoing the
locking screws (5) completely and then pressing
out the shaft studs (1).
1
6
3
4
3. Drive: Bend down the tabs of the tab washer (3)
and remove the locking screw (4), tab washer and
nut (6).
Reverse gear: Remove the nut (7), washer (8) and
then the locking screws (9).
4. Pull off the propeller hub and the spacing sleeve
(drive). Clean and lubricate as described.
5
Installing
1. Reinstall the spacing sleeve (drive) and the
propeller hub on the shaft.
2. Drive: Install the nut (6). Place a propeller blade on
the hub and place a wooden block between the
propeller blade and the underwater hull. Tighten
locknut to 70 Nm.
Reverse gear: Install the washer (8) and tighten the
nut (7) to 220 Nm. Apply thread sealant to the
locking screws (9). After the locking screws have
been tightened apply thread sealant to the screw
heads as well.
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B
1
5
3. Drive: Locate the tab washer (3) on the nut. Install
and tighten the locking screw (4) to 20 Nm and
bend one of the tab washer tabs to the screw head.
6
3
4
IMPORTANT! The tab washer (3) must be replaced if necessary. Use only Volvo Penta original locking screws (4).
4. Install one propeller blade in the propeller hub and
push in the stud (1) in such a position so the
groove in the stud is exactly centered in the hole
for the locking screw (5). Apply thread sealant to
the locking screw and tighten to 10 Nm.
C
1
5. Install the other blades in the same way. Check
the blades are at the same angle to the propeller
shaft and that they move easily.
9
7 8
9
5
A = 3-blade folding propeller (drive)
B = 2-blade folding propeller (drive)
C = 3-blade folding propeller (reverse)
51
Maintenance: S drive and reverse gear
Propeller shaft seal. Reverse gear
If the boat has a Volvo Penta shaft the shaft seal
must be vented and lubricated directly after launching.
Vent the bushing by pressing it together while pressing down on the shaft until water appears. Then press
in approx. 1 cc water repellent grease into the seal.
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IMPORTANT! The seal must be replaced every
500 running hours or every 5th year.
Rubber seal. S-drive
Check the rubber seal between the drive and the hull
regularly for cracks and wear.
WARNING! The seal must be changed every
seven years or earlier if it is defective. This work
should be carried out by an authorized workshop.
52
Laying up and launching
Before taking the boat out of the water for winter/out-of-season storage have an authorized Volvo Penta workshop inspect the engine and other equipment.
Inhibition should be carried out to ensure that the engine and transmission are not damaged while out of commission during the winter/off-season. It is important this is done properly and than nothing is forgotten. We have
therefore provided a checklist covering the most important points.
WARNING! Read the chapter on Maintenance carefully before starting work. It contains instructions on how
to carry out the work safely and correctly.
Inhibiting
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The following are best carried out with the boat in
the water:
●
Change engine oil and replace oil filter.
●
Change oil in the reverse gear.
●
Replace fuel filter. Replace fuel pre-filter if installed.
●
Run engine to normal operating temperature.
●
Take the boat out of the water:
The following should be carried out with the boat
out of the water:
●
Clean the hull and drive directly after taking up the
boat (before it dries).
IMPORTANT! Be careful when cleaning with a
high pressure water spray. Never direct the water
jet at the propeller shaft seal, grommets etc.
●
Change oil in the drive.
●
Clean the vacuum valve and seawater filter (accessory).
●
Clean and inhibit the seawater system.
●
Remove the impeller from the seawater pump.
Store the impeller in a sealed plastic bag in a cool
place.
●
Check the condition of the engine coolant antifreeze. Top up if required.
●
Clean the outside of the engine. Do not use a high
pressure spray to clean the engine. Touch up any
damaged areas of paintwork with Volvo Penta
original paint.
●
Check all control cables and treat with rust inhibitor.
●
Repair any damaged areas of paintwork with Volvo
Penta original paint. NOTE! Read the special
instructions on painting the drive under the heading: Painting the drive and underwater hull
●
Disconnect battery leads. Clean and charge the
batteries. NOTE! A poorly charged battery may
burst as a result of freezing.
●
Spray electrical system components with moisture
repellent spray.
●
Remove the propeller for storage. Grease the
propeller shaft using water repellent grease.
Disassemble folding propellers, clean and grease.
●
Check the rubber seal between the drive and hull
carefully.
IMPORTANT! An anti-corrosion mixture in the
engine coolant system provides no protection
against freezing. If there is any possibility the
engine will be subjected to freezing temperatures then the system must be drained.
●
Drain any water and contaminants from the fuel
tank. Fill the tank completely with fuel to avoid
condensation.
53
Maintenance: Laying up and launching
Bringing out of storage
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●
Check oil level in the engine and drive/reverse
gear. Top up if necessary. If there is inhibiting oil
in the system drain and fill with new oil, change oil
filter. For correct oil grade: See the chapter ”Technical Data”.
●
Drain the antifreeze from the seawater system.
●
Install the impeller in the seawater pump (replace if
the old one looks worn).
●
Close/tighten drain cocks/plugs.
●
Check drive belts.
●
Check the condition of rubber hoses and tighten
hose clamps.
●
Check engine coolant level and antifreeze protection. Top up if necessary.
●
Connect the fully charged batteries.
54
●
Paint the drive and hull: See next page.
●
Check the sacrificial anode on the drive. If there is
less than 50% of the anode left it must be replaced. Clean with emery cloth just before the boat
is launched.
IMPORTANT! Do not use a wire brush or other
steel tools when cleaning, as these may damage
the galvanic protection.
●
Reinstall the propeller.
●
Launch the boat. Check for leaks.
●
Vent and lubricate the propeller shaft seal (reverse
gear).
●
Start the engine. Check that there are no fuel,
engine coolant or exhaust gas leaks and that all
control functions are operating.
Maintenance: Laying up and launching
Painting the drive and underwater
hull
General
Most countries have introduced legislation controlling
the use of anti-fouling agents. In some cases these
agents are completely forbidden for use on leisure
craft. In these cases ask your Volvo Penta dealer
for advice about alternative methods.
IMPORTANT! Find out what regulations apply to
the use of anti-fouling agents.
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Drive
The paintwork is part of the drive’s anti-corrosion
protection and it is therefore important that any
paintwork damage is remedied.
Sand down metal surfaces lightly using a 120 grade
paper and a finer grade for painted surfaces. Wash off
using thinners or similar. Any pores in the surface
should be filled and sanded down. Paint using Volvo
Penta original primer and topcoat. Let the paint dry.
The drive should be painted with Volvo Penta antifouling to prevent fouling. Apply according to the
instructions on the packaging.
IMPORTANT! The sacrificial anodes on the drive
and propeller must not be painted.
Underwater hull
Anti fouling agent containing copper oxide can increase the risk of galvanic corrosion and therefore
should never be used.
55
Fault-tracing
A number of symptoms and possible reasons for engine problems are described in the table below. In case of
faults or mishaps which you cannot solve, always contact the Volvo Penta dealership.
WARNING! Read the safety precautions for maintenance and service in the chapter: Safety Precautions,
before starting work.
7742957 - Downloaded from www.volvopenta.com 22/09/2008 11:33:23
Symptoms and possible causes
Starter motor not turning or slow
1, 2, 3
Engine will not start
4, 5, 6, 7, 8, 9
Engine starts but stops again
6, 7, 8, 9
Engine difficult to start
6, 7, 8, 9
Engine does not reach correct speed at wide open throttle (WOT)
7, 8, 9, 10, 11, 12, 13, 18
Engine knocks
14
Engine runs unevenly
6, 7, 8, 9, 13, 14
Engine vibrates
18, 19
High fuel consumption
10, 11, 13, 15, 18
Black exhaust smoke
5, 13, 15, 18
Blue or white exhaust smoke
15, 25
Low oil pressure
16, 17
Engine coolant temperature too high
20, 21, 22, 23, 24
No or poor charging
2, 26
1. Discharged battery
2. Loose connection/open-circuit
3. Fuse tripped
4. Stop control pulled out
5. Inadequate pre-heating
6. Lack of fuel
7. Fouled fuel filter
8. Air in the fuel injection system
9. Water/contaminants in the fuel
10. Boat abnormally loaded
56
11. Fouling on underwater hull/drive/
propeller
19. Defective engine mounting
12. Limited speed control lever
movement
21. Blocked seawater intake/pipe/filter
13. Insufficient air supply
14. Engine coolant temperature too high
15. Engine coolant temperature is too low
16. Lubricating oil level too low
17. Blocked fuel filter
18. Defective/incorrect propeller
20. Too little coolant
22. Circulation pump drive belt slipping
23. Defective impeller
24. Defective/incorrect thermostat
25. Lubricating oil level too high
26. Generator drive belt slipping
Technical Data
General
Engine designation ..................................................
No. of cylinders .......................................................
Cylinder bore ............................................................
Cylinder stroke ........................................................
Overall cylinder displacement .................................
Power, see sales literature
Idling speed .............................................................
Rotation, viewed from in front .................................
Max. permitted rake backwards while running .......
Max. list while running .............................................
Valve clearance (stopped, cold engine)
inlet and outlet ........................................................
Weight, dry engine ...................................................
D2-55 A
4
84 mm (3.31 in)
100 mm (3.94 in)
2.2 liters (134 in³)
D2-75A
4
84 mm (3.31 in)
100 mm (3.94 in)
2.2 liters (134 in³)
850 ±25 rpm
Clockwise
20o
30o
850 ±25 rpm
Clockwise
20o
30o
0.20 mm (0.0078 in)
225 kg (496 lb)
0.20 mm (0.0078 in)
233 kg (514lb)
7742957 - Downloaded from www.volvopenta.com 22/09/2008 11:33:23
Lubrication system
Oil volume incl. oil filter, approx.:
no engine inclination ............................................. 10.5 liters (2.8 US gals)
Oil quality ................................................................. VDS–2, ACEA E5, API CH–4
Viscosity at –5o – +50oC* ........................................ SAE 15W/40,
SAE 20W/50
Oil drain plug tightening torque ............................... 30–40 Nm (22-30 lbf.ft)
10.5 liters (2.8 US gals)
VDS–2, ACEA E5, API CH–4
SAE 15W/40,
SAE 20W/50
30–40 Nm (22-30 lbf.ft)
* Constant ambient air temperature
Cooling system
Thermostats, no. .....................................................
The thermostat starts opening at ............................
fully open at ........................................
Freshwater system capacity, approx. ....................
1 screws
82o ±2oC (176-183°F)
95oC (203°F)
9.5 liters (2.5 US gals)
1 screws
83o ±2oC (178-185°F)
95oC (203°F)
9.5 liters (2.5 US gals)
12 V
15A
70 Ah
14 V/60 A
840 W
2.0 kW
12 V
15A
70 Ah
14 V/115 A
1610 W
2.0 kW
Electrical system
System voltage .......................................................
Fuses .......................................................................
Battery capacity (starter battery) ............................
AC generator voltage/max. current .......................
output approx. .................................
Starter motor, output approx. ..................................
57
Technical Data
Reverse gear
MS25
Type designation ......................................................
Gear ratio
Left rotating (Position B) .....................................
Right rotating (Position A) ...................................
Angle (output shaft): .................................................
Oil volume, approx. ..................................................
Oil grade ...................................................................
MS25L
2.27:1 ; 2.74:1
2.10:1 ; 2.72:1
0o
0.75 liters (0.2 US gals)
CD SAE 15W/40* or
ATF (Dexron II, III)*
Weight ....................................................................... 25 kg (55 lbs)
MS25A
2.23:1 ; 2.74:1
2.74:1
8o
0.75 liters (0.2 US gals)
CD SAE 15W/40* or
ATF (Dexron II, III)*
25 kg (55 lbs)
HS25
7742957 - Downloaded from www.volvopenta.com 22/09/2008 11:33:23
Type designation ......................................................
Gear ratio ..................................................................
Angle (output shaft) ..................................................
Oil volume, approx. ..................................................
Oil grade ...................................................................
Weight .......................................................................
HS25A
2.29:1 ; 2.71:1
8°
1.8 liters (0.48 US gals)
ATF (Dexron II, III)
31 kg (68 lbs)
Sailing boat drive
Type designation ......................................................
Gear ratio ..................................................................
Oil volume, approx. ..................................................
volume difference min.-max. ................................
Oil grade ...................................................................
Viscosity ...................................................................
Weight .......................................................................
Tightening torque:
oil drain plug ..........................................................
*
MS25S, MS25SR
2.19:1
2.0 liters (0.53 US gals)
0.3 liters (0.08 US gals)
CD
SAE 15W/40
32 kg (71 lbs)
150S, 150SR
2.19:1
3.25 liters (0.86 US gals)
0.1 liters (0.03 US gals)
ATF
10 ±5 Nm (7.4 ±3.7 lbf.ft)
10 ±5 Nm (7.4 ±3.7 lbf.ft)
31 kg (68 lbs)
WARNING! Never mix oil qualities when topping up, the same oil quality must be used that already is
filled in the reverse gear.
Fuel specification
Fuel must meet national and international standards at least. For example:
EN 590 (with national environmental and cold standards)
ASTM D 975 No 1-D and 2-D
JIS KK 2204
Sulphur content: According to statutory requirements.
Fuels with low density (“urban diesel” in Sweden and “city diesel” in Finland) can cause a drop in
output of 5% and an increase in fuel consumption of 2–3%.
58
Notes
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
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________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
59
Notes
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
7742957 - Downloaded from www.volvopenta.com 22/09/2008 11:33:23
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
________________________________________________
60
✂
Yes please,
I would like an operator’s manual in English at no charge.
Orders can also be placed via
the Internet:
http://www.volvopenta.com/
manual/coupon
Publication number: 774 2957
42200/615001/155099900192
Post or fax this coupon to:
Document & Distribution Center
Order Department
ARU2, Dept. 64620
SE-405 08 Göteborg
Sweden
Fax: +46 31 545 772
Name
Address
Country
NB! This offer is valid for a period of 12 months from delivery of the boat.
Availability after this period will be as far as supplies admit.
ich will kostenlos eine Betriebsanleitung in deutscher Sprache erhalten.
Die Bestellung kann auch über
das Internet erfolgen:
http://www.volvopenta.com/
manual/coupon
Publikationsnummer: 7742958
42200/615001/155099900192
Schicken Sie den Coupon
per Post oder als Fax an:
Document & Distribution Center
Order Department
ARU2, Dept. 64620
SE-405 08 Göteborg
Schweden
Fax: +46 31 545 772
Name
Anschrift
Land
Bitte beachten Sie, dass dieses Angebot für die Dauer von 12 Monaten ab dem
Lieferdatum des Bootes gilt, danach bis zum Aufbrauchen des Lagerbestandes.
✂
Oui merci,
Envoyez ou faxez le bon de
commande à:
Document & Distribution Center
Order Department
ARU2, Dept. 64620
SE-405 08 Göteborg
Suède
Fax: +46 31 545 772
Vous pouvez également passer
la commande par Internet:
http://www.volvopenta.com/
manual/coupon
Je souhaite recevoir un manuel d’instructions gratuit en français.
Numéro de publication: 774 2959
Nom
Adresse
42200/615001/155099900192
7742957 - Downloaded from www.volvopenta.com 22/09/2008 11:33:23
✂
Ja,
Pays
Notez que l’offre est valable pendant 12 mois à partir de la date de livraison du bateau, ensuite seulement en fonction des stocks disponibles.
61
✂
Sí gracias,
deseo recibir gratuitamente un libro de instrucciones en español.
El pedido puede hacerse también por internet:
http://www.volvopenta.com/
manual/coupon
Número de publicación: 774 2961
42200/615001/155099900192
Franquear o enviar fax a:
Document & Distribution Center
Order Department
ARU2, Dept. 64620
SE-405 08 Göteborg
Suecia
Fax: +46 31 545 772
Nombre
Dirección
País
Nótese que el ofrecimiento vale durante 12 meses después de la fecha de entrega
de la embarcación, y posteriormente solamente mientras duren las existencias.
desidero ricevere gratuitamente un manuale d’istruzioni in lingua italiana.
L’ordinazione può essere fatta
anche su Internet:
http://www.volvopenta.com/
manual/coupon
Public. No.: 774 2962
42200/615001/155099900192
Spedire il tagliando per posta o
per fax a:
Document & Distribution Center
Order Department
ARU2, Dept. 64620
SE-405 08 Göteborg
Svezia
Fax: +46 31 545 772
Nome e Cognome
Indirizzo
Paese
Si ricorda che l’offerta è valida per 12 mesi dalla data di consegna dell’imbarcazione; dopo il suddetto periodo l’offerta resta valida solo in base alla disposizione della
pubblicazione in oggetto.
✂
Ja tack,
jag vill kostnadsfritt ha en instruktionsbok på svenska.
Posta eller faxa kupongen till:
Dokument & Distribution center
Ordermottagningen
ARU2, Avd. 64620
SE-405 08 Göteborg
Sverige
Fax: +46 31 545 772
Beställningen kan även göras
via internet:
http://www.volvopenta.com/
manual/coupon
Publikationsnummer: 7742956
Namn
Adress
Land
Observera att erbjudandet gäller i 12 månader från båtens leveransdatum,
därefter endast i mån av tillgång.
62
42200/615001/155099900192
7742957 - Downloaded from www.volvopenta.com 22/09/2008 11:33:23
✂
Sì, grazie,
✂
Ja graag,
Ik wil kosteloos een instructieboek in het Nederlands ontvangen.
U kunt ook bestellen via
internet:
http://www.volvopenta.com/
manual/coupon
Publicatienummer: 774 2965
42200/615001/155099900192
Stuur of fax de coupon naar:
Document & Distribution Center
Order Department
ARU2, Dept. 64620
SE-405 08 Göteborg
Zweden
Fax: +46 31 545 772
Naam
Adres
Land
Denk eraan dat het aanbod geldt gedurende 12 maanden na de datum
waarop de boot werd afgeleverd, daarna alleen indien nog verkrijgbaar.
jeg vil gerne gratis have en instruktionsbog på dansk
Bestillingen kan også ske på
internet:
http://www.volvopenta.com/
manual/coupon
Publikationsnummer: 7742963
42200/615001/155099900192
Send kuponen med post eller
fax til:
Document & Distribution Center
Order Department
ARU2, Dept. 64620
SE-405 08 Göteborg
Sverige
Fax: +46 31 545 772
Navn
Adresse
Land
Bemærk at tilbudet gælder i 12 måneder fra bådens leveringsdato, Derefter kun så længe lager haves.
✂
Kyllä kiitos,
haluan suomenkielisen ohjekirjan veloituksetta.
Postita tai faksaa kuponki
osoitteella:
Document & Distribution Center
Order Department
ARU2, Dept. 64620
SE-405 08 Göteborg
Ruotsi
Fax: +46 31 545 772
Tilauksen voi tehdä myös
Internetissä:
http://www.volvopenta.com/
manual/coupon
Julkaisunumero: 7742964
Nimi
Osoite
Maa
42200/615001/155099900192
7742957 - Downloaded from www.volvopenta.com 22/09/2008 11:33:23
✂
Ja tak,
Huomaa, että tarjous on voimassa 12 kuukautta veneen toimituspäivämäärästä lukien ja sen jälkeen vain niin kauan kuin kirjoja riittää.
63
✂
Sim, obrigado(a)!
Gostaria de receber gratuitamente um manual de instruções em português.
A encomenda também pode
ser feita através da Internet:
http://www.volvopenta.com/
manual/coupon
Número de publicação: 774 2966
42200/615001/155099900192
Envie o talão pelo correio ou
um fax para:
Document & Distribution Center
Order Department
ARU2, Dept. 64620
SE-405 08 Göteborg
Suécia
Fax: +46 31 545 772
Nome
Endereço
País
Íáé,
✂
Èá Þèåëá Ýíá áíôßôõðï ôïõ åã÷åéñéäßïõ ÷ñÞóçò óôçí áããëéêÞ ãëþóóá ÷ùñßò êáìéÜ ÷ñÝùóç.
Ôá÷õäñïìÞóôå áõôü ôï êïõðüíé
óôçí ðáñáêÜôù äéåýèõíóç Þ
óôåßëôå ôï ìå öáî óôïí
ðáñáêÜôù áñéèìü öáî:
Document & Distribution Center
Order Department
ARU2, Dept. 64620
SE-405 08 Göteborg
Sweden
Fax: +46 31 545 772
Ìðïñåßôå åðßóçò íá äþóåôå ôçí
ðáñáããåëßá óáò ìÝóù ôïõ
Internet, óôç äéåýèõíóç:
http://www.volvopenta.com/
manual/coupon
64
Áñéèìüò Ýêäïóçò: 7742967
¼íïìá
Äéåýèõíóç
×þñá
ÐÑÏÓÏ×Ç: ÁõôÞ ç ðñïóöïñÜ éó÷ýåé ãéá ÷ñïíéêÞ ðåñßïäï 12 ìçíþí áðü ôçí
ðáñÜäïóç ôïõ óêÜöïõò. ÌåôÜ ôï ðÝñáò ôçò åí ëüãù ÷ñïíéêÞò ðåñéüäïõ ç äéáèåóéìüôçôá
ôùí áíôéôýðùí èá åîáñôÜôáé áðü ôçí ðïóüôçôá ôùí áðïèåìÜôùí.
42200/615001/155099900192
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Observar que esta oferta é válida durante um período de 12 meses a contar da
data de entrega do barco. Após este período, a oferta está dependente do número
de exemplares disponíveis.
7742957 - Downloaded from www.volvopenta.com 22/09/2008 11:33:23
English 06-2003
7742957-9
AB Volvo Penta
SE-405 08 Göteborg, Sweden
www.volvopenta.com