Volvo Penta 22 Series Instruction Book Download Page 53

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Oil level. Check

Trim the drive to the normal drive position. Remove
the dipstick (1) and check the oil level covers the
entire marked area.

IMPORTANT!

The dipstick must always be

screwed in completely

before it is pulled up for

reading the oil level.

Oil. Draining and filling

1. Trim the drive to normal operating position and

remove the dipstick.

2. Position a suitable container under the drain hole.

Remove the plug (1) and the gasket.

3. Allow all the oil to run out.

Deposit the used engine

oil at a properly designated disposal site.

4. Install the plug and gasket (replace the seal if it is

bad).

IMPORTANT!

If the oil is

colored gray

then

water has entered the drive. Please contact
your authorized Volvo Penta dealer.

5. Trim the drive up slightly. Remove the rear cover

(2) and remove the plug (3) and its gasket.

6. Measure out the correct amount of oil and fill up

through the hole for the oil dipstick. Correct
capacity and grade: See chapter ”Technical Data”.

7. Install the plug and gasket.

8. Trim the drive to the normal drive position. Wait

approx. 15 minutes to give the oil time to run
down.

The dipstick should not be installed

during the waiting time.

9. Check the oil level. Top up if required.

7738666 - Downloaded from www.volvopenta.com 31/05/2007 12:43:18

Summary of Contents for 22 Series

Page 1: ...INSTRUCTIONBOOK 22 Series ...

Page 2: ...rating with Power Trim 22 Stopping the engine 25 26 After stopping the engine 25 Coldweatherprecautions 26 Laying up 26 Transporting on a trailer 26 Laying up on land 26 Maintenanceschedule 27 28 Maintenanceandcare 29 57 Engine general 29 Lubrication system 31 Cooling system 32 Fuel injection system 38 Electrical system 41 Wiringdiagram 45 S drive and reverse gear 47 SX drive 52 Layingup Launching...

Page 3: ...in the book and on the engine to make you aware of safety information Always read these safety precautions very carefully In the Instruction Manual warning texts have the following priority WARNING If these instructions are not followed there is a danger of personal injury extensive damage to the product or serious mechanical malfunction IMPORTANT Used to draw your attention to something that can ...

Page 4: ...compartment visually before operating the boat before the engine is started and after operating the boat after the engine has been stopped This will help you to quickly detect fuel coolant and oil leaks and spot anything else unusual that has or is about to happen Maneuvering Avoid violent and unexpected changes in course and gear engagement This could cause someone on the boat to lose their balan...

Page 5: ...ealer where the boat was purchased to get more information on how to solve this problem should it occur on your boat Checklist Safety equipment Life jackets for all passengers communication equipment emergency rockets approved fire extinguisher first aid equipment life belt anchor paddle torch etc Replacement parts and tools impeller fuel filters fuses tape hose clamps engine oil propeller and too...

Page 6: ...in order to maintain the correct balance and make the engine safe to handle Never carry out work on an engine suspended on a hoist Beforestartingtheengine Reinstall all guards removed during service operations before starting the engine Check that no tools or other items have been left on the engine Never start a turbocharger engine without installing the air cleaner ACL The rotating compressor in...

Page 7: ...must be carried out with the engine at operating temperature and the coolant filler cap or a cock open or a coolant hose disconnected open the coolant filler cap carefully and slowly to release pressure before removing the cap completely Note that the coolant may still be hot and can cause burns Lubrication system Hot oil can cause burns Avoid skin contact with hot oil Ensure that the lubrication ...

Page 8: ...l waste such as engine and transmission oil coolant old paint degreasing agents paint and cleaning residue and old batteries at designated disposal areas for destruction Together we can work to make a valuable improvement to the environment Running in The engine must be run in for its first 10 operating hours as follows Operate the engine normally Do not operate it at full load except for short pe...

Page 9: ...ontained in the Instruction Manual concerning operation service and maintenance must be followed IMPORTANT Lateorinadequatemaintenance service or the use of spare parts other than Volvo Penta original spare parts will invalidate AB Volvo Penta s responsibility for the engine specification being in accordance with the certificated variant Volvo Penta accepts no responsibility or liability for any d...

Page 10: ... refer to the location of the identification numbers on the identification plate Engine Product designation 1 Serial number 2 Product number 3 Certification number 4 Drive Shield Reverse gear Product designation 5 Serial number 6 Product number 7 Gear ratio 8 Propeller designation Engine and transmission decal xxx 5 8 xxxxxx 7 No xxxxxxxxxx 6 XXXXXX 7 XXX 5 XXXXXXXXXX 6 XX 8 xxxx 1 xxxxxx 3 No xxx...

Page 11: ...es coveredhere 1 Coolant filler cap 2 Heat exchanger 3 Oil scavenging bilge pump pipe 4 Oil filter 5 Starter motor 6 Generator 7 Injection pump 8 Fuel feed pump 9 Dipstick engine 10 Oil filler cap engine 11 Fuel filter 12 Seawater pump 13 Central electronics module 14 Oil filler drive 15 Oil dipstick drive 16 Seacock 17 Sacrificial anode 18 Oil draining drive 19 Seawater intake 13 8 9 10 11 12 7 6...

Page 12: ...25 18 19 21 17 11 12 13 14 15 10 9 8 20 17 11 12 13 14 15 10 9 8 20 TMD22 MS2 2 3 4 5 7 TMD22P HS25 1 21 18 19 17 11 12 13 14 15 10 9 8 20 21 18 18 2 3 4 5 7 1 7738666 Downloaded from www volvopenta com 31 05 2007 12 43 18 ...

Page 13: ... 10 Injection pump 11 Fuel feed pump 12 Dipstick engine 13 Oil filler cap engine 14 Fuel filter 15 Seawater pump 16 Seawater filter SX 17 Central electronics module 18 Oil dipstick reverse gear SX 19 Oil filler reverse gear SX 20 Oil cooler reverse gear 21 Seawater intake 22 Trim cylinder SX 23 Oil draining SX 24 Servo pump SX 25 Sacrificial anode SX 26 Sacrificial anode SX 27 Trim fin SX 7738666 ...

Page 14: ... counter displays engine operating time in hours and tenths of an hour 2 Siren for acoustic alarm 3 Warning display See 10 13 4 Switch for instrument lighting 5 Alarm test acknowledgment switch To test alarm Press the switch All warning lights light and the acoustic alarm sounds Alarm acknowledgment Press the switch if there is an alarm The acoustic alarm stops but the relevant warning lamp contin...

Page 15: ...a new start attempt can only be made when the ignition key has been returned to the 0 position S Stop position The stop solenoid is connected and cuts off the fuel supply to the engine 0 The key can be inserted and removed I Operating position II Glow plug position The glow plugs are connected and pre heating the engine III Start position The starter motor is engaged IMPORTANT Read the starting in...

Page 16: ...ear disengaged Friction brake The friction brake only affects the engine speed control movements 1 Lift the cover over the control For side mounted controls the lever must first be removed 2 Set the lever to the half open throttle reverse position 3 Adjust the friction brake Turning the screw clockwise makes the lever movement stiffer while turning counterclockwise makes it easier to move the leve...

Page 17: ...stern of the boat raises the bow in relation to the horizontal while moving it towards the stern will lower the bows Press the down button 1 to lower the bow of the boat drive is trimmed inward Press the Up button 2 to raise the bow of the boat drive is trimmed out Button 3 has no function Press the button in the control lever 4 upwards to raise the bow and downwards to lower the bow Trim instrume...

Page 18: ...ectively Switch on the main switch IMPORTANT Never break the circuit with the main switches while the engine is running This could damage the generator Check there is sufficient fuel for the planned journey Lower the SX drive if it was raised Check there are no obstacles in the water near the propellers Starting the engine 1 Move the control lever to the neutral idle position 2 Turn key to the I p...

Page 19: ...ave the same rated voltage as the engine s system voltage 2 First connect the red jump lead to the discharged battery s terminal A and then to the auxiliary battery s terminal B 3 Then connect the black jump lead to the auxiliary battery terminal C and then to a spot a short distance from the discharged batteries for example at the main switch on the negative cable or at the negative cable s conne...

Page 20: ...e engine does reach the wide open throttle range it may be due to one of the reasons covered in the chapter Fault tracing If the engine speed exceeds wide open throttle range a propeller with a higher pitch should be selected Ask your Volvo Penta service dealer for advice Maneuvering All shifting between ahead and astern must be done at engine idle speed Shifting at higher speeds may damage the dr...

Page 21: ...d warning display directly after starting the engine and then at regular intervals while driving the boat Oil pressure A Normal operating oil pressure is between 150 500 kPa 21 71 psi At engine idle this is normally lower The acoustic alarm will automatically go off and the warning lamp will light up if the oil pressure is too low IMPORTANT At the alarm the engine should be stopped immediately Inv...

Page 22: ...im range The trim range is used to achieve maximum comfort under normal operation at all speeds from start to maximum speed Since every boat has its own unique characteristics and will be effected in different ways by the load wind etc only general advice is given here on how to get the best trimming angle for your boat It can generally be said that when the boat feels well balanced easy to steer ...

Page 23: ... seas or running against a heavy sea Trim drive so the bows drop This will provide more comfortable running Beach range The beach range is used for operation at reduced speed in shallow water or where water depth is uncertain IMPORTANT Max permitted engine speed rpm when running in the Beach range is 1 000 rpm Check that the cooling water intake for the drive is never trimmed out of the water Lift...

Page 24: ...MPORTANT Damagedpropellersshouldbereplaced immediately Operating the boat with a damaged propeller should be undertaken with extreme care and only at reduced engine speeds Take the boat out of the water Check the oil level in the drive If it is colored gray then water has entered the drive If this is the case or if other damage has occurred to the drive it must be inspected at an authorized Volvo ...

Page 25: ...re is a risk that the drive can run aground it must instead be trimmed out to its maximum lift position Shut the fuel cock and the seacock not standard on SX drive IMPORTANT Do not forget to open the cocks before the engine is started again Switch off the main switch if the boat is not to be used for some time IMPORTANT Never break the circuit with the main switches while the engine is running Thi...

Page 26: ...the drive to the highest position when the boat is put on the trailer the drive is stopped automatically at the highest position IMPORTANT The engine must not be run with the SX drive is in the lift range Before transporting the boat by trailer always secure the drive in the lift position with a Trailer Kit accessory or similar so that it cannot drop down IMPORTANT Boats with reverse gear S drive ...

Page 27: ...e filter Drain water page39 Generator and circulation pump drive belts Check page30 Servo pump drive belt SX Check page30 Servo pump SX Check oil level page29 Seawaterfilter Cleaning page37 Battery Check electrolyte level page42 Reverse gear Check oil level page47 48 S drive Check oil level page47 SX drive Check corrosion protection page52 SX drive Check oil level in trim pump page54 AFTER THE FIR...

Page 28: ...e glycol mixture it must be changed every other year EVERY OTHER YEAR Coolant Replacing1 page34 SX drive Replace universal joint and exhaust bellows notshown 1 If the freshwater system is filled with an anti corrosion agent mixture it must be changed every year If the freshwater system is filled with an antifreeze glycol mixture it must be changed every other year EVERY 500 OPERATING HOURS OR AT L...

Page 29: ... Check the camshaft belt every year If must be changed every 2000 hours of operation or earlier if it appears worn or cracked Replacement should be left to authorized service personnel Wastegate TMD22 TAMD22 If the engine is not used for a longer period of time there is a risk that the turbocharger boost pressure valve may stick Check that the shaft turns Servo pump SX Oil level Turn the filler ca...

Page 30: ...ssary 2 Adjust to correct tension Tighten the screws Replacing Unscrew the screws 1 and 2 so the belt can be removed Clean off the pulley grooves Install the new belt Adjust as above Seawaterpump It should be possible to depress a belt at the correct tension approx 5 mm 0 4 down between the pulleys A torque wrench is required for adjustment Unscrew the screws 1 and 2 Locate the torque wrench s squ...

Page 31: ...s Changing 1 Run the engine to operating temperature so that the oil is easier to suck out Stop the engine 2 Suck out the oil using an oil drain pump through oil drain pipe 1 WARNING Hot oil and hot surfaces can cause burns 3 Unscrew the old filter To avoid oil spills put a plastic bag over the filter before it is unscrewed 4 Check that the engine mating surface is clean 5 Moisten the filter rubbe...

Page 32: ...f this is not possible the boat must be taken out of the water before work begins Coolant General The freshwater system must be filled with a coolant that protects the engine against internal corrosion and from freezing if the climate requires it IMPORTANT Never use water alone If the freshwater system is filled with an anti corrosion agent mixture it must be changed every year If the freshwater s...

Page 33: ...when the engine is still hot Steam or hot coolant may spray out Turn the pressure cap 1 to the first stop and let any pressure escape from the system before removing the cap Top up coolant so that the level reaches the lower edge of the filler pipe Reinstall the cap NOTE IMPORTANT The coolant level must not be below the level spur 2 in the heat exchanger Fill with the same sort of coolant already ...

Page 34: ...NOTE To protect the environment please dispose of used coolant at a properly designated disposal site 1 2 1 Impeller Check Replace WARNING If the engine is installed so that the seawater pump is located under the water line there is a risk of water penetration if the boat is in thewater Close the seacocks 1 Remove the cover and sealing plate on the seawater filter if installed 2 Remove the cover f...

Page 35: ...xchanger and charge air cooler CAC by opening the cock plug 2 on the charge air cooler CAC 4 Engines with seawater filter Remove the cover 3 and sealing plate 4 on the sea water filter Detach the hose on the seawater pump inlet side 5 and empty it of water 5 MS25 HS25 Drain the water from the oil cooler by opening the plug 6 6 SX drive Trim drive out to max raised position Remove drain plug 7 Trim...

Page 36: ... will be damaged if it runs dry 4 Set the gear control lever in the neutral position Check that nobody is near the propellers Start the engine Let it run at idle a few minutes Stop the engine WARNING Approachingorworkingona running engine is dangerous Watch out for rotating components and hot surfaces 5 Empty and clean the seawater filter if installed according to the description on the next page ...

Page 37: ...p working WARNING Risk for water penetration Close the seacocks 2 3 1 Seawater filter Cleaning The seawater filter is only standard on engines with SX drive If the boat is used in water that has a lot of contaminants seaweed etc the filter must be checked more frequently than indicated in the maintenance schedule Otherwise there is a risk the filter will clog and the engine will overheat WARNING S...

Page 38: ...e vented after fuel filters have been replaced or after refilling the fuel tank after it has been run dry 1 Open vent screw 1 on the filter mounting approx three turns Avoid fuel spillage Use rags around the venting point 2 Pump the fuel using hand pump 2 until there are no more air bubbles visible in the fuel Continue pumping and at the same time tighten the venting screw If the pump effect is po...

Page 39: ...oisten the new filter s rubber gasket with a little fuel 3 Screw on the new filter by hand until it is in contact with the mating surface And then a further half turn but no more 4 Bleed fuel system 5 Start the engine and check for leaks WARNING Approaching or working on a running engine is dangerous Watch out for rotating components and hot surfaces Fuel pre filter Draining Fuel pre filters and w...

Page 40: ... reinstall glass Open fuel cock Undo the screw 3 a few turns and the glass will fill with fuel Bleed fuel system Fuel pre filter type B Remove cover 2 and lift up the insert Drain water and contaminants through the drain cock 1 Install new filter insert and fill container with clean diesel oil Screw on cover and tighten by hand Open fuel cock Bleed fuel system WARNING Approachingorworkingonarunnin...

Page 41: ... while the engine is running IMPORTANT Never break the circuit with the main switches while the engine is running Fuses If the engine cannot be started or if all instruments read zero an engine fuse can have blown Always investigate the reason The engine has two semi automatic fuses which will cut off the current if there is an overload Reset the fuses by pressing in the two reset buttons 1 The en...

Page 42: ...e battery terminal Then connect the black battery lead to the battery terminal When disconnecting the battery disconnect the lead black first and then the lead red Cleaning Keep batteries dry and clean Oxidation or dirt on the battery and battery terminals can cause short circuits voltage drop and discharge especially in damp weather Clean the battery terminals and leads to remove oxidation using ...

Page 43: ...he boat has not been used for some time charge the battery and then trickle charge it see manufacturer s recommendations A poorly charged battery will be damaged and may burst in cold weather IMPORTANT Follow the instructions supplied with the battery charger carefully To avoid electrolytic corrosion when an external charger is connected always disconnect the battery leads before connecting the ch...

Page 44: ...ic cables so that they will not be exposed to rubbing damp or bilge water in the keelson 3 Protective grounds for the radio navigational equipment rudder bathing steps or other equipment with separate ground leads must be connected to a common ground terminal which is not connected to the engine drive or reverse gear IMPORTANT Engine drive or reverse gear must never be used as a ground point 4 The...

Page 45: ...lor code GR Gray SB Black BN Brown LBN Light brown R Red Engine 1 Enginecoolanttemperature ECT 2 Engine coolant temperature ECT switch 3 Oil pressure sensor switch 4 Glowplugs 5 Relay 6 Ground fault fuse 55 A 7 Automatic fuse 7738666 Downloaded from www volvopenta com 31 05 2007 12 43 18 ...

Page 46: ...erature warning lamp 8 Oil pressure warning lamp 9 Charge warning lamp 10 Control lamp pre heating 11 Switch instrument panel lighting 12 Switch alarm test 13 Tachometer 14 Ignition switch 15 Alarm 16 Neutral position switch terminal 17 16 pin connector 18 2 pin connector for auxiliary panel Standard Color code GR Gray SB Black BN Brown LBN Light brown R Red PU Purple GN Green W White BL Blue LBL ...

Page 47: ...he drive without screwing it into place Remove again and check that the oil level is between the MAX and MIN markings on the dipstick Top up oil if necessary IMPORTANT The oil level should always be within the MAX and MIN range marked on the dipstick Oil change S drive Remove the oil dipstick Remove the plug on the propeller gear housing and let the oil run out Check that the plug o ring is intact...

Page 48: ... the cover 2 and gasket 3 3 Carefully remove the filter 4 Clean the filter in kerosene leave the gasket 5 in place Clean the filter housing 4 Suck up oil using an oil pump through the hole for the dipstick 5 Measure out the correct amount of oil and fill up through the hole for the oil dipstick or filter housing For oil quality and capacity See the chapter TechnicalData IMPORTANT Neveroverfillreve...

Page 49: ...anodes for salt water and magnesium anodes for freshwater Replacingsacrificialanodes Folding propellers for the S drive have three sacrificial anodes 1 installed on the propeller hub To replace the sacrificial anodes 2 on the S drive the propeller must first be removed see separate description Remove the sacrificial anode Thoroughly scrape the mating surfaces Install and tighten the new anodes so ...

Page 50: ...Then press in approx 1 cm3 0 06 cu in water repellent grease into the seal IMPORTANT The seal must be replaced every 500 running hours or every 5th year Folding propeller Maintenance The propeller should be disassembled once a year for cleaning and lubrication Clean carefully Apply waterproof grease to the propeller blade teeth and bearing surfaces so that the propeller can fold easily Also apply ...

Page 51: ...Install the nut 6 and tighten to 70 Nm Reverse gear Install the washer 8 and tighten the nut 7 to 220 Nm Apply thread sealant to the locking screws 9 After the locking screws have been tightened apply thread sealant to the screw heads as well 7 Drive Locate the tab washer 3 on the nut Install and tighten the locking screw 4 to 20 Nm and bend one of the tab washer tabs to the screw head 8 Install o...

Page 52: ...nodes when approximately 30 of the anode has been eroded Note that most stainless steel propellers accessories use the sacrificial anodes faster than normal IMPORTANT Tighten the new anodes so that there is a good metallic contact is retained IMPORTANT Use zinc sacrificial anodes for salt water and magnesium anodes for freshwater The sacrificial anodes oxidize in contact with air which diminishes ...

Page 53: ...sposal site 4 Install the plug and gasket replace the seal if it is bad IMPORTANT If the oil is colored gray then water has entered the drive Please contact your authorized Volvo Penta dealer 5 Trim the drive up slightly Remove the rear cover 2 and remove the plug 3 and its gasket 6 Measure out the correct amount of oil and fill up through the hole for the oil dipstick Correct capacity and grade S...

Page 54: ... is under pressure Before removing the filler plug the drive must be trimmed up completely so that the system is not under pressure Always use a rag over the filler hole when the plug is being removed so that should the system still be under pressure the oil does not spray out Trim the drive to the maximum up position Remove the oil filler plug 1 and check that the oil level reaches the bottom edg...

Page 55: ...split pin 1 and the locking tab washer 2 2 Put a wooden block between the propeller blade and the cavitation plate 3 Remove the nut 3 spacer 4 propeller 5 and the bushing 6 4 Grease the propeller shaft using water repellant grease 5 Install the bushing 6 with the inner cone turned toward the propeller shaft cone 6 Install the propeller 5 Press the propeller against the bushing until the spline edg...

Page 56: ...ows every year If there are cracks or other defects they must be replaced Otherwise replace every other year WARNING Removal of the drive requires special knowledge and tools A falling drive can cause serious personal injury Please contact your nearest authorized Volvo Penta dealer for assistance Lubrication CV joint Remove the drive from mounting fork The CV joint is lubricated by the two lubrica...

Page 57: ... until it is forced out of the bearing If the old grease indicates water contamination the bearing must be inspected and replaced if damaged WARNING Removal of the drive requires special knowledge and tools A falling drive can cause serious personal injury Please contact your nearest authorized Volvo Penta dealer for assistance 7738666 Downloaded from www volvopenta com 31 05 2007 12 43 18 ...

Page 58: ...haft seal exhaust or drive joint bellows and the trim cylinder seals Check the condition of the engine coolant antifreeze Top up if required Replace the coolant according to the maintenance schedule IMPORTANT An anti corrosion mixture in the engine coolant system provides no protection against freezing If there is any possibility the engine will be subjected to freezing temperatures then the syste...

Page 59: ...ies Check that the Turbos boost pressure valve is not stuck TMD and TAMD 22 Paint the drive and hull See following section The drive s sacrificial anodes must be cleaned off with emery paper immediately before launching If there is less than 50 of the anode left it must be replaced IMPORTANT Do not use steel brushes or any steel tools for cleaning the anodes This can result in reduced galvanic pro...

Page 60: ... and a finer grade for painted surfaces Wash off using thinners or similar Any pores in the surface should be filled and sanded down Paint using Volvo Penta original primer and topcoat Let the paint dry The drive should be painted with Volvo Penta anti fouling to prevent fouling Apply according to the instructions on the packaging IMPORTANT The sacrificial anodes on the drive must not be painted U...

Page 61: ...service in the chapter Safety Precautions before starting work 1 Dischargedbattery 2 Looseconnection open circuit 3 Ground protection fuse or one of the semi automatic fuses in the terminalboxhasblown beentriggered 4 Preheatinginsufficient 5 Lack of fuel 6 Blockedfuelfilter supplypump 7 Air in the fuel injection system 8 Water contaminantsinthefuel 9 Boatabnormallyloaded 10 Foulingonunderwaterhull...

Page 62: ... Fully open at 95 C 3 C Electrical system System voltage 12 V Starter battery capacity 70 Ah AC generator 14V 60A Lubricating oil recommendations Oil volume including oil filter 6 0 liters Oil quality according to API CD CF CF 4 CG 4 ACEA E1 E2 E3 VDS VDS VDS 2 Viscosity is selected from the table API American Petroleum Institute ACEA Association des Constructeurs Européenne d Automobiles VDS Volv...

Page 63: ...e designation MS25L Gear ratio Left rotating Position B 2 1 1 2 72 1 Right rotating Position A 2 3 1 2 74 1 Angle output shaft 0 Oil grade ATF Dexron II Oil capacity approximately 0 75 liters Weight 18 kg HS25 Type designation HS25A Gear ratio 2 29 1 2 71 1 Angle output shaft 8 Oil grade ATF Dexron II Oil capacity approximately 1 8 liters Weight 24 kg SX drive Type designation SX R Gear ratio 2 18...

Page 64: ...__________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ______________________________________...

Page 65: ...7738666 Downloaded from www volvopenta com 31 05 2007 12 43 18 ...

Page 66: ...7738666 2 English 11 1998 AB Volvo Penta SE 405 08 Göteborg Sweden www volvopenta com ...

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Volvo Penta 22 Series, Instruction Book

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