Volvo Penta KAD/KAMD300 Operator'S Manual Download Page 64

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Maintenance: Electrical components diagram

KAMD44P, KAMD300

1. Starter motor
2. Generator
3. Starter relay
4. Main relay
5. Stop relay
6. Ground relay
7. Semi-automatic fuses,

engine/instrumentation

8. EDC control module
9. Boost pressure sensor, connection

10. Charge air temperature sensor
11. Engine coolant temperature sensor

12. Injection pump
13. Stop solenoid
14. Engine speed (rpm) sensor
15. Service socket
16. Needle lift sensor
17. Emergency stop
18. Standard fuse, EDC system/compressor
19. Connector, instrumentation
20. DC/DC converter

21. Electronic valves, shifting

12, 13

4 5

Summary of Contents for KAD/KAMD300

Page 1: ...OPERATOR S MANUAL KAD KAMD44P KAD KAMD300 ...

Page 2: ... 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 alla fine del manuale Dit instructieboek kan worden besteld in het Nederlands De bestelcoupon vindt u achter in het instruc tieboek Denne instruktionsbog kan bestilles på dansk Bestillings...

Page 3: ...nce and long service life We also believe that this is what you demand and expect of your Volvo Penta engine We would like you to read this operator s manual thoroughly and consider the advice we give on running and maintenance before you cast off on your maiden voyage so that you will be ensured of fulfilling your expectations With warm regards AB VOLVO PENTA IMPORTANT These instructions do not c...

Page 4: ...ns 38 Maintenance schedule 39 42 Maintenance 42 74 Engine general 42 Lubrication system 47 Freshwater system 49 Coolants 49 Seawater system 51 Fuel injection system 54 Electrical system 56 Electrical components diagram 61 Reverse gear 63 Drive 65 Steering 70 Propellers 73 Laying up Launching 75 77 Inhibiting 75 Bringing out of winter storage 76 Painting the drive and underwater hull 77 Fault traci...

Page 5: ...nta dealer for assistance This symbol is used in the book and on the engine to make you aware of safety information Always read these safety precautions very carefully In the operator s manual warning texts have the following priority WARNING If these instructions are not followed there is a danger of personal injury exten sive damage to the product or serious mechanical malfunction IMPORTANT Used...

Page 6: ...d and after operating the boat after the engine has been stopped This will help you to quickly detect fuel coolant or oil leaks and spot anything else unusual that has or is about to hap pen Maneuvering Avoid violent and unexpected changes in course and gear engagement This could cause someone on the boat to lose their balance and fall over or overboard A rotating propeller can cause serious injur...

Page 7: ...nging the setup of the cover as well Get in touch with your boat dealer for help in obtaining the best solution for 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 propelle...

Page 8: ...ts center of gravity Special lifting equipment may then be required in order to maintain the correct bal ance and make the engine safe to handle Never carry out work on an engine suspended on a hoist Beforestartingtheengine Reinstall all protective parts removed during service operations before starting the engine Check that no tools or other items have been left on the engine Never start a turboc...

Page 9: ...t can spray out and cause burns If work must be carried out with the engine at operat ing temperature and the coolant filler cap or a cock open or a coolant hose disconnected open the cool ant 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...

Page 10: ...nd them Remember to always leave hazardous waste such as waste oil coolant paint and wash residue flat batteries etc for disposal at a de struction plant Our joint efforts will make a valuable contribution to our 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 periods Never run ...

Page 11: ... all engines manufactured of that type correspond to the certified engine This places special requirements for mainte nance and service as follows The maintenance and service intervals recommen ded by Volvo Penta must be observed Only genuine Volvo Penta replacement parts may be used The service of injection pumps and injectors or pump settings must always be carried out by an authorized Volvo Pen...

Page 12: ...ial number 2 Product number 3 Drive Reverse gear Product designation 4 Gear ratio 5 Serial number 6 Product number 7 Shield Drive Product designation 8 Serial number 9 Product number 10 The numbers refer to the position of the identification numbers on the information decal Location of information decal and identification plates Engine Drive Reverse gear information decal XXX XXX RATED POWER xxx R...

Page 13: ...d on seven bearings Lubrication system Pressure lubrication system with replaceable full flow oil filter Gear driven oil pump Washable pipe type oil cooler Intake and exhaust system Intake silencer with replaceable filter Seawater cooled exhaust pipe made of cast iron with a stainless steel insert Exhaust driven freshwater cooled turbocharger TC Mechanically driven compressor Fuel system Rotor typ...

Page 14: ...he engine always receives the correct volume of fuel in all operating conditions This means lower fuel consumption and minimal exhaust emissions Diagnostic function The task of the diagnostic function is to discover and localise any disturbances within the EDC system to protect the engine and to ensure operation in event of serious disturbances If a disturbance is found the diagnostic button indic...

Page 15: ...C control module 4 Oil filter engine 5 Charge air cooler 6 Dipstick reverse gear 7 Starter motor 8 Fuel feed pump 9 Fuel filter 10 Injection pump 11 Generator 12 Sea water pump KAMD44P KAMD300 HS63 13 Turbocharger 14 Air Cleaner ACL 15 Dipstick engine 16 Coolant filler 17 Expansion tank 18 Compressor 19 Heat exchanger 20 Oil filter reverse gear ...

Page 16: ...eed pump 9 Fuel filter 10 Injection pump 11 Generator 12 Sea water pump KAD44P Professional DP E 13 Turbocharger 14 Air Cleaner ACL 15 Dipstick engine 16 Coolant filler 17 Expansion tank 18 Compressor 19 Power steering pump 20 Heat exchanger 21 Trim cylinder 22 Cooling water intake 23 Guide cylinder 24 Topping up oil drive 22 21 13 20 14 15 16 17 18 19 24 23 1 2 3 5 6 7 8 9 10 11 12 4 ...

Page 17: ...el filter 10 Injection pump 11 Generator 12 Sea water pump KAD44P DPX A 13 Turbocharger 14 Air Cleaner ACL 15 Dipstick engine 16 Coolant filler 17 Expansion tank 18 Compressor 19 Power steering pump 20 Heat exchanger 21 Trim cylinder 22 Cooling water intake 23 Guide cylinder 24 Topping up oil drive 25 Oil dipstick drive 22 21 13 20 14 15 16 17 18 19 25 24 23 1 2 3 4 5 6 7 8 9 10 11 12 ...

Page 18: ...d pump 9 Fuel filter 10 Injection pump 11 Generator 12 Sea water pump KAD300 DP G 13 Turbocharger 14 Air Cleaner ACL 15 Dipstick engine 16 Coolant filler 17 Expansion tank 18 Compressor 19 Power steering pump 20 Heat exchanger 21 Trim cylinder 22 Cooling water intake 23 Topping up oil drive 24 Oil dipstick drive 22 21 13 20 14 15 16 17 18 19 24 23 1 2 3 4 5 6 7 8 9 10 11 12 ...

Page 19: ... iary control position 1 Temperature gauge Indicates the engine coolant temperature 2 Oil pressure gauge Indicates the pressure of the engine lubricant 3 Voltmeter Indicates the charge voltage from the alternator when the engine is running and the bat tery voltage when the engine is stopped 4 Tachometer Indicates the speed of the engine in rpm recommended cruising speed is shown in the chapter Ope...

Page 20: ... alarm 1 Coolant temperature too high 2 Lubricant pressure too low 3 Alternator not charging 4 Not used 5 Lubricant level too low accessory 6 Coolant level too low accessory 7 Water in fuel pre filter accessory 8 Auxiliary accessory Warns for low level with stationary engine and starter key in position I Drive position Refill to correct level before starting the engine After an alarm Press the Ala...

Page 21: ...code required when ordering additional starter keys Do not keep the code where unauthorized per sons can access it S Stop position 0 Key can be inserted and removed I Voltage on drive position II Not used III Start position IMPORTANT Read the starting instructions in the chapter Starting the engine ...

Page 22: ...utton By pressing the button at the same time as the con trol lever is moved forward to the shifting position the control lever shift function is disengaged so that the engine can be revved freely Indicator green No light Reverse gear drive is engaged Light on The control lever is in neutral position Flashing The control lever shift mechanism is disen gaged 3 Diagnostics button The button is used ...

Page 23: ...tion the control lever shift function is disengaged so that the engine can be revved freely Indicator No light Reverse gear drive is engaged Light on The control lever is in neutral position Flashing The control lever shift mechanism is disen gaged 3 Diagnostic button yellow The button is used if the diagnostic function has re gistered malfunction indicator flashes By pressing the button the messa...

Page 24: ...e speed control NOTE The engine can be started only if the control lever is in the neutral position Disengaging the shift function The shift function can be disengaged so that the control lever only affects the engine speed 1 Move the lever to the neutral position N 2 Press the neutral button in and hold it down while mov ing the control lever forward to the shift position F 3 Release the neutral ...

Page 25: ...n Adjusting the friction brake 1 Stop the engine 2 Mover the control lever forwards so that the groove in the hub of the control lever is accessible 3 Position a screwdriver in the groove and remove the plug 4 Adjust the friction brake 8 mm wrench Clockwise heavier lever action Counter clockwise lighter lever action 5 Reinstall the plug ...

Page 26: ...ow in relation to the horizontal while moving it towards the stern will lower the bows Button 1 Press button to raise the bow of the boat drive is trimmed out Button 2 Press button to lower the bow of the boat drive is trimmed inward Button 3 Press the button while simultaneously pressing button 2 or 4 is pressed up to raise or trim the drive out to Beach range Button 4 Press button up to raise bo...

Page 27: ...Otherwise no indication 2 Yellow light indicates that the bows are below the hori zontal line Flashes when the drive moves and the bow is lowered Otherwise no indication 3 Green light comes on in the trim range 9 to 0 Other wise no indication 4 Green light comes on in the trim range 0 to 2 Other wise no indication 5 Green light comes on in the trim range 2 to 5 Other wise no indication 6 Red light...

Page 28: ...een the Trim and Beach ranges Take care to observe the instrument when trimming the drive out so that the drive does not enter the Beach range Twin and triple installations In twin and triple installations the drives may be trimmed individually within the permitted trim range WARNING When lifting drives within the Beach range both drives must be always lifted at the same time in parallel so as not...

Page 29: ...is installed and let it run for at least four minutes Lower the drive s if raised WARNING Twin and triple installations DPX the drives must be trimmed at the same time parallel General about starting The engine speed control must be set to idle when the en gine is started The EDC system ensures that the engine receives the correct amount of fuel even when the engine is cold The EDC system allows t...

Page 30: ...trol position Press the activation button for at least one second The indicator lights to confirm the control position is activat ed when the button is released NOTE If the indicator flashes the control position has not been activated because the control lever s are not in the neutral position 5 Start the engine Start using the ignition switch Turn the key to position III Release the key and let i...

Page 31: ...vent the starter motor from overheating If possible allow the starter motor to cool down for at least five minutes before making a new start attempt Start using auxiliary batteries Refer to the description in the chapter Troubleshoot ing 6 Check the instruments and run the engine warm Let the engine idle for the first ten seconds and make sure the instruments and warning display show normal values...

Page 32: ...ounds and the lamp in the warning dis play starts to flash if the oil pressure is too low IMPORTANT In the event of a low oil pressure alarm Stop the engine immediately Investigate and correct the malfunction Enginecoolanttemperature ECT The temperature gauge must display 75 90 C during normal operation The acoustic alarm sounds and the lamp in the warning dis play starts to flash if the engine co...

Page 33: ... time NOTE In the Diagnostic function chapter there is more information about the diagnostic function reading off diag nostic trouble codes DTCs etc Cruising speed Avoid running at full speed to obtain the best operating economy We recommend a cruising speed of at least 10 lower than the maximum rpm at full speed wide open throt tle The maximum rpm at full speed can vary depending on choice of pro...

Page 34: ...he conditions are no longer met The synchronisation function is automatically activated at start However the function can also be engaged and disen gaged by pressing the synchronisation button for at least one second Changing control position For reasons of safety the engine can only be changed to the new control position if the control lever s are in neutral in both the control position that was ...

Page 35: ...ING Never shift to reverse when the boat is planing 2 Move the reverse gear control lever quickly and firmly into the neutral position Wait for a moment 3 Move the gear control lever quickly and firmly into astern then increase the speed IMPORTANT If the boat has two engines it is impor tant that they are both running during maneuvers astern rearwardmovement otherwisewatermight get into the exhaus...

Page 36: ...im 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 factors involved 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 and pleas an...

Page 37: ... within the beach range both drives must always be lifted at the same time in parallel so as not to place an undue strain on the parallel strut between the drives Drives must also be lowered simultaneously parallel For maximum fuel economy Operate engine at a steady throttle opening Trim the drive out in slightly The boat is most easily propelled and speed will increase in the position that gives ...

Page 38: ... 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 Penta workshop If only the propeller has been damaged it must be replaced Launch the boat and test drive If there are still vibrations it must be inspected by an authorized Volvo Penta workshop IMPORTANT To prevent galvanic corrosion any dam...

Page 39: ...ne compartment for any leaks Boats with drives The drive must be trimmed in to its maximum to protect the trim cylinders untreated surfac es from fouling IMPORTANT If there is a risk that the drive can run aground it must instead be trimmed out to its maximum lift position WARNING Twin and triple installations DPX The drives must be lifted at the same time parallel Switch off the main switches if ...

Page 40: ...ec tion in chapter Maintenance IMPORTANT A poorly charged battery may burst as a result of freezing Transporting on a trailer Before pulling boats with on to a trailer trim the drive out to Lift range maximum lift An automatic stop will cut off the current to the hydraulic pump when the drive has reached its max lift point The stop is automatically reset when trimming down NOTE Check local legisla...

Page 41: ...t of the fuel Please refer to page 46 2 Change the filters during each oil change 3 If the fresh water system is filled with a rust protection mixture it must be changed every year On the other hand if the fresh water system is filled with anti freeze glycol mixture it must be changed every second year 4 IMPORTANT In operation situations where the number of forward reverse operations averages more...

Page 42: ... shown Every second year Coolant Change3 page 51 Every 600 hours at least every 5 years Drive belt circulation pump Change page 45 Drive belt supercharger Change page 46 Reversing gear Changing the propeller seal not shown Turbo Inspection cleaning as necessary not shown Trim cylinders hoses hydraulic hoses Leakage check not shown Rubber valves for exhaust outlet in cavitation plate Inspection not...

Page 43: ...for wear and damage Any faults are rectified If necessary the complete drive is changed 1 Oil change intervals vary depending on oil grade and sulfur content of the fuel Please refer to page 46 2 Change the filters during each oil change 3 If the fresh water system is filled with a rust protection mixture it must be changed every year On the other hand if the fresh water system is filled with anti...

Page 44: ...oom before starting the engine and after stop ping when the engine has been turned off This will help you to quickly detect abnormalities that have oc curred or are about to occur Look especially carefully for oil fuel and coolant leaks loose bolts worn or slack drive belts loose connections damaged hoses and electric cables This inspection takes only a few minutes but can pre vent serious operati...

Page 45: ...d Take care that no contaminants enter the engine Install the new air filter and air cleaner cover Compressor Checking oil Checking and topping up Unscrew and remove the dipstick Wipe off oil Screw the dipstick down fully and then remove it again Check that the level oil is between the markings If the dipstick is not screwed down fully the oil level will be slightly above the MIN marking if the oi...

Page 46: ...loose they can slip For this reason check belt tension regularly Proce dure please refer to the advice for each belt below Adjust as necessary Do checks and any adjust ment after driving when the belts are warm Check that the belts are free from cracks and other damage Replace worn belts Adjustment and replacement IMPORTANT The belts must be tensioned in the following order to avoid uneven loading...

Page 47: ...the protective cover Undo the nut 1 enough so the belt slackens off Tension the belt by tightening the domed nut 2 on the tensioner screw to 35 40 Nm Use a torque wrench and a suitable socket Lock the tensioner screw with the nut 1 4 Servo pump belt Undo the fixing screw 1 Tension the belt with the adjustment screw 2 so that the belt can be pressed down about 10 mm 3 8 between the pulleys using no...

Page 48: ...t springs back to 0 3 Press in the neutral button Hold it depressed until point 5 inclusive 4 Turn the ignition key to position l drive position The indicator on the diagnostic button lights 5 Release the neutral button when the indicator on the diagnostic button goes out 6 The indicators for the neutral and diagnostic but tons flash to confirm that the idling speed can now be adjusted If the boat...

Page 49: ...ures Refers to synthetic or semi synthetic oils Oil change volume Please refer to the Technical Data chapter 1 When oil quality specifications are joined by or Type 1 2 and 3 either engine oil specification can be used When oil quality specifications are joined by and Type 2 and 3 the engine oil must fulfill both re quirements 2 ACEA E7 has replaced ACEA E5 but if available ACEA E5 can be used 3 I...

Page 50: ...k out Stop the engine Suck up oil us ing an oil scavenging pump through the hole for the dipstick WARNING Hot oil and hot surfaces can cause burns Unscrew the old filter To avoid oil spills put a plastic bag over the filter before it is unscrewed Check that the mating surface on the engine is clean and that the old rubber gasket is removed Moisten the filter rubber gasket with a little oil Screw o...

Page 51: ...expansion tank when the engine is at normal operating tempera ture The level is normally lower when the engine is cold Reinstall the filler cap 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 Never use freshwater alone WARNING Anti corrosiveagentsandantifreeze products are harmful t...

Page 52: ...lant from the other drain cocks 2 4 Flush out the heat exchanger as follows before fill ing coolant NOTE Deposit old coolant at a properly designated disposal site Heat exchanger Flushing out Cooling performance is reduced by scaling in the heat exchanger It should therefore be flushed when the coolant is changed 1 Drain the coolant as above 2 Insert a hose into the filler pipe on the expansion ta...

Page 53: ...ust be replaced Lubricate the pump housing and the inside of the cov er with a little waterproof grease for rubber Reinstall the impeller using a rotating movement In stall the seal washers on the shaft center Install the cover together with a new gasket Reverse gear Open the sea cock Seawater system The sea water system is the engine s external cooling system On engines with stern drives the sea ...

Page 54: ...ries the drive must be completely trimmed down in the water Engine with reverse gear Close the sea cock Drain oil cooler by opening the plug 2 Disconnect hose 3 and bend down so that the water runs out Disconnect hose 4 by the sea cock and empty it of water 2 Undo hose 5 and empty the water out of it Drain the intercooler by opening the plug 6 drain the oil cooler by opening the plug on the hose w...

Page 55: ...hed behind the exhaust outlet WARNING Approaching a running engine is dangerous Watch out for rotating components and hot surfaces IMPORTANT The impeller 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 fast idle a few minutes Stop the engine 5 For inhibiting fill a bucket with antifreeze mix...

Page 56: ...ge 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 poor turn the engine over slightly so that the pump drive cam changes position If the engine does not start continue venting as follows 3 Use the handpump 2 and pump for about half a minu...

Page 57: ... the new filter by hand until it is in contact with the mating surface And then a further half turn but no more Vent fuel system Deposit the old filter at a properly designated disposal site Start the engine and check for leaks WARNING Approaching a running engine is dan gerous Watch out for rotating components and hot surfaces Fuel pre filter Replacing filter insert Close fuel cock at the fuel ta...

Page 58: ...ts stop working when driving a circuit breaker might have tripped Re set the circuit breaker by pressing in the button on the distribution box The EDC system 1 and the compressor 2 have 7 5 A fuses beneath the distribution box There are spare fuses in the distribution box IMPORTANT Always investigate the reason for the overload The control lever with integrated Power Trim control button has a 5A f...

Page 59: ...ery 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 weath er Clean the battery terminals and leads to remove oxidation using a brass brush Tighten the cable ter minals well and grease them w...

Page 60: ... be charged If the boat has not been used for some time charge the battery and then trickle charge it see manufacturer s recommendations A poorly charged battery will be damaged and may burst in cold weather IMPORTANT Follow the instructions supplied with the battery charger carefully To avoid elec trolytic corrosion when an external charger is connected always disconnect the battery leads before ...

Page 61: ...nd should be ashore never in the boat Shore power should always have a ground fault circuit breaker Shore power units transformer rectifier battery chargers etc must be intended for marine usage and the high tension circuit must be galvani cally separated from the low tension circuit 2 Route and clamp electric cables so that they will not be exposed to rubbing damp or bilge water in the keelson 3 ...

Page 62: ...al and the fuse block and the terminal and the termi nal block for the boat s electrical equipment The main switch for the auxiliary battery must cut off all power consuming equipment connected to that battery and be turned off when power is no longer needed All equipment connected to the auxiliary battery should have separate switches To simultaneously charge two independent battery circuits fit ...

Page 63: ...ule 9 Boost pressure sensor connection 10 Charge air temperature sensor 11 Engine coolant temperature sensor 12 Injection pump 13 Stop solenoid 14 Engine speed rpm sensor 15 Service socket 16 Needle lift sensor 17 Emergency stop 18 Standard fuse EDC system compressor 19 Connector instrumentation 20 DC DC converter 21 Gearshift control actuator 22 Fuse gearshift control actuator 1 10 11 14 16 21 22...

Page 64: ...ol module 9 Boost pressure sensor connection 10 Charge air temperature sensor 11 Engine coolant temperature sensor 12 Injection pump 13 Stop solenoid 14 Engine speed rpm sensor 15 Service socket 16 Needle lift sensor 17 Emergency stop 18 Standard fuse EDC system compressor 19 Connector instrumentation 20 DC DC converter 21 Electronic valves shifting 1 12 13 2 10 11 14 16 21 8 9 17 3 4 5 6 7 15 18 ...

Page 65: ...through the dipstick hole Please refer to the Technical Data chapter for oil grades and volume IMPORTANT Never over fill the reversing gear The oil level must always be inside or at the rec ommended levels Maintenance Reverse gear Oil change and filter change 1 Clean around the lid 2 so that there is no risk that dirt could fall down into the filter housing 2 Undo screw 1 with a 6 mm Allen key Rem...

Page 66: ...r launching Vent the bushing by pressing it together while press ing down on the shaft until water appears Then press in approx 1 cc water repellent grease into the seal IMPORTANT The seal must be checked every 600 hours and changed as necessary The seal must be changed every five years however Maintenance Reverse gear ...

Page 67: ...e is equipped with a cone clutch for shifting using a control cable with either mechanical operation or an electric actuator and electronic operation Corrosion protection Checking Replacing Check the sacrificial anodes regularly Replace with new anodes when approximately 1 3 of the anode has been eroded Tighten the new anode so that there is a good electrical contact Where boats are kept laid up o...

Page 68: ...n the drive clean Install new anode Maintenance Drive 2 3 1 4 1 2 DPX drive The protective anodes are located on both sides of the upper bevel drive housing 1 the steering cylinders 2 on top of the cavitation plate 3 and underneath the shield 4 All anodes are fixed with screws Undo the screws which hold the anode Clean the mating surface and install the new anode There is a support plate inside th...

Page 69: ...e dipstick after a while to check the oil level The dipstick must not be screwed down when the oil level check is done If the level is too high drain some oil off If the level is too low top up the oil through the dipstick hole Check tightening of the dipstick and drain plug Re install the protective cover Oil level Power Trim Trim the drive in as far as possible Check the oil lev el is between th...

Page 70: ...raised position so that it cannot fall down A fall ing drive can cause serious personal injury Tool 885143 8 when properly installed prevents the drive falling Install the tool as follows Trim the drive down to 0 Remove cotter pins and knock out trim cyl inder bolts DPX Also remove steering cylinders by removing pins Tie up the steering cylinder so that they do not hang in the way The drive can no...

Page 71: ...ned DP If the drive has been removed the steering rack and drive controlling the trim sensor may have come out of position Turn the cog until the notched tooth is visible Install the steering rack so that the first cog position meshes with the marked tooth Maintenance Drive ...

Page 72: ...hange oil consumption is negligible over a year If the oil level drops there is probably a leak This leak must immediately be localized and remedied Please contact your nearest authorized Volvo Penta work shop for repairs The steering system is filled with au tomatic transmission fluid ATF the fluid should not normally require changing As long as the oil is red and contains no visible contaminants...

Page 73: ...belts or pulleys Fill the system Start the engine s The steering system engine circuit is automatically vented when the engines have been running for 2 3 minutes Other parts of the system are vented as follows Turn the wheel 2 3 times port and starboard to full lock Check the oil level as the wheel is being turned and top up as necessary The oil level can drop rapidly when the wheel is turned Be r...

Page 74: ...orst steer ing can be lost altogether Please contact your nearest authorized Volvo Penta workshop for as sistance DPX Parallel strut Checking The parallel strut twin and triple installation is a vital safety component Inspect it carefully if the drive kick up function has been triggered by the boat going aground or hitting an object in the water Check paral lel strut ball joints and for cracks or ...

Page 75: ...rse position Take the starter key out of the starter switch 2 Remove the lock screw 1 and the nut 2 Re move the rear propeller 3 3 Switch the ignition on and put the control lever in the forwards position Take the starter key out of the starter switch 4 Remove the lock nut 4 Remove the front propel ler 3 5 Dry the propellers off Installation 1 Grease both the propeller hubs Use Volvo Penta grease ...

Page 76: ...e nut 7 Remove the front propeller 8 and the thrust washer 9 6 Dry the propellers off Installation 1 Apply some Volvo Penta water resistant grease to the propeller hubs 2 Switch the ignition on and put the control lever in the forwards position Take the starter key out of the starter switch 3 Slide the thrust washer 9 and the front propeller 8 on 4 Install the nut 7 and torque it to 70 80 Nm 52 60...

Page 77: ...filter Clean and inhibit the seawater system Remove the impeller from the seawater pump Store the impeller in a sealed plastic bag in a cool place Check the condition of the engine coolant anti freeze Top up if required IMPORTANT An anti corrosion mixture in the engine coolant system provides no pro tection against freezing If there is any possi bility the engine will be subjected to freezing temp...

Page 78: ...rubber hoses and tighten hose clamps Check engine coolant level and antifreeze protec tion Top up if necessary Connect the fully charged batteries Paint the drive and hull See next page Check the sacrificial anode on the drive If there is less than 2 3 of the anode left it must be replaced Clean with emery cloth just before the boat is launched IMPORTANT Do not use a wire brush or other steel tool...

Page 79: ... the original paintwork on the drive without sanding it down first Teflon is the registered trademark of the Du Pont Corp Underwaterhull All types of paints with anti fouling properties are poi sonous and cause damage to the marine environment Avoid the use of such agents Most countries have in troduced legislation controlling the use of anti fouling agents Always abide by these regulations In man...

Page 80: ...peller 16 Defective engine mounting 17 Too little coolant 18 Blocked seawater intake pipe filter 19 Circulation pump drive belt slipping 20 Defective impeller 21 Defective incorrect thermostat 22 Lubricating oil level too high 23 Generator drive belt slipping 24 Stored diagnostic trouble codes DTCs Symptom and possible cause The diagnostic button indicator flashes See the Diagnostic function chapt...

Page 81: ...ect the black jump lead to the auxiliary bat tery negative terminal and then to a position slightly away from the discharged batteries for ex ample at the negative cable s connection to the starter motor WARNING The black auxiliary cable must not come in contact with the positive connec tion on the starter motor 4 Start the engine and run at fast idling speed for about ten minutes to charge the ba...

Page 82: ... of the reversing gear 1 Stop the engine and remove the ignition key from the ignition lock 2 Undo the screw 1 on the side where the cable harness marked A is connected 3 Remove washer 2 and tighten the screw 4 Undo cables A and B from the solenoid valves Drive Drives are shifted electronically by means of a gear actuator 3 installed in the engine bay NOTE If the drive can not be shifted this coul...

Page 83: ... it springs back to 0 3 Press in the neutral button Hold it depressed until point 5 inclusive 4 Turn the ignition key to position I drive position The indicator on the diagnostic button lights 5 Release the neutral button when the indicator on the diagnostic button goes out 6 The indicators for the neutral and diagnostic lamps will flash confirming that the EDC system is in cali bration mode 7 Rep...

Page 84: ...ition for full speed ahead 2 Release the lever and confirm the position by pressing the neutral button for at least three sec onds 4 Move the lever to the position where reverse throt tle opening is to begin 3 Release the lever and confirm the position by pressing the neutral button for at least three sec onds 5 Move the lever to the position for full speed re verse 4 Release the lever and confirm...

Page 85: ...he cable movement does not exceed the val ue obtained earlier 3 Acknowledge the position by pressing the neutral button for at least three seconds 4 Move the lever to the neutral position 2 Release the lever and confirm the position by pressing the neutral button for at least 3 seconds 5 Move the control lever to the position where For ward movement throttle opening is to start 3 Re lease the leve...

Page 86: ...y pressing the neutral button for at least three seconds 5 Move the gear operation lever to the position at which the reverse gear is engaged for Ahead for ward movement 3 Release the lever Acknowledge the position by pressing the neutral button for at least three seconds 6 Move the gear operation lever to the position at which the reverse gear is engaged for Astern rear ward movement 4 Release th...

Page 87: ...ble code DTC is flashed out if the diagnostic button is pressed and then released This code can be found in the list of DTCs with information about cause consequences and corrective action The diagnostic function affects the engine as followswhen 1 The diagnostic function has detected a minor fault which will not damage the engine Consequence The engine is unaffected 2 The diagnostic function has ...

Page 88: ...rouble code DTC consists of two groups of flashes with a break of two seconds in be tween A diagnostic trouble code DTC is obtained by counting the number of flashes in each group Example break Diagnostic trouble code DTC 2 4 The diagnostic trouble code DTC is stored and can be read off as long as the malfunction remains In the next page there is a list of diagnostic trouble codes DTCs with inform...

Page 89: ...ction checks whether there are any malfunctions in the EDC system New diagnostic trouble codes DTCs are stored if there are malfunctions This means that 1 Diagnostic trouble codes DTCs for malfunctions that have been remedied or are no longer present are erased automatically 2 Diagnostic trouble codes DTCs for malfunctions that have not been remedied must be acknowl edged and read off each time th...

Page 90: ... Calibration Cause The control module is unable to identify the con trol system Consequence The control cannot be calibrated Corrective action Check the fuses connections and wiring for the main relay control relay and reverse gear actuator drive Erase the diagnostic trouble code DTC Recalibrate the control see the Fault tracing chapter Code 1 6 Calibration Cause The control on the main control po...

Page 91: ...ion from the potentiometer in the control applies to the potentiom eter for the engine speed lever in dual lever controls Consequence The gear is disengaged and the engine speed RPM is set to 1000 rpm NOTE The fault applies to the relevant control position the boat can be driven from another control position if there are multiple control positions Corrective action Check the wiring and connections...

Page 92: ...in relay and the control module Erase the diagnostic trouble code DTC Start the engine Contact an authorised workshop if the fault persists Code 5 4 Forward gear Cause Short circuit or open circuit in the wiring for re verse gear gearshift control actuator drive for the forward gear Consequence Shifting is not possible Reverse gear The gear is disengaged if possible Drive The engine is stopped in ...

Page 93: ...fault persists Code 8 1 Control module Cause Fault in the control module Consequence The engine stops cannot be started the control position cannot be activated Corrective action Erase the diagnostic trouble code DTC Start the engine Contact an authorised workshop if the fault persists Code 8 3 Calibration Cause The calibration values cannot be stored by the control module Consequence The control ...

Page 94: ...4 or VDS 2 and API CI 4 Technical Data Engine General information Engine designation KAD44P C KAD44 Professional KAMD44P C KAD300 A KAMD300 A Idling speed 590 610 rpm Swept volume 3 59 liter 3 8 US quart Injection sequence 1 5 3 6 2 4 Direction of rotation seen from front Clockwise Max forwards inclination 4 Max rearwards inclination in operation 15 Max sideways inclination in operation 20 Valve c...

Page 95: ...int Oil grade and viscosity VP 1141666 6 API GL5 SAE75W 140 Synthetic Tightening torque steering cap bolt 3 5 kpm 35 Nm 26 lbf ft DPX A Oil volume 2 6 liter 2 7 US quart Oil volume between min and max markings 0 20 liter 0 4 US pint Oil grade and viscosity VP 1141634 4 API GL5 SAE75W 90 Synthetic Reversing gear HS63AE Oil volume 3 0 liter 3 2 US quart Oil grade ATF Dexron II HS63VE Oil volume 4 0 ...

Page 96: ... II III Steering Power steering DP Oil grade ATF Dexron II VP hydraulic steering optional DP HS63 Oil grade Volvo Penta part no 1141640 1 Shell Aero 4 Texaco HO15 Esso Univis N15 Chevron Aviation Fluid A Mobil Aero HFA VP Xact hydraulic steering DPX Oil grade ATF type G ...

Page 97: ...95 Notes ...

Page 98: ...96 Notes ...

Page 99: ... als Fax an Document Distribution Center Order Department ARU2 Dept 64620 SE 405 08 Göteborg Schweden Fax 46 31 545 772 Die Bestellung kann auch über das Internet erfolgen http www volvopenta com manual coupon Ja ich will kostenlos eine Betriebsanleitung in deutscher Sprache erhalten Publikationsnummer 7742204 6 Name Anschrift Land 42200 615001 155099900192 Notez que l offre est valable pendant 12...

Page 100: ...ción y posteriormente solamente mientras duren las existencias Franquear o enviar fax a Document Distribution Center Order Department ARU2 Dept 64620 SE 405 08 Göteborg Suecia Fax 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 7742206 1 Nombre Direcci...

Page 101: ...ler fax til Document Distribution Center Order Department ARU2 Dept 64620 SE 405 08 Göteborg Sverige Fax 46 31 545 772 Bestillingen kan også ske på internet http www volvopenta com manual coupon Ja tak jeg vil gerne gratis have en instruktionsbog på dansk Publikationsnummer 7742208 7 Navn Adresse Land 42200 615001 155099900192 Huomaa että tarjous on voimassa 12 kuukautta veneen toimituspäivä määrä...

Page 102: ...742214 5 Nome Endereço País 42200 615001 155099900192 ÐÑÏÓÏ Ç ÁõôÞ ç ðñïóöïñÜ éó ýåé ãéá ñïíéêÞ ðåñßïäï 12 ìçíþí áðü ôçí ðáñÜäïóç ôïõ óêÜöïõò ÌåôÜ ôï ðÝñáò ôçò åí ëüãù ñïíéêÞò ðåñéüäïõ ç äéáèåóéìüôçôá ôùí áíôéôýðùí èá åîáñôÜôáé áðü ôçí ðïóüôçôá ôùí áðïèåìÜôùí Ôá õäñïìÞóôå áõôü ôï êïõðüíé óôçí ðáñáêÜôù äéåýèõíóç Þ óôåßëôå ôï ìå öáî óôïí ðáñáêÜôù áñéèìü öáî Document Distribution Center Order Departm...

Page 103: ......

Page 104: ...7742203 English 03 2006 ...

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