Care and maintenance
Knowledge
The Operators Manual contains instructions for doing
the most common service and maintenance tasks in
a safe and correct manner. Read them carefully
before starting work.
Literature for more major tasks is available from your
Volvo Penta dealer.
Never do a job if you are not entirely sure about how
to do it. Please contact your Volvo Penta dealer and
ask for assistance instead.
Before starting
Re-install all guards which have been removed during
service work, before re-starting the engine. Make sure
that there are no tools or other objects left behind on
the engine.
Never start a turbocharged engine without the air filter
in place. The rotating compressor turbine in the tur-
bocharger can cause severe injury. There is also a
risk that foreign bodies could be sucked in and cause
damage to the machinery.
Stopping the engine
Stop the engine before opening or removing the
engine hatch/hood. Service and maintenance work
should be done with the engine stopped unless oth-
erwise specified.
Prevent the engine from being started by pulling out
the starter key and disconnect the power with the
main switch. Lock them in the “Off” position.
If the instrument panel does not have a key switch,
remove the system voltage with the main switch.
Fix a notice by the operator position to say that work
is in progress.
Working with, or approaching a running engine is a
safety risk. Hair, fingers, loose clothes, or dropped
tools can catch on rotating components and cause
severe injury. Volvo Penta recommends that all serv-
ice work which requires the engine to be running
should be done by an authorized Volvo Penta work-
shop.
Lifting the engine
The lifting eyes fitted on the engine should be used
for lifting. Always check that the lifting devices are in
good condition and that they have the correct capacity
for the lift (engine weight together with auxiliaries, if
fitted). The engine should be lifted with an adjustable
lifting boom for safe handling. All chains or cables
should be parallel to each other and should be as
square as possible to the top of the engine. Please
note that auxiliary equipment installed on the engine
could change its center of gravity. Special lifting devi-
ces may then be needed to obtain the correct balance
and safe handling. Never carry out work on an engine
that is
only
suspended in a hoist.
Fire and explosion
Fuel and lubrication oil
All fuel, most lubricants and many chemicals are flam-
mable. Always read and observe the advice on the
packages.
Work on the fuel system must be done with the engine
cold. Fuel leakage and spills on hot surfaces or elec-
trical components can cause fires.
Store oil and fuel soaked rags and other flammable
material in a fireproof manner. Oil soaked rags can
self-ignite in certain circumstances.
Never smoke when filling fuel, lubrication oil or when
close to fuel filling stations or the engine bay.
Batteries
Batteries contain and give off an explosive gas, espe-
cially when charged. This gas is very flammable and
highly explosive.
Smoking, open flames or sparks must never occur in
or near to batteries or the battery locker.
Incorrect connection of a battery cable or start cable
can cause a spark which can be sufficient, in its turn,
to make the battery explode.
Spare parts
Components in fuel systems and electrical systems
on Volvo Penta engines are designed and manufac-
tured to minimize the risk of explosions and fire, in
accordance with applicable legal requirements.
The use of spare parts not approved by Volvo Penta
can cause an explosion or fire.
Start spray
Never use start spray or similar preparations to help
in starting an engine with air pre-heating (glow plugs /
starting heater). They may cause an explosion in the
inlet manifold. Danger of personal injury.
Safety Information
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