OPERATOR’S MANUAL - - Hjemmeside, nettbutikk, · PDF fileAB VOLVO PENTA IMPORTANT! ......

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OPERATOR’S MANUAL D9-500, D9-575

Transcript of OPERATOR’S MANUAL - - Hjemmeside, nettbutikk, · PDF fileAB VOLVO PENTA IMPORTANT! ......

OPERATOR’S MANUALD9-500, D9-575

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

Diese Betriebsanleitung ist auch aufDeutsch erhältlich.Ein Bestellcoupon ist am Ende der Betriebs-anleitung zu finden.

Ce manuel d’instructions peut êtrecommandé en français.Vous trouverez un bon de commande à la findu manuel d’instructions.

Este libro de instrucciones puede soli-citarse en español.El cupón de pedido se encuentra al final dellibro.

Den här instruktionsboken kan bestäl-las på svenska.Beställningskupong finns i slutet av instrukti-onsboken.

Questo manuale d’istruzioni può esse-re ordinato in lingua italiana.Il tagliando per l’ordinazione è riportato allafine del manuale.

Dit instructieboek kan worden besteldin het Nederlands.De bestelcoupon vindt u achter in het instruc-tieboek.

Denne instruktionsbog kan bestilles pådansk.Bestillingskupon findes i slutningen af in-struktionsbogen.

Tämän ohjekirjan voi tilata myös suo-menkielisenä.Tilauskuponki on ohjekirjan lopussa.

Este manual de instruções pode serencomendado em português.O talão de requerimento encontra-se no fimdo manual.

Áõôü ôï åã÷åéñßäéï ÷ñÞóçòäéáôßèåôáé óôçí áããëéêÞ ãëþóóá.

Ãéá íá ðáñáããåßëåôå Ýíá áíôßôõðï,óõìðëçñþóôå ôç öüñìá ðïõ âñßóêåôáé óôïôÝëïò áõôïý ôïõ åã÷åéñéäßïõ ÷ñÞóçò.

Welcome aboardVolvo Penta marine engines are used all over the world these days. They are used inall 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 enginessupplied, the name of Volvo Penta has come to symbolise reliability, technical inno-vation, first class performance and long life. We also believe that this is what you de-mand and expect from your Volvo Penta marine engine.

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

Yours sincerely

AB VOLVO PENTA

IMPORTANT! This instruction book does not describe controls or opera-tion of boats with water jet drive. If your boat is equipped with a VolvoPenta water jet, there is information about it in the handbook supplied withthe water jet.

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© 2004 AB VOLVO PENTAWe reserve the right to make modifications without prior notice.

Printed on environmentally compatible paper.(Cover: Department of transport (shipping), license 9809095)

Contents

Stopping the engine ........................................... 30Stop .................................................................... 30Cold weather precautions .................................... 31Laying up ............................................................ 31

In case of emergency .......................................... 32Starting with auxiliary batteries ........................... 32Emergency shifting ............................................. 33Fault-tracing ........................................................ 34Diagnostic function ............................................. 35Reading fault codes ............................................ 36Erasing fault codes ............................................. 37

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

Maintenance ........................................................ 40Engine, general ................................................... 40Lubrication system .............................................. 43Freshwater system ............................................. 46Seawater system ................................................ 51Fuel system ........................................................ 56Electrical system ................................................ 61Reverse gear ...................................................... 66

Laying up/Launching ......................................... 68Inhibiting ............................................................. 68Bringing out of storage ........................................ 69

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

Technical data ..................................................... 78Engine ................................................................ 78Reverse gear ...................................................... 80

Safety information ............................................... 3General information ............................................. 3Boat trips ............................................................ 4Care and maintenance ........................................ 6

Introduction ......................................................... 8Running in ........................................................... 8Fuel and oils ....................................................... 8Certified engines ................................................. 9Warranty information ........................................... 9Identification number ........................................... 10

Presentation ........................................................ 11Technical description .......................................... 11Orientation .......................................................... 12

Instruments ......................................................... 15Instruments ......................................................... 15Ignition lock ........................................................ 15Start/stop panel .................................................. 15Alarm display ...................................................... 16EVC control panel ............................................... 19

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

Starting the engine .............................................. 23Before starting .................................................... 23General information about starting ....................... 23Starting method .................................................. 24

Operation ............................................................. 26Reading instruments ........................................... 26Cruising speed .................................................... 27Synchronising engine speed ............................... 27Changing the control position .............................. 28Operation ............................................................ 29Propeller shaft brake ........................................... 30

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

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

Incorrect operation can lead to personal injury and damage to products or property. Soread the instruction book through very carefully before you start the engine or do anymaintenance or service work. If there is still something which is unclear or if you feel un-sure 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 thefact 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 se-rious malfunctions if the instruction is ignored.

IMPORTANT! Is used to call attention to things which could cause damage or malfunctionsto 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 inthe instruction book. Make sure that warning and information symbols on the engine areclearly visible and legible. Replace symbols which have been damaged or painted over.

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Safety information

Safety advice for boat operation

Your new boatRead the instruction books and other information care-fully, which came with your new boat. Learn to handlethe engine, controls and other equipment in a safe andcorrect manner.

If this is your first boat, or a type of boat you are notexperienced in using, we recommend that you prac-tice operating the boat in peace and quiet. Get toknow the way the boat reacts to sea and to the con-trols under different speed, sea and loading conditionsbefore you cast off for your first “real” maiden voyage.

Remember that the captain of every boat is requiredby law to know and to observe applicable rules fortraffic and safety at sea. Get to know the rules whichapply to you and your waters, by contacting the rele-vant authority or sea safety organisation.

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

Accidents and near missesLife saving statistics show that inadequate care of bo-ats and engines, and deficiencies in safety equipmentare frequent causes of accidents and near misses at sea.

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

Daily checksMake it a habit to give the engine and engine bay avisual check before driving (before starting the en-gine) and after operation (when you have stoppedthe engine). This helps you to quickly discoverwhether any leakage of fuel, coolant, oil or any otherabnormal event has happened, or is about to happen.

ManoeuvringAvoid sudden or surprising rudder movements andgear shifting. There is a risk that passengers could fallover, or overboard.

A rotating propeller can cause severe injury. Checkthat there is nobody in the water before you engageforward / astern (reverse) drive. Never drive close tobathers or in areas where you could reasonably ex-pect that people could be in the water.

Fuel fillingThere is always a risk of fire and explosion during fuelfilling. Smoking is not permissible, and the engineshould be stopped.

Never over-fill the tank.

Shut the tank cap securely. Only use the fuel recom-mended in the instruction book. The wrong grade offuel can cause malfunctions or stop the engine. In adiesel engine, it can also cause the regulation rod tobind and the engine will over-rev, entailing a strongrisk of personal injury and machinery damage.

Do not start the engine.Do not start the engine if you suspect a fuel or LPGleak in the boat, close to explosive media, or if thereis a spillage of explosive media. An explosive environ-ment entails a risk of fire and/or explosion.

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Safety information

Carbon monoxide poisoningWhen a boat moves forwards, an area of low pressureair forms behind the boat. In adverse conditions, thislow pressure can be so strong that the boat’s own ex-haust fumes are sucked into the cockpit or cabin,which entails a risk of carbon monoxide poisoning forall aboard.

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

Most modern boats are designed so that the problemof low-pressure suction is very rare, however. If low-pressure suction does occur anyway, do not openhatches or ventilators in the forward part of the boat.Strangely enough, this makes the problem worse. Trychanging speed, trimming or load distribution instead.Also try taking down/opening the hood or modifying itin some other manner. Ask your boat dealer for adviceabout the best solution for your particular boat.

Remember● Safety equipment: Life jackets for everybody aboard, communication equipment, emergency rock-

ets, 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 andtools 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 notifychanged plans or delays.

● Inform everybody aboard about where the safety equipment is located, and how it works. Makesure 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, andwhere or how it is used etc. We recommend that you ask a regional boat or sea safety organisationfor more detailed maritime safety information.

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Safety information

Safety advice for care and maintenance work

PreparationsKnowledgeThe Instruction Book contains instructions for doingthe most common service and maintenance tasks in asafe and correct manner. Read them carefully beforestarting work.

Literature for more major tasks is available from yourVolvo Penta dealer.

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

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

Prevent the engine from being started by cutting thecurrent with the battery isolator, or remove the cablefrom the battery positive pole before you start servicework. Fix a notice by the helmsman’s seat to say thatwork is in progress.

Working with, or going close to a running engine is asafety risk. Loose clothes, long hair, fingers or drop-ped tools can catch on rotating components and cau-se severe injury. Volvo Penta recommends that allservice work which requires the engine to be runningshould be done by a Volvo Penta authorised workshop.

Lifting the engineThe existing lugs on the engine (or reverse gear)should be used for lifting. Always check that the liftingdevices are in good condition and that they have thecorrect capacity for the lift (engine weight togetherwith reverse gear and auxiliaries, if fitted). The engineshould be lifted with an adjustable lifting boom for safehandling. All chains or cables should be parallel toeach other and should be as square as possible to thetop of the engine. Please note that auxiliary equip-ment installed on the engine could change its centreof gravity. Special lifting devices may then be neededto obtain the correct balance and safe handling. Neverdo any work on an engine which just hangs from a lift-ing device.

Before startingRe-install all guards which have been removed duringservice work, before re-starting the engine. Make surethat there are no tools or other objects left behind onthe engine.

Never start a turbocharged engine without the air filterin place. The rotating compressor turbine in the turbo-charger can cause severe injury. There is also a riskthat foreign bodies could be sucked in and cause ma-chinery damage.

Fire and explosionFuel and lubrication oilAll fuel, most lubricants and many chemicals areflammable. Always read and observe the advice onthe packages.

Work on the fuel system must be done with the en-gine cold. Fuel leakage and spills on hot surfaces orelectrical components can cause fires.

Store oil and fuel soaked rags and other flammablematerial in a fire-proof manner. Oil soaked rags canself-ignite in certain circumstances.

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

Non-original spare partsComponents in fuel systems and electrical systemson Volvo Penta engines are designed and manufac-tured to minimise the risk of explosions and fire, in ac-cordance with applicable legal requirements.

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

BatteriesBatteries contain and give off an explosive gas, espe-cially when charged. This gas is very flammable andhighly explosive.

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

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

Start sprayNever use start spray or similar products as a startingaid. Explosions could occur in the inlet manifold. Dan-ger of personal injury.

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Safety information

Hot surfaces and fluidsA hot engine always offers the risk of burns. Be onyour guard against hot surfaces, such as the ex-haust manifold, turbocharger, sump, charge air pipe,starting heater, hot coolant and hot lubricating oil in pi-pes and hoses.

Carbon monoxide poisoningOnly start the engine in a well-ventilated area. Whenoperated in a confined space, exhaust fumes andcrankcase gases must be ventilated.

ChemicalsMost chemicals, such as glycol, rust preventer, con-servation oils, degreasers etc. are hazardous. Alwaysread and observe the advice on the packages.

Some chemicals, such as conservation oils, are flam-mable and also hazardous to breathe. Ensure goodventilation and use a protective mask for spraying. Al-ways read and observe the advice on the packages.

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

Cooling systemThere is always a risk of water entry when any work isdone on the seawater system. For this reason, stopthe engine and close the sea cocks before you start work.

Avoid opening the coolant filling cap when the engineis hot. Steam or hot coolant can spray out and causescalding.

If the filler cap, coolant hose etc., still has to be ope-ned or removed when the engine is hot, undo the fillercap slowly and carefully, to let the pressure out beforeremoving the filler cap completely and starting work.Note that the coolant can still be hot and cause scalding.

Lubrication systemHot oil can cause burns. Avoid skin contact with hotoil. Make sure that the oil system is de-pressurisedbefore starting work. Never start or run the engine with theoil filler cap removed, because of the risk of oil spillage.

Fuel systemAlways protect your hands when searching for leaks.Fluids which leak under pressure can force their wayinto body tissue and cause severe injury. Risk ofblood poisoning (septicaemia).

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

Electrical systemCut the currentBefore any work is done on the electrical system, theengine must be stopped and the current cut by switch-ing off the battery isolator. Shore current for engineheaters, battery chargers or other auxiliary equipmentconnected to the engine must be disconnected.

BatteriesBatteries contain a highly corrosive electrolyte. Pro-tect your eyes, skin and clothes during charging andother handling of batteries. Always use protective gog-gles and gloves. If this comes into contact with yourskin, wash at once with soap and a lot of water. If youget battery acid in your eyes, flush at once with a lotof water, and get medical assistance at once.

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IntroductionThis instruction book has been prepared to give you the greatest possible benefit from your Volvo Penta marineengine. 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 safemanner 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 ifyou sell your boat.

Environmental careAll 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 toenjoy the sunlight without fearing for our health. Unfor-tunately, this is not self-evident these days, it issomething all of us must work hard for.

As a manufacturer of marine engines, Volvo Pentahas particular responsibility and for this reason, envi-ronmental care is a core value in our product develop-ment. Volvo Penta has a wide engine programme the-se days, where considerable progress has been madein reducing exhaust fumes, fuel consumption, enginenoise etc.

We hope that you will be want to preserve these val-ues. Always observe the advice in the instructionbook about fuel grades, operation and maintenance, toavoid unnecessary environmental impact. Please con-tact your Volvo Penta dealer if you notice any chang-es such as increased fuel consumption or increasedexhaust smoke.

Moderate your speed and distance so that wake andnoise do not disturb or damage animal life, moored bo-ats, jetties etc. Leave the archipelago and harbours inthe same state you would like to find them. Remem-ber to always hand in drained oil, coolant, paint andwash residue, used batteries etc. for destruction at arecycling station.

If we all pull together, we can make a valuable contri-bution to the environment together.

Higher oil consumption is normal during the running inperiod. For this reason, check the oil level more fre-quently than normally recommended.

After the first period of operation, the specified warran-ty inspection “First service inspection” can be done.For more information: Please refer to the Warrantyand Service book.

Fuel and oilsOnly use the fuels and oils recommended in the in-struction book. Other grades can cause malfunctions,increased fuel consumption and eventually evenshorten the life of the engine.

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

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

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

Service and spare partsVolvo Penta marine engines are designed for high reli-ability and long life. They are built to withstand a ma-rine environment, but also to have the smallest possi-ble environmental impact. Through regular service anduse of Volvo Penta original spare parts, these quali-ties are retained.

Volvo Penta’s world-wide network of authorised deal-ers is at your service. They are Volvo Penta productspecialists, and have the accessories, original spares,test equipment and special tools needed for high qual-ity service and repair work.

Always observe the maintenance intervals in the in-struction book, and remember to note the engine/transmission identification number when you orderservice and spare parts.

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Introduction

Certified enginesIf you own or operate an emission certified engine it isimportant to be aware of the following:

Certification means that an engine type has beenchecked and approved by the relevant authority. Theengine manufacturer guarantees that all engines madeof the same type are equivalent to the certified engine.

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

● Maintenance and service intervals recommendedby Volvo Penta must be complied with.

● Only Volvo Penta original spares may be used.

● Service on injection pumps, pump settings and in-jectors must always be done by an authorisedVolvo Penta workshop.

● The engine must not be converted or modified, ex-cept for the accessories and service kits whichVolvo Penta has approved for the engine.

● Installation changes to the exhaust pipe and en-gine air inlet ducts must not be done.

● No seals may be broken by unauthorised personnel.

The general advice in the instruction book about oper-ation, care and maintenance apply.

IMPORTANT! Delayed or inferior care/mainte-nance, and the use of non-original spares, meanthat AB Volvo Penta can no longer be responsi-ble for guaranteeing that the engine complieswith the certified version.

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

WarrantyYour new Volvo Penta marine engine is covered by a limited warranty, under the conditions and instruc-tions compiled in the Warranty and Service book.

Please note that AB Volvo Penta’s liability is limited to the specification in the Warranty and Servicebook. Read it carefully, as soon as possible after delivery. It includes important information about war-ranty cards, service, maintenance, which it is the responsibility of the owner to know, check and carryout. 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, ora customer copy of the warranty card.

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Introduction

Identification numbersThere are type plates on the engine and transmission, marked with identification numbers. This information mustalways be used as reference when service and spare parts are ordered. You will probably find similar plates onyour boat and its equipment. Note this information below, make a copy of the page and store it in a safe place, sothat 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 theidentification number on the type plate.

Warranty decalTHIS ENGINE TYPE IS CERTIFIED

ACC. TO IMO NOx TECHNICAL CODE

ANNEX VI

Engine

Product number (1)

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

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

Reverse gear

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

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

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

Certification decal

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

Together with a large swept volume and the EVC (Electronic Vessel Control), this results in a very smooth runningengine 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 manufac-tured of alloyed cast iron

– Induction hardened crankshaft journalled in sevenmain 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 rollerrocker 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 electromagneti-cally 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 ofspin-on type and by-pass filter

Turbocharging system

– Mid positioned turbo with twin entry chargersystem

Cooling system

– Seawater-cooled tubular heat exchanger

– Coolant systen prepared for hot water outlet

– Easily accessible seawater impeller pump in rearend

Electrical system

– 12V/115 A or 24V/80A alternator

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Presentation

D9-575 ZF305

1. Expansion tank2. Coolant filler cap3. Emergency stop4. Crankcase breather filter5. Fuel feed pump (hand pump)6. Fine fuel filter with watertrap7. Alternator8. Heat exchanger9. Control unit10. Oil sump11. Seawater pump12. Reverse gear ZF305A-E

D9-575 ZF305

1. By-pass filter for lubrication oil2. Lubrication oil filter3. Water-cooled exhaust outlet4. Turbocharger5. Air filter6. Oil cooler, reverse gear7. Starter motor8. Aftercooler9. Oil dipstick, engine10. Oil filler cap11. Coolant pump

3 5

6 7 8 9 10

1 2

11

4

7

1 2 3 5 6

8 9 10 11 12

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Orientation

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Presentation

D9-500 ZF280

1. Expansion tank2. Coolant filler cap3. Emergency stop4. Crankcase breather filter5. Fuel feed pump (hand pump)6. Fine fuel filter with watertrap7. Alternator8. Heat exchanger9. Control unit10. Oil sump11. Seawater pump12. Reverse gear ZF280A-E

D9-500 ZF280

1. By-pass filter for lubrication oil2. Lubrication oil filter3. Water-cooled exhaust outlet4. Turbocharger5. Air filter6. Oil cooler, reverse gear7. Starter motor8. Aftercooler9. Oil dipstick, engine10. Oil filler cap11. Coolant pump

7

1 2 3 5 6

8 9 10 11

3 5

6 7 8 9 10

1 2

12

11

4

4

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Presentation

D9-500 MG5075

1. Expansion tank2. Coolant filler cap3. Emergency stop4. Crankcase breather filter5. Fuel feed pump (hand pump)6. Fine fuel filter with watertrap7. Heat exchanger8. Aftercooler9. Control unit10. Oil sump11. Seawater pump12. Reverse gear MG5075A-E

D9-500 MG5075

1. By-pass filter for lubrication oil2. Lubrication oil filter3. Water-cooled exhaust outlet4. Turbocharger5. Air filter6. Oil cooler, reverse gear7. Starter motor8. Aftercooler9. Oil dipstick, engine10. Oil filler cap11. Coolant pump

7

1 2 3 5 6

8 9 10 11 12

4

3 5

6 7 8 9 10

1 2

11

4

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InstrumentsThis 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, oryou are not sure about their function, please contact your Volvo Penta dealer.

1. Tachometer

2. Voltmeter

3. Oil pressure gauge

4. Temperature gauge

5. Hours counter

Ignition lockA tab with the key code accompanies the ignition keys,and is used to order extra ignition keys. Do not store thecode 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.

2. 3. 4.

5.

1.

Instruments

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

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

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Instruments

Alarm displayThe following warning lamps should never light up during operation. On the other hand, the warning lamps light upwhen 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 thefault has been acknowledged, the lamp gives continuous light.

Warning lamps (should never light upduring operation).

Oil pressure (red indication)

If the oil pressure lamp lights up during operation, the oilpressure 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. Pleaserefer to “Maintenance: Lubrication system”

Please refer to the “If something happens” chapter, andyou will find detailed information about recommended ac-tion in the “Diagnostic function” section.

WARNING! Continued operation when the oil pres-sure 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 thewater trap in the fuel filters.

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

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

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Instruments

Battery. (orange indication)

The battery lamp lights up if the alternator is notcharging. Stop the engine if this lamp lights up duringoperation. If the lamp lights up, this can be due to afault in the electrical system or because the alternatordrive 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, andyou will find detailed information about recommendedaction in the “Diagnostic function” section.

WARNING! Do not continue operation if there isany problem with the alternator drive belts. Thiscould cause serious engine damage.

Coolant temperature (red indication)

The coolant temperature lamp lights up when thecoolant temperature is too high. Stop the engine if thislamp 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, andyou will find detailed information about recommendedaction in the “Diagnostic function” section.

WARNING! Do not open the coolant filler capwhen the engine is warm, except inemergencies. Steam or hot fluid could spray out.

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Instruments

Coolant level (orange indication)

The coolant lamp lights up when the coolant level istoo 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 recommen-ded 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 recommen-ded 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 recommen-ded 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 recommen-ded action in the “Diagnostic function” section.

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Instruments

EVC control panelThere 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 enginecan 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 activatedbecause the control lever is not in the neutral position orthe system has been locked from another control panel.

Indication (padlock):

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

Neutral button

Used to activate de-activate the reversing gear / sterndrive, 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 theengines 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 malfunc-tion.

Indication (yellow):

No light: Normal operation.

Light on: Fault codes can be read.

Flashing: Diagnostic function has registered a malfunc-tion.

Dimmer function

Used to light up and extinguish background lighting inthe instruments and panels.

Press the button for 5 seconds to light or extinguishbackground lighting. Background lighting can be adjustedin five stages, by pressing the dimmer button.

20

Instruments

EVC-Display (extra optional)The Volvo Penta EVC-display is an on-board instru-ment for indication of engine operating values. Thedisplay consists of a self-contained, computerisedunit for fixed installation in a control panel.

Indications are presented on a Liquid Crystal Display(LCD) screen. The operator selects presentation modeusing five keys on the front of the instrument.

21

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

Disengaging the shift functionThe shift function can be disengaged so that the control le-ver 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 whilemoving the control lever forward to the shift position (F).

3. Release the neutral button. The green indicator beginsto flash to acknowledge that the shift function is disen-gaged.

The lever now only controls engine speed.

When the lever is moved back to the neutral position it willautomatically re-engage. This is confirmed by the green in-dication which gives constant light.

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

Single lever control. Electronic

OperationBoth the shift function and engine speed control are control-led using the single lever control.

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

F = Reversing gear/stern drive engaged for movementahead.

R = Reversing gear/stern drive engaged for movement as-tern.

T = Adjustment of engine speed.

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

22

Controls

Friction brakeThe control is also equipped with a friction brake which canbe adjusted for easier or stiffer lever movement asnecessary.

Friction brake adjustment:

1. Stop the engine.

2. Move the control lever forwards to make the groove in thecontrol 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.

23

Starting the engineMake it a habit to give the engine and engine bay a visual check before starting. This will help you to discoverquickly if anything abnormal has happened, or is about to happen. Also check that instruments and warning dis-plays 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 enginebay 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 currentwith the main switches when the engine isrunning. This can damage the alternator.

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

● Check that the amount of fuel aboard is enough foryour planned voyage.

General information about startingThe engine control lever must always be in neutralbefore starting. The engine management systemensures that the engine receives the correct amountof fuel - even when the engine is cold.

The engine is pre-heated by the engine control unit,which allows the engine to crank several revolutionswith the starter motor before fuel is injected. Thecolder the engine is, the more revolutions the enginemakes. This raises the temperature in the combustionchambers, which ensures reliable starting and reducesstarting smoke.

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

24

Starting the engine

Starting method

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

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

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

Check the warning lamps and LEDsEach time the ignition is turned on, all bulbs andLEDs are illuminated on the main control panel.Check that all bulbs and LEDs function.

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

Activate the control position and lock thesystem.Press the activation button for at least one second.When the button is released, the indication lights upto confirm that the control position is activated.

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

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

Unlock the system by pressing the activation buttonfor one second. This can only be done from an acti-vated control panel.

25

Starting the engine

Start the engine

Start using the ignition switchTurn the key to position III. Release the key and let itkey spring back to position I as soon as the enginehas started.

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

Starting with the starter buttonPress the starter button. Release the button as soonas the engine has started. Please note that if you startfrom an alternative control station, the starter key atthe main control station must be in position I.

Overheating protectionIf the starter motor is engaged for its maximumactivation time (30 seconds), the starter motor circuitis cut automatically to protect the starter motor fromoverheating. Leave the starter motor to cool for atleast five minutes (if possible) before making a newstart attempt.

Read the instruments and warm theengine upAllow the engine to idle for the first ten seconds, andcheck that instruments and warning displays shownormal values. Check that no warning lamps flash onthe alarm display.

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

IMPORTANT! Never race the engine when it iscold.

Check the oil level in the reversing gear

Check the oil level when the reversing gear hasreached operating temperature (please refer to thedescription in the “Maintenance” chapter under the“Reversing Gear” heading)

26

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

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

Reading the instrumentsRead all instruments and alarm displays directly after star-ting, and then regularly during your voyage.

Oil pressureThe 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 soundautomatically at the same time as the lamp in the warningdisplay will flash.

Coolant temperatureThe temperature gauge should normally indicate between75– 95°C (167-203°F) in normal operation.

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

ChargingDuring operation, system voltage should be about 28 V for24 Volt system voltage.

If there is a charge failure, the audible warning will soundautomatically at the same time as the lamp in the warningdisplay will flash.

AlarmIf a fault occurs, the audible warning will sound and the re-levant 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 acknow-ledge the message. The audible warning will become silentand the alarm panel will stop flashing. The relevant warninglamp gives a constant light.

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

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

27

Operation

Cruising speedAvoid operation at full throttle, for best fuel economy. We re-commend a cruising speed which is at least 10% below themaximum engine speed at full speed (full throttle). The maxi-mum engine speed will vary due to propeller choice, load andsea 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 couldbe caused by a number of factors which are noted in the“Fault tracing” chapter. If the engine speed exceeds the fullthrottle range, select a coarser pitch propeller. Ask yourVolvo Penta dealer for advice.

Synchronizing engine speedWhen driving with twin engines, both the operating economyand comfort can be increased when the engines are opera-ting at the same engine speed (rpm).

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

When the synchronization function is activated, the enginespeed (rpm) of the starboard engine is automatically adjus-ted to that of the port engine. The synchronization functionis activated automatically if the following conditions are met.

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

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

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

1

28

Operation

Changing control position during operation(optional extra)

This function must be enabled to permit the control panel tobe changed during operation. The function can only be ena-bled by authorized Volvo Penta personnel. Please contactyour Volvo Penta dealer.

1. Press the activation button (1) to unlock the system.The padlock sign goes out on all control panels to indi-cate that it is possible to change control panel.

2. Press the activation button (1) on the alternative controlpanel. The activation button indication flashes on the al-ternative control panel, and on the main control panel itgives constant light.

3. The alternative control panel becomes active when thecorrect gear and approved engine speed is demanded.The activation button (1) gives constant light to confirmthat the control panel is activated. The system is nowlocked, which is indicated by the padlock sign, whichlights up.

NOTE! If the correct gear or engine speed is not de-manded within 15 sec, the system ramps engine speeddown to neutral and the gearbox engages neutral.

Changing the control positionThe first time you change control panel after starting the EVCsystem, a bulb check is done automatically. All LEDs andbulbs light up for 2 seconds.

1. Check that the control lever(s) is (are) in neutral on boththe 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 con-firm that the control position is activated.

4. Press the activation button (1) for a further second to lockthe EVC system. The padlock sign lights up in confirma-tion. Unlock the system by pressing the activation buttonfor one second. This can only be done from an activatedcontrol panel.

1

29

Operation

OperationShifting between forward and reverse should be done at id-ling. Shifting at higher engine speeds can be uncomfortablefor passengers and cause unnecessary stress on the sterndrive/reversing gear, or cause the engine to stop.

If you attempt to shift gear at an excessive engine speed, asafety function cuts in automatically, and delays shiftinguntil 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 orless lose way.

WARNING! Never shift to reverse when the boat isplaning.

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

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

IMPORTANT! If the boat has twin engines, it is im-portant that both should be running during reversingmaneuvers, to avoid the risk of water entry (via theexhaust pipe) into the stationary engine.

1

2

3

Propeller shaft brakeIn certain conditions, the propeller can make the propellershaft rotate when the engine is stopped. This parasitic rota-tion is uncomfortable, and can damage the reversing gearsince its oil pump, which is driven by the input shaft, is sta-tionary together with the engine.

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

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

Maximum permissible temperature is 95°C for the ZF re-versing gear.

When the above-mentioned rules can not be met, or if youwant to stop the shaft for comfort reasons, a shaft brakehas to be installed. On isolated occasions, the propellershaft flange can be locked mechanically by some suitablemeans.

30

Stopping the engine

Stop1. Disengage the reversing gear by putting the control le-

ver in neutral.

2. Turn the key to stop position “S”. Keep the key turneduntil the engine stops. The key will automatically returnto the “0” position when it is released and can then beremoved. Alternatively press the stop button. To stopthe engine using the stop button is only possible if thecontrol panel is activated.

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 nexttime the engine is started.

● Read off the hours counter and do preventive mainte-nance as in the maintenance schedule.

● Turn off the main switches before any long stoppage.

IMPORTANT! Never break the circuit with the mainswitches while the engine is running. This could da-mage the alternator and electronics.

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

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

Emergency stop

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

31

Stopping the engie

Cold weather precautionsIf the engine bay can not be kept frost-free, the sea-water system must be drained and the freshwater sys-tem coolant must have enough anti-freeze to preventfrost damage. Please refer to the “Seawater system”and “Freshwater system” maintenance chapters.

WARNING! If the engine bay can not be keptfrost-free, the seawater system must be drained.Frost damage in the seawater system can makethe boat sink.

IMPORTANT! If the coolant does not have suffi-cient frost protection, this can cause expensiveengine damage. Check the battery charge. Apoorly charged battery can freeze and burst.

Laying upIf the boat is not used, but left in the water, the enginemust be warmed up at least once every fortnight. Thisprevents corrosion damage in the engine.

IMPORTANT! If you expect the boat to be unu-sed for two months or more, it must be laid up:Please refer to the Laying up chapter.

32

In case of emergencyDespite regular maintenance according to the maintenance schedule and perfect operation, it may occur that afault occurs which must be attended to before the boat can travel further. This chapter contains tips for rectifyingsome of the possible faults.

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

● 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.

1. Check that the rated voltage of the help startbattery is the same as the system voltage of theengine.

2. Connect the red jumper cable to the positive pole(+) of the flat battery, and then to the positive poleof the help start battery.

3. Connect the black jumper cable to the negativepole (–) of the help start battery, and then to aplace some distance from the flat batteries, suchas the negative connection on the starter motor.

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

4. Start the engine and run at a fast idle for aboutten minutes to charge the batteries.

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

WARNING! Do not touch the connections duringthe start attempt: Risk of arcing. Do not standbending over any of the batteries either.

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

Starting with auxiliary batteriesWARNING! Ventilate well. Batteries contain andgive off an explosive gas which is highlyflammable and explosive. A short circuit, openflame or spark could cause a violent explosion.

WARNING! Never confuse the positive andnegative poles on the batteries. Risk of arcingand explosion.

33

In case of emergency

Emergency shiftingIf a fault occurs which prevents the revers gear frombeing operated (shifted) with the control lever, it ispossible to shift manually, using the descriptionbelow.

Note. The descriptions refer to electrically shifted re-vers gear.

WARNING! In emergency shifting, the unit islocked in forwards operation. Please note thatthe revers gear can not then be disengagedwith the control lever. Forward motion can onlybe cut off by stopping the engine with the igni-tion key or stop button.

1. Stop the engine and remove the start key from thekey 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 wasconnected to the “Primary” cable.

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

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

The reverse gear is now connected for forwardmotion and cannot be disengaged by the controllever.

1

2

34

In case of emergency

Fault-tracingA number of symptoms and possible causes of engine malfunctions are described in the table below. Always con-tact 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” chap-ter before starting work.

1. Flat batteries2. Poor contact/open circuit in cables3. Main switch turned off4. One of the circuit breakers in the dis-

tribution box has tripped.5. Faulty key switch6. Control lever not in neutral/control po-

sition not activated7. Faulty stop relay8. Faulty main relay9. Faulty starter relay

10. Faulty starter motor relay11. Faulty starter motor/solenoid12. Lack of fuel:

– fuel taps closed– fuel tank empty/wrong tank con-

nected13. Blocked fine fuel filter/pre-filter

(caused by contamination or fuelstratification at low temperature)

14. Air in the fuel system15. Water/contamination in fuel16. Boat abnormally loaded17. Fouling on hull/propeller18. Faulty injectors (nozzles)19. Insufficient air supply to engine:

– blocked air filter– air leakage between turbocharger

and engine inlet pipe.– fouled compressor section in turbo-

charger– faulty turbocharger– poor engine bay ventilation

20. Excessive coolant temperature21. Too low coolant temperature22. Too low oil level23. Faulty / wrong propeller24. Faulty engine mounting25. Coolant level too low

26. Air in the freshwater system27. Faulty circulation pump28. Closed seawater inlet29. Blocked seawater inlet/pipe/filter30. Defective impeller in seawater pump31. Defective thermostat32. Blocked heat exchanger insert33. Blocked aftercooler34. Too high oil level35. Alternator drive belt slips36. Water entry into engine37. High back pressure in exhaust system 38. Stored fault codes* 39. Check that the emergency stop but-

ton is in the running position (notpressed down).

40. Engine drive belt slips

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

Symptoms and possible causes

The diagnosis button lamp flashes. Please refer to the “Diagnostic information”chapter.

Engine can not be stopped 2, 4, 5, 7

Starter motor does not rotate 1, 2, 3, 4, 5, 6, 8, 9, 10, 11, 36, 38, 39

Starter motor rotates slowly 1, 2

Starter motor rotates normally but engine does not start 12, 13, 14, 15, 38

Engine starts but stops again 12, 13, 14, 15, 19, 38

Engine does not reach full operating speed at full throttle 13, 14, 15, 16, 17, 18, 19, 20, 23, 33, 37, 38

Engine runs unevenly 14, 15

Engine vibrates 24

High fuel consumption 16, 17, 21

Black exhaust smoke 19

Blue or white exhaust smoke 20, 21, 34

Lubrication oil pressure too low 22

Coolant temperature too high 25, 26, 27, 28, 29, 30, 31, 32, 40

Coolant temperature too low 31

No charge or poor charge 2, 35

35

In case of emergency

Diagnostic functionThe diagnostic function monitors and checks that the engine, stern drive/reversing gear and EVC system functionnormally.

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 messageIf the diagnostic function discovers a malfunction, itwarns the driver by starting to flash the indicator onthe diagnostic button. To acknowledge the alarm,press button D on the control panel. When the faulthas been acknowledged, the lamp concerned givesconstant light.

The diagnostic function affects the engine in thefollowing ways when:

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

Reaction: The engine is not affected.

2. The diagnostic function has discovered a seriousmalfunction which will not immediately damage theengine (e.g. high coolant temperature):

Reaction: Engine power is cut until the relevantvalue is normalized.

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

4. The diagnostic function has discovered a seriousmalfunction which makes it impossible to controlthe engine.

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

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

36

In case of emergency

Fault codesThe fault codes are flashed out on the diagnosticbutton indication. The fault code consists of threegroups of flashes, separated by a pause of twoseconds. A fault code is obtained by counting the num-ber of flashes in each group:

Example:

pause pause = 2.4.2The fault code is stored and can be read as long as themalfunction remains.

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

Reading fault codes1. Reduce engine speed to idling if fault codes are

read when the engine is running. If the engine isstopped, check that the starter key is in position I(drive position).

2. Press the diagnostic button D for at least 5 sec-onds. Release the D button and the yellow indica-tion lamp will give constant light, which means thatyou are in Service mode and fault codes can beread.

3. The diagnostic button must be depressed to makethe codes flash. Make a note of the three digitfault code that is flashed out.

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

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

5. Look up the fault code in the fault code list andtake the necessary measures.

Alternatively: If the controls, warning display andother instrumentation indicate normal function, theoperator can continue the journey and remedy themalfunction at a later time.

6. To leave Service mode press D button for at least5 sec. or turn the ignition off.

37

In case of emergency

Erasing fault codesAny fault codes in the diagnostic function areautomatically erased every time the starter key is tur-ned to the stop position (S).

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

When system voltage is switched on again, thediagnostic function checks to see whether there areany faults in the EVC system. If this is the case, newfault codes are set.

This means that:

1. Fault codes for malfunctions which have beenattended to or have disappeared are automaticallyerased.

2. Fault codes for malfunctions which have not beenattended to must be acknowledged every time thesystem voltage is switched on.

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

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

IMPORTANT! When both operation and calendar time are specified, do the maintenancejob at the interval which is reached first. Maintenance points marked must be doneby 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 661) 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 451) Oil change intervals vary, depending on oil grade and sulphur content of the fuel. Please refer to page 43.2) Change the filters during each oil change.

Every 200 hours / at least every 6 months● Reverse gear (ZF). Clean the oil strainer ...................................................... page 66

Maintenance scheduleGeneral informationYour Volvo Penta engine and its equipment are designed for high reliability and long life. They are built to with-stand a marine environment, but also to have the smallest possible environmental impact. If given preventivemaintenance, according to the maintenance schedule, and if Volvo Penta original spares are used, these qualitiesare retained and unnecessary malfunctions can be avoided.

Warranty inspectionDuring the first period of operation, the specified warranty inspection “First service inspection” must be done by anauthorised Volvo Penta workshop. Instructions about when and where this should be done are found in theWarranty and service book.

39

Maintenance schedule

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 asnecessary every 800 hours of operation, or at least once every 12 months.

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 671) 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 monthsValve 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 571) Not at same time as coolant change.2) 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 hoursTurbocharger. Inspection................................................................................. not shown

Every 12 monthsEVC 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 monthsCooling system Inspection/cleaning ................................................................ not shown

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

Newly renovated engineAfter the first 150 hours

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

40

Maintenance

Engine, general

General inspectionMake 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 theengine. This will help you to discover if anything ab-normal has happened, or is about to happen.

Look especially carefully at oil, fuel and coolant leak-age, loose screws, worn or poorly tensioned drivebelts, loose connections, damaged hoses and electri-cal cables. This inspection only takes a few minutesand can prevent serious malfunctions and expensiverepairs.

WARNING! Deposits of fuel, oils and grease onthe engine or in the engine bay are a fire hazardand must be removed as soon as they are dis-covered.

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

IMPORTANT! Observe the following when clean-ing with a high pressure washer: Never aim thewater jet at seals, rubber hoses or electricalcomponents. Never use a high pressure washerfor engine cleaning.

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

WARNING! Read through the safety advice for care and maintenance work in the Safety information chap-ter 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 byremoving the start key and cutting the system voltage with the main switches.

41

Maintenance. Engine, general

Crankcase ventilation. Changing the filterRemove the air filter cover. Remove the old air filter.Clean the air filter cover/housing if necessary. Takecare not to allow impurities to enter the engine. Fit thenew air filter and the air filter cover.

Air filter. Change

1. Remove the old filter. Be careful to ensure that nocontamination gets into the engine.

2. Install a new filter and tighten the hose clamps ca-refully.

IMPORTANT! Scrap the old filter. It must not becleaned.

42

Maintenance. Engine, general

Drive belts. Inspection/adjustmentWARNING! Stop the engine before doing anymaintenance work.

General information

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

IMPORTANT! Always change a belt which looksworn or cracked (belts which operate in pairsmust be changed together).

Adjusting the alternator belt

The standard alternator, plus the extra alternator if in-stalled, are driven by a Poly-Vee belt each, for bestfunction and service life.

1. Undo the fixing screw (1) and tighten it again tight-ening torque 30 Nm.

Adjusting the alternator belt

1. Remove the protective cover over the alternatordrive belt.

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

3. Srew a M10 nut (3) to the tensioner screw so thespring is pressed together and it is possible to loo-sen the alternator belt

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

5. Tighten the fixing screw (1) tightening torque 30Nm and fixingscrew (2) tightening torque 20 Nm.

6. Install the protective cover over the alternatordrive belt.

7. Let the engine run on idle. Stop the engine after afew minutes.

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

2

3

43

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. Notethat 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 bythe oil manufacturers through regular oil testing.

SAE5W/30

−−−−−30 −−−−−20 −−−−−10 ±0 +10 20 30 40

−−−−−22 −−−−− 4 +++++14 32 50 68 86 104

−−−−−15oC SAE15W/40

−−−−−25oC SAE10W/30

−−−−−10oC SAE20W/30

±0oC SAE30

SAE40+10oC

oC

oF

✱✱✱✱✱

ViscositySelect the viscosity from the table below.Note. The temperature values refer to stable ambienttemperatures.

* Refers to synthetic or semi-synthetic oils.

Oil change volumePlease refer to the “Technical Data” chapter.

Oil grade Sulphur content in fuel, by weight

up to 0.5% 0.5–1.0% more than 1.0% 1)

Oil change interval: Reached first in operation:VDS-3VDS-2 and ACEA E5 400 hr. or 12 months. 200 hr. or 12 months. 100 hr. or 12 months.VDS-2 and Global DHD-1

VDS and ACEA E3 2) 300 hr. or 12 months. 150 hr. or 12 months. 75 hr. or 12 months.

ACEA: E4, E3, E2API: CF, CF-4, CG-4 200 hr. or 12 months. 100 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 qualityrequirements above.1) If sulphur content is > 1.0% by weight, use oil with TBN > 15.2) Lubrication oil must comply with both requirements.

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

VDS = Volvo Drain SpecificationACEA = Association des Constructeurs Européenne d’AutomobilesAPI = American Petroleum InstituteTBN = Total Base Number

44

Maintenance. Lubrication system

Oil level. Checking and fillingThe oil level must be inside the marked area on thedipstick (1) and should be checked daily before thefirst start.Top up the oil through the filling hole on the side of theengine (2) . Check that the correct level has beenachieved. But wait a few minutes to allow the oil torun down into the sump.

IMPORTANT! Do not fill up above the maximumoil level. Only use a recommended grade of oil(please refer to previous page).

Engine oil. ChangeAlways observe the recommended oil change interval.

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

WARNING! Hot oil and hot surfaces cancause burns.

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

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

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

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

5. Start the engine and let it idle. Check that the lowoil pressure warning lamp goes out and that noleakage occurs by the filters.

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

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

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

45

Maintenance. Lubrication system

Oil filter and bypass filter. ChangeChange the oil filter and bypass filter during each oilchange.

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

WARNING! Hot oil and hot surfaces can causeburns.

1. Put a suitable vessel underneath the filter drip panto 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 brack-ets are clean, and that no residue from the oldseals remains.

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

6. Screw the filters on by hand until the rubber sealsjust touch the mating surface on the filter brack-ets. Then tighten a further 1/2 to 3/4 turn.

7. Start the engine (low idle) and check that no leak-age occurs. Check the oil level once the enginehas stopped.

2 2 1

46

Maintenance. Freshwater system

Freshwater system

The freshwater system is the internal cooling system of the engine. This is a closed system and shall always befilled 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 acertain temperature and is fully open when the engine has reached its normal operating temperature. When thethermostat opens, the hot coolant is directed through the heat exchanger, where heat is lead away via the seawa-ter system (please refer to the next section).

Coolant. General informationThe freshwater system shall always be filled withcoolant which protects the engine from internal corro-sion and from frost damage if the climate requires it.

The corrosion protection additives become less effec-tive as time passes, which means that the coolantmust be changed.

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

Water qualityThe coolant must be mixed with clean water comply-ing with ASTM D4985 to avoid any risk of blockage inthe cooling system. If there is any doubt about waterpurity, 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 SiO2 /l

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

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

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

Organic content, CODMn .............................. < 15 mg KMnO4 /l

47

Maintenance. Freshwater system

Frost protection mixtureIf there is a risk of frost, use a mixture of 50% VolvoPenta anti-freeze (glycol) and 50% water (to ASTMD4985). This mixture prevents against frost burstingdown to about – 40°C (– 40°F), and should be used allyear round.

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

Mix the glycol with water in a separate vessel beforefilling the system.

WARNING! Glycol is poisonous (dangerous todrink).

IMPORTANT! Do not use alcohol in the coolingsystem.

Corrosion protection mixture

When there is never any risk of frost, water (to ASTMD4985), mixed with Volvo Penta anti-corrosion addi-tive, can be used as a coolant.

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

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

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

WARNING! Anti-corrosion additive is poisonous(dangerous to drink).

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

48

Maintenance. Freshwater system

Coolant level. Inspection

WARNING! Never open the pressure cap whenthe engine is hot. Steam or hot coolant canspray out at the same time as the pressurewhich has built up is lost.

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

If a separate expansion tank is installed, the coolantlevel must be between the MAX and MIN markings.Top up the coolant as necessary, following the de-scription below.

Coolant. FillingWARNING! Stop the engine and let it cool beforefilling. Hot fluids and hot surfaces can cause burns.

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

Topping up

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

When you fill up an empty system, or if the coolanthas fallen so low for any reason that it is no longervisible through the filling hole, fill up as in the de-scription for “Filling a completely empty system”.

Filling a completely empty system

1. Mix a sufficient quantity of coolant in a vessel be-fore filling. Please note that a heating system, tapwater heater etc. if connected to the engine cool-ing system, mean that a correspondingly greateramount of coolant will be needed..

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

49

Maintenance. Freshwater system

3. Fill up with coolant via the filling hole on the ex-pansion tank.

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

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

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

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

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

Coolant. Draining.WARNING! Stop the engine and let it cool be-fore draining. Hot fluids and hot surfaces cancause burns.

WARNING! Glycol is poisonous (dangerous todrink). Collect the old coolant and hand it to a re-cycling station for destruction. Drain the coolantvia taps (F).

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

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

IMPORTANT! Check that all coolant reallydoes drain out. Deposits may need to becleared away, inside the drain plug(s)/tap(s).

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

4. Close all drain taps.

1

F F

F

F

50

Maintenance. Freshwater system

Freshwater system. FlushingThe cooling system should be flushed when the cool-ant is changed, to avoid loss of cooling performancedue to deposits in the cooling system.

1. Drain the coolant, as in the description on the pre-vious page.

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

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

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

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

51

Maintenance. Seawater system

Seawater system

The seawater system is the engine’s external cooling system. The seawater system sucks in water through theseawater inlet and pumps it through the heat exchanger and the reverse gear oil cooler. The system is protectedfrom 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 inthe 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 safemanner. If this is not possible, the boat must be drawn up on land before work starts.

Seawater system. Draining.The seawater system must be drained in cold weath-er, if there is a risk of frost, to prevent frost damage.

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

An alternative to draining is to keep the engine bayabove freezing temperature, by means of a fan heaterwhich is approved for outdoor use.

Draining:

1. Close the sea cock.

2. Connect a hose to each drain tap before openingthe 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 reallydoes drain out. Deposits may need to becleared away, inside the drain plug/tap.

4. Also drain/empty any auxiliary equipment suchas 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 youleave the boat.

S

S

52

Maintenance. Seawater system

Zinc anodes. Check/changeWARNING! Risk of water entry. Close the sea cockbefore doing any work on the seawater system.

1. Close the sea cock.

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

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

4. Check the zinc anodes and replace them if morethan 50% of their original size has been used up.If not, clean the zinc anodes with emery cloth toremove the oxide layer before re-installing them.

IMPORTANT! Use an emery cloth for clean-ing. Do not use steel tools, since this couldimpair the galvanic protection.

5. Install the zinc anodes. Make sure that good me-tallic contact is obtained between the anode andthe 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

1

Z

53

Maintenance. Seawater system

Impeller. Check/changeWARNING! Risk of water entry. Close the sea cockbefore doing any work on the seawater system.

1. Remove the seawater pump lid, and pull the im-peller out with water pump pliers.

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

3. Lubricate the pump housing and the inside of thelid with water-resistant grease (which is not ag-gressive to rubber). The impeller will be easier towork 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 aninternal thread (M8). Screw a stud into the end ofthe shaft and press the impeller in using a washerand nut. Fit the cover, using a new O-ring.

5. Open the sea cock.

IMPORTANT! Always carry a spare impeller onboard.

Seawater filter. Inspection/cleaningThe seawater filter is optional equipment.

If the water where the boat is operated contains a lotof contamination, weed etc., check the filter more fre-quently than specified in the maintenance schedule.There is otherwise a risk that the filter would beblocked, which would make the engine overheat.

WARNING! Risk of water entry. Close the sea-water cock before doing any work on the seawa-ter 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 noleakage occurs.

54

Maintenance. Seawater system

Inlet manifold. Checking the drain holeWater can condense in the aftercooler during opera-tion. The condensate is drained via a hole in thecharge air cooler.

Check that the drain hole is not blocked.

WARNING! If a large amount of water flows outof the drain hole, from the inlet manifold, the af-tercooler must be removed and proof tested.

This task must be done by an authorised workshop.

Oil cooler, reverse gear. CleaningWARNING! Risk of water entry. Close the sea-water cock before doing any work on the seawa-ter system.

If you suspect leakage, remove the oil cooler from theengine 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 theoil 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 cleanwith compressed air (or leave it to drain). Clean theinsides of the tubes and the end walls of the insertwith 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 leak-age occurs.

1

55

Maintenance. Seawater system

Heat exchanger. CleaningThis job requires specialist knowledge, and should bedone by an authorised workshop.

WARNING! Risk of water entry. Close the seacock and drain off the water in the seawater andfreshwater systems before doing any work on thecooling system.

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

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

It is frequently enough to clean the pipes in the heatexchanger insert, once the end covers have been re-moved. This means that the freshwater system doesnot need to be drained.

Heat exchanger insert. Cleaning

1. Remove the heat exchanger from the engine.

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

3. Press the insert out.

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

4. Clean the entire length of the heat exchanger in-sert, using suitable brushes. Flush the pipes andkeep brushing until no more loose particles comeaway with the water. Also flush and clean the in-sert externally.

5. Clean the housing and the end covers.

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

7. Install the heat exchanger on the engine. Use newseal rings.

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

9. Start the engine and check carefully that no leak-age occurs.

56

Maintenance. Fuel system

Fuel systemOnly use the grades of fuel recommended in the fuel specification, see Technical Data. Always observe the great-est 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 onhot surfaces or electrical components can cause fires. Store fuel-soaked rags and other flammable materialin fireproof conditions.

WARNING! Hot fuel can cause burns.

Fuel system ventingThe fuel system must be vented, e.g. after changingfuel filter, if the fuel tank has been run dry and afterlong 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 thehand pump (2) until air-free fuel flows out. Tightenthe venting nipple while fuel is flowing out.

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

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

1 2

57

Maintenance. Fuel system

Fuel filter

DrainWARNING! Hot fuel can cause burns.

1. Put a suitable vessel underneath the filter.

2. Open the tap (1) and drain water and contamina-tion from the water trap (2) by pumping with thehand pump (3) until clean fuel flows out.

Change the filter elements1. Close the fuel valve/valves.

2. Clean the filter bracket and put a suitable vesselunder the filter.

3. Relieve pressure inside the filter by first openingthe drain tap (1) at the bottom of the water trapand then the venting nipple (2) so the filter isdrained off fuel.

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

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

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

3

2

1

1 3

2

4

5

58

Maintenance. Fuel system

6. Clean the sealing surfaces of the filter bracket.Make sure the filter is absolutely clean and thesealing surfaces are undamaged. Moisten the se-aling rings with engine oil, including the inner rub-ber seal located inside the threaded hole in thecenter of the filter.

NOTE! Do not fill the new filter with fuel before as-sembly. Contaminations may get into the systemand cause damage and malfunction.

7. Screw the new filter on by hand until the seal justtouches the mating surface. Then tighten a further1/2 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 thehand pump (5) until air-free fuel flows out. Tightenthe venting nipple while fuel is flowing out.

10. Remove the hose and put the protective cap backon the venting nipple.

11. Start the engine and check for leakages.

59

Maintenance. Fuel system

Fuel pre-filter

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

Fuel pre-filter. InspectionThis filter is equipped with a pressure gauge (1) whichindicates when it is time to change the filter insert.

Change the filer inserts as recommended in the main-tenance schedule, or earlier if the pressure gaugeshows a negative pressure of 6-10 (in. Hg) at idle or16–20 (in. Hg) at full speed/loaded engine.

WARNING! Working with, or going close to a run-ning engine is a safety risk. Watch out for rotatingcomponents and hot surfaces.

DrainPlace a receptacle under the filter. Drain off water andcontaminants through the plug (2).

Fuel pre-filter. Changing the filter insertThe fuel pre-filter/water trap supplied by Volvo Pentais available in single and twin versions. The twin filterinserts can be changed with the engine running, byclosing off fuel flow to one filter housing at a time.

Fuel flow is controlled by putting the handle (1) in thefollowing 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.

2

60

Maintenance. Fuel system

Change the filter elementsIf the engine is not running close the fuel cocks on thetank before changing filters. If the engine is runningcut off the flow of fuel with the handle (1) on the filteritself.

1. Place a receptacle under the filters and shut offthe 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 thedrain plug (4).

5. Fit a new filter insert and fill the container with cle-an fuel.

6. Change the gasket on the cover and the O-ring onthe T-bolt. Moisten the gasket and O-ring with fuelbefore 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 positionfor normal running. Make sure there are no leaks.

61

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 currentcut by switching off the battery isolator. Shore current for engine heaters, battery chargers or other auxiliaryequipment connected to the engine must be disconnected.

Main switchesThe main switches must never be disconnected be-fore the engine has been stopped. If the circuit be-tween the alternator and the batteries is disconnectedwhen the engine is running, the alternator and elec-tronics can be damaged. The charging circuits mustnever be re-connected with the engine running, for thesame reason.

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

FusesThe engine is fitted with two automatic circuit brea-kers. The circuit breakers cut the power if the systemis overloaded.

If it is not possible to start the engine or if the instru-ment stops working while running, the circuit breakermay have been activated. Reset by pressing in thecircuit breaker.

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

IMPORTANT ! Always investigate the cause ofthe overload!

EVC systemThe EVC system is protected through the engine cir-cuit breakers.

IMPORTANT ! Always investigate the cause ofthe overload!

Electrical connectionsCheck that electrical connections are dry, free fromoxide and that they are securely tightened. Spraythese connections as necessary with water-repellentspray (Volvo Penta universal oil).

62

Maintenance. Electrical system

Batteries. MaintenanceWARNING! Fire and explosion hazard. Batteriesmust never be exposed to open flames orsparks.

WARNING! Never confuse the positive and neg-ative poles on the batteries. Risk of arcing andexplosion.

WARNING! Battery electrolyte is highly corro-sive. Always protect your eyes, skin and clotheswhen handling batteries. Always use protectivegoggles and gloves. If acid comes into contactwith your skin, wash at once with soap and a lotof water. If you get battery acid in your eyes,flush at once with a lot of water, and get medicalassistance 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 – ca-ble (black) first, then the + cable (red).

Cleaning

Keep the batteries dry and clean. Contamination andoxide on the batteries and battery poles can causestray currents, voltage drop and discharge, especiallyin wet weather. Clean oxidation from the battery polesand terminals, using a copper brush. Tighten the ter-minals securely and grease them with terminal greaseor 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 bat-tery water as necessary. After topping up, the batter-ies should be charged by connecting them to a batterycharger, or by running the engine at normal speed for30 minutes.

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

IMPORTANT! Never confuse the positive andnegative poles on the batteries.

63

Maintenance. Electrical system

Batteries. ChargingWARNING! Explosion risk! Hydrogen is givenoff when batteries are charged. This forms an ex-plosive mixture with air. A short circuit, openflame or spark could cause a violent explosion.Ventilate well.

WARNING! Battery electrolyte is highly corro-sive. Protect your eyes, skin and clothes. Al-ways use protective goggles and gloves. If acidcomes into contact with your skin, wash at oncewith soap and a lot of water. If you get batteryacid in your eyes, flush at once with a lot of wa-ter, and get medical assistance at once.

Charge batteries if they have become discharged. Ifthe boat is not used for a longer period of time, thebatteries should be fully charged, then trickle charged(please refer to the battery manufacturer’s recommen-dations). Batteries are damaged by being left discharged,and can also freeze and burst easier in cold weather.

IMPORTANT! Observe the instruction manual forthe battery charger carefully. To avoid the risk ofelectrochemical corrosion when an externalcharger is connected, the battery cables in theboat should be removed from the batteries beforethe charger is connected.

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

WARNING! Always switch off the charge currentbefore undoing the charging clamps. Never con-fuse the positive and negative poles on the bat-teries. Risk of arcing and explosion.

Special instructions apply to so-called quick charg-ers. Quick charging can shorten battery life, andshould therefore be avoided.

64

Maintenance. Electrical system

Electric weldingRemove the positive and negative cables from thebatteries. Then disconnect all cables connected to thealternator.

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

Always connect the welder earth clamp to the compo-nent to be welded, and as close as possible to the weldsite. The clamp must never be connected to the engineor in such a way that current can pass through a bearing.

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

Electrical installationsAn incorrectly done electrical installation can generatestray currents from the electrical system. Stray cur-rents, in their turn, can weaken the galvanic protectionof the propeller, propeller shaft, rudder, keel etc., andcause damage because of electrochemical corrosion.

IMPORTANT! Work on the low voltage circuits inthe boats should be done by a person with elec-trical training or knowledge. Installation or workon land current equipment must only be done bya competent electrician, in accordance with localregulations for mains electricity.

Always consider the following:

1. If land current is connected, its protective earthmust be connected ashore, never to the boat. Theland current installation must also be providedwith an earth fault breaker (RCCB). The land cur-rent installation (transformer, inverter, batterycharger etc. ) must be intended for marine use,where the high voltage section is galvanicallyisolated from the low voltage section.

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

65

Maintenance. Electrical system

1

3. Protective earth cables for radio, navigation equip-ment, rudder, bathing steps etc., or other equip-ment which uses protective earthing, shall be con-nected to a common earthing point which is notconnected to the engine or reverse gear.

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

4. The starter battery shall have a main switch onthe positive (+) side of the battery. The mainswitch must disconnect all loads and shall beswitched 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 bat-tery positive (+) pole and the fuse box for theboat’s electrical equipment. The main switch mustdisconnect all loads connected to the auxiliarybattery and shall be switched off when the loadsare not used. All equipment connected to the aux-iliary battery shall have separate switches.

A charge splitter (optional) should be installed tocharge two independent battery circuits from thestandard alternator.

66

Maintenance. Reverse gear

Reverse gear

Oil level. Checking and filling

InspectionCheck the oil level when the reverse gear has reachedoperating temperature, with the engine idling and thecontrol lever in neutral.

WARNING! Working with, or going close to arunning engine is a safety risk. Watch out for ro-tating components and hot surfaces.

Remove the dipstick (1), wipe it off and put it backinto the reverse gear. Remove the dipstick again andcheck the oil level. The correct oil level is between theMAX and MIN marks.

FillingIf 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 recom-mended range.

Oil strainer. CleaningWARNING! Working with, or going close to arunning engine is a safety risk. Watch out for ro-tating components and hot surfaces.

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

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

2. Clean the strainer and other components in paraf-fin (kerosene).

3. Carefully put the components back again.

4. Tighten the plug/screw.

5. Start the engine and check carefully that no leak-age occurs

1

12

67

Maintenance. Reverse gear

Oil. Change1. 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 vol-ume: Please refer to the “Technical Data” chapter.

IMPORTANT! Never over-fill the reverse gear.

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

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

Oil filter. ChangeWARNING! Working with, or going close to arunning engine is a safety risk. Watch out for ro-tating components and hot surfaces.

ZF reverse gear

1. Put a suitable vessel beneath the filter, to avoidoil 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 sealjust touches the mating surface on the filter brack-et. 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 theprevious page.

Seal. Lubrication

Applies only to TwinDisc reverse gearLubricate theseal on the output shaft bearing (with thelubricating nipple) using a hand gun and lithium-basedgrease such as Mobilux EP2, Statoil Uniway EP2N,Texaco Multifak EP2, Q8 Rembrandt EP2.

68

Laying up/LaunchingThe boat must be laid up to prevent damage to the engine and other equipment if the boat is not used for twomonths 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 overthe 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. Thiscontains 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 aface mask when spraying.

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

Inhibiting● Warm the engine up to normal operating tempera-

ture and check that the oil level in the reversegear reaches the MAX mark on the dipstick. Stopthe engine.

● Max 8 month’s stoppage:Change the oil and oil filter on the engine, thenwarm it up afterwards.

● More than 8 month’s stoppage:Conserve the lubrication and fuel systems withconservation oil.Please refer to the instructionon the next page.

● Check that the coolant offers sufficient frost pro-tection. Top up as necessary. Alternatively, youcan drain the coolant (also drain the coolant filter).

● Close the sea cock and drain the water from theseawater system.

● Remove the impeller from the seawater pump.Store the impeller in a sealed plastic bag, in acool place.

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

● Disconnect the battery cables, clean and chargethe batteries. Trickle charge the batteries whilethe boat is laid up. A poorly charged battery canfreeze and burst.

● Clean the outside of the battery. Do not use a highpressure washer for engine cleaning. Touch uppaint damage with Volvo Penta original paint.

● Spray the components of the electrical systemwith water-repellent spray (Volvo Penta universaloil).

● Check and rust-proof any control cables.

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

● Cover over the engine air inlet, exhaust openingand engine if necessary.

69

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, ifnecessary. Install a new oil filter if the filter wasnot 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 re-tighten the hose clamps.

● Close the drain taps and install the drain plugs.

● Insert the impeller in the seawater pump, using arotating movement (anti-clockwise).

● Check the coolant level and anti-freeze. Top up asnecessary.

● Connect the fully charged batteries.

● Open the sea cocks

● Start the engine (if the boat is in the water) andwarm 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 asnecessary.

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

● Drain the oil from the sump and engine and fillthe engine up with conservation oil* to justabove 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 about2 litres (0.5 US gal.) have been used. Stop theengine and connect the ordinary fuel pipes.

● Empty the conservation oil out of the engine

● Follow the other instructions on the previouspage.

* Conservation oils are sold by oil companies.1

2

70

Fault code register

1.5.6 O/R

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

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

1. 3.2.

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)

ExplanationFault codes are presented in numerical order, with information about reason, system reaction and proposed mea-sures to be taken.

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.

71

Fault code register

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.

72

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.

73

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.

74

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 incorrectlysense that the engine is too low. If this happens, acknowledge the fault, and check the points below for safetyreasons.

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.

75

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.

76

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.

77

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.

78

Technical dataGeneralType designation ............................................ D9-500 A, D9-575 ANumber of cylinders ....................................... 6Displacement ................................................. 9.36 dm3, (571 in3)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, withoutreverse 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 specificationThe 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-DJIS KK 2204Sulfur 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 anincrease in fuel consumption of about 2–3%.

79

Technical data

SAE5W/30

−−−−−30 −−−−−20 −−−−−10 ±0 +10 20 30 40

−−−−−22 −−−−− 4 +++++14 32 50 68 86 104

−−−−−15oC SAE15W/40

−−−−−25oC SAE10W/30

−−−−−10oC SAE20W/30

±0oC SAE30

SAE40+10oC

oC

oF

✱✱✱✱✱

Lubricating systemOil capacity including oil filters, approx.,

no engine inclination ........................................ 31 liters (8.2 US gals)engine inclination 6o ......................................... 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

Viscosity at different outside air temperatures ....(Temperature based on constant outside airtemperature.

* Refers to synthetic or semi-synthetic oil.

Cooling systemFreshwater system capacity including heatexchanger, approx. ............................................. 39 liters (10.3 US gals)

Electrical systemSystem voltage ................................................... 12V/24VAC generator,

voltage/max. amperage ................................... 28V/60Aoutput, approx. ................................................. 1700W

Alternative generator equipment (accessory):voltage/max. amperage ................................... 28V/80Aoutput, approx. ................................................. 2800W

Alternative generator equipment (accessory):voltage/max. amperage ................................... 14V/115Aoutput, approx. ................................................. 1820W

Battery capacity .................................................. 2 connected in series 12V, max. 152AhBattery electrolyte density at +25°C (77°F):

fully charged battery ........................................ 1.28 g/cm3 = 0.0462 lb/in3 (1.24 g/cm3 = 0.0448 lb/in3 )*battery recharged at ......................................... 1.24 g/cm3 = 0.0448 lb/in3 (1.20 g/cm3 = 0.0434 lb/in3 )*

* Note. Applies to batteries with tropical acid.

80

Technical data

Reverse gearZFType designation 280A E 280IVGear ratios 1,48:1; 1,77:1; 2,00:1 1,56:1; 1,77:1Angle (output shaft) 7° 14°Oil capacity, approx 3,6 liter (0.9 US gal) 5,5 liter (1.4 US gal)Oil grade (in accordance with API-system) CD, CE, CF, CF-4,CG-4,CH-4, CD, CE, CF, CF-4,CG-4,CH-4,

CI-4, SF, SG, SH,SJ, SL, CI-4, SF, SG, SH,SJ, SL,ACEA category A,B,E ACEA category A,B,E

Viscosity at oil temperature 66–85°C SAE30* SAE30*Viscosity at oil temperature 85–100°C SAE40* SAE40*Oil pressure during** neutral 0,08 – 0,12 MPa (11.6 – 17.4PSI) 0,02 – 0,20 MPa (2.9 – 29.0 PSI)Oil pressure during** operation 2,3 – 2,4 MPa (333 – 348 PSI) 2,3 – 2,4 MPa (333 – 348 PSI)Weight, approx. 95 kg (209 lbs) 125 kg (276 lbs)* NOTE! Only single grade lubricating oil (only one viscosity number) may be used in the reverse gear.

Type designation 305A EGear ratios 1,48:1; 1,73:1; 2,04:1Angle (output shaft) 7°Oil capacity, approx 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,ACEA category A,B,E

Viscosity at oil temperature 66–85°C SAE30*Viscosity at oil temperature 85–100°C SAE40*Oil pressure during** neutral 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 DiscType designation MG5075A E MG5075IVGear ratios 1,53:1; 1,77:1; 2,05:1 1,49:1; 1,72:1Angle (output shaft) 7° 15°Oil capacity, approx 5 liter (1.3 US gal) 8,5 liter (22.4 US gal)Oil grade (in accordance with API-system) CC, CD to pass TO-2 oil test, CC, CD to pass TO-2 oil test,

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

Viscosity at oil temperature 66–85°C SAE30* SAE30*Viscosity at oil temperature 85–100°C SAE40* SAE40*Oil pressure during** neutral 0,17 – 0,27 MPa (24.6 – 39.2 PSI) 0,17 – 0,27 MPa (24.6 – 39.2 PSI)Oil pressure during** operation 2,2 MPa (319 PSI) 2,2 MPa (319 PSI)Weight, approx. 125 kg (276 lbs) 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.

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.

Post or fax this coupon to:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgSwedenFax: +46 31 545 772

Orders can also be placed viathe Internet:http://www.volvopenta.com/manual/coupon

Yes please,I would like an operator’s manual in English at no charge.

Publication number: 7743774

Name

Address

Country 4220

0/61

5001

/155

0999

0019

2

Bitte beachten Sie, dass dieses Angebot für die Dauer von 12 Monaten ab demLieferdatum des Bootes gilt, danach bis zum Aufbrauchen des Lagerbestandes.

Schicken Sie den Couponper Post oder als Fax an:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgSchwedenFax: +46 31 545 772

Die Bestellung kann auch überdas Internet erfolgen:http://www.volvopenta.com/manual/coupon

Ja,ich will kostenlos eine Betriebsanleitung in deutscher Sprache erhalten.

Publikationsnummer: 7743788

Name

Anschrift

Land 4220

0/61

5001

/155

0999

0019

2

Notez que l’offre est valable pendant 12 mois à partir de la date de livrai-son du bateau, ensuite seulement en fonction des stocks disponibles.

Envoyez ou faxez le bon decommande à:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgSuèdeFax: +46 31 545 772

Vous pouvez également passerla commande par Internet:http://www.volvopenta.com/manual/coupon

Oui merci,Je souhaite recevoir un manuel d’instructions gratuit en français.Numéro de publication: 7743789

Nom

Adresse

Pays 4220

0/61

5001

/155

0999

0019

2

Si ricorda che l’offerta è valida per 12 mesi dalla data di consegna dell’imbarcazio-ne; dopo il suddetto periodo l’offerta resta valida solo in base alla disposizione dellapubblicazione in oggetto.

Spedire il tagliando per posta oper fax a:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgSveziaFax: +46 31 545 772

L’ordinazione può essere fattaanche su Internet:http://www.volvopenta.com/manual/coupon

Sì, grazie,desidero ricevere gratuitamente un manuale d’istruzioni in lingua italiana.

Public. No.: 7743792

Nome e Cognome

Indirizzo

Paese 4220

0/61

5001

/155

0999

0019

2

Nótese que el ofrecimiento vale durante 12 meses después de la fecha de entregade la embarcación, y posteriormente solamente mientras duren las existencias.

Franquear o enviar fax a:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgSueciaFax: +46 31 545 772

El pedido puede hacerse tam-bién por internet:http://www.volvopenta.com/manual/coupon

Sí gracias,deseo recibir gratuitamente un libro de instrucciones en español.

Número de publicación: 7743791

Nombre

Dirección

País 4220

0/61

5001

/155

0999

0019

2

Observera att erbjudandet gäller i 12 månader från båtens leveransdatum,därefter endast i mån av tillgång.

Posta eller faxa kupongen till:Dokument & Distribution centerOrdermottagningenARU2, Avd. 64620SE-405 08 GöteborgSverigeFax: +46 31 545 772

Beställningen kan även görasvia internet:http://www.volvopenta.com/manual/coupon

Ja tack,jag vill kostnadsfritt ha en instruktionsbok på svenska.

Publikationsnummer: 7743787

Namn

Adress

Land 4220

0/61

5001

/155

0999

0019

2

Denk eraan dat het aanbod geldt gedurende 12 maanden na de datumwaarop de boot werd afgeleverd, daarna alleen indien nog verkrijgbaar.

Stuur of fax de coupon naar:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgZwedenFax: +46 31 545 772

U kunt ook bestellen viainternet:http://www.volvopenta.com/manual/coupon

Ja graag,Ik wil kosteloos een instructieboek in het Nederlands ontvangen.

Publicatienummer: 7743795

Naam

Adres

Land 4220

0/61

5001

/155

0999

0019

2

Bemærk at tilbudet gælder i 12 måneder fra bådens leveringsdato, Deref-ter kun så længe lager haves.

Send kuponen med post ellerfax til:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgSverigeFax: +46 31 545 772

Bestillingen kan også ske påinternet:http://www.volvopenta.com/manual/coupon

Ja tak, jeg vil gerne gratis have en instruktionsbog på dansk

Publikationsnummer: 7743793

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Huomaa, että tarjous on voimassa 12 kuukautta veneen toimituspäivä-määrästä lukien ja sen jälkeen vain niin kauan kuin kirjoja riittää.

Postita tai faksaa kuponkiosoitteella:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgRuotsiFax: +46 31 545 772

Tilauksen voi tehdä myösInternetissä:http://www.volvopenta.com/manual/coupon

Kyllä kiitos,haluan suomenkielisen ohjekirjan veloituksetta.

Julkaisunumero: 7743794

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Observar que esta oferta é válida durante um período de 12 meses a contar dadata de entrega do barco. Após este período, a oferta está dependente do númerode exemplares disponíveis.

Envie o talão pelo correio ouum fax para:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgSwedenFax: +46 31 545 772

A encomenda também podeser 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

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ÐÑÏÓÏ×Ç: ÁõôÞ ç ðñïóöïñÜ éó÷ýåé ãéá ÷ñïíéêÞ ðåñßïäï 12 ìçíþí áðü ôçíðáñÜäïóç ôïõ óêÜöïõò. ÌåôÜ ôï ðÝñáò ôçò åí ëüãù ÷ñïíéêÞò ðåñéüäïõ çäéáèåóéìüôçôá ôùí áíôéôýðùí èá åîáñôÜôáé áðü ôçí ðïóüôçôá ôùí áðïèåìÜôùí.

Ôá÷õäñïìÞóôå áõôü ôï êïõðüíéóôçí ðáñáêÜôù äéåýèõíóç Þóôåßëôå ôï ìå öáî óôïíðáñáêÜôù áñéèìü öáî:

Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgSwedenFax: +46 31 545 772

Ìðïñåßôå åðßóçò íá äþóåôå ôçíðáñáããåëßá óáò ìÝóù ôïõ Inter-net, 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

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