OPERATOR'S MANUAL


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OPERATOR'S MANUAL | Manualzz

OPERATOR’S MANUAL

D9-500, D9-575

This operator’s manual is also available in the following languages:

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Welcome aboard

Volvo Penta marine engines are used all over the world these days. They are used in all conceivable operating conditions and by both professional and leisure skippers.

This is not a coincidence.

After 90 years as an engine manufacturer, and more than 500,000 marine engines supplied, the name of Volvo Penta has come to symbolise reliability, technical innovation, first class performance and long life. We also believe that this is what you demand and expect from your Volvo Penta marine engine.

We expect that you will want to read though the instruction book carefully, to gain the benefit you expect, and will take our advice about operation and maintenance before you cast off on your maiden voyage.

Yours sincerely

AB VOLVO PENTA

IMPORTANT! This instruction book does not describe controls or operation of boats with water jet drive. If your boat is equipped with a Volvo

Penta water jet, there is information about it in the handbook supplied with the water jet.

2

Contents

Safety information ...............................................

3

General information .............................................

3

Boat trips ............................................................

4

Care and maintenance ........................................

6

Introduction .........................................................

8

Running in ...........................................................

8

Fuel and oils .......................................................

8

Certified engines .................................................

9

Warranty information ...........................................

9

Identification number ........................................... 10

Presentation ........................................................ 11

Technical description .......................................... 11

Orientation .......................................................... 12

Instruments ......................................................... 15

Instruments ......................................................... 15

Ignition lock ........................................................ 15

Start/stop panel .................................................. 15

Alarm display ...................................................... 16

EVC control panel ............................................... 19

Controls ............................................................... 21

Single lever control ............................................. 21

Starting the engine .............................................. 23

Before starting .................................................... 23

General information about starting ....................... 23

Starting method .................................................. 24

Operation ............................................................. 26

Reading instruments ........................................... 26

Cruising speed .................................................... 27

Synchronising engine speed ............................... 27

Changing the control position .............................. 28

Operation ............................................................ 29

Propeller shaft brake ........................................... 30

Stopping the engine ........................................... 30

Stop .................................................................... 30

Cold weather precautions .................................... 31

Laying up ............................................................ 31

In case of emergency .......................................... 32

Starting with auxiliary batteries ........................... 32

Emergency shifting ............................................. 33

Fault-tracing ........................................................ 34

Diagnostic function ............................................. 35

Reading fault codes ............................................ 36

Erasing fault codes ............................................. 37

Maintenance schedule ........................................ 38

Maintenance ........................................................ 40

Engine, general ................................................... 40

Lubrication system .............................................. 43

Freshwater system ............................................. 46

Seawater system ................................................ 51

Fuel system ........................................................ 56

Electrical system ................................................ 61

Reverse gear ...................................................... 66

Laying up/Launching ......................................... 68

Inhibiting ............................................................. 68

Bringing out of storage ........................................ 69

Fault code register .............................................. 70

Technical data ..................................................... 78

Engine ................................................................ 78

Reverse gear ...................................................... 80

© 2004 AB VOLVO PENTA

We reserve the right to make modifications without prior notice.

Printed on environmentally compatible paper.

(Cover: Department of transport (shipping), license 9809095)

Safety information

Read this chapter very carefully. It has to do with your safety. This describes how safety information is presented in the instruction book and on the product. It also gives you an introduction to the basic safety rules for using and looking after the engine.

Check that you heave received the correct instruction book before you read on. If not, please contact your

Volvo Penta dealer.

Incorrect operation can lead to personal injury and damage to products or property. So read the instruction book through very carefully before you start the engine or do any maintenance or service work. If there is still something which is unclear or if you feel unsure about it, please contact your Volvo Penta dealer for assistance.

This symbol is used in the instruction book and on the product, to call your attention to the fact that this is safety information. Always read such information very carefully.

Safety texts in the instruction book have the following order of priority:

WARNING! Warns for the risk of personal injury, major damage to product or property, or serious malfunctions if the instruction is ignored.

IMPORTANT! Is used to call attention to things which could cause damage or malfunctions to product or property.

NOTE! Is used to call attention to important information, to facilitate work processes or operation.

This symbol is used on our products in some cases and refers to important information in the instruction book. Make sure that warning and information symbols on the engine are clearly visible and legible. Replace symbols which have been damaged or painted over.

3

4

Safety information

Safety advice for boat operation

Your new boat

Read the instruction books and other information carefully, which came with your new boat. Learn to handle the engine, controls and other equipment in a safe and correct manner.

If this is your first boat, or a type of boat you are not experienced in using, we recommend that you practice operating the boat in peace and quiet. Get to know the way the boat reacts to sea and to the controls under different speed, sea and loading conditions before you cast off for your first “real” maiden voyage.

Remember that the captain of every boat is required by law to know and to observe applicable rules for traffic and safety at sea. Get to know the rules which apply to you and your waters, by contacting the relevant authority or sea safety organisation.

It is a good idea to go on some kind of boat operation course. We recommend that you contact a regional boat or sea safety organisation to find a suitable course.

Manoeuvring

Avoid sudden or surprising rudder movements and gear shifting. There is a risk that passengers could fall over, or overboard.

A rotating propeller can cause severe injury. Check that there is nobody in the water before you engage forward / astern (reverse) drive. Never drive close to bathers or in areas where you could reasonably expect that people could be in the water.

Fuel filling

There is always a risk of fire and explosion during fuel filling. Smoking is not permissible, and the engine should be stopped.

Never over-fill the tank.

Shut the tank cap securely. Only use the fuel recommended in the instruction book. The wrong grade of fuel can cause malfunctions or stop the engine. In a diesel engine, it can also cause the regulation rod to bind and the engine will over-rev, entailing a strong risk of personal injury and machinery damage.

Accidents and near misses

Life saving statistics show that inadequate care of boats and engines, and deficiencies in safety equipment are frequent causes of accidents and near misses at sea.

Make sure that your boat and engine are maintained in accordance with the advice in each instruction book, and that the necessary safety equipment is on board, and is in working condition.

Do not start the engine.

Do not start the engine if you suspect a fuel or LPG leak in the boat, close to explosive media, or if there is a spillage of explosive media. An explosive environment entails a risk of fire and/or explosion.

Daily checks

Make it a habit to give the engine and engine bay a visual check before driving (before starting the en-

gine) and after operation (when you have stopped

the engine). This helps you to quickly discover whether any leakage of fuel, coolant, oil or any other abnormal event has happened, or is about to happen.

Safety information

Carbon monoxide poisoning

When a boat moves forwards, an area of low pressure air forms behind the boat. In adverse conditions, this low pressure can be so strong that the boat’s own exhaust fumes are sucked into the cockpit or cabin, which entails a risk of carbon monoxide poisoning for all aboard.

The problem of low-pressure suction is worst in high, wide boats with a square transom. But even in other types of boats, low-pressure suction can be a problem in some conditions, such as if you drive with the hood up. Other factors which increase the low-pressure effect are wind conditions, load distribution, pitching, trimming, open windows and ventilators etc.

Most modern boats are designed so that the problem of low-pressure suction is very rare, however. If lowpressure suction does occur anyway, do not open hatches or ventilators in the forward part of the boat.

Strangely enough, this makes the problem worse. Try changing speed, trimming or load distribution instead.

Also try taking down/opening the hood or modifying it in some other manner. Ask your boat dealer for advice about the best solution for your particular boat.

Remember

Safety equipment: Life jackets for everybody aboard, communication equipment, emergency rockets, approved fire extinguisher, first aid kit, life buoy, anchor, paddle, torches etc.

Spare parts and tools: Impeller, fuel filters, fuses, tape, hose clamps, engine oil, propeller and tools for the jobs you could be expected to have to do.

Take your chart out and study your planned route. Calculate distance and fuel consumption.

Listen to weather reports.

Tell your friends/relatives about route plans if you undertake a long journey. Remember to notify changed plans or delays.

Inform everybody aboard about where the safety equipment is located, and how it works. Make sure that there is more than one person aboard who can start and operate the boat safely.

This list can be extended, since the need for safety equipment varies with the type of boat, and where or how it is used etc. We recommend that you ask a regional boat or sea safety organisation for more detailed maritime safety information.

5

6

Safety information

Safety advice for care and maintenance work

Preparations

Knowledge

The Instruction Book contains instructions for doing the most common service and maintenance tasks in a safe and correct manner. Read them carefully before starting work.

Literature for more major tasks is available from your

Volvo Penta dealer.

Never do a job if you are not entirely sure about how to do it. Contact a Volvo Penta dealer for assistance instead.

Stop the engine.

Stop the engine before opening or removing the engine hatch/hood. Care and maintenance work should be done with the engine stopped unless otherwise specified.

Prevent the engine from being started by cutting the current with the battery isolator, or remove the cable from the battery positive pole before you start service work. Fix a notice by the helmsman’s seat to say that work is in progress.

Working with, or going close to a running engine is a safety risk. Loose clothes, long hair, fingers or dropped tools can catch on rotating components and cause severe injury. Volvo Penta recommends that all service work which requires the engine to be running should be done by a Volvo Penta authorised workshop.

Lifting the engine

The existing lugs on the engine (or reverse gear) should be used for lifting. Always check that the lifting devices are in good condition and that they have the correct capacity for the lift (engine weight together with reverse gear and auxiliaries, if fitted). The engine should be lifted with an adjustable lifting boom for safe handling. All chains or cables should be parallel to each other and should be as square as possible to the top of the engine. Please note that auxiliary equipment installed on the engine could change its centre of gravity. Special lifting devices may then be needed to obtain the correct balance and safe handling. Never do any work on an engine which just hangs from a lifting device.

Before starting

Re-install all guards which have been removed during service work, before re-starting the engine. Make sure that there are no tools or other objects left behind on the engine.

Never start a turbocharged engine without the air filter in place. The rotating compressor turbine in the turbocharger can cause severe injury. There is also a risk that foreign bodies could be sucked in and cause machinery damage.

Fire and explosion

Fuel and lubrication oil

All fuel, most lubricants and many chemicals are flammable. Always read and observe the advice on the packages.

Work on the fuel system must be done with the engine cold. Fuel leakage and spills on hot surfaces or electrical components can cause fires.

Store oil and fuel soaked rags and other flammable material in a fire-proof manner. Oil soaked rags can self-ignite in certain circumstances.

Never smoke when filling fuel, lubrication oil or close to fuel filling stations or the engine bay.

Non-original spare parts

Components in fuel systems and electrical systems on Volvo Penta engines are designed and manufactured to minimise the risk of explosions and fire, in accordance with applicable legal requirements.

The use of non-original spare parts can cause a fire.

Batteries

Batteries contain and give off an explosive gas, especially when charged. This gas is very flammable and highly explosive.

Smoking, open flames or sparks must never occur in or near to batteries or the battery locker.

Incorrect connection of a battery cable or start cable can cause a spark which can be sufficient, in its turn, to make the battery explode.

Start spray

Never use start spray or similar products as a starting aid. Explosions could occur in the inlet manifold. Danger of personal injury.

Hot surfaces and fluids

A hot engine always offers the risk of burns. Be on your guard against hot surfaces, such as the exhaust manifold, turbocharger, sump, charge air pipe, starting heater, hot coolant and hot lubricating oil in pipes and hoses.

Safety information

Fuel system

Always protect your hands when searching for leaks.

Fluids which leak under pressure can force their way into body tissue and cause severe injury. Risk of blood poisoning (septicaemia).

Always cover the alternator if it is located beneath the fuel filters. Fuel spillage can damage the alternator.

Carbon monoxide poisoning

Only start the engine in a well-ventilated area. When operated in a confined space, exhaust fumes and crankcase gases must be ventilated.

Chemicals

Most chemicals, such as glycol, rust preventer, conservation oils, degreasers etc. are hazardous. Always read and observe the advice on the packages.

Some chemicals, such as conservation oils, are flammable and also hazardous to breathe. Ensure good ventilation and use a protective mask for spraying. Always read and observe the advice on the packages.

Store chemicals and other hazardous material out of the reach of children. Hand in surplus or used chemicals to a recycling station for destruction.

Electrical system

Cut the current

Before any work is done on the electrical system, the engine must be stopped and the current cut by switching off the battery isolator. Shore current for engine heaters, battery chargers or other auxiliary equipment connected to the engine must be disconnected.

Batteries

Batteries contain a highly corrosive electrolyte. Protect your eyes, skin and clothes during charging and other handling of batteries. Always use protective goggles and gloves. If this comes into contact with your skin, wash at once with soap and a lot of water. If you get battery acid in your eyes, flush at once with a lot of water, and get medical assistance at once.

Cooling system

There is always a risk of water entry when any work is done on the seawater system. For this reason, stop the engine and close the sea cocks before you start work.

Avoid opening the coolant filling cap when the engine is hot. Steam or hot coolant can spray out and cause scalding.

If the filler cap, coolant hose etc., still has to be opened or removed when the engine is hot, undo the filler cap slowly and carefully, to let the pressure out before removing the filler cap completely and starting work.

Note that the coolant can still be hot and cause scalding.

Lubrication system

Hot oil can cause burns. Avoid skin contact with hot oil. Make sure that the oil system is de-pressurised before starting work. Never start or run the engine with the oil filler cap removed, because of the risk of oil spillage.

7

Introduction

This instruction book has been prepared to give you the greatest possible benefit from your Volvo Penta marine engine. It contains the information you need to be able to operate and maintain the engine safely and correctly.

Please read the instruction book carefully and learn to handle the engine, controls and other equipment in a safe manner before you cast off on your maiden voyage.

Always have the instruction book available. Store it safely and do not forget to hand it over to the next owner if you sell your boat.

Environmental care

All of us want to live in a clean, healthy environment.

Where we can breathe clean air, see healthy trees, have clean water in lakes and seas, and be able to enjoy the sunlight without fearing for our health. Unfortunately, this is not self-evident these days, it is something all of us must work hard for.

As a manufacturer of marine engines, Volvo Penta has particular responsibility and for this reason, environmental care is a core value in our product development. Volvo Penta has a wide engine programme these days, where considerable progress has been made in reducing exhaust fumes, fuel consumption, engine noise etc.

We hope that you will be want to preserve these values. Always observe the advice in the instruction book about fuel grades, operation and maintenance, to avoid unnecessary environmental impact. Please contact your Volvo Penta dealer if you notice any changes such as increased fuel consumption or increased exhaust smoke.

Moderate your speed and distance so that wake and noise do not disturb or damage animal life, moored boats, jetties etc. Leave the archipelago and harbours in the same state you would like to find them. Remember to always hand in drained oil, coolant, paint and wash residue, used batteries etc. for destruction at a recycling station.

If we all pull together, we can make a valuable contribution to the environment together.

Running in

The engine must be “run in” during its first 10 hours, as follows:

Use the engine in normal operation. Full load should only be applied for short periods. Never run the engine for a long period of time at constant speed during this period.

Higher oil consumption is normal during the running in period. For this reason, check the oil level more frequently than normally recommended.

After the first period of operation, the specified warranty inspection “First service inspection” can be done.

For more information: Please refer to the Warranty and Service book.

Fuel and oils

Only use the fuels and oils recommended in the instruction book. Other grades can cause malfunctions, increased fuel consumption and eventually even shorten the life of the engine.

Always change the oil, oil filter and fuel filter at the specified intervals.

Service and spare parts

Volvo Penta marine engines are designed for high reliability and long life. They are built to withstand a marine environment, but also to have the smallest possible environmental impact. Through regular service and use of Volvo Penta original spare parts, these qualities are retained.

Volvo Penta’s world-wide network of authorised dealers is at your service. They are Volvo Penta product specialists, and have the accessories, original spares, test equipment and special tools needed for high quality service and repair work.

Always observe the maintenance intervals in the instruction book, and remember to note the engine/ transmission identification number when you order service and spare parts.

8

Introduction

Certified engines

If you own or operate an emission certified engine it is important to be aware of the following:

Certification means that an engine type has been checked and approved by the relevant authority. The engine manufacturer guarantees that all engines made of the same type are equivalent to the certified engine.

This makes special demands on the care and maintenance you give your engine, as follows:

Maintenance and service intervals recommended by Volvo Penta must be complied with.

Only Volvo Penta original spares may be used.

Service on injection pumps, pump settings and injectors must always be done by an authorised

Volvo Penta workshop.

The engine must not be converted or modified, except for the accessories and service kits which

Volvo Penta has approved for the engine.

Installation changes to the exhaust pipe and engine air inlet ducts must not be done.

● No seals may be broken by unauthorised personnel.

The general advice in the instruction book about operation, care and maintenance apply.

IMPORTANT! Delayed or inferior care/maintenance, and the use of non-original spares, mean that AB Volvo Penta can no longer be responsible for guaranteeing that the engine complies with the certified version.

Damage, injury and/or costs which arise from this will not be compensated by Volvo Penta.

Warranty

Your new Volvo Penta marine engine is covered by a limited warranty, under the conditions and instructions compiled in the Warranty and Service book.

Please note that AB Volvo Penta’s liability is limited to the specification in the Warranty and Service book. Read it carefully, as soon as possible after delivery. It includes important information about warranty cards, service, maintenance, which it is the responsibility of the owner to know, check and carry out. If this is not done, AB Volvo Penta may fully or partly refuse to honour its warranty undertakings.

Please contact your Volvo Penta dealer if you have not received a Warranty and Service book, or a customer copy of the warranty card.

9

Introduction

Identification numbers

There are type plates on the engine and transmission, marked with identification numbers. This information must always be used as reference when service and spare parts are ordered. You will probably find similar plates on your boat and its equipment. Note this information below, make a copy of the page and store it in a safe place, so that you can have the information available if the boat is stolen.

The appearance and location of the type plates is shown below. The figures in brackets refer to the location of the identification number on the type plate.

Engine

Product number (1)

Produkt designatinon (2) .................................................................................................

Engine number (3) ...........................................................................................................

Reverse gear

Product designation (6) ..................................................................................................

Serial number (7) .............................................................................................................

Product number (8) .........................................................................................................

THIS ENGINE TYPE IS CERTIFIED

ACC. TO IMO NOx TECHNICAL CODE

ANNEX VI

Certification decal

Warranty decal

10

Presentation

The D9 in-line diesel has a robust block with ladder frame, high pressure unit injector system, 4 valves per cylinder, “twin entry” turbo and aftercooler.

Together with a large swept volume and the EVC (Electronic Vessel Control), this results in a very smooth running engine with world-class diesel performance, combined with low fuel consumption and emissions.

Technical description

Engine and cylinder block

– The cylinder block and cylinder head are manufactured of alloyed cast iron

– Induction hardened crankshaft journalled in seven main bearings

– Replaceable wet cylinder liners

– Gallery oil cooled cast aluminium pistons

– Three piston rings, including a “keystone” type top ring

– Induction hardened overhead camshaft with roller rocker arms and totional vibration damper

– Four valves per cylinder

– Replaceable valve seats and valve guides

Fuel system

– Microprocessor based fuel supply control unit

– Gear driven fuel feed pump

– Centrally located unit injectors with electromagnetically controlled fuel valves

– Spin-on fine fuel filter with water trap

– Water in fuel alarm

Lubrication system

– Freshwater cooled oil cooler

– Gear driven oil pump

– Symmetrically positioned twin full flow oil filter of spin-on type and by-pass filter

Turbocharging system

– Mid positioned turbo with twin entry charger system

Cooling system

– Seawater-cooled tubular heat exchanger

– Coolant systen prepared for hot water outlet

– Easily accessible seawater impeller pump in rear end

Electrical system

– 12V/115 A or 24V/80A alternator

11

Presentation

Orientation

1 2 3 4 5 6

D9-575 ZF305

1.

Expansion tank

2.

Coolant filler cap

3.

Emergency stop

4.

Crankcase breather filter

5.

Fuel feed pump (hand pump)

6.

Fine fuel filter with watertrap

7.

Alternator

8.

Heat exchanger

9.

Control unit

10. Oil sump

11. Seawater pump

12. Reverse gear ZF305A-E

7

8 9 10 11 12

1 2 3 4 5

D9-575 ZF305

1.

By-pass filter for lubrication oil

2.

Lubrication oil filter

3.

Water-cooled exhaust outlet

4.

Turbocharger

5.

Air filter

6.

Oil cooler, reverse gear

7.

Starter motor

8.

Aftercooler

9.

Oil dipstick, engine

10. Oil filler cap

11. Coolant pump

6 7 8 9 10 11

12

Presentation

1 2 3 4 5 6

D9-500 ZF280

1.

Expansion tank

2.

Coolant filler cap

3.

Emergency stop

4.

Crankcase breather filter

5.

Fuel feed pump (hand pump)

6.

Fine fuel filter with watertrap

7.

Alternator

8.

Heat exchanger

9.

Control unit

10. Oil sump

11. Seawater pump

12. Reverse gear ZF280A-E

7 8 9 10 11 12

1 2 3 4 5

D9-500 ZF280

1.

By-pass filter for lubrication oil

2.

Lubrication oil filter

3.

Water-cooled exhaust outlet

4.

Turbocharger

5.

Air filter

6.

Oil cooler, reverse gear

7.

Starter motor

8.

Aftercooler

9.

Oil dipstick, engine

10. Oil filler cap

11. Coolant pump

6 7 8 9 10 11

13

Presentation

1 2 3 4 5 6

D9-500 MG5075

1.

Expansion tank

2.

Coolant filler cap

3.

Emergency stop

4.

Crankcase breather filter

5.

Fuel feed pump (hand pump)

6.

Fine fuel filter with watertrap

7.

Heat exchanger

8.

Aftercooler

9.

Control unit

10. Oil sump

11. Seawater pump

12. Reverse gear MG5075A-E

7 8 9 10 11

12

14

1 2 3 4 5

D9-500 MG5075

1.

By-pass filter for lubrication oil

2.

Lubrication oil filter

3.

Water-cooled exhaust outlet

4.

Turbocharger

5.

Air filter

6.

Oil cooler, reverse gear

7.

Starter motor

8.

Aftercooler

9.

Oil dipstick, engine

10. Oil filler cap

11. Coolant pump

6 7 8 9 10 11

Instruments

This chapter describes the instrument and control panels sold by Volvo Penta for your engine.

If you want to supplement the instrumentation, or if your boat is equipped with instruments not described here, or you are not sure about their function, please contact your Volvo Penta dealer.

Instruments

1.

2.

3.

4.

5.

1. Tachometer

2. Voltmeter

3. Oil pressure gauge

4. Temperature gauge

5. Hours counter

Ignition lock

A tab with the key code accompanies the ignition keys, and is used to order extra ignition keys. Do not store the code where it is accessible to unauthorized persons.

S = Stop position.

0 = Key can be inserted and removed.

I = System voltage on (drive position).

II = Not used.

III = Start position.

IMPORTANT! Read the starting instructions in the

“Engine starting” chapter.

Start/stop panel

The start/stop panel is used to start or stop the engine. The starter key in the main control panel must be in position “I” (driving position) for the engine to start. The engine can only be stopped if the control panel is activated.

IMPORTANT! Read the starting instructions in the “Engine starting” chapter.

15

Instruments

Alarm display

The following warning lamps should never light up during operation. On the other hand, the warning lamps light up when the starter key is first turned to the drive position. Check that all lamps function. When the engine has started, all lamps should have gone out. The lamps flash if the diagnostic function has registered malfunction. When the fault has been acknowledged, the lamp gives continuous light.

Warning lamps (should never light up during operation).

Oil pressure (red indication)

If the oil pressure lamp lights up during operation, the oil pressure in the engine is too low. Stop the engine at once.

Check the oil level in the engine. Please refer to

“Maintenance: Lubrication” to check and top the oil up.

Also check that the oil filters are not blocked. Please refer to “Maintenance: Lubrication system”

Please refer to the “If something happens” chapter, and you will find detailed information about recommended action in the “Diagnostic function” section.

WARNING! Continued operation when the oil pressure is too low can cause serious engine damage.

Water in fuel filter (orange indication)

If the lamp lights up, there is too much water in the water trap in the fuel filters.

Empty the water trap underneath the secondary fuel filter. Please refer to “Maintenance: Fuel system”.

Please refer to the “In case of emergency” chapter, and you will find detailed information about recommended action in the “Diagnostic function” section.

16

Instruments

Battery. (orange indication)

The battery lamp lights up if the alternator is not charging. Stop the engine if this lamp lights up during operation. If the lamp lights up, this can be due to a fault in the electrical system or because the alternator drive belt is slack.

Check the alternator drive belts. Please refer to

“Maintenance: Engine, general”.

Also check that there is no poor contact/broken wires.

Please refer to the “If something happens” chapter, and you will find detailed information about recommended action in the “Diagnostic function” section.

WARNING! Do not continue operation if there is any problem with the alternator drive belts. This could cause serious engine damage.

Coolant temperature (red indication)

The coolant temperature lamp lights up when the coolant temperature is too high. Stop the engine if this lamp lights up during operation.

Check the coolant level. Please refer to

“Maintenance: Fresh water system”.

Check that the sea water filter is not blocked.

Please refer to “Maintenance: Sea water system”

Also check the impeller in the sea water pump.

Please refer to “Maintenance: Sea water system”.

Please refer to the “If something happens” chapter, and you will find detailed information about recommended action in the “Diagnostic function” section.

WARNING! Do not open the coolant filler cap when the engine is warm, except in emergencies. Steam or hot fluid could spray out.

17

Instruments

Coolant level (orange indication)

The coolant lamp lights up when the coolant level is too low.

Check coolant level. Please refer to

“Maintenance: Lubrication system”.

Please refer to the “If something happens” chapter, and you will find detailed information about recommended action in the “Diagnostic function” section.

Oil level (orange indication)

The oil level lamp lights up when the oil level is too low.

Check the oil level. Please refer to “Maintenance:

Fresh water system”.

Please refer to the “If something happens” chapter, and you will find detailed information about recommended action in the “Diagnostic function” section.

Serious fault (red indication)

The lamp lights up when a serious fault occurs.

Please refer to the “If something happens” chapter, and you will find detailed information about recommended action in the “Diagnostic function” section.

Fault (orange indication)

The lamp lights up when a fault occurs.

Please refer to the “If something happens” chapter, and you will find detailed information about recommended action in the “Diagnostic function” section.

18

Instruments

EVC control panel

There are two versions of the EVC control panel, one for single engine installations and another for twin installations.

Activation button

Used to activate the control panel, so that the engine can be started and stopped.

Indication (red):

No light: The control position is not activated.

Light on: Control position activated.

Flashing: The control position cannot be activated because the control lever is not in the neutral position or the system has been locked from another control panel.

Indication (padlock):

Light on: The system is locked and the engine can only be controlled from an activated control panel.

Neutral button

Used to activate de-activate the reversing gear / stern drive, so that the engine can be revved up.

Indicator (green):

No light: Reversing gear/stern drive is engaged.

Light on: The Control lever is in neutral position.

Flashing: Reversing gear/stern drive is in neutral.

Synchronization indication

The synchronization function automatically adjusts the engines to the same speed (rpm).

Indication (blue):

No light: The synchronization function is not activated.

Light on: The synchronization function is activated

Diagnostic button

Used if the diagnostic function has registered malfunction.

Indication (yellow):

No light: Normal operation.

Light on: Fault codes can be read.

Flashing: Diagnostic function has registered a malfunction.

Dimmer function

Used to light up and extinguish background lighting in the instruments and panels.

Press the button for 5 seconds to light or extinguish background lighting. Background lighting can be adjusted in five stages, by pressing the dimmer button.

19

Instruments

EVC-Display (extra optional)

The Volvo Penta EVC-display is an on-board instrument for indication of engine operating values. The display consists of a self-contained, computerised unit for fixed installation in a control panel.

Indications are presented on a Liquid Crystal Display

(LCD) screen. The operator selects presentation mode using five keys on the front of the instrument.

20

Controls

This chapter describes the instrument panels sold by Volvo Penta for your engine. If your boat is equipped with controls which are not described here and you feel uncertain about the function, please contact the dealer you purchased the boat from.

Single lever control. Electronic

Operation

Both the shift function and engine speed control are controlled using the single lever control.

N = Neutral position (reverse/stern drive is disengaged and the engine runs at idle speed).

F = Reversing gear/stern drive engaged for movement ahead.

R = Reversing gear/stern drive engaged for movement astern.

T = Adjustment of engine speed.

NOTE! The engine can only be started if the Control lever is in the neutral position.

Disengaging the shift function

The shift function can be disengaged so that the control lever only affects the engine speed.

1. Move the lever to the neutral position (N)

2. Press the neutral button (N) in and hold it down while moving the control lever forward to the shift position (F).

3. Release the neutral button. The green indicator begins to flash to acknowledge that the shift function is disengaged.

The lever now only controls engine speed.

When the lever is moved back to the neutral position it will automatically re-engage. This is confirmed by the green indication which gives constant light.

WARNING! Take care not to engage the reversing gear/stern drive unintentionally.

21

Controls

Friction brake

The control is also equipped with a friction brake which can be adjusted for easier or stiffer lever movement as necessary.

Friction brake adjustment:

1. Stop the engine.

2. Move the control lever forwards to make the groove in the control lever hub accessible.

3. Put a screwdriver in the groove and disassemble the plug.

4. Adjust the friction brake (spanner size 8 mm):

Clockwise = stiffer lever movement

Anti-clockwise = easier lever movement

5. Install the plug.

22

Starting the engine

Make it a habit to give the engine and engine bay a visual check before starting. This will help you to discover quickly if anything abnormal has happened, or is about to happen. Also check that instruments and warning displays show normal values after you have started the engine.

To minimize starting smoke in cold starting, we recommend that a heater should be installed to warm the engine bay at temperatures below +5°C.

WARNING! Never use start spray or similar products as a starting aid. Explosion risk!

Before starting

Open the fuel tap

Open the sea cock (reversing gear)

Do the tasks under the “Daily before first start” heading in the maintenance schedule.

● Turn the main switches on.

IMPORTANT! Never disconnect the current with the main switches when the engine is running. This can damage the alternator.

● Start the engine bay fan, if one is installed, and let it run for at least four minutes.

Check that the amount of fuel aboard is enough for your planned voyage.

General information about starting

The engine control lever must always be in neutral before starting. The engine management system ensures that the engine receives the correct amount of fuel - even when the engine is cold.

The engine is pre-heated by the engine control unit, which allows the engine to crank several revolutions with the starter motor before fuel is injected. The colder the engine is, the more revolutions the engine makes. This raises the temperature in the combustion chambers, which ensures reliable starting and reduces starting smoke.

The idling speed is also governed by engine temperature, and is somewhat raised after a cold start.

23

Starting the engine

Starting method

Put the reversing gear in neutral

Put the reversing gear in neutral by moving the control lever(s) to neutral at all control positions.

Two lever control: Also check that the engine speed lever is in the idling position.

Turn the ignition on

Turn the starter key to position I to switch the ignition on.

Check the warning lamps and LEDs

Each time the ignition is turned on, all bulbs and

LEDs are illuminated on the main control panel.

Check that all bulbs and LEDs function.

If the boat has more than one control panel, the lamps on the other panel(s) are not checked until the control panel(s) is(are) activated.

Activate the control position and lock the system.

Press the activation button for at least one second.

When the button is released, the indication lights up to confirm that the control position is activated.

NOTE! If the indicator flashes, the control position has not been activated because the control lever(s) are not in the neutral position or the system has been locked from another control panel.

If the boat has more than one control panel, the system can be locked, so that the engine can only be controlled from the activated control board. Press the activation button for a further second to lock the system. The padlock sign lights up in confirmation.

Unlock the system by pressing the activation button for one second. This can only be done from an activated control panel.

24

Starting the engine

Start the engine

Start using the ignition switch

Turn the key to position III. Release the key and let it key spring back to position I as soon as the engine has started.

NOTE! If repeated start attempts are needed, the key must be turned back to position 0 first.

Starting with the starter button

Press the starter button. Release the button as soon as the engine has started. Please note that if you start from an alternative control station, the starter key at the main control station must be in position I.

Overheating protection

If the starter motor is engaged for its maximum activation time (30 seconds), the starter motor circuit is cut automatically to protect the starter motor from overheating. Leave the starter motor to cool for at least five minutes (if possible) before making a new start attempt.

Read the instruments and warm the engine up

Allow the engine to idle for the first ten seconds, and check that instruments and warning displays show normal values. Check that no warning lamps flash on the alarm display.

Then warm the engine up at low speed and low load, so that reaches normal operating temperature before full power is used.

IMPORTANT! Never race the engine when it is cold.

Check the oil level in the reversing gear

Check the oil level when the reversing gear has reached operating temperature (please refer to the description in the “Maintenance” chapter under the

“Reversing Gear” heading)

25

Operation

Learn to handle the engine, controls and other equipment in a safe and correct manner before you cast off on your maiden voyage. Remember to avoid sudden or surprising rudder movements and gear shifting. There is a risk that passengers could fall over, or overboard.

WARNING! A rotating propeller can cause severe injury. Check that there is nobody in the water before you engage forward / aft drive. Never drive close to bathers or in areas where you could reasonably expect that people could be in the water.

Reading the instruments

Read all instruments and alarm displays directly after starting, and then regularly during your voyage.

Oil pressure

The oil pressure gauge should normally indicate between 4-

5.5 bar. It will indicate a somewhat lower value when idling.

If the oil pressure is too low, the audible warning will sound automatically at the same time as the lamp in the warning display will flash.

Coolant temperature

The temperature gauge should normally indicate between

75– 95°C (167-203°F) in normal operation.

If the coolant temperature is too low, the audible warning will sound automatically at the same time as the lamp in the warning display will flash.

Charging

During operation, system voltage should be about 28 V for

24 Volt system voltage.

If there is a charge failure, the audible warning will sound automatically at the same time as the lamp in the warning display will flash.

Alarm

If a fault occurs, the audible warning will sound and the relevant warning lamp on the alarm panel will start to flash.

The diagnostic button LED will also flash rapidly

Reduce engine speed to idling. Press the button to acknowledge the message. The audible warning will become silent and the alarm panel will stop flashing. The relevant warning lamp gives a constant light.

Please refer to the “If something happens” chapter, and you will find detailed information about recommended action in the “Diagnostic function” section.

The fault will also be stored in the form of a fault code for as long as the malfunction remains. It is possible to read the fault code during a subsequent service.

26

Operation

Cruising speed

Avoid operation at full throttle, for best fuel economy. We recommend a cruising speed which is at least 10% below the maximum engine speed at full speed (full throttle). The maximum engine speed will vary due to propeller choice, load and sea conditions, but it should be in the full throttle range.

Full throttle range:

D9 rating 4 .......................... 2400–2650 rpm.

rating 5 .......................... 2300–2600 rpm.

If the engine does not reach the full throttle range, this could be caused by a number of factors which are noted in the

“Fault tracing” chapter. If the engine speed exceeds the full throttle range, select a coarser pitch propeller. Ask your

Volvo Penta dealer for advice.

1

Synchronizing engine speed

When driving with twin engines, both the operating economy and comfort can be increased when the engines are operating at the same engine speed (rpm).

The synchronization function is indicated by a blue equals sign (1) on the EVC control panel.

When the synchronization function is activated, the engine speed (rpm) of the starboard engine is automatically adjusted to that of the port engine. The synchronization function is activated automatically if the following conditions are met.

1. The engine speed levers for both engines are in (approximately) the same position.

2. The engine speed on both engines must exceed 800 rpm.

NOTE! The synchronizer is disengaged as soon as the conditions are no longer met.

27

Operation

1

Changing the control position

The first time you change control panel after starting the EVC system, a bulb check is done automatically. All LEDs and bulbs light up for 2 seconds.

1. Check that the control lever(s) is (are) in neutral on both the control panel you leave and on the new control panel.

2. Check that the EVC system is not locked.

3. Press the activation button (1) for at least one second.

When the button is released, the indication lights up to confirm that the control position is activated.

4. Press the activation button (1) for a further second to lock the EVC system. The padlock sign lights up in confirmation. Unlock the system by pressing the activation button for one second. This can only be done from an activated control panel.

Changing control position during operation

(optional extra)

This function must be enabled to permit the control panel to be changed during operation. The function can only be enabled by authorized Volvo Penta personnel. Please contact your Volvo Penta dealer.

1. Press the activation button (1) to unlock the system.

The padlock sign goes out on all control panels to indicate that it is possible to change control panel.

2. Press the activation button (1) on the alternative control panel. The activation button indication flashes on the alternative control panel, and on the main control panel it gives constant light.

3. The alternative control panel becomes active when the correct gear and approved engine speed is demanded.

The activation button (1) gives constant light to confirm that the control panel is activated. The system is now locked, which is indicated by the padlock sign, which lights up.

NOTE! If the correct gear or engine speed is not demanded within 15 sec, the system ramps engine speed down to neutral and the gearbox engages neutral.

28

1

2

3

Operation

Operation

Shifting between forward and reverse should be done at idling. Shifting at higher engine speeds can be uncomfortable for passengers and cause unnecessary stress on the stern drive/reversing gear, or cause the engine to stop.

If you attempt to shift gear at an excessive engine speed, a safety function cuts in automatically, and delays shifting until engine speed has fallen to 1000 rpm.

Always do a forwards/reverse operation as follows:

1. Reduce engine speed to idle and let the boat more or less lose way.

WARNING! Never shift to reverse when the boat is planing.

2. Move the control lever to neutral with a rapid, distinct movement. Make a brief pause.

3. Then move the control lever to reverse with a rapid, distinct movement and increase engine speed.

IMPORTANT! If the boat has twin engines, it is important that both should be running during reversing maneuvers, to avoid the risk of water entry (via the exhaust pipe) into the stationary engine.

Propeller shaft brake

In certain conditions, the propeller can make the propeller shaft rotate when the engine is stopped. This parasitic rotation is uncomfortable, and can damage the reversing gear since its oil pump, which is driven by the input shaft, is stationary together with the engine.

The propeller shaft can be permitted to rotate with a stationary engine for up to 6-8 h. After this, the engine must be started and run for at least 5 min to lubricate and cool the reversing gear.

If the shaft is likely to rotate faster than in normal operation, such as when sailing, a temperature gauge should be installed to monitor the oil temperature.

Maximum permissible temperature is 95°C for the ZF reversing gear.

When the above-mentioned rules can not be met, or if you want to stop the shaft for comfort reasons, a shaft brake has to be installed. On isolated occasions, the propeller shaft flange can be locked mechanically by some suitable means.

29

Stopping the engine

Allow the engine to idle (in neutral) for at least three minutes after the end of your journey. This evens out the temperatures inside the engine, and stops after-boiling.

IMPORTANT! The above is particularly important if the engine has been driven at high speed and/or heavily loaded.

Stop

1. Disengage the reversing gear by putting the control lever in neutral.

2. Turn the key to stop position “S”. Keep the key turned until the engine stops. The key will automatically return to the “0” position when it is released and can then be removed. Alternatively press the stop button. To stop the engine using the stop button is only possible if the control panel is activated.

Emergency stop

If the engine cannot be stopped in a normal procedure, it is possible to stop the engine via auxiliary stop mounted on the side of the engine.

After stopping the engine

Check the engine and engine bay for leakage.

Shut off the fuel taps and sea cocks.

IMPORTANT! Do not forget to open the taps next time the engine is started.

Read off the hours counter and do preventive maintenance as in the maintenance schedule.

Turn off the main switches before any long stoppage.

IMPORTANT! Never break the circuit with the main switches while the engine is running. This could damage the alternator and electronics.

30

Stopping the engie

Cold weather precautions

If the engine bay can not be kept frost-free, the seawater system must be drained and the freshwater system coolant must have enough anti-freeze to prevent frost damage. Please refer to the “Seawater system” and “Freshwater system” maintenance chapters.

WARNING! If the engine bay can not be kept frost-free, the seawater system must be drained.

Frost damage in the seawater system can make the boat sink.

IMPORTANT! If the coolant does not have sufficient frost protection, this can cause expensive engine damage. Check the battery charge. A poorly charged battery can freeze and burst.

Laying up

If the boat is not used, but left in the water, the engine must be warmed up at least once every fortnight. This prevents corrosion damage in the engine.

IMPORTANT! If you expect the boat to be unused for two months or more, it must be laid up:

Please refer to the Laying up chapter.

31

In case of emergency

Despite regular maintenance according to the maintenance schedule and perfect operation, it may occur that a fault occurs which must be attended to before the boat can travel further. This chapter contains tips for rectifying some of the possible faults.

There are safety functions which are activated when certain faults occur, to protect the engine. The following can occur:

Engine can not be started

Reversing gear in neutral and engine speed is limited to 1000-1200 rpm, depending on engine.

The engine stops

Flash out any fault codes and take the recommended measures. Please refer to the “Diagnostic function” and

“Fault codes” chapters.

Starting with auxiliary batteries

WARNING! Ventilate well. Batteries contain and give off an explosive gas which is highly flammable and explosive. A short circuit, open flame or spark could cause a violent explosion.

WARNING! Never confuse the positive and negative poles on the batteries. Risk of arcing and explosion.

1. Check that the rated voltage of the help start battery is the same as the system voltage of the engine.

2. Connect the red jumper cable to the positive pole

(+) of the flat battery, and then to the positive pole of the help start battery.

3. Connect the black jumper cable to the negative

pole (–) of the help start battery, and then to a place some distance from the flat batteries, such as the negative connection on the starter motor.

WARNING! Under no circumstances may the black jumper cable (–) come into contact with the positive connection on the starter motor.

4.

Start the engine and run at a fast idle for about ten minutes to charge the batteries.

WARNING! Working with, or going close to a running engine is a safety risk. Watch out for rotating components and hot surfaces.

WARNING! Do not touch the connections during the start attempt: Risk of arcing. Do not stand bending over any of the batteries either.

5. Stop the engine. Remove the jumper cables in the exact reverse order from installation.

32

1

2

In case of emergency

Emergency shifting

If a fault occurs which prevents the revers gear from being operated (shifted) with the control lever, it is possible to shift manually, using the description below.

Note. The descriptions refer to electrically shifted revers gear.

WARNING! In emergency shifting, the unit is locked in forwards operation. Please note that the revers gear can not then be disengaged with the control lever. Forward motion can only be cut off by stopping the engine with the ignition key or stop button.

1. Stop the engine and remove the start key from the key switch.

2. Note the valve (P or S) to which the cable marked

“Primary” is connected. Then undo the connectors

(1 and 2) from the solenoid valves.

3. Remove the cap nut from the valve which was connected to the “Primary” cable.

4. Press the valve (A) on the valve.

5. Turn the button a 1/2 turn anti-clockwise (the button is forced out by spring action).

The reverse gear is now connected for forward motion and cannot be disengaged by the control lever.

33

In case of emergency

Fault-tracing

A number of symptoms and possible causes of engine malfunctions are described in the table below. Always contact your Volvo Penta dealer if problems occur which you can not solve by yourself.

WARNING! Read through the safety advice for care and maintenance work in the “Safety information” chapter before starting work.

Symptoms and possible causes

The diagnosis button lamp flashes.

Engine can not be stopped

Starter motor does not rotate

Starter motor rotates slowly

Starter motor rotates normally but engine does not start

Engine starts but stops again

Engine does not reach full operating speed at full throttle

Engine runs unevenly

Engine vibrates

High fuel consumption

Black exhaust smoke

Blue or white exhaust smoke

Lubrication oil pressure too low

Coolant temperature too high

Coolant temperature too low

No charge or poor charge

Please refer to the “Diagnostic information” chapter.

2, 4, 5, 7

1, 2, 3, 4, 5, 6, 8, 9, 10, 11, 36, 38, 39

1, 2

12, 13, 14, 15, 38

12, 13, 14, 15, 19, 38

13, 14, 15, 16, 17, 18, 19, 20, 23, 33, 37, 38

14, 15

24

16, 17, 21

19

20, 21, 34

22

25, 26, 27, 28, 29, 30, 31, 32, 40

31

2, 35

1. Flat batteries

2. Poor contact/open circuit in cables

3. Main switch turned off

4. One of the circuit breakers in the distribution box has tripped.

5. Faulty key switch

6. Control lever not in neutral/control position not activated

7. Faulty stop relay

8. Faulty main relay

9. Faulty starter relay

10. Faulty starter motor relay

11. Faulty starter motor/solenoid

12. Lack of fuel:

– fuel taps closed

– fuel tank empty/wrong tank connected

13. Blocked fine fuel filter/pre-filter

(caused by contamination or fuel stratification at low temperature)

14. Air in the fuel system

15. Water/contamination in fuel

16. Boat abnormally loaded

17. Fouling on hull/propeller

18. Faulty injectors (nozzles)

19. Insufficient air supply to engine:

– blocked air filter

– air leakage between turbocharger and engine inlet pipe.

– fouled compressor section in turbocharger

– faulty turbocharger

– poor engine bay ventilation

20. Excessive coolant temperature

21. Too low coolant temperature

22. Too low oil level

23. Faulty / wrong propeller

24. Faulty engine mounting

25. Coolant level too low

26. Air in the freshwater system

27. Faulty circulation pump

28. Closed seawater inlet

29. Blocked seawater inlet/pipe/filter

30. Defective impeller in seawater pump

31. Defective thermostat

32. Blocked heat exchanger insert

33. Blocked aftercooler

34. Too high oil level

35. Alternator drive belt slips

36. Water entry into engine

37. High back pressure in exhaust system

38. Stored fault codes*

39. Check that the emergency stop button is in the running position (not pressed down).

40. Engine drive belt slips

* Note. Please refer to the “Diagnostic information” chapter. for further information.

34

In case of emergency

Diagnostic function

The diagnostic function monitors and checks that the engine, stern drive/reversing gear and EVC system function normally.

The diagnostic function has the following tasks:

Discover and localize malfunctions

Notify that malfunctions have been discovered

Give advice in fault finding

Protect the engine and ensure continued operation when serious malfunctions are discovered.

Malfunction message

If the diagnostic function discovers a malfunction, it warns the driver by starting to flash the indicator on the diagnostic button. To acknowledge the alarm, press button D on the control panel. When the fault has been acknowledged, the lamp concerned gives constant light.

The diagnostic function affects the engine in the following ways when:

1. The diagnostic function has discovered a minor malfunction which does not damage the engine.

Reaction: The engine is not affected.

2. The diagnostic function has discovered a serious malfunction which will not immediately damage the engine (e.g. high coolant temperature):

Reaction: Engine power is cut until the relevant value is normalized.

3. The diagnostic function has discovered a serious malfunction which will cause serious engine damage. Reaction: The engine is stopped.

4. The diagnostic function has discovered a serious malfunction which makes it impossible to control the engine.

Reaction: The reversing gear is disengaged and engine speed is cut to 1000 rpm.

It is possible to do an emergency shift: Please refer to the “Emergency shifting” section.

35

In case of emergency

Fault codes

The fault codes are flashed out on the diagnostic button indication. The fault code consists of three groups of flashes, separated by a pause of two seconds. A fault code is obtained by counting the number of flashes in each group:

Example:

pause pause = 2.4.2

The fault code is stored and can be read as long as the malfunction remains.

A fault code list, containing information about cause and effect, is found in the “Fault code list” chapter.

Reading fault codes

1.

Reduce engine speed to idling if fault codes are read when the engine is running. If the engine is stopped, check that the starter key is in position I

(drive position).

2.

Press the diagnostic button D for at least 5 seconds. Release the D button and the yellow indication lamp will give constant light, which means that you are in Service mode and fault codes can be read.

3.

The diagnostic button must be depressed to make the codes flash. Make a note of the three digit fault code that is flashed out.

4.

Repeat the points above. A new fault code is flashed out if more are stored. Repeat until fault code 1.1 is flashed.

NOTE! When the fault code 1.1 is flashed, all fault codes have been read out.

5.

Look up the fault code in the fault code list and take the necessary measures.

Alternatively: If the controls, warning display and other instrumentation indicate normal function, the operator can continue the journey and remedy the malfunction at a later time.

6.

To leave Service mode press D button for at least

5 sec. or turn the ignition off.

36

In case of emergency

Erasing fault codes

Any fault codes in the diagnostic function are automatically erased every time the starter key is turned to the stop position (S).

NOTE! Stop the engine and check that the ignition key(s) is(are) in position 0 in all control positions.

When system voltage is switched on again, the diagnostic function checks to see whether there are any faults in the EVC system. If this is the case, new fault codes are set.

This means that:

1. Fault codes for malfunctions which have been attended to or have disappeared are automatically erased.

2. Fault codes for malfunctions which have not been attended to must be acknowledged every time the system voltage is switched on.

If the diagnostic button is pressed after all stored fault codes have been erased, code 1.1 (“No fault”) will be flashed out.

37

Maintenance schedule

General information

Your Volvo Penta engine and its equipment are designed for high reliability and long life. They are built to withstand a marine environment, but also to have the smallest possible environmental impact. If given preventive maintenance, according to the maintenance schedule, and if Volvo Penta original spares are used, these qualities are retained and unnecessary malfunctions can be avoided.

Warranty inspection

During the first period of operation, the specified warranty inspection “First service inspection” must be done by an authorised Volvo Penta workshop. Instructions about when and where this should be done are found in the

Warranty and service book.

MAINTENANCE SCHEDULE

WARNING! Before you start to do any maintenance work, read the “Maintenance” chapter carefully. This contains instructions for doing work in a safe and correct manner.

IMPORTANT! When both operation and calendar time are specified, do the maintenance job at the interval which is reached first. Maintenance points marked must be done by an authorised Volvo Penta workshop.

Daily, before first start

Engine and engine bay. General inspection .................................................... page 40

Air filter indicator. Inspection 1) ....................................................................... page 41

Engine oil. Check level .................................................................................. page 44

Coolant. Check level ...................................................................................... page 48

Reverse gear. Check oil level (after starting) .................................................. page 66

1) Change the air filter every 12 months.

After the first 50 hours

Reverse gear. Oil change/Clean the oil strainer ........................................... page 66

Reverse gear (ZF305). Filter change ............................................................ page 67

Every 50 hours / at least every 12 months

Fuel filter. Drain water/contamination ........................................................... page 57

Reverse gear (Twin Disc).

Seal. Lubrication ................................................. page 67

Every 50-400 hours / at least every 12 months

Engine oil Change

1)

....................................................................................... page 44

Oil filter / Bypass filter. Change

2)

.................................................................. page 45

1)

2)

Oil change intervals vary, depending on oil grade and sulphur content of the fuel. Please refer to page 43.

Change the filters during each oil change.

Every 200 hours / at least every 6 months

Reverse gear (ZF). Clean the oil strainer ...................................................... page 66

Every 200 hours / at least every 12 months

● Fuel pre-filter (twin filter). Inspection

1)

................................................................ page 59

1)

Only applies to the double filter: Check the pressure gauge and change the filter as necessary every 800 hours of operation, or at least once every 12 months.

Maintenance schedule

Every 400 hours / at least every 12 months

Crankcase breather. Change filter ....................................................................... page 41

Drive belts. Inspection/adjustment ...................................................................... page 42

Coolant (corrosion protection mixture). Topping up

1)

........................................... page 48

Zinc anodes. Check/change ................................................................................ page 52

Seawater pump. Check/change the impeller ........................................................ page 53

Batteries. Checking the electrolyte ...................................................................... page 63

Reverse gear (ZF). Oil change / Change oil filter ................................................. page 67

1)

Top up with ½ litre corrosion protection fluid. IMPORTANT! This only applies if the cooling system is filled with a corrosion protection mixture (not a glycol mixture).

Every 800 hours / at least every 12 months

Valve clearance. Inspection/adjustment .......................................................... not shown

Clean the insert in the heat exchanger and in the reverse gear oil cooler ..... pages 54/55

Seawater filter. Checking/cleaning

2)

................................................................... page 53

Fuel pre-filter. Change filter insert ....................................................................... page 59

Fuel fine filter. Changing. Venting the fuel system ............................................ pages 57

1)

2)

Not at same time as coolant change.

Adjust the time by experience, after a period of operation.

Every 1000 hours / at least every 6 months

● Reverse gear (Twin Disc ). Oil change / Clean the oilstrainer ........................... page 66

Every 2000 hours

Turbocharger. Inspection ................................................................................. not shown

Every 12 months

EVC system. Inspection with diagnosis tool ................................................... not shown

Engine and reverse gear. General inspection .................................................. not shown

Air filter insert. Change ..................................................................................... page 41

Engine and reverse gear. Cleaning/painting ..................................................... not shown

Every 24 months

Cooling system Inspection/cleaning ................................................................ not shown

Coolant. Change ............................................................................................... pages 49

Newly renovated engine

After the first 150 hours

Valve clearance. Inspection ............................................................................ not shown

39

Maintenance

This chapter contains general technical information and instructions for carrying out the specified maintenance points. Read them carefully before starting work. The times when maintenance points need to be attended to are given in the previous chapter: Maintenance schedule

WARNING! Read through the safety advice for care and maintenance work in the Safety information chapter before you start work.

WARNING! Care and maintenance work should be done with the engine stopped unless otherwise specified.

Stop the engine before opening or removing the engine hatch/hood. Make it impossible to start the engine by removing the start key and cutting the system voltage with the main switches.

Engine, general

General inspection

Make it a habit to give the engine and engine bay a

“visual” check before driving before starting the en-

gine and after operation when you have stopped the

engine. This will help you to discover if anything abnormal has happened, or is about to happen.

Look especially carefully at oil, fuel and coolant leakage, loose screws, worn or poorly tensioned drive belts, loose connections, damaged hoses and electrical cables. This inspection only takes a few minutes and can prevent serious malfunctions and expensive repairs.

WARNING! Deposits of fuel, oils and grease on the engine or in the engine bay are a fire hazard and must be removed as soon as they are discovered.

IMPORTANT! If you discover a leakage of oil, fuel or coolant, investigate the cause and fix the fault before you start the engine.

IMPORTANT! Observe the following when cleaning with a high pressure washer: Never aim the water jet at seals, rubber hoses or electrical components. Never use a high pressure washer for engine cleaning.

40

Maintenance. Engine, general

Crankcase ventilation. Changing the filter

Remove the air filter cover. Remove the old air filter.

Clean the air filter cover/housing if necessary. Take care not to allow impurities to enter the engine. Fit the new air filter and the air filter cover.

Air filter. Change

1. Remove the old filter. Be careful to ensure that no contamination gets into the engine.

2. Install a new filter and tighten the hose clamps carefully.

IMPORTANT! Scrap the old filter. It must not be cleaned.

41

Maintenance. Engine, general

3

1

Drive belts. Inspection/adjustment

WARNING! Stop the engine before doing any maintenance work.

General information

Check belt tension and condition regularly. A belt which is to tense can damage the bearings and a belt which is too loose can slip.

IMPORTANT! Always change a belt which looks worn or cracked (belts which operate in pairs must be changed together).

Adjusting the alternator belt

The standard alternator, plus the extra alternator if installed, are driven by a Poly-Vee belt each, for best function and service life.

1. Undo the fixing screw (1) and tighten it again tightening torque 30 Nm.

Adjusting the alternator belt

1. Remove the protective cover over the alternator drive belt.

2. Undo the fixing screws (1) and (2).

3. Srew a M10 nut (3) to the tensioner screw so the spring is pressed together and it is possible to loosen the alternator belt

4. Change the alternator belt. Remove the nut (3).

5. Tighten the fixing screw (1) tightening torque 30

Nm and fixingscrew (2) tightening torque 20 Nm.

6. Install the protective cover over the alternator drive belt.

7. Let the engine run on idle. Stop the engine after a few minutes.

8. Adjust the alternator belt by undoing the the fixing screw (1) and tighten it again, tightening torque 30

Nm.

2

42

Maintenance. Lubrication system

Lubrication system

Oil change intervals can vary from 50 to 400 hours, depending on oil grade and sulphur content of the fuel. Note

that oil change intervals must never exceed a period of 12 months.

If you want longer oil change intervals than given in the table below, the condition of the oil must be checked by the oil manufacturers through regular oil testing.

Oil grade

VDS-3

VDS-2 and ACEA E5

VDS-2 and Global DHD-1

VDS and ACEA E3 2)

ACEA: E4, E3, E2

API: CF, CF-4, CG-4

up to 0.5%

Sulphur content in fuel, by weight

0.5–1.0% more than 1.0%

1)

Oil change interval: Reached first in operation:

400 hr. or 12 months.

200 hr. or 12 months.

100 hr. or 12 months.

300 hr. or 12 months.

150 hr. or 12 months.

200 hr. or 12 months.

100 hr. or 12 months.

75 hr. or 12 months.

50 hr. or 12 months.

NOTE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the quality requirements above.

1)

2)

If sulphur content is > 1.0% by weight, use oil with TBN > 15.

Lubrication oil must comply with both requirements.

Note. API: CG4 or CH4 can be approved in markets outside Europe.

VDS = Volvo Drain Specification

ACEA = Association des Constructeurs Européenne d’Automobiles

API = American Petroleum Institute

TBN = Total Base Number

−−−−−30 −−−−−20 −−−−−10

±0 +10 20 30 40 o C

−−−−−25

o

C

−−−−−15

o

C

SAE 10W/30

SAE 5W/30

SAE 15W/40

−−−−−10

o

C

SAE 20W/30

±0 o

C

SAE 30

+10 o

C

SAE 40

−−−−−22 −−−−−4 +++++14

32 50 68 86 104 o

F

Viscosity

Select the viscosity from the table below.

Note. The temperature values refer to stable ambient temperatures.

* Refers to synthetic or semi-synthetic oils.

Oil change volume

Please refer to the “Technical Data” chapter.

43

Maintenance. Lubrication system

Oil level. Checking and filling

The oil level must be inside the marked area on the dipstick (1) and should be checked daily before the first start.

Top up the oil through the filling hole on the side of the engine (2) . Check that the correct level has been achieved. But wait a few minutes to allow the oil to run down into the sump.

IMPORTANT! Do not fill up above the maximum oil level. Only use a recommended grade of oil

(please refer to previous page).

Engine oil. Change

Always observe the recommended oil change interval.

1. Warm the engine up (this makes it easier to suck the oil up from the sump). Then stop the engine.

WARNING! Hot oil and hot surfaces can cause burns.

2. Connect the suction pipe of the oil drain pipe to the drain pipe. Pump up the oil.

3. Change the oil filter and bypass filter at each oil change (please refer to the instructions on the next page).

4. Fill up with oil to the correct level through the filling hole on the side of the engine (please refer to the “Technical Data” chapter for oil volume).

IMPORTANT! Only use a recommended grade of oil (please refer to previous page).

5. Start the engine and let it idle. Check that the low oil pressure warning lamp goes out and that no leakage occurs by the filters.

WARNING! Working with, or going close to a running engine is a safety risk.Watch out for rotating components and hot surfaces.

6. Stop the engine. Wait a few minutes before checking the oil level. Top up as necessary.

NOTE! Hand the old oil in to a re-cycling station.

44

2

2

1

Maintenance. Lubrication system

Oil filter and bypass filter. Change

Change the oil filter and bypass filter during each oil change.

Remember to hand the old filters in to a re-cycling station.

WARNING! Hot oil and hot surfaces can cause burns.

1. Put a suitable vessel underneath the filter drip pan to avoid oil spillage.

2. Clean the filter bracket.

3. Unscrew the bypass filter (1) and the oil filters (2) with a suitable extractor.

4. Check that the mating surfaces on the filter brackets are clean, and that no residue from the old seals remains.

5. Moisten the seals on the new filters with engine oil.

6. Screw the filters on by hand until the rubber seals just touch the mating surface on the filter brackets. Then tighten a further 1/2 to 3/4 turn.

7. Start the engine (low idle) and check that no leakage occurs. Check the oil level once the engine has stopped.

45

Maintenance. Freshwater system

Freshwater system

The freshwater system is the internal cooling system of the engine. This is a closed system and shall always be filled with coolant which protects the engine from internal corrosion and from frost damage if the climate requires it.

The circulation pump is responsible for circulation in the freshwater system. The thermostat begins to open at a certain temperature and is fully open when the engine has reached its normal operating temperature. When the thermostat opens, the hot coolant is directed through the heat exchanger, where heat is lead away via the seawater system (please refer to the next section).

Coolant. General information

The freshwater system shall always be filled with coolant which protects the engine from internal corrosion and from frost damage if the climate requires it.

The corrosion protection additives become less effective as time passes, which means that the coolant must be changed.

IMPORTANT! Never use water by itself as the coolant. Change the coolant as recommended in the maintenance schedule.

Water quality

The coolant must be mixed with clean water complying with ASTM D4985 to avoid any risk of blockage in the cooling system. If there is any doubt about water purity, use distilled water or ready-mixed coolant

ASTM D4985:

Total solid particles ...................................... < 340 ppm

Total hardness ............................................. 9.5° dH

Chloride ......................................................... < 40 ppm

Sulphate ........................................................ < 100 ppm pH value ........................................................ 5.5– 9

Silica .............................................................. < 20 mg SiO

2

/l

Iron ................................................................ < 0.10 ppm

Manganese ................................................... < 0.05 ppm

Conductivity .................................................. < 500 µS/cm

Organic content, COD

Mn

.............................. < 15 mg KMnO

4

/l

46

Maintenance. Freshwater system

Frost protection mixture

If there is a risk of frost, use a mixture of 50% Volvo

Penta anti-freeze (glycol) and 50% water (to ASTM

D4985). This mixture prevents against frost bursting down to about – 40°C (– 40°F), and should be used all year round.

IMPORTANT! Even if the temperature never falls down as far as – 40°C (– 40°F), use the above-mentioned mixture ratio to give full corrosion protection.

Mix the glycol with water in a separate vessel before filling the system.

WARNING! Glycol is poisonous (dangerous to drink).

IMPORTANT! Do not use alcohol in the cooling system.

Corrosion protection mixture

When there is never any risk of frost, water (to ASTM

D4985), mixed with Volvo Penta anti-corrosion additive, can be used as a coolant.

We recommend that an anti-freeze mixture should be used all year round, irrespective of the climate.

Mix, following the instructions on the package. Warm the engine up after filling, to give the additive the best effect.

If operation time exceeds 400 hours per annum, the corrosion protection of the coolant must be topped up with 1/2 liter of anti-corrosion additive every 400 hours of operation.

WARNING! Anti-corrosion additive is poisonous

(dangerous to drink).

IMPORTANT! Never mix anti-corrosion additive with anti-freeze (glycol). This can cause foaming, and severely affect cooling ability.

47

Maintenance. Freshwater system

Coolant level. Inspection

WARNING! Never open the pressure cap when the engine is hot. Steam or hot coolant can spray out at the same time as the pressure which has built up is lost.

The coolant level should be about five centimetres (2”) below the pressure cap sealing plane in the expansion tank.

If a separate expansion tank is installed, the coolant level must be between the MAX and MIN markings.

Top up the coolant as necessary, following the description below.

Coolant. Filling

WARNING! Stop the engine and let it cool before filling. Hot fluids and hot surfaces can cause burns.

IMPORTANT! Top up with the same type of coolant as already used in the system.

Topping up

Fill up with coolant to the correct level via the filling hole on the expansion tank. Fill slowly, to allow the air which is forced out a chance to flow out of the filling hole.

When you fill up an empty system, or if the coolant has fallen so low for any reason that it is no longer visible through the filling hole, fill up as in the description for “Filling a completely empty system”.

Filling a completely empty system

1. Mix a sufficient quantity of coolant in a vessel before filling. Please note that a heating system, tap water heater etc. if connected to the engine cooling system, mean that a correspondingly greater amount of coolant will be needed..

2. Also ensure that the heating system, tap water heater etc. if connected to the engine cooling system, are also vented (open the heater control valve).

48

Maintenance. Freshwater system

3. Fill up with coolant via the filling hole on the expansion tank.

Fill slowly, to allow the air which is forced out a chance to flow out of the filling hole.

4. Fill up with coolant to about 5 cm (2") below the filling cap seal plane.

5. Start the engine and let it idle for about 1 hour.

IMPORTANT! Do not start the engine until the system is vented and completely filled.

6. Stop the engine and let it cool. Check the coolant level. Top up as necessary.

1

F

F F

F

Coolant. Draining.

WARNING! Stop the engine and let it cool before draining. Hot fluids and hot surfaces can cause burns.

WARNING! Glycol is poisonous (dangerous to drink). Collect the old coolant and hand it to a recycling station for destruction. Drain the coolant via taps (F).

1. Remove the filling cap (1) from the expansion tank.

2. Connect a suitable hose to each drain tap. Open the taps and allow all the coolant to drain off into a suitable vessel.

IMPORTANT! Check that all coolant really does drain out. Deposits may need to be cleared away, inside the drain plug(s)/tap(s).

3. Also drain the heating system, tap water heater etc., if connected to the engine’s freshwater system.

4. Close all drain taps.

49

Maintenance. Freshwater system

Freshwater system. Flushing

The cooling system should be flushed when the coolant is changed, to avoid loss of cooling performance due to deposits in the cooling system.

1. Drain the coolant, as in the description on the previous page.

2. Put a hose into the filling hole in the heat exchanger and flush with fresh water.

3. Flush until the water which runs out of the drain points is clean.

4. Close all drain points when all coolant has run out.

5. Fill up with coolant, as in the description on the previous page.

50

Maintenance. Seawater system

Seawater system

The seawater system is the engine’s external cooling system. The seawater system sucks in water through the seawater inlet and pumps it through the heat exchanger and the reverse gear oil cooler. The system is protected from galvanic corrosion by means of zinc anodes located in the heat exchanger and the reverse gear oil cooler.

WARNING! There is a risk of water entry when you do any work on the seawater system (if the boat is in the water). If any hose, plug etc. located below the waterline is removed, water will flow into the boat.

Always close the sea cocks. If the boat does not have sea cocks, the water flow must be blocked in a safe manner. If this is not possible, the boat must be drawn up on land before work starts.

S

Seawater system. Draining.

The seawater system must be drained in cold weather, if there is a risk of frost, to prevent frost damage.

WARNING! Risk of water entry. Close the seawater cocks before doing any work on the seawater system.

An alternative to draining is to keep the engine bay above freezing temperature, by means of a fan heater which is approved for outdoor use.

Draining:

1. Close the sea cock.

2. Connect a hose to each drain tap before opening the tap (one at a time).

3. Open the drain taps/remove the drain plugs (S) and allow the water to run out.

Drain points:

– tap at rear of heat exchanger

– tap at rear of charge air cooler

IMPORTANT! Check that all water really does drain out. Deposits may need to be cleared away, inside the drain plug/tap.

4.

Also drain/empty any auxiliary equipment such as the seawater filter, flushing/bilge pump etc.

5.

Install the lid on the flushing/bilge pump if fitted.

Connect all hoses.

6.

Close/install all drain taps and plugs before you leave the boat.

S

51

Maintenance. Seawater system

Z

1

Zinc anodes. Check/change

WARNING! Risk of water entry. Close the sea cock before doing any work on the seawater system.

1. Close the sea cock.

2. Open the drain tap (1) on the heat exchanger and the tap (2) on the charge air cooler, and drain off the seawater.

3. Remove the zinc anodes (Z) in the heat exchanger and in the reverse gear oil cooler.

4. Check the zinc anodes and replace them if more than 50% of their original size has been used up.

If not, clean the zinc anodes with emery cloth to remove the oxide layer before re-installing them.

IMPORTANT! Use an emery cloth for cleaning. Do not use steel tools, since this could impair the galvanic protection.

5. Install the zinc anodes. Make sure that good metallic contact is obtained between the anode and the casting.

6. Close the drain taps (1 and 2).

7. Open the sea cock before starting the engine.

8. Check that no leakage occurs.

Z

2

52

Maintenance. Seawater system

Impeller. Check/change

WARNING! Risk of water entry. Close the sea cock before doing any work on the seawater system.

1. Remove the seawater pump lid, and pull the impeller out with water pump pliers.

2. Check the impeller. If any cracks or other defects are visible, the impeller must be changed.

3. Lubricate the pump housing and the inside of the lid with water-resistant grease (which is not aggressive to rubber). The impeller will be easier to work with if it is put in hot water prior to fitting.

4. Press the impeller in with a circular motion

(counter clockwise). The shaft of the pump has an internal thread (M8). Screw a stud into the end of the shaft and press the impeller in using a washer and nut. Fit the cover, using a new O-ring.

5. Open the sea cock.

IMPORTANT! Always carry a spare impeller on board.

Seawater filter. Inspection/cleaning

The seawater filter is optional equipment.

If the water where the boat is operated contains a lot of contamination, weed etc., check the filter more frequently than specified in the maintenance schedule.

There is otherwise a risk that the filter would be blocked, which would make the engine overheat.

WARNING! Risk of water entry. Close the seawater cock before doing any work on the seawater system.

1. Close the sea cock.

2. Remove the lid (1) and lift up the insert.

3. Clean the insert and the housing (2).

4. Install the components as in the illustration.

Check the O-ring. Change as necessary.

5. Open the sea cock and check carefully that no leakage occurs.

53

Maintenance. Seawater system

Inlet manifold. Checking the drain hole

Water can condense in the aftercooler during operation. The condensate is drained via a hole in the charge air cooler.

Check that the drain hole is not blocked.

WARNING! If a large amount of water flows out of the drain hole, from the inlet manifold, the aftercooler must be removed and proof tested.

This task must be done by an authorised workshop.

54

1

Oil cooler, reverse gear. Cleaning

WARNING! Risk of water entry. Close the seawater cock before doing any work on the seawater system.

If you suspect leakage, remove the oil cooler from the engine and proof test it separately.

This task must be done by an authorised workshop.

1. Open the drain tap by the charge air cooler.

2. Remove the cooling water hoses to and from the oil cooler.

3. Empty the oil cooler from oil.

4. Remove both end caps (1) and press out the insert.

5. Wash the insert in white spirit etc., and blow it clean with compressed air (or leave it to drain). Clean the insides of the tubes and the end walls of the insert with suitable brushes. Also clean the housing.

6. Install the components in reverse order. Use new, greased seal rings.

7. Close the drain tap and open the seawater cock.

Start the engine and check carefully that no leakage occurs.

Maintenance. Seawater system

Heat exchanger. Cleaning

This job requires specialist knowledge, and should be done by an authorised workshop.

WARNING! Risk of water entry. Close the sea cock and drain off the water in the seawater and freshwater systems before doing any work on the cooling system.

Clean it at the first signs of blockage, slowly increasing engine temperature and increased seawater pressure.

First check/clean the seawater filter. Also check the impeller in the seawater pump.

It is frequently enough to clean the pipes in the heat exchanger insert, once the end covers have been removed. This means that the freshwater system does not need to be drained.

Heat exchanger insert. Cleaning

1. Remove the heat exchanger from the engine.

2. Remove both end covers and the screws holding the insert.

3. Press the insert out.

Note. The insert can only be pressed out forwards since it has a flange at the rear edge.

4. Clean the entire length of the heat exchanger insert, using suitable brushes. Flush the pipes and keep brushing until no more loose particles come away with the water. Also flush and clean the insert externally.

5. Clean the housing and the end covers.

6. Re-install the insert and both end caps. Use new seal rings.

7. Install the heat exchanger on the engine. Use new seal rings.

8. Fill the engine up with coolant. Open the sea cock.

9. Start the engine and check carefully that no leakage occurs.

55

Maintenance. Fuel system

Fuel system

Only use the grades of fuel recommended in the fuel specification, see Technical Data. Always observe the greatest cleanliness during re-fuelling and work on the fuel system.

All work on the unit injectors of the engine must be carried out by an authorised workshop.

WARNING! Fire hazard. Work on the fuel system must be carried out when the engine is cold. Fuel spills on hot surfaces or electrical components can cause fires. Store fuel-soaked rags and other flammable material in fireproof conditions.

WARNING! Hot fuel can cause burns.

1 2

Fuel system venting

The fuel system must be vented, e.g. after changing fuel filter, if the fuel tank has been run dry and after long stops.

1. Put a suitable vessel underneath the hose.

2. Remove the protective cap from the venting nipple

(1) on the filter bracket.

3. Open the venting nipple and pump up fuel with the hand pump (2) until air-free fuel flows out. Tighten the venting nipple while fuel is flowing out.

4. Fold the hose back and put the protective cap back on the venting nipple.

5. Run the engine at idling speed for a couple of minutes to allow any remaining air out of the system. Make sure there are no leaks.

56

1

2

3

Maintenance. Fuel system

Fuel filter

Drain

WARNING! Hot fuel can cause burns.

1. Put a suitable vessel underneath the filter.

2. Open the tap (1) and drain water and contamination from the water trap (2) by pumping with the hand pump (3) until clean fuel flows out.

2 5

4

1

3

Change the filter elements

1. Close the fuel valve/valves.

2. Clean the filter bracket and put a suitable vessel under the filter.

3. Relieve pressure inside the filter by first opening the drain tap (1) at the bottom of the water trap and then the venting nipple (2) so the filter is drained off fuel.

WARNING! High pressure, open the tap with caution. Hot fuel can spray out in any direction.

4. Remove the cables (3) from the water trap (4) and unscrew the water trap from the filter.

5. Unscrew the filter, use a filter wrench if needed.

57

Maintenance. Fuel system

6. Clean the sealing surfaces of the filter bracket.

Make sure the filter is absolutely clean and the sealing surfaces are undamaged. Moisten the sealing rings with engine oil, including the inner rubber seal located inside the threaded hole in the center of the filter.

NOTE! Do not fill the new filter with fuel before assembly. Contaminations may get into the system and cause damage and malfunction.

7. Screw the new filter on by hand until the seal just touches the mating surface. Then tighten a further

1/2 turn. Reinstall the water trap and the cables.

Close the drain tap.

8. Open the fuel valve.

9. Open the venting nipple and pump up fuel with the hand pump (5) until air-free fuel flows out. Tighten the venting nipple while fuel is flowing out.

10. Remove the hose and put the protective cap back on the venting nipple.

11. Start the engine and check for leakages.

58

2

Maintenance. Fuel system

Fuel pre-filter

The fuel pre-filter supplied by Volvo Penta is available in single and twin versions.

Fuel pre-filter. Inspection

This filter is equipped with a pressure gauge (1) which indicates when it is time to change the filter insert.

Change the filer inserts as recommended in the maintenance schedule, or earlier if the pressure gauge shows a negative pressure of 6-10 (in. Hg) at idle or

16–20 (in. Hg) at full speed/loaded engine.

WARNING! Working with, or going close to a running engine is a safety risk. Watch out for rotating components and hot surfaces.

Drain

Place a receptacle under the filter. Drain off water and contaminants through the plug (2).

Fuel pre-filter. Changing the filter insert

The fuel pre-filter/water trap supplied by Volvo Penta is available in single and twin versions. The twin filter inserts can be changed with the engine running, by closing off fuel flow to one filter housing at a time.

Fuel flow is controlled by putting the handle (1) in the following positions:

A: Normal operation (both filters are connected).

B: The left filter insert can be changed.

C: The right filter insert can be changed.

D: Both filters shut off.

59

Maintenance. Fuel system

Change the filter elements

If the engine is not running close the fuel cocks on the tank before changing filters. If the engine is running cut off the flow of fuel with the handle (1) on the filter itself.

1. Place a receptacle under the filters and shut off the filter to be changed.

2. Undo the T-bolt (2) and remove the cover (3).

3. Take out the insert carefully while turning it.

4. Drain off water and contaminants through the drain plug (4).

5. Fit a new filter insert and fill the container with clean fuel.

6. Change the gasket on the cover and the O-ring on the T-bolt. Moisten the gasket and O-ring with fuel before assembling.

7. Fit the cover and tighten it by hand.

8. Wipe off any fuel from the heat shield.

9. Change the other filter in the same way.

10. Open the fuel cocks and put the handle in position for normal running. Make sure there are no leaks.

60

Maintenance. Electrical system

Electrical system

The engine is equipped with a 2-pole electrical system and an alternator. System voltage is 24V.

WARNING! Before any work is done on the electrical system, the engine must be stopped and the current cut by switching off the battery isolator. Shore current for engine heaters, battery chargers or other auxiliary equipment connected to the engine must be disconnected.

Main switches

The main switches must never be disconnected before the engine has been stopped. If the circuit between the alternator and the batteries is disconnected when the engine is running, the alternator and electronics can be damaged. The charging circuits must never be re-connected with the engine running, for the same reason.

IMPORTANT! Never disconnect the current with the main switches when the engine is running.

Fuses

The engine is fitted with two automatic circuit breakers. The circuit breakers cut the power if the system is overloaded.

If it is not possible to start the engine or if the instrument stops working while running, the circuit breaker may have been activated. Reset by pressing in the circuit breaker.

If the fault persists, read out the flash codes and take the necessary measures.

IMPORTANT ! Always investigate the cause of the overload!

EVC system

The EVC system is protected through the engine circuit breakers.

IMPORTANT ! Always investigate the cause of the overload!

Electrical connections

Check that electrical connections are dry, free from oxide and that they are securely tightened. Spray these connections as necessary with water-repellent spray (Volvo Penta universal oil).

61

Maintenance. Electrical system

Batteries. Maintenance

WARNING! Fire and explosion hazard. Batteries must never be exposed to open flames or sparks.

WARNING! Never confuse the positive and negative poles on the batteries. Risk of arcing and explosion.

WARNING! Battery electrolyte is highly corrosive. Always protect your eyes, skin and clothes when handling batteries. Always use protective goggles and gloves. If acid comes into contact with your skin, wash at once with soap and a lot of water. If you get battery acid in your eyes, flush at once with a lot of water, and get medical assistance at once.

Connection and disconnection

When you connect batteries, first connect the + cable

(red) to the + pole on the battery. Then connect the – cable (black) to the – pole on the battery

When you disconnect batteries, disconnect the – cable (black) first, then the + cable (red).

Cleaning

Keep the batteries dry and clean. Contamination and oxide on the batteries and battery poles can cause stray currents, voltage drop and discharge, especially in wet weather. Clean oxidation from the battery poles and terminals, using a copper brush. Tighten the terminals securely and grease them with terminal grease or Vaseline.

Electrolyte level

The electrolyte level should be 5–10 mm (0.2–0.4") above the cell plates in the battery. Top up with battery water as necessary. After topping up, the batteries should be charged by connecting them to a battery charger, or by running the engine at normal speed for

30 minutes.

NOTE! Some maintenance-free batteries have special instructions, which must be observed.

IMPORTANT! Never confuse the positive and negative poles on the batteries.

62

Maintenance. Electrical system

Batteries. Charging

WARNING! Explosion risk! Hydrogen is given off when batteries are charged. This forms an explosive mixture with air. A short circuit, open flame or spark could cause a violent explosion.

Ventilate well.

WARNING! Battery electrolyte is highly corrosive. Protect your eyes, skin and clothes. Always use protective goggles and gloves. If acid comes into contact with your skin, wash at once with soap and a lot of water. If you get battery acid in your eyes, flush at once with a lot of water, and get medical assistance at once.

Charge batteries if they have become discharged. If the boat is not used for a longer period of time, the batteries should be fully charged, then trickle charged

(please refer to the battery manufacturer’s recommendations). Batteries are damaged by being left discharged, and can also freeze and burst easier in cold weather.

IMPORTANT! Observe the instruction manual for the battery charger carefully. To avoid the risk of electrochemical corrosion when an external charger is connected, the battery cables in the boat should be removed from the batteries before the charger is connected.

During charging, unscrew the cell plugs but leave them in the plug holes. Ventilate well, especially if the batteries are charged in an enclosed space.

WARNING! Always switch off the charge current before undoing the charging clamps. Never confuse the positive and negative poles on the batteries. Risk of arcing and explosion.

Special instructions apply to so-called quick charg-

ers. Quick charging can shorten battery life, and should therefore be avoided.

63

Maintenance. Electrical system

Electric welding

Remove the positive and negative cables from the batteries. Then disconnect all cables connected to the alternator.

Also undo the connector for the EDC system from the control unit. Press in the lock tab, move the locking brace up and pull the connector out.

Always connect the welder earth clamp to the component to be welded, and as close as possible to the weld site. The clamp must never be connected to the engine or in such a way that current can pass through a bearing.

IMPORTANT! After you have finished welding, re-connect the EDC connector and the alternator terminals before you connect the battery cables.

Electrical installations

An incorrectly done electrical installation can generate stray currents from the electrical system. Stray currents, in their turn, can weaken the galvanic protection of the propeller, propeller shaft, rudder, keel etc., and cause damage because of electrochemical corrosion.

IMPORTANT! Work on the low voltage circuits in the boats should be done by a person with electrical training or knowledge. Installation or work on land current equipment must only be done by a competent electrician, in accordance with local regulations for mains electricity.

Always consider the following:

1. If land current is connected, its protective earth must be connected ashore, never to the boat. The land current installation must also be provided with an earth fault breaker (RCCB). The land current installation (transformer, inverter, battery charger etc. ) must be intended for marine use,

where the high voltage section is galvanically

isolated from the low voltage section.

2. Electrical cables must be installed and clamped in such a way that they are not exposed to chafing, damp or splashing water in the bilge.

64

1

Maintenance. Electrical system

3. Protective earth cables for radio, navigation equipment, rudder, bathing steps etc., or other equipment which uses protective earthing, shall be connected to a common earthing point which is not connected to the engine or reverse gear.

IMPORTANT! The engine and reverse gear must never be used as earth planes.

4. The starter battery shall have a main switch on the positive (+) side of the battery. The main switch must disconnect all loads and shall be switched off when the boat is not used.

5. If an extra auxiliary battery is used, a main switch

(1) must be connected between the auxiliary battery positive (+) pole and the fuse box for the boat’s electrical equipment. The main switch must disconnect all loads connected to the auxiliary battery and shall be switched off when the loads are not used.

All equipment connected to the auxiliary battery shall have separate switches.

A charge splitter (optional) should be installed to charge two independent battery circuits from the standard alternator.

65

Maintenance. Reverse gear

Reverse gear

2

1

Oil level. Checking and filling

Inspection

Check the oil level when the reverse gear has reached operating temperature, with the engine idling and the control lever in neutral.

WARNING! Working with, or going close to a running engine is a safety risk. Watch out for rotating components and hot surfaces.

Remove the dipstick (1), wipe it off and put it back into the reverse gear. Remove the dipstick again and check the oil level. The correct oil level is between the

MAX and MIN marks.

Filling

If necessary, top up with oil through the filler hole (2) on top of the reverse gear. Oil grade and volume:

Please refer to the “Technical Data” chapter.

IMPORTANT! Never over-fill the reverse gear.

The oil level must always be within the recommended range.

66

1

Oil strainer. Cleaning

WARNING! Working with, or going close to a running engine is a safety risk. Watch out for rotating components and hot surfaces.

1. Remove the lid/plug and carefully remove the strainer (1) from the housing.

IMPORTANT! Cleanliness! Dirt must not be allowed to get into the reverse gear.

2. Clean the strainer and other components in paraffin (kerosene).

3. Carefully put the components back again.

4. Tighten the plug/screw.

5. Start the engine and check carefully that no leakage occurs

Maintenance. Reverse gear

Oil. Change

1. Remove the dipstick. Connect a hose from the oil scavenging pump to the dipstick tube.

2. Suck the oil up and put the dipstick back.

3. Fill up with oil to the correct level. Oil grade and volume: Please refer to the “Technical Data” chapter.

IMPORTANT! Never over-fill the reverse gear.

4. Start the engine and run until the reverse gear has reached operating temperature.

5. Check the oil level, as in the description on the previous page.

Oil filter. Change

WARNING! Working with, or going close to a running engine is a safety risk. Watch out for rotating components and hot surfaces.

ZF reverse gear

1. Put a suitable vessel beneath the filter, to avoid oil spillage.

2. Unscrew the oil filter with a suitable extractor.

3. Clean the filter mating surface on the filter bracket.

4. The seal on the new filter with engine oil.

5. Screw the filter on by hand until the rubber seal just touches the mating surface on the filter bracket. Then tighten a further 3/4 turn.

6. Top up with oil.

7. Start the engine and check that no leakage occurs.

8. Check the oil level, as in the description on the previous page.

Seal. Lubrication

Applies only to TwinDisc reverse gear

Lubricate theseal on the output shaft bearing (with the lubricating nipple) using a hand gun and lithium-based grease such as Mobilux EP2, Statoil Uniway EP2N,

Texaco Multifak EP2, Q8 Rembrandt EP2.

67

Laying up/Launching

The boat must be laid up to prevent damage to the engine and other equipment if the boat is not used for two months or more. It is important that this is done in the correct manner, and nothing is forgotten. For this reason, we have compiled a check list of the most important points.

Before the boat is taken out of service for a long period of time, an authorised Volvo Penta workshop should over the engine and other equipment. Have any faults and deficiencies attended to, so that the equipment is in order, ready for the next start.

WARNING! Before you start to do any maintenance work, read the “Maintenance” chapter carefully. This contains instructions for doing work in a safe and correct manner.

Some conservation oils are flammable. Some are also dangerous to breathe. Ensure good ventilation. Use a face mask when spraying.

IMPORTANT! Observe the following when cleaning with a high pressure washer: Never aim the water jet at seals, rubber hoses or electrical components. Never use a high pressure washer for engine cleaning.

Inhibiting

Warm the engine up to normal operating temperature and check that the oil level in the reverse gear reaches the MAX mark on the dipstick. Stop the engine.

Max 8 month’s stoppage:

Change the oil and oil filter on the engine, then warm it up afterwards.

More than 8 month’s stoppage:

Conserve the lubrication and fuel systems with conservation oil.Please refer to the instruction

on the next page.

Check that the coolant offers sufficient frost protection. Top up as necessary. Alternatively, you can drain the coolant (also drain the coolant filter).

Close the sea cock and drain the water from the seawater system.

Remove the impeller from the seawater pump.

Store the impeller in a sealed plastic bag, in a cool place.

Drain any water and contamination from the fuel filters and fuel tank. Fill the fuel tank completely, to avoid condensation.

Disconnect the battery cables, clean and charge the batteries. Trickle charge the batteries while the boat is laid up. A poorly charged battery can

freeze and burst.

Clean the outside of the battery. Do not use a high pressure washer for engine cleaning. Touch up paint damage with Volvo Penta original paint.

Spray the components of the electrical system with water-repellent spray (Volvo Penta universal oil).

Check and rust-proof any control cables.

Put a note on the engine with the date, type of conservation and the conservation oil used.

Cover over the engine air inlet, exhaust opening and engine if necessary.

68

Laying up/Launching

Bringing out of storage

● Remove any covers from the engine, air inlet and exhaust pipe.

Top the engine up with the correct grade of oil, if necessary. Install a new oil filter if the filter was not changed during conservation.

Check that there is oil in the reverse gear.

Install new fuel filters and vent the fuel system.

Check the drive belt(s).

Check the condition of all rubber hoses, and retighten the hose clamps.

Close the drain taps and install the drain plugs.

Insert the impeller in the seawater pump, using a rotating movement (anti-clockwise).

Check the coolant level and anti-freeze. Top up as necessary.

Connect the fully charged batteries.

Open the sea cocks

Start the engine (if the boat is in the water) and warm up at a fast idle before loading the engine.

Check that no oil, fuel or coolant leakage occurs.

Check the oil level in the reverse gear. Top up as necessary.

Conservation of the lubrication and fuel systems for more than 8 months’ stoppage:

2

1

Drain the oil from the sump and engine and fill the engine up with conservation oil* to just above the MIN marking on the dipstick.

Connect the fuel supply (1) and return fuel pipes

(2) to a jerrican filled with 1/3 conservation oil* and 2/3 diesel fuel.

Vent the fuel system.

Start the engine and run at a fast idle until about

2 litres (0.5 US gal.) have been used. Stop the engine and connect the ordinary fuel pipes.

Empty the conservation oil out of the engine

Follow the other instructions on the previous page.

* Conservation oils are sold by oil companies.

69

Fault code register

WARNING! Read the safety precautions for maintenance and service in the ”Safety information” chapter before starting work.

IMPORTANT! Certain fault codes are related to engine type and can thus be different from engine to engine.

Explanation

Fault codes are presented in numerical order, with information about reason, system reaction and proposed measures to be taken.

1.

1.5.6

2.

O/R

3.

1. Current fault code which is flashed out on the diagnostic button display.

2. Current warning lamp which flashes during an alarm. O/R means that an orange or red lamp flashes.

3. Audible warning(buzzer)

1.1

Explanation: No fault codes are stored and no malfunctions have been registered.

1.2.1

R

Explanation: Water in water trap in fuel filters.

Reaction: None

Action:

• Empty the water trap underneath the fuel filters. Please refer to “Maintenance: Fuel system”

• Contact a Volvo Penta workshop if the fault remains.

1.2.2

O

Explanation: Coolant level too low.

Reaction: Engine power is reduced.

Action:

• Check coolant level. Please refer to “Maintenance: Lubrication system”

• Check that no leakage occurs in auxiliary equipment connected to the engine cooling system.

• Contact a Volvo Penta workshop if the fault remains.

70

1.2.4

O

Explanation: Fault in engine speed sensor on flywheel.

Reaction: Engine power is reduced. Engine is difficult to start.

Action:

• Please contact a Volvo Penta workshop.

1.2.5

O

Explanation: Fault in engine speed sensor on camshaft.

Reaction: Engine is difficult to start.

Action:

• Please contact a Volvo Penta workshop.

1.2.8

R

Explanation: Excessive exhaust temperature

Reaction: Engine power is reduced.

Action:

• Please contact a Volvo Penta workshop.

1.2.9

O

Explanation: Fault in engine speed sensor.

Reaction: Engine power is reduced.

Action:

• Please contact a Volvo Penta workshop.

1.4.6

O

Explanation: Starter failure.

Reaction: Engine can not be started.

Action:

• Please contact a Volvo Penta workshop.

1.4.9

O/R

Explanation: Sensor fault in engine.

Reaction: Engine power is reduced.

Action:

• Please contact a Volvo Penta workshop.

Fault code register

71

Fault code register

1.5.3

O

Explanation: Oil pressure difference too high.

Reaction: Engine power is reduced.

Action:

• Check the oil level. Please refer to “Maintenance: Lubrication system”.

• Check that the oil filters are not blocked. Please refer to “Maintenance: Lubrication system”.

• Check that no leakage occurs.

• Contact a Volvo Penta workshop if the fault remains.

1.5.6

R

Explanation: Charge air pressure too high.

Reaction: Engine power is reduced.

Action:

• Please contact a Volvo Penta workshop.

1.5.7

R

Explanation: Coolant pressure too low.

Reaction: Engine power is reduced.

Action:

• Check the coolant level. Please refer to Please refer to “Maintenance: Fresh water system”.

• Check that the sea water filter is not blocked. Please refer to “Maintenance: Sea water system”.

• Check the impeller in the sea water pump. Please refer to “Maintenance: Sea water system”.

• Check that no leakage occurs.

• Check that no leakage occurs in auxiliary equipment connected to the engine cooling system.

• Contact a Volvo Penta workshop if the fault remains.

1.5.8

R

Explanation: Excessive engine oil temperature

Reaction: Engine power is reduced.

Action:

• Check the oil level. Please refer to ”Maintenance: Lubrication system”.

• Check that the oil filters are not blocked. Please refer to ”Maintenance: Lubrication system”.

• Check that no leakage occurs.

• Contact a Volvo Penta workshop if the fault remains.

72

Fault code register

1.5.9

R

Explanation: Piston cooling level too low.

Reaction: Engine power is reduced.

Action:

• Check the oil level. Please refer to “Maintenance: Lubrication system”.

• Check that the oil filters are not blocked. Please refer to “Maintenance: Lubrication system”.

• Check that no leakage occurs.

• Contact a Volvo Penta workshop if the fault remains.

1.6.1

R

Explanation: Excessive coolant temperature .

Reaction: Engine power is reduced.

Action:

• Check coolant level. Please refer to “Maintenance: Fresh water system”.

• Check that the sea water filter is not blocked. Please refer to “Maintenance: Sea water system”.

• Check the impeller in the sea water pump. Please refer to “Maintenance: Sea water system”.

• Check that no leakage occurs.

• Contact a Volvo Penta workshop if the fault remains.

1.6.2

R

Explanation: Excessive charge air temperature.

Reaction: Engine power is reduced.

Action:

• Please contact a Volvo Penta workshop.

1.6.6

R

Explanation: Oil pressure to low.

Reaction: Engine power is reduced.

Action:

• Check the oil level in the engine. Please refer to “Maintenance: Lubrication system” to check and top the oil up.

• Check that the air filters are not blocked. Please refer to “Maintenance: Lubrication system”

• Check that no leakage occurs.

• Contact a Volvo Penta workshop if the fault remains.

73

Fault code register

1.6.7

O

Explanation: Incorrect fuel pressure.

Reaction: Engine power is reduced.

Action:

• Check the fuel level.

• Open the fuel taps and check that no leakage occurs.

• Check that the fuel filters are not blocked. Please refer to “Maintenance: Fuel system”.

• Contact a Volvo Penta workshop if the fault remains.

1.6.8

O

Explanation: Oil level too low in the engine. In rough following seas or head seas, the system can incorrectly sense that the engine is too low. If this happens, acknowledge the fault, and check the points below for safety reasons.

Reaction: Engine power is reduced.

Action:

• Check the oil level in the engine. Please refer to “Maintenance: Lubrication system” to check and top the oil up.

• Check the oil filters. Please refer to “Maintenance: Lubrication system”.

• Check that no leakage occurs.

• Contact a Volvo Penta workshop if the fault remains.

1.6.9

O

Explanation: Sea water pressure too low.

Reaction: Engine power is reduced.

Action:

• Check that the sea water filter is not blocked. Please refer to “Maintenance: Sea water system”.

• Check the impeller in the sea water pump. Please refer to “Maintenance: Sea water system”.

• Check that no leakage occurs.

• Contact a Volvo Penta workshop if the fault remains.

1.7.1–1.7.6

O

Explanation: Injector system failure, injector 1-6.

Reaction: Engine power is reduced.

Action:

• Please contact a Volvo Penta workshop.

1.8.8

O

Explanation: Battery voltage failure.

Reaction:

Action:

• Check battery fluid level.

• Check belt tension.

• Please contact a Volvo Penta workshop.

74

Fault code register

1.9.9

O/R

Explanation: Internal system fault in engine.

Reaction: Engine power is reduced.

Action:

• If the engine can not be operated from the chosen control panel, use an alternative control panel.

• Please contact a Volvo Penta workshop.

2.1.2

R

Explanation: Incompatible engine type.

Reaction: System does not work.

Action:

• Check the driveline installation.

• Please contact a Volvo Penta workshop.

2.1.8

O

Explanation: External unit is not correctly configured.

Reaction: The EVC system does not work.

Action:

• Check the driveline installation.

2.3.5

O

Explanation: Faulty reverse gear.

Reaction: Engine power is reduced.

Action:

• Check oil level. Please refer to Please refer to “Maintenance: Lubrication system”

• Check that the oil strainer is not blocked. Please refer to “Maintenance: Lubrication system”

• Check that no leakage occurs.

• Please contact a Volvo Penta workshop if the fault remains.

2.4.5

R

Explanation: Faulty solenoid, primary.

Reaction: Can not engage a gear.

Action:

• Please contact a Volvo Penta workshop.

2.4.7

R

Explanation: Faulty solenoid, secondary

Reaction: Can not engage a gear.

Action:

• Please contact a Volvo Penta workshop.

75

Fault code register

2.7.3

O

Explanation: Faulty slipping valve function in reverse gear.

Reaction: Can not operate the engine with the slipping control.

Action:

• Please contact a Volvo Penta workshop.

2.9.9

O/R

Explanation: Internal fault in the EVC system.

Reaction: Engine power is reduced.

Action:

• If the engine can not be operated from the chosen control panel, use an alternative control panel.

• Please contact a Volvo Penta workshop

3.1.2

O

Explanation: Faulty control lever detection.

Reaction: It is not possible to calibrate the control lever.

Action:

• Check that the control lever is connected.

• Check that the lever combination is approved by Volvo Penta.

• Please contact a Volvo Penta workshop if the fault remains.

3.1.3

O

Explanation: Too short lever movement between calibration points.

Reaction: It is not possible to calibrate the control lever.

Action:

• Check that there is enough room, so that the control lever can reach the end points.

• Check the mechanical connection to the potentiometer.

• Switch the ignition off, and repeat the calibration procedure.

• Check that the control levers are approved by Volvo Penta.

• Please contact a Volvo Penta workshop if the fault remains.

3.1.4

O

Explanation: Incorrect lever calibration procedure.

Reaction: It is not possible to calibrate the control levers.

Action:

• Switch the ignition off, and repeat the calibration procedure.

• Check that the control levers are approved by Volvo Penta.

• Please contact a Volvo Penta workshop if the fault remains.

76

Fault code register

3.1.6

O

Explanation: Control lever is not calibrated.

Reaction: It is not possible to activate a control panel.

Action:

• Switch the ignition off, and repeat the calibration procedure.

• Check that the control levers are approved by Volvo Penta.

• Please contact a Volvo Penta workshop if the fault remains.

3.2.5

O

Explanation: Fault in EVC control panel.

Reaction: EVC control panel is out of order.

Action:

• If the engine can not be operated from the chosen control panel, use an alternative control panel.

• Please contact a Volvo Penta workshop.

77

Technical data

General

Type designation ............................................

D9-500 A, D9-575 A

Number of cylinders .......................................

6

Displacement .................................................

9.36 dm 3 , (571 in 3 )

Low idle speed ...............................................

550 (±25) rpm*

Valve clearance,, stationary, cold engine:

Setting values, inlet ..........................................................

0.30 mm (0.0118") exhaust ....................................................

0.50 mm (0.0197")

Check values, inlet ..........................................................

0.25–0.35 mm (0.0098–0.0138") exhaust ....................................................

0.45–0.55 mm (0.0177–0.0216")

Weight, engine with heat exchanger, without reverse gear, approx. .....................................

1,075 kg (2,370 lbs)

* At delivery, the idling speed is adjusted to 550 rpm.

If needed, the speed can be adjusted within the range 500–750 rpm.

Fuel system

Fuel specification

The fuel must comply with national and international standards for commercially supplied fuels, such as:

EN 590 (with national environment and cold requirements)

ASTM D 975 No 1-D and 2-D

JIS KK 2204

Sulfur content: Complying with legal requirements in each country.

Low density fuel (urban diesel in Sweden and city diesel in Finland) can cause a loss of up to 5% of power and an increase in fuel consumption of about 2–3%.

78

Technical data

Lubricating system

Oil capacity including oil filters, approx., no engine inclination ........................................

31 liters (8.2 US gals) engine inclination 6 o

.........................................

20 liters (5.3 US gals)

Oil pressure, hot engine, at normal running rpm ......................................

390 kPa (56.5 PSI ) at idling rpm (min.) ...........................................

220 kPa (31.9 PSI )

Oil grade .............................................................

Refer to specification on page 43

−−−−−30 −−−−−20 −−−−−10

±0 +10

Viscosity at different outside air temperatures ....

(Temperature based on constant outside air temperature.

* Refers to synthetic or semi-synthetic oil.

20 30

−−−−−25

o

C

−−−−−15

o

C

SAE 10W/30

SAE 5W/30

SAE 15W/40

−−−−−10

o

C

SAE 20W/30

±0 o

C

+10 o

C

SAE 30

SAE 40

40 o

C

−−−−−22 −−−−−4 +++++14

32 50 68 86 104 o

F

Cooling system

Freshwater system capacity including heat exchanger, approx. .............................................

39 liters (10.3 US gals)

Electrical system

System voltage ...................................................

12V/24V

AC generator, voltage/max. amperage ...................................

28V/60A output, approx. .................................................

1700W

Alternative generator equipment (accessory): voltage/max. amperage ...................................

28V/80A output, approx. .................................................

2800W

Alternative generator equipment (accessory): voltage/max. amperage ...................................

14V/115A output, approx. .................................................

1820W

Battery capacity ..................................................

2 connected in series 12V, max. 152Ah

Battery electrolyte density at +25°C (77°F): fully charged battery ........................................

1.28 g/cm 3 = 0.0462 lb/in 3 (1.24 g/cm 3 = 0.0448 lb/in 3 )* battery recharged at .........................................

1.24 g/cm 3 = 0.0448 lb/in 3 (1.20 g/cm 3 = 0.0434 lb/in 3 )*

* Note. Applies to batteries with tropical acid.

79

Technical data

Reverse gear

ZF

Type designation

Gear ratios

Angle (output shaft)

Oil capacity, approx

280A E

1,48:1; 1,77:1; 2,00:1

3,6 liter (0.9 US gal)

280IV

1,56:1; 1,77:1

14°

5,5 liter (1.4 US gal)

Oil grade (in accordance with API-system) CD, CE, CF, CF-4,CG-4,CH-4,

CI-4, SF, SG, SH,SJ, SL,

CD, CE, CF, CF-4,CG-4,CH-4,

CI-4, SF, SG, SH,SJ, SL,

Viscosity at oil temperature 66–85°C

Viscosity at oil temperature 85–100°C

Oil pressure during** neutral

Oil pressure during** operation

Weight, approx.

ACEA category A,B,E

SAE30*

SAE40*

0,08 – 0,12 MPa (11.6 – 17.4PSI)

2,3 – 2,4 MPa (333 – 348 PSI)

95 kg (209 lbs)

ACEA category A,B,E

SAE30*

SAE40*

0,02 – 0,20 MPa (2.9 – 29.0 PSI)

2,3 – 2,4 MPa (333 – 348 PSI)

125 kg (276 lbs)

* NOTE! Only single grade lubricating oil (only one viscosity number) may be used in the reverse gear.

Type designation

Gear ratios

Angle (output shaft)

Oil capacity, approx

Oil grade (in accordance with API-system)

Viscosity at oil temperature 66–85°C

Viscosity at oil temperature 85–100°C

Oil pressure during** neutral

305A E

1,48:1; 1,73:1; 2,04:1

5,5 liter (1,4 US gal)

CD, CE, CF, CF-4,CG-4,CH-4,

CI-4, SF, SG, SH,SJ, SL,

ACEA category A,B,E

SAE30*

SAE40*

0,02 – 0,08 MPa (2.9 – 11.6 PSI)

Oil pressure during** operation 2,3 – 2,4 MPa (333 – 348 PSI)

Weight, approx.

130 kg (286 lbs)

* NOTE! Only single grade lubricating oil (only one viscosity number) may be used in the reverse gear.

Twin Disc

Type designation

Gear ratios

Angle (output shaft)

Oil capacity, approx

Oil grade (in accordance with API-system)

Viscosity at oil temperature 66–85°C

Viscosity at oil temperature 85–100°C

Oil pressure during** neutral

Oil pressure during** operation

Weight, approx.

MG5075A E

1,53:1; 1,77:1; 2,05:1

5 liter (1.3 US gal)

CC, CD to pass TO-2 oil test,

MIL-L 2104 B and transmission fluid type C-3

SAE30*

MG5075IV

1,49:1; 1,72:1

15°

8,5 liter (22.4 US gal)

CC, CD to pass TO-2 oil test,

MIL-L 2104 B and transmission fluid type C-3

SAE30*

SAE40* SAE40*

0,17 – 0,27 MPa (24.6 – 39.2 PSI) 0,17 – 0,27 MPa (24.6 – 39.2 PSI)

2,2 MPa (319 PSI)

125 kg (276 lbs)

2,2 MPa (319 PSI)

155 kg (342 lbs)

* NOTE! Only single grade lubricating oil (only one viscosity number) may be used in the reverse gear.

** At oil temperature 82°C and 1800 rpm.

80

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Order Department

ARU 2, Dept. 64620

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Sweden

Fax: +46 31 545 772

Orders can also be placed via the Internet:

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Yes please,

I would like an operator’s manual in English at no charge.

Publication number: 7743774

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.

Ja,

ich will kostenlos eine Betriebsanleitung in deutscher Sprache erhalten.

Publikationsnummer: 7743788

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Anschrift

Schicken Sie den Coupon per Post oder als Fax an:

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Land

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Lieferdatum des Bootes gilt, danach bis zum Aufbrauchen des Lagerbestandes.

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Sí gracias,

deseo recibir gratuitamente un libro de instrucciones en español.

Número de publicación: 7743791

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http://www.volvopenta.com/ manual/coupon

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.

Publikationsnummer: 7743787

Namn

Adress

Land

Observera att erbjudandet gäller i 12 månader från båtens leveransdatum, därefter endast i mån av tillgång.

Stuur of fax de coupon naar:

Document & Distribution Center

Order Department

ARU 2, Dept. 64620

SE-405 08 Göteborg

Zweden

Fax: +46 31 545 772

U kunt ook bestellen via internet:

http://www.volvopenta.com/ manual/coupon

Ja graag,

Ik wil kosteloos een instructieboek in het Nederlands ontvangen.

Publicatienummer: 7743795

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.

Send kuponen med post eller fax til:

Document & Distribution Center

Order Department

ARU 2, Dept. 64620

SE-405 08 Göteborg

Sverige

Fax: +46 31 545 772

Bestillingen kan også ske på internet:

http://www.volvopenta.com/ manual/coupon

Ja tak,

jeg vil gerne gratis have en instruktionsbog på dansk

Publikationsnummer: 7743793

Navn

Adresse

Land

Bemærk at tilbudet gælder i 12 måneder fra bådens leveringsdato, Derefter kun så længe lager haves.

Postita tai faksaa kuponki osoitteella:

Document & Distribution Center

Order Department

ARU 2, Dept. 64620

SE-405 08 Göteborg

Ruotsi

Fax: +46 31 545 772

Tilauksen voi tehdä myös

Internetissä:

http://www.volvopenta.com/ manual/coupon

Kyllä kiitos,

haluan suomenkielisen ohjekirjan veloituksetta.

Julkaisunumero: 7743794

Nimi

Osoite

Maa

Huomaa, että tarjous on voimassa 12 kuukautta veneen toimituspäivämäärästä lukien ja sen jälkeen vain niin kauan kuin kirjoja riittää.

Envie o talão pelo correio ou um fax para:

Document & Distribution Center

Order Department

ARU 2, Dept. 64620

SE-405 08 Göteborg

Sweden

Fax: +46 31 545 772

A encomenda também pode ser feita através da Internet:

http://www.volvopenta.com/ manual/coupon

Sim, obrigado(a)!

Gostaria de receber gratuitamente um manual de instruções em português.

Número de publicação: 7743796

Nome

Endereço

País

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.

Ôá÷õäñïìÞóôå áõôü ôï êïõðüíé

óôçí ðáñáêÜôù äéåýèõíóç Þ

óôåßëôå ôï ìå öáî óôïí

ðáñáêÜôù áñéèìü öáî:

Document & Distribution Center

Order Department

ARU 2, 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

Íáé,

Èá Þèåëá Ýíá áíôßôõðï ôïõ åã÷åéñéäßïõ ÷ñÞóçò óôçí áããëéêÞ ãëþóóá ÷ùñßò êáìéÜ ÷ñÝùóç.

Áñéèìüò Ýêäïóçò: 7743797

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.

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