Volvo Penta D9 MH Operator'S Manual Download

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765

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42200/615001/155099900192

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and

other reproductive harm.

Summary of Contents for D9 MH

Page 1: ...vd 64620 SE 405 08 Göteborg Ýsveç Faks 46 31 545 772 Sipariþler Ýnternet üzerinden de verilebilir http www volvopenta com manual coupon Evet lütfen ücretsiz Türkçe kullaným el kitabý istiyorum Yayýn numarasý 7746765 Ýsim Adres Ülke 42200 615001 155099900192 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birt...

Page 2: ...OPERATOR S MANUAL D9 MH EVC 7746262 English 12 2007 ...

Page 3: ...OPERATOR S MANUAL D9 MH EVC ...

Page 4: ...CaLiFornia proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm ...

Page 5: ... this manual Do not hesi tate to consult your Volvo Penta dealer Failure to follow the instructions and cautions in this manual may result in serious accidents Keep this manual at hand for easy reference If this manual is damaged or misplaced immediately order a new copy from your dealer All information and illustrations in this manual are based on the speciﬁcations that were avai lable at the tim...

Page 6: ...Maintenance Lubrication system 61 Lubrication oil level check 61 Filters and by pass ﬁlter change 62 Switchable oil ﬁlters 62 Maintenance Fuel system 63 Fuel system venting 63 Fuel ﬁlter 64 Twin fuel pre ﬁlter water separator 67 Maintenance Air Inlet and Exhaust Systems 68 Changing the air ﬁlters 68 Inlet manifold Checking the drain hole 68 Maintenance Cooling system 69 Freshwater system 71 Raw wa...

Page 7: ...er for assistance This symbol is used in the book and on the engine to make you aware of safety infor mation Always read these safety precautions very carefully In the Operator s Manual warning texts have the following priority Warning If these instructions are not followed there is a danger of personal injury extensive damage to the product or serious mechanical malfunction important Used to draw...

Page 8: ...u lations concerning trafﬁc and safety at sea Inform yourself of the regulations applicable to your vessel and the waters your in by getting in touch with the re levant authorities or marine safety organization accidents and other incidents Sea rescue statistics show that deﬁcient mainte nance of vessels and engines together with defective safety equipment often causes accidents and other incident...

Page 9: ...etc We recommend you get in touch with a regional boat or marine safety organization to obtain more detailed marine safety information Carbon monoxide poisoning When a vessel is moving forward it will cause a certain vacuum to form behind the vessel In unfortunate circumstances the suction from this vacuum can be so great that the exhaust gases from the vessel are drawn into the bridge or cabin an...

Page 10: ...tains directions for perfor ming normal maintenance and service in a safe and correct manner Read the directions carefully before starting work More detailed service literature is av ailable from your Volvo Penta dealer Never perform a task unless you are absolutely sure how it is to be carried out call your Volvo Penta dealer for assis tance instead Stop the engine Stop the engine before opening ...

Page 11: ...r or used chemicals to a destruction plant Cooling system There is a risk of water entering when working on the seawater system Therefore stop the engine and close the seawater cock before starting work Avoid opening the coolant ﬁller cap when the engine is warm Steam or hot coolant may spurt out and cause burn injuries If the ﬁller cap coolant pipe cock etc must ne vertheless be opened or dismant...

Page 12: ... your hand Never adjust the V belts while the engine is running Service batteries carefully If you spill electrolyte on yourself ﬂush skin imme diately with lots of water Apply baking soda to help neutralize the acid If electrolyte gets in your eyes rinse immediately with large amounts of water then contact a doctor at once Handle antifreeze carefully Antifreeze contains alkali Avoid contact with ...

Page 13: ...terference to the environment Get in touch with your Volvo Penta dealer if you notice any changes such as increased fuel consumption exhaust smoke Adapt speed and distance to avoid wash and noise disturbing or injuring animal life moored boats jetti es etc Leave islands and harbours in the same con dition as you want to ﬁnd them Remember to always leave hazardous waste such as waste oil coolant pa...

Page 14: ...other than authorized personnel Otherwise general directions concerning running care and maintenance given in the operator s manual apply important Late or inadequate maintenance service or the use of spare parts other than by Volvo Penta approved spare parts will invalidate AB Volvo Penta s responsibility for the engine speciﬁcation being in accordance with the certiﬁcated variant Volvo Penta acc...

Page 15: ...ing Induction hardened overhead camshaft with roller rocker arms and torsional 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 electromag netically controlled fuel valves Spin on ﬁne fuel ﬁlter with water trap Water in fuel alarm Lubrication ...

Page 16: ...itch fuel ﬁlter w watertrap 7 Raw water pump 8 Fuel shut off valve 9 Engine control unit 10 Heat exchanger 11 Alternator 12 Eng oil ﬁlter w by pass ﬁlter 13 Air ﬁlter 14 Fresh water pump 15 Conn for optional starter 16 Oil ﬁller 17 Air cooler 18 El starter w Aux start button 19 Reverse gear oil cooler 14 Presentation ...

Page 17: ...nition keys Do not store the code where it is accessible to unauthorized per sons 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 panel The start stop panel is used to start or stop the engi ne The starter key in the main contr...

Page 18: ...Check the oil level in the engine Please refer to Maintenance Lubrication to check and top the oil up Also check that the oil ﬁlters are not blocked Please refer to Maintenance Lubrication system Please refer to the If something happens chapter and you will ﬁnd detailed information about recom mended action in the Diagnostic function section Warning Continued operation when the oil pressure is too...

Page 19: ...y problem with the alternator drive belts This could cause serious engine damage Coolant temperature red indication The coolant temperature lamp lights up when the coolant temperature is too high Stop the engine if this lamp lights up during operation Check the coolant level Please refer to Mainte nance Fresh water system Check that the sea water ﬁlter is not blocked Please refer to Maintenance Se...

Page 20: ...to Maintenance Fresh water system Please refer to the If something happens chapter and you will ﬁnd detailed information about recom mended 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 recom mended action in the Diagnostic function se...

Page 21: ...buttons ﬁrmly and for at least one second each time activation button Used to activate and lock the control panel and the helm station indication red off Control panel not activated Lit Control panel activated Flashes Control panel not activated due to the con trol lever not being in neutral or the system has been locked from another control panel padlock The padlock symbol lights if the control p...

Page 22: ...se Views with a POIN TING HAND symbol indicates a SUB MENU To enter a SUB MENU push NAVIGATION WHEEL Speed option Boat speed Requires multisensor or GPS Water temp option Water temperature Requires multisensor Depth option Water depth Requires multisensor trip menu option Shows trip information Requires the following Multisensor or NMEA 0183 NMEA 2000 compat ible component plotter GPS paddle wheel...

Page 23: ...ENU Push BACK BUTTON to return to MAIN MENU without setting a new favorite Units are user selectable See section Units trip rESEt Reset all trip data FUEL rEmaining Fuel remaining l Gal FUEL EConomY Instantaneous fuel rate per dis tance l nm l km l mile Gal nm Gal km Gal mile FUEL ratE Instantaneous fuel rate per hour l h Gal h DiStanCE to EmptY Distance to empty based on instantaneous fuel rate r...

Page 24: ...g NAVIGATION WHEEL To select view as favorite push NAVI GATION WHEEL System returns to MAIN MENU Push BACK BUTTON to return to MAIN MENU without setting a new favorite VoLtagE V EnginE HoUrS h EnginE rpm RPM CooLant tEmp C F EnginE oiL prESSUrE kPa PSI EXHaUSt tEmp C F tUrBo prESSUrE kPa PSI tranSmiSSion oiL tEmpEratUrE C F rUDDEr angLE FUEL LEVEL FrESH WatEr LEVEL gauges menu structure 22 Instrum...

Page 25: ... SUB MENU To enter a SUB MENU push NAVIGATION WHEEL Push BACK BUTTON to return to MAIN MENU inFo BEEp Set info beep sound level for the built in buzzer in EVC tachometer DEptH aLarm Settings for depth alarm functions UnitS Choose which units to display Set US or metric and units for distance nm km miles FUEL tanK CaLiBration Calibration of the fuel tank CHaSSiS iD Shows information about the EVC s...

Page 26: ...e value can be adjusted at a resolu tion of 0 1 m or 1 ft Once adjustment value is reached the data is stored by pushing NAVIGATION WHEEL Depth alarm pop up The depth alarm pop up will appear when the depth is less than the depth alarm setpoint The pop up shows the actual depth Acknowledge depth alarm by pushing NAVIGATION WHEEL The depth alarm pop up will re appear every 30 sec onds until the dep...

Page 27: ...EL and conﬁrm by pushing NAVIGATION WHEEL DiStanCE 1 Activate helm station by pushing the ACTIVATION BUTTON 2 Select SETTINGS from MAIN MENU by turn ing NAVIGATION WHEEL Push NAVIGATION WHEEL to enter SETTINGS MENU 3 Select UNITS and push NAVIGATION WHEEL 4 Select DISTANCE and push NAVIGATION WHEEL 5 Set distance unit km nm or miles and conﬁrm by pushing NAVIGATION WHEEL LangUagE 1 Activate helm s...

Page 28: ...NU please contact your Volvo Penta dealer When FUEL MULTIPOINT CALIBRATION is select ed the fuel level sender is calibrated in ﬁve equally divided steps 20 full 40 full 60 full 80 full and 100 full 1 Activate helm station by pushing the ACTIVA TION BUTTON 2 Select SETTINGS from MAIN MENU by turn ing NAVIGATION WHEEL Push NAVIGATION WHEEL to enter SETTINGS MENU 3 Select FUEL TANK CALIBRATION and pu...

Page 29: ...urning NA VIGATION WHEEL Push NAVIGATION WHEEL to enter FULL TANK CALIBRATION 5 Fill fuel tank and push NAVIGATION WHEEL Push BACK BUTTON to return to SETTINGS MENU Fuel alarm pop up The fuel level alarm pop up will appear when the fuel level is lower than fuel alarm setpoint The pop up shows the percentage of fuel remaining Acknowledge fuel alarm by pushing NAVIGATION WHEEL Fuel level alarm pop u...

Page 30: ...ent value is reached the data is stored by pushing NAVIGATION WHEEL information message Start attempt with gear engaged The engine control lever must always be in neutral before starting If not this pop up will be shown approximated trip data This pop up will be shown every time after start up if start up if if FUEL FULL TANK CALIBRATION is performed retrieving faults The EVC system is retrieving ...

Page 31: ...play mode functions in the same way as the display in the tachometer EVC System Ta chometer Before the display is used it may be necessary to modify the way that the display shows operating in formation to comply with user requirements You can see the settings that can be changed in the section about the conﬁguration menu Structure of the display functions Button 1 Engine 10 different fuel informa...

Page 32: ...ow in the instructions Once the display has been used it will always show the display mode when it starts up that was selected when the display was last switched off Figure for single engine installation Figure for twin engine installation Connection fault If the display does not register transfer of operating information from the electrical system the pop up window will ﬂash CONNECTION LOST When ...

Page 33: ...n when display settings are chan ged Conﬁguration menu structure System Information Language 8 available Bleep ON OFF Engine PORT STARBOARD TWIN SINGLE Engine series D1 D2 D2 Settings GLOBAL LOCAL Display Units Settings System Engine 2500 rpm 9000 r min in stages of 500 rpm Speed On off Speed 10 KNOT 100 KNOT in stages of 10 in appropriate units Graph interval 2MIN 10MIN 30MIN 60MIN 2 H 4 H 8 H Re...

Page 34: ...tan ding control panel In display mode SYSTEM INFORMATION there are several functions Display of operating information information mes sages and alarm NOTE The display is adapted to suit the size of the panel in the tachometer Settings for displaying operating information in this display mode All calibrations Detailed instructions for the functions in display mode SYSTEM INFORMATION are found in t...

Page 35: ...essure kPa PSI Volume LITER GAL Imperial GAL Fuel consumption time is adjusted to suit the volume unit L H GAL H IGAL H Temperature C CELSIUS F Fahrenheit System Menu SYSTEM is intended to provide the necessary functions and information for service technicians Demo Switches between demo mode ON OFF The unit is in normal operation mode when Demo is OFF Com Viewer Shows the latest messages recei ved...

Page 36: ...omputer and fuel level gauge The fuel level gauge are displayed if there is a tank sender installed note Trip information is only displayed if following are installed Multisensor or NMEA 0183 NMEA 2000 compa Multisensor or NMEA 0183 NMEA 2000 compa tible component plotter GPS paddle wheel etc Fuel level sender Software for trip computer order and download from VODIA website The trip computer shows...

Page 37: ...setting mode is reached by pressing button 5 furthest right when you are in the display mode MULTI Please refer to the illustrations below note The type of operating information available depends on the electrical system in the boat and the sensors that the boat is equipped with Optional sen sors include depth gauge water temperature speed trim angle and rudder angle note This applies to the graph...

Page 38: ... mode shows Fuel used after last reset Instantaneous fuel consumption amount of fuel used per hour If speed information is available instantaneous fuel consumption can also be cal culated in relation to distance Operation time after last reset Total operating time can not be reset If you want to reset the trip values trip fuel consump tion and trip operating time keep button 3 depres sed for 1 sec...

Page 39: ...trols which are not described here and you feel uncertain about the function please contact the dealer you purchased the boat from The shift function can be disengaged so that the con trol lever only affects the engine speed 1 Move the lever to the neutral position N 2 Press the neutral button N in and hold it down while moving the control lever forward to the shift position F 3 Release the neutra...

Page 40: ...ting the friction brake 1 Stop the engine 2 Move the control lever forwards to make the groo ve in the control lever hub 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 38 Controls ...

Page 41: ...st Broken wire All channels are equipped with broken wire detection that activate an alarm if connection is lost or power supply to SDU is lost Yellow LED indicates broken wire Reset alarm on Broken wire reset button A notE Use only plastic tool for reset overspeed shutdown The overspeed function shuts down the engine in case of overspeed overspeed test To test the overspeed function push the over...

Page 42: ...tdown active 10 Red S1 Shutdown active A Broken wire reset button B Yellow Fuel valve Broken wire detected C Yellow Speed sender Broken wire detected D Yellow S6 Broken wire detected E Yellow S5 Broken wire detected F Yellow S4 Broken wire detected G Yellow S3 Broken wire detected H Yellow S2 Broken wire detected I Yellow S1 Broken wire detected J Overspeed shutdown test button SDU indications 40 ...

Page 43: ...trical box The diode goes out if the fault has been rectiﬁed as does the lamp 1 2 on the panel 4 Start the engine Shutdown override When activated only overspeed and broken wire shutdowns are active notE Check the local classiﬁcation requirements to determine when the shutdown override should beu sed Activate SHUTDOWN OVERRIDE by turning key switch 5 clockwise SHUTDOWN OVERRIDE is indi cated by La...

Page 44: ... new or overhau led engine important All covers must be mounted be fore attempting to start your engine Valves and plugs Make sure the following valves and plugs are open or closed properly Fuel supply valve Open Coolant drain cock engine Closed Coolant drain cock water pump Closed Coolant drain cock heat exchanger Closed important If the coolant drain cocks are not closed the coolant will drain f...

Page 45: ...amount of fuel even when the engine is cold The engine is pre heated by the engine control unit which allows the engine to crank several revolutions with the starter motor before fuel is injected The colder the engine is the more revolutions the engine makes This raises the temperature in the combustion chambers which ensures reliable starting and reduces starting smoke The idling speed is also go...

Page 46: ...life of the engine important Do not turn OFF the battery switch when the engine is running since this may damage the alternator Warning At operating temperature the engine and its components are hot A hot engine always invol ves risk for burn injuries Take care with hot surfaces E g exhaust manifold turbocharger oil pan charge air pipe starting heater hot coolant and warm lubricant in pipes and ho...

Page 47: ... of operation For more information See Warranty and Service Book Forced propeller rotation When the vessel is towed or anchoring in strong currents the propeller can make the propeller shaft rotate even though the engine is stationary This may damage the marine gear manoeuvring The marine gear must be engaged at low idling speed There must be a brief pause after engaging gear before increasing the...

Page 48: ...as not been activated because the control lever s are not in the neutral position or the system has been locked from another control panel running preparations 1 Put the control lever s to neutral at all control po sitions two lever control Also check that the engine speed lever is in the idling position 2 Turn the starter key to position I to switch the igni tion on If the boat has more than one ...

Page 49: ...ically to protect the starter motor from overheating Leave the starter motor to cool for at least ﬁve minutes if possible before making a new start attempt read the instruments and warm the engine up Allow the engine to idle for the ﬁrst ten seconds and check that instruments and displays show normal val ues Check that no alarms are displayed and that no warning lamps are ﬂashing Then warm the eng...

Page 50: ...ion system voltage should be within normal values not in any of the red ﬁelds If there is a charge failure the lamp in the warning display will ﬂash alarm If a fault occurs the audible warning will sound and the relevant warning lamp on the alarm panel will start to ﬂash and the display will show a alarm pop up 1 Reduce engine speed to idling 2 Acknowledged the larm by pressing the naviga ton whee...

Page 51: ...ol panel Cruising speed Avoid operation at full throttle for best fuel economy We recommend a cruising speed which is at least 10 below the maximum engine speed at full speed full throttle The maximum engine speed will vary due to propeller choice load and sea conditions Synchronizing engine speed When driving with twin engines both the operating economy and comfort will be increased when the en g...

Page 52: ...o neutral with a rapid dis tinct movement Make a brief pause notE A beep will sound to indicate that the con trol lever is in neutral 3 Then move the control lever to reverse with a rap id distinct movement and increase engine speed important If the boat has twin engines it is important that both should be running during reversing maneuvers to avoid the risk of water entry via the exhaust pipe int...

Page 53: ...ion of the autopilot along with other user information is described in the autopilot suppliers documentation notE The system can refuse activation if the steer ing wheel is turned at the same time as an attempt is made to activate the autopilot The autopilot does not work when traveling back wards The steering wheel is braked while the autopilot is in control AUTO position Disconnection The autopi...

Page 54: ...When Lowspeed is engaged a pop up A is shown on the tachometer display It is pos sible to acknowledge pop up by pushing NAVIGA TION WHEEL 3 Active Lowspeed is indicated by an icon on the tachometer display D important If Lowspeed initializing pop up B and then icon are shown on the ta chometer display C Lowspeed is not ready to use Normal gear shifting until Lowspeed is activated D important Delay...

Page 55: ...ncrease rapidly operation Move the throttle gear lever to a position where the engine speed is within the permissible engine speed range and move the slip control lever to a slip posi tion Active Trolling is indicated by an icon on the tachometer display B important If Trolling initializing icon is shown on the tachometer display A Trolling is not ready to use Normal gear shifting until Trol ling ...

Page 56: ...he 0 position when it is re leased and can then be removed important Never switch off the main swit ches while the engine is running This could da mage the alternator important Never switch off the main swit ches before the starter key is turned off is in 0 position or removed This could damage the electrical system auxiliary stop If a fault occurs that prevents you stopping the engine in the norm...

Page 57: ... the coolant in the fresh water system must contain sufﬁcient anti freeze to prevent it from freezing Refer to chapter Maintenance Seawater system and Freshwater system respectively Warning If the seawater system bursts due to freezing the vessel may sink important If the coolant does not give sufﬁcient anti freeze protection it may cause costly damage to the engine Check the charge of the battery...

Page 58: ...nd will lessen the down time to save time and money for servicing maintenance records Volvo Penta recommends that accurate maintenance records are kept With accurate maintenance records your Volvo Penta Dealer can help in ﬁne tuning the recommended service intervals to meet the speciﬁc operating si tuation This should result in a lower engine operation cost Fluids It is also important to keep reco...

Page 59: ... Rawwater pressure and rawwater temperature before and after heat exchanger Ambient tem perature and engine room temperature at turbo charger inlet 6 Parts serviced and kinds of service adjustment repairs or replacement 7 Change in operating conditions for example Ex haust smoke turned black etc Daily recording is a preventive maintenance program and when comparing values with engine history it wi...

Page 60: ...fer to note 1 l Drain water from fuel tank l Drain fuel ﬁlter l Daily operation records Weekly l Check starting batteries electrolyte level load l Check electrical system for loose terminals contacts l Check foundation bolts l Check lubrication oil for abnormal smell or waterdilution after ﬁrst 50 operating hours l Change oil in reverse gear l Clean reverse gear oil strainer Every 50 operating hou...

Page 61: ...l ﬁne ﬁlter Bleed the fuel system Every 1000 operating hours or every 12 months l Change oil in reverse gear l Clean reverse gear oil strainer Every 2000 operating hours l Check turbocharger refer to note 2 Every 12 months l Check EVC system with diagnostic tool refer to note 2 l Change air ﬁlter l General inspection of engine and reverse gear l Clean and paint the engine and reverse gear Every 24...

Page 62: ...ive cover over the alternator drive belt 2 Undo the ﬁxing screws 1 and 2 3 Screw a M10 nut 3 to the tensioner screw so the spring is pressed together and it is possible to loosen the alternator belt 4 Change the alternator belt Remove the nut 3 5 Tighten the ﬁxing screw 1 tightening torque 30 Nm and ﬁxing screw 2 tightening torque 20 Nm 6 Install the protective cover over the alternator drive belt...

Page 63: ... val Use the oil drain pump optional to drain the oil from the sump important Only use recommended grades of oil refer to chapter Technical Data 1 Warm the engine up this makes it easier to pump the oil from the sump Then stop the engi ne Warning Hot oil and hot surfaces may cause burns 2 Connect the suction pipe of the oil drain pump to the drain pipe Pump the oil out 3 Change the oil ﬁlters and ...

Page 64: ...portant Though possible the switchable ﬁlters should not be replaced during engine ope ration other than in case of an emergency 1 Clean the ﬁlter bracket 2 Disconnect the left ﬁlter by turning the lever to the right hand end position To unlock the lever pull the knob beneath the lever downwards 3 Unscrew the left hand oil ﬁlter and discard it Use a ﬁlter wrench if necessary 4 Check that the matin...

Page 65: ...p 2 until air free fuel ﬂows out Tighten the venting nipple while fuel is ﬂowing out Repeat with second ﬁlter 4 Remove the hose and put the protective cap back on the venting nipple 5 Run the engine at idling speed for a couple of mi nutes to get any remaining air out of the system and make sure that there are no leaks Warning Fire hazard Work on the fuel system should be carried out on a cold eng...

Page 66: ... ﬁlters only 1 Shut off fuel to the ﬁlter to be changed A 2 Put a suitable vessel underneath the ﬁlter 3 Open the tap 1 carefullly pressure on the in side hot ﬂuids might spurt out 4 Drain water and contamination from the water trap by turning the handle to venting position B Tighten the venting nipple when clean fuel ﬂows out 5 Repeat the procedure with the other ﬁlter 6 Turn the handle to normal...

Page 67: ...g surface on the ﬁlter bracket Make sure the new ﬁlter is absolutely clean and that the sealing surfaces are undamaged Mois ten the seals with engine oil including the inner rubber seal on the inside of the threaded hole in the center of the ﬁlter notE Do not ﬁll the new ﬁlter with fuel before as sembly Contaminations may get into the system and cause damage and malfunction 7 Screw the new ﬁlter o...

Page 68: ...ket Make sure the new ﬁlter is absolutely clean and that the sealing surfaces are undamaged Mois ten the seals with engine oil including the inner rubber seal on the inside of the threaded hole in the center of the ﬁlter notE Do not ﬁll the new ﬁlter with fuel before as sembly Contaminations may get into the system and cause damage and malfunction 7 Screw the new ﬁlter on by hand until the seal ju...

Page 69: ...r 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 posi tion for normal running Make sure there are no leaks twin fuel pre ﬁlter water separator The twin ﬁlter is equipped with a pressure gauge 1 The ﬁlter inserts must be changed according to the maintenance schedule or earlier if the pressure gaug...

Page 70: ...Fit the new air ﬁlters and the air ﬁlter cover important Scrap the old ﬁlters It must not be cleaned inlet manifold Checking the drain hole Water can condense in the aftercooler during ope ration The condensate is drained via a hole in the charge air cooler Check that the drain hole is not blocked Warning If a large amount of water ﬂows out of the drain hole from the inlet manifold the af tercoole...

Page 71: ...ver open the pressure cap or drain the cooling system when the engine is warm Steam or hot ﬂuid may spurt out Warning The coolant is dangerous to your health and an environmental hazard Handle coolant with care and dispose of old coolant in accordance with local regulations important For coolant speciﬁcation refer to chapter technical data in the back of this manual important Check the coolant lev...

Page 72: ...ater system is connected to a seawater inlet or a central cooling system Drain points fresh water system 1 Exp tank 2 Heat exchanger 3 Engine 4 Oil cooler 5 Exhaust manifold 6 Rawwater outlet 7 Rawwater inlet 8 Rawwater pump 9 Charge air cooler 10 Freshwater pump F F F F Drain points raw water system r r 70 Maintenance Cooling System ...

Page 73: ...correct level refer to section coolant level check Fill slowly so that evacuated air is able to pass the ﬁl ler opening notE For coolant speciﬁcation refer to sec tion technical data coolant Filling when the system is empty 1 Make sure that systems connected to the cooling system are ventilated e g heater water heater 3 Fill the system with coolant through the ﬁller ope ning in the expansion tank ...

Page 74: ...drained off 4 Drain all other systems connected to the freshwa ter system e g heater water heater etc 5 Close all drains Freshwater system ﬂushing The system should be ﬂushed before changing coo lant to avoid inferior cooling performance due to de posits in the cooling system 1 Drain the coolant as described earlier 2 Insert a hose into the ﬁller opening on the expan sion tank and ﬂush with fresh ...

Page 75: ...es sel important Check that the raw water really drains Deposits may need to be removed from inside the drain plugs taps Zinc anodes Check change Warning Risk of water entry Close the raw water cock before doing any work on the rawwa ter system 1 Close the rawwater cock 2 Open the drain tap 1 on the heat exchanger and the tap 2 on the charge air cooler and drain off the rawwater 3 Remove the zinc ...

Page 76: ...haft and press the impeller in using a was her and nut Fit the cover using a new O ring 5 Open the rawwater cock important Always carry a spare impeller on board Seawater ﬁlter inspection cleaning The rawwater ﬁlter is optional equipment If the water where the boat is operated contains a lot of contamination weed etc check the ﬁlter more frequently than speciﬁed in the maintenance sche dule There ...

Page 77: ...re connected with the engine running for the same reason important Never disconnect the current with the main switches when the engine is running Fuses The engine is ﬁtted with two automatic circuit brea kers The circuit breakers cut the power if the system is overloaded If it is not possible to start the engine or if the instru ment stops working while running the circuit breaker may have been ac...

Page 78: ...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 and oxide on the batteries and battery poles can cause stray currents voltage drop and discharge especi ally in wet weather Clean oxidation from the battery poles and terminals using a copper brush Tighten the terminals securely and grease them wi...

Page 79: ...the boat should be removed from the batteries be fore the charger is connected During charging unscrew the cell plugs but leave them in the plug holes Ventilate well especially if the batteries are charged in an enclosed space Warning Always switch off the charge cur rent before undoing the charging clamps Never confuse the positive and negative poles on the batteries Risk of arcing and explosion ...

Page 80: ...posed to cha ﬁng damp or splashing water in the bilge 3 Protective earth cables for radio navigation equip Protective earth cables for radio navigation equip ment rudder bathing steps etc or other equip ment which uses protective earthing shall be connected to a common earthing point which is not connected to the engine or reverse gear important The engine and reverse gear must never be used as ea...

Page 81: ... 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 Cleaning Warning Working with or going close to a running engine is a safety risk Watch out for ro tating components and hot surfaces 1 Remove the lid plug and carefully...

Page 82: ... Never over ﬁll the reverse gear 4 Start the engine and run until the reverse gear has reached operating temperature 5 Check the oil level as in the description on the previous page Seal Lubrication applies only to twinDisc reverse gear Lubricate theseal on the output shaft bearing with the lubricating nipple using a hand gun and lithium based grease such as Mobilux EP2 Statoil Uniway EP2N Texaco ...

Page 83: ...e clutch Lubrication Use lithium based grease such as Mobilux EP2 Statoil Uniway EP2N Texaco Multifac EP2 Q8 Rembrandt EP2 main bearing and clutch mechanism Lubricate the inner support bearing with lubricating nipple the main bearings release shaft and the moving parts in the clutch mechanism with grease Lubricate spar ingly 20 30 grams 0 6 1 0 oz for the main bearings Lubricate the inner link arm...

Page 84: ...r on the engine and then run it warm Stop over eight months Treat the lubricating and fuel systems with conserva tion oil See directions on next page 2 Make sure there is enough anti freeze in the coo lant Add more if necessary An alternative is to drain the coolant 3 Drain the rawwater system 4 Remove the impeller from the rawwater pump Keep the impeller in a cool place in a closed plastic bag 5 ...

Page 85: ...nd run it at idling speed until it reaches operating temperature before loading it 11 Check for oil fuel or coolant leaks 12 When the engine has run long enough to warm up apply the load and bring it to operating speed Conserving the lubricating and fuel systems for stops longer than eight months 1 Drain the oil from the engine and ﬁll with con servation oil to just over the MIN mark on the dipsti...

Page 86: ...ga tive connection on the starter motor Shutdown override EVC only When activated only overspeed and broken wire shutdowns are active Activate SHUTDOWN OVERRIDE by turning key switch on the shutdown panel clockwise SHUT DOWN OVERRIDE is indicated by Lamp on the pa nel important When shutdown override is active the engine is not protected by the SDU Warning Black jumper cable must not touch positiv...

Page 87: ...nly be cut off by stopping the engine 1 Stop the engine and remove the start key from the key switch 2 Note the valve P or S to which the cable marked Primary is connected Then undo the connectors 1 and 2 from the solenoid valves 3 Remove the cap nut from the valve which was connected to the Primary cable 4 Push and turn button A 1 2 turn counter clock wise the button is forced out by spring actio...

Page 88: ...d aftercooler 34 Too high oil level 35 Alternator drive belt slips 36 Water entry into engine 37 High back pressure in exhaust system 38 Stored fault codes 39 Check that the emergency stop button is in the running position not pressed down 40 Engine drive belt slips NOTE The codes can only be read and erased by a service technician Please refer to the Diagnostic informa tion chapter for further in...

Page 89: ...oolant temperature or drive unit reaction Engine power is reduced till the rele vant value is normalized 3 The diagnostic function has discovered a serious malfunction which will cause serious damage on the engine or the drive unit reaction Engine power is reduced 4 The diagnostic function has discovered a serious malfunction which makes it impossible to control the engine or the drive unit reacti...

Page 90: ... ack nowledged Danger pop up If the Danger pop up is shown during operation a serious fault has occured notE Acknowledge the alarm and stop the engine at once Information regarding cause of fault and measures to take is found in chapter Fault register Warning pop up If the Waring pop up is shown during operation a fault has occured notE Acknowledge the alarm and stop the engine at once Information...

Page 91: ...pter Fault register Erasing faults in faults list Any fault pop up in the diagnostic function are auto matically erased every time the starter key is turned to the stop position S notE Stop the engine and check that the ignition key s is are in position 0 in all control positions When system voltage is switched on again the diag nostic function checks to see whether there are any faults in the EVC...

Page 92: ...r Explanation Fault in engine speed sensor reaction Engine power is reduced action Please contact a Volvo Penta workshop Water in fuel o Explanation Water in water trap in fuel ﬁlters reaction None action Empty the water trap underneath the fuel ﬁlters please refer to Please refer to Maintenance Fuel system Please contact a Volvo Penta workshop if the fault remains Seawater pressure r Explanation ...

Page 93: ... to Maintenance Seawater system Check the impeller in the seawater pump Please refer to Maintenance Seawater system Check that no leakage occurs Check that no leakage occurs in auxiliary equipment connected to the engine cooling system Please contact a Volvo Penta workshop if the fault remains Coolant temperature r Explanation Ccoolant temperature too high reaction Engine power is reduced action C...

Page 94: ...ead seas the system can incorrectly sense that the engine oil level is too low If this happens acknowledge the fault and check the points below for safety reasons reaction Engine power is reduced action Check the oil level in the engine Please refer to Maintenance Lubrication system to check and top the oil up Check the oil ﬁlters Please refer to Maintenance Lubrication system Check that no leakag...

Page 95: ...if the fault remains Crankcase pressure r Explanation Crankcase pressure too high reaction Engine power reduced action Check that the crankcase ventilation is not blocked Please refer to Maintenance Engine general Please contact a Volvo Penta workshop if the fault remains Exhaust temperature r Explanation Exhaust temperature too high reaction Engine power is reduced action Please contact a Volvo P...

Page 96: ...e engine Emergency stop Please contact a Volvo Penta workshop if the fault remains primary battery r Explanation poor battery or charging reaction action Check battery ﬂuid level Check belt tension Please contact a Volvo Penta workshop if the fault remains Secondary battery r Explanation poor battery or charging reaction action Check battery ﬂuid level Check belt tension Please contact a Volvo Pen...

Page 97: ...anel use an alternative control panel Please contact a Volvo Penta workshop if the fault remains Lever calibration o Explanation incorrect lever calibration reaction It is not possible to choose active helm station action Restart engine s Please contact a Volvo Penta workshop if the fault remains Check EVC system o r Explanation internal fault in the EVC system reaction Engine power is reduced act...

Page 98: ...Penta workshop if the fault remains Check shift actuator r Explanation Fault in shift actuator reaction Cannot engage gears Engine in emergency mode action Emergency shifting Please refer to In case of emergency Emergency shifting Please contact a Volvo Penta workshop if the fault remains 96 Fault register ...

Page 99: ...0 rpm 403 C 757 F at 800 rpm 494 C 921 F at 1000 rpm 518 C 964 F at 1200 rpm 481 C 898 F at 1400 rpm 441 C 826 F at 1500 rpm 416 C 781 F at 1600 rpm 397 C 747 F at 1800 rpm 373 C 703 F Lubricating system Oil capacity approx Incl oil filters No engine inclination 46 liters 12 2 US gals volume difference min max 12 liters 3 2 US gals Cooling system Freshwater system capacity including heat exchanger...

Page 100: ... F at 800 rpm 494 C 921 F at 1000 rpm 519 C 966 F at 1200 rpm 480 C 896 F at 1400 rpm 438 C 820 F at 1500 rpm 422 C 792 F at 1600 rpm 413 C 775 F at 1800 rpm 401 C 754 F Lubricating system Oil capacity approx Incl oil filters No engine inclination 46 liters 12 2 US gals volume difference min max 12 liters 3 2 US gals Cooling system Freshwater system capacity including heat exchanger approx 39 lite...

Page 101: ...F at 1000 rpm 519 C 966 F at 1200 rpm 476 C 889 F at 1400 rpm 434 C 813 F at 1500 rpm 415 C 779 F at 1600 rpm 410 C 770 F at 1800 rpm 393 C 739 F at 2000 rpm 385 C 725 F at 2200 rpm 387 C 729 F Lubricating system Oil capacity approx Incl oil filters No engine inclination 46 liters 12 2 US gals volume difference min max 12 liters 3 2 US gals Cooling system Freshwater system capacity including heat ...

Page 102: ...F at 1000 rpm 515 C 959 F at 1200 rpm 480 C 896 F at 1400 rpm 435 C 815 F at 1600 rpm 426 C 799 F at 1800 rpm 461 C 862 F at 2000 rpm 456 C 853 F at 2100 rpm 456 C 853 F at 2200 rpm 460 C 860 F Lubricating system Oil capacity approx Incl oil filters No engine inclination 46 liters 12 2 US gals volume difference min max 12 liters 3 2 US gals Cooling system Freshwater system capacity including heat ...

Page 103: ...MIL L 2104 B and MIL L 2104 B and transm ﬂuid type C 3 transm ﬂuid type C 3 Viscosity at oil temperature 66 85 C SAE30 SAE30 Viscosity at oil temperature 85 100 C SAE40 SAE40 Oil pressure neutral MPa PSI 0 17 0 27 24 6 39 2 0 17 0 27 24 6 39 2 Oil pressure operation MPa PSI 2 2 319 2 2 319I Weight dry kg lbs 203 447 368 810 notE Only single grade lubricating oil only one viscosity number may be us...

Page 104: ...ment and cold requirements Sulfur content Complying with legal requirements in each country If the sulfur content exceeds 0 5 wt service intervals must be changed refer to chapter Maintenance lubrication system Fuels with low density urban diesel in Sweden and city diesel in Finland can result in a loss of power by ap prox 5 and an increase in fuel consumption of approx 2 3 102 Technical data ...

Page 105: ...40 10o C o C o F Refers to synthetic or semi synthetic oils 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 3 600 hr or 12 months 200 hr or 12 months 100 hr or 12 months VDS 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 1...

Page 106: ...nta s engines and provides excellent protection against corrosion cavitation and frost damage Volvo penta Coolant ready mixed A ready mixed coolant 40 Volvo Penta Coolant and 60 water This concentration protects the engine against corrosion cavitation damage and freezing conditions down to 28 C 18 F mixing ratio Mix 40 Volvo Penta Coolant and 60 water This mixture protects the engine against inter...

Page 107: ... Serial and basic engine number Product number EPA decal 3 Model Year Displacement Cylinder Engine Family Engine Model Conformas To Useful Life of Engine Low Idle Speed Static Timing degrees before T D C Valve Lash inl exh 1 2 3 4 5 6 D9 mH RATED POWER kW RATED SPEED RPM DATASET SPEC NO ECU BATCH 6 7 8 Call off identity decal 4 Chassi No Serial engine number Engine Plate 5 Product designation Seri...

Page 108: ... intake O C Charge air temp O C Charge air press Bar Exhaust gas temp O C Exhaust gas temp common O C Fuel temp engine in O C Fuel press Bar Type and brand of lubrication oil Type and brand of coolant Mixture of coolant Type of fuel during normal operation Sea trial data Date Name Vessel Engine no All values to be measured at full load All values to be measured with approved instrumentation If in ...

Page 109: ... notes 107 ...

Page 110: ... 108 ...

Page 111: ... 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 7746755 Name Anschrift Land 42200 615001 155099900192 Notez que l offre est valable pendant 12 m...

Page 112: ...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 7746757 Nombre Dirección...

Page 113: ...er 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 7746759 Navn Adresse Land 42200 615001 155099900192 Huomaa että tarjous on voimassa 12 kuukautta veneen toimituspäivä määrästä...

Page 114: ...í ðïóüôçôá ôùí áðïèåìÜôùí Ôá õäñïìÞóôå áõôü ôï êïõðüíé óôçí ðáñáêÜôù äéåýèõíóç Þ óôåßëôå ôï ìå öáî óôïí ðáñáêÜôù áñéèìü öáî Document Distribution Center Order Department ARU2 Dept 64620 SE 405 08 Göteborg Sweden Fax 46 31 545 772 Ìðïñåßôå åðßóçò íá äþóåôå ôçí ðáñáããåëßá óáò ìÝóù ôïõ Inter net óôç äéåýèõíóç http www volvopenta com manual coupon Íáé Èá Þèåëá Ýíá áíôßôõðï ôïõ åã åéñéäßïõ ñÞóçò óôçí á...

Page 115: ... þu adrese postalayýn veya fakslayýn Dokument Distribution center Ordermottagningen ARU2 Avd 64620 SE 405 08 Göteborg Ýsveç Faks 46 31 545 772 Sipariþler Ýnternet üzerinden de verilebilir http www volvopenta com manual coupon Evet lütfen ücretsiz Türkçe kullaným el kitabý istiyorum Yayýn numarasý 7746765 Ýsim Adres Ülke 42200 615001 155099900192 ...

Page 116: ...7746262 English 12 2007 ...

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