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54

Maintenance

Engine, general

General inspection

Make it a habit to give the engine and engine bay
a “visual” check before driving

before starting the

engine

and after operation

when you have stopped

the engine

. This will help you to discover if anything

abnormal has happened, or is about to happen.

Look especially carefully at oil, fuel and coolant lea-
kage, loose screws, worn or poorly tensioned drive
belts, loose connections, damaged hoses and elec-
trical cables. This inspection only takes a few minutes
and can prevent serious malfunctions and expensive
repairs.

WARNING!

Deposits of fuel, oils and grease on

the engine or in the engine bay are a fire hazard
and must be removed as soon as they are dis-
covered.

IMPORTANT!

If you discover a leakage of oil,

fuel or coolant, investigate the cause and fix the
fault before you start the engine.

IMPORTANT!

Observe the following when

cleaning with a high pressure washer: Never
aim the water jet at seals, rubber hoses or elec-
trical components. Never use a high pressure
washer for engine cleaning.

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

WARNING!

Read through the safety advice for care and maintenance work in the Safety information

chapter before you start work.

WARNING!

Care and maintenance work should be done with the engine stopped unless otherwise spe-

cified. Stop the engine before opening or removing the engine hatch/hood. Make it impossible to start the
engine by removing the start key and cutting the system voltage with the main switches.

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Содержание D12

Страница 1: ...OPERATOR SMANUAL D12 ...

Страница 2: ...ò 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 Bestillingskupon findes i slutningen af instruk tionsbogen Tämän ohjekirjan voi tilata myös suo menkielisenä Tilauskuponki on ohjekirjan lopus...

Страница 3: ...ou to read this operator s manual thoroughly and consider the advice we give on operation and maintenance before your maiden voyage so that you will be ensured of fulfilling your expectations Please pay attention to the safety instructions contained in the manual As owner of a Volvo Penta marine engine we would also like to welcome you to a worldwide network of dealers and service workshops to ass...

Страница 4: ...egister 92 Technical data 100 Engine 100 Reverse gear 102 Safety information 3 General information 3 Boat trips 4 Care and maintenance 6 Introduction 8 Running in 8 Fuel and oils 8 Certified engines 9 Warranty information 9 Identification number 10 Presentation 11 Technical description 11 Orientation 12 Instruments 13 Instruments 13 Ignition lock 13 Start stop panel 13 Alarm display optional extra...

Страница 5: ...ct your Volvo Penta dealer for assistance This symbol is used in the instruction book and on the product to call your attention to the fact that this is safety information Always read such information very carefully Safety texts in the instruction book have the following order of priority WARNING Warns for the risk of personal injury major damage to product or property or serious malfunctions if t...

Страница 6: ...nd that the necessary safety equipment is on board and is in working condition Daily checks Make it a habit to give the engine and engine bay a visual check before driving before starting the engine and after operation when you have stop ped the engine This helps you to quickly discover whether any leakage of fuel coolant oil or any other abnormal event has happened or is about to happen Manoeuvri...

Страница 7: ...load distribution instead Also try taking down opening the hood or modifying it in some other manner Ask your boat dealer for ad vice about the best solution for your particular boat Remember Safety equipment Life jackets for everybody aboard communication equipment emergency rockets approved fire extinguisher first aid kit life buoy anchor paddle torches etc Spare parts and tools Impeller fuel fi...

Страница 8: ...s centre of gravity Special lifting devices may then be needed to obtain the correct balance and safe handling Never do any work on an engine which just hangs from a lifting device 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 eng...

Страница 9: ...ler cap coolant hose etc still has to be ope ned or removed when the engine is hot undo the filler cap slowly and carefully to let the pressure out before removing the filler cap completely and starting work Note that the coolant can still be hot and cause scalding Lubrication system Hot oil can cause burns Avoid skin contact with hot oil Make sure that the oil system is de pressurised before star...

Страница 10: ...o and harbours in the same state you would like to find them Re member to always hand in drained oil coolant paint and wash residue used batteries etc for destruction at a recycling station If we all pull together we can make a valuable contri bution to the environment together Higher oil consumption is normal during the running in period For this reason check the oil level more frequently than no...

Страница 11: ... personnel The general advice in the instruction book about ope ration care and maintenance apply IMPORTANT Late or inadequate maintenance service or the use of spare parts not approved by Volvo Penta will invalidate AB Volvo Penta s responsibility for the engine specification being in accordance with the certificated variant Volvo Penta accepts no responsibility or liabi lity for any damage or co...

Страница 12: ...ance and location of the type plates is shown below The figures in brackets refer to the location of the identification number on the type plate Engine Product designation 1 D12D C MH Serial and base engine number 2 Product number 3 Control unit Dataset parameter file 4 Main software 5 Certification IMO Reverse gear Product designation 6 Serial number 7 Product number 8 Reverse gear plate Engine p...

Страница 13: ... piston rings including a keystone type top ring Induction hardened overhead camshaft with roller rocker arms 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 Lubrication syst...

Страница 14: ...er 11 Seawater pump D12D C MH 1 Exhaust pipe dry 2 Turbocharger 3 Fine fuel filter with water trap 4 Emergency stop button 5 Oil filler cap 6 Coolant pump 7 Oil sump 8 Oil cooler engine loc in engine block 9 Lubrication oil filter 10 By pass filter for lubrication oil 11 Coolant filter 12 Oil dipstick engine 13 Oil filler cap 14 Oil drain pump optional 15 Starter motor 16 Reverse gear Twin Disk MG...

Страница 15: ...on keys and is used to order extra ignition keys Do not store the code where it is accessible to unauthorized persons S Stop position 0 Key can be inserted and removed I System voltage on drive position II Not used III Start position IMPORTANT Read the starting instructions in the Starting the engine chapter 2 3 4 1 Instruments Start stop panel The start stop panel is used to start or stop the eng...

Страница 16: ... the engine at once Check the oil level in the engine Please refer to Maintenance Lubrication to check and top the oil up Also check that the oil filters are not blocked 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 t...

Страница 17: ...if there is any 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...

Страница 18: ... Please refer 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 Diagno...

Страница 19: ...to activate and lock the control panel and 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 panel is locked manually by depressing the button or if exchange has been activa...

Страница 20: ...U To enter a SUB MENU push NAVIGATION WHEEL Speed Optional Boat speed Requires multisensor or GPS Water temp Optional Water temperature Requires multisensor Depth Optional Water depth Requires multisensor Trip menu Optional Shows trip information Requires the following Multisensor or NMEA 0183 NMEA 2000 compat ible component plotter GPS paddle wheel etc Fuel level sender Trip computer software Gau...

Страница 21: ...m returns to MAIN MENU 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 instan...

Страница 22: ... view by turning 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 struc...

Страница 23: ...bol indicates a 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 ...

Страница 24: ...ON WHEEL The 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 un...

Страница 25: ...NAVIGATION WHEEL 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...

Страница 26: ... will not be correct 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 push NAVIGATION WHEEL 4 Select FUEL MULTIPOINT CALIBRATION by turning NAVIGATION WHEEL Push NAVIGA TION WHEEL to enter FUEL MULTIPOINT CALI BRATION NOTE The fuel multipoint calibr...

Страница 27: ...TION WHEEL Push NAVIGATION WHEEL to enter FULL TANK CALIBRATION 4 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 up will re appe...

Страница 28: ...TION WHEEL Once adjustment 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 FUEL FULL TANK CALIBRATION is performed Retrieving faults The EVC system is ret...

Страница 29: ... This display mode functions in the same way as the display in the tachometer EVC System Tacho meter 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 fu...

Страница 30: ...electrical system the pop up window will flash CONNECTION LOST When opera ting information has been registered reset the pop up window disappears Start image This is the starting image that is shown on the display for a brief period after starting If the unit gives a constant audible warning after star ting the self test has failed The unit will still work but may behave in an unexpected manner Sy...

Страница 31: ...ition switched on 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 60M...

Страница 32: ...s on the free stan 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...

Страница 33: ...il or Turbo pressure 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 mess...

Страница 34: ... instruments together with a trip computer 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 tible component plotter GPS paddle wheel etc Fuel level sender Software for trip computer order and download from VODIA website The trip computer shows vario...

Страница 35: ...each window The 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 appl...

Страница 36: ...val can be set to one of the following values in the configuration menu 2 min 10 min 30 min 1 h 2 h 4 h 8 h The interval on the Y axis is automatically adjusted for best indication Display mode Trip button 3 This display mode shows Fuel used after last zeroing Instantaneous fuel consumption amount of fuel used per hour If speed information is available instantaneous fuel consumption can also be ca...

Страница 37: ...s to flash to acknowledge that the shift func tion is disengaged The lever now only controls engine speed When the lever is moved back to the neutral position it will automatically re engage This is confirmed by the green indication which gives constant light WARNING Take care not to engage the rever sing gear stern drive unintentionally Single lever control Electronic Operation Both the shift fun...

Страница 38: ...as necessary Friction brake adjustment 1 Stop the engine 2 Move the control lever forwards to make the groove in the control lever hub accessible 3 Put a screwdriver in the groove and disassemble the plug 4 Adjust the friction brake spanner size 8 mm Clockwise stiffer lever movement Anti clockwise easier lever movement 5 Install the plug ...

Страница 39: ...n neutral Black lever 1 N Neutral position Reversing gear is disengaged F Reversing gear engaged for movement ahead R Reversing gear engaged for movement astern Red lever 2 Engine speed control A B A Friction brake The control has an adjustable friction brake for speed control Adjust the friction brake by turning the screw control A or lever control B Turn clockwise for heavier lever movement or a...

Страница 40: ...he fuel tap Open the sea cock reverse gear Do the tasks under the Daily before first start heading in the maintenance schedule Turn the main switches on IMPORTANT Never disconnect the current with the main switches when the engine is running This can damage the alternator Start the engine bay fan if one is installed and let it run for at least four minutes Check that the amount of fuel aboard is e...

Страница 41: ...e control panel s is are activated Activate the control position and lock the system Press the activation button for at least one second When the button is released the indication lights up to confirm that the control position is activated NOTE If the indicator flashes the control position has not been activated because the control lever s are not in the neutral position or the system has been loc...

Страница 42: ...seconds the starter motor circuit is cut automatically 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 warning displays show normal values Check that no alarms are displaye...

Страница 43: ...ing and then regularly during your voyage Oil pressure The oil pressure gauge should normally indicate between 4 5 5 bar It will indicate a somewhat lower value when idling If the oil pressure is too low the audible warning will sound automatically at the same time as the lamp in the warning display will flash Coolant temperature The temperature gauge should normally indicate bet ween 75 95 C 167 ...

Страница 44: ...tored in the form of a fault code for as long as the malfunction remains It is possible to read the fault code during a subsequent service 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 condition...

Страница 45: ... disengaged as soon as the conditions are no longer met 1 Changing the helm station The first time you change control panel after starting the EVC system a bulb check is done automatically All LEDs and bulbs light up for 2 seconds 1 Check that the control lever s is are in neutral on both the control panel you leave and on the new control panel 2 Check that the EVC system is not locked 3 Press the...

Страница 46: ...in neutral before it is possible to change control panel 3 Press the activation button 1 on the alternative control panel The activation button indication flas hes on the alternative control panel and on the main control panel it gives constant light 4 The alternative control panel becomes active when the correct gear and approved engine speed is demanded The activation button 1 gi ves constant li...

Страница 47: ... forwards reverse operation as fol lows 1 Reduce engine speed to idle and let the boat more or less lose way WARNING Never shift to reverse when the boat is planing 2 Move the control lever to 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 rapid distinct movement and...

Страница 48: ...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 tachome ter display C Lowspeed is not ready to use Normal gear shifting until Lowspeed is activated D IMPORTANT Delay in g...

Страница 49: ...t speed can increase 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 unt...

Страница 50: ...or up to 6 8 h After this the engine must be started and run for at least 5 min to lubricate and cool the reversing gear If the shaft is likely to rotate faster than in normal operation such as when sailing a temperature gau ge should be installed to monitor the oil temperature Maximum permissible temperature is 95 C for the ZF reversing gear When the above mentioned rules can not be met or if you...

Страница 51: ...od of operation Adjustment may be required to compensate for disc wear Refer to Maintenance Accessories when adjusting Flush and bilge pump The bilge pump has a vacuum switch 1 that auto matically disengages the pump when water is no lon ger being drawn into the pump The flush and bilge pump are engaged and disen gaged from a switch that is normally located at the main control position The bilge p...

Страница 52: ...n off the main switches before any long stopp age 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 Allow the engine to idle in neutral for at least three minutes after the end of your journey This evens out the temperatures inside the engine and stops after boiling IMPORTANT The above is particula...

Страница 53: ...seawater system must be drained Frost damage in the seawater system can make the boat sink IMPORTANT If the coolant does not have suf ficient frost protection this can cause expensive engine damage Check the battery charge A poorly charged battery can freeze and burst Laying up If the boat is not used but left in the water the engi ne must be warmed up at least once every fortnight This prevents c...

Страница 54: ...le clutch Lubrication 1 page 83 Every 50 500 hours at least every 12 months Engine oil Change 2 page 58 Oil filter Bypass filter Change 3 page 60 1 Applies to release bearing when operated more than 15 times a day Otherwise every 500 operating hours 2 Oil change intervals vary depending on oil grade and sulphur content of the fuel Please refer to page 57 3 Change the filters during each oil change...

Страница 55: ...lycol mixture Every 1000 hours at least every 12 months Valve clearance Inspection adjustment not shown Coolant filter Change 1 page 65 Clean the insert in the heat exchanger and in the reverse gear oil cooler not shown Seawater filter Checking cleaning 2 page 68 Fuel pre filter Change filter insert page 74 Fuel fine filter Changing Venting the fuel system page 70 Reverse gear Oil strainer Cleanin...

Страница 56: ... coolant investigate the cause and fix the fault before you start the engine IMPORTANT Observe the following when cleaning with a high pressure washer Never aim the water jet at seals rubber hoses or elec trical components Never use a high pressure washer for engine cleaning This chapter contains general technical information and instructions for carrying out the specified maintenance points Read ...

Страница 57: ...e 2 Check the rubber seals change as necessary Screw the new filters on by hand Air filter Change 1 If indicator is all red after the engine is stopped change the filter 2 Undo the clamps and remove the lid from the fil ter housing 3 Remove the old filter Be careful to ensure that no contamination gets into the engine 4 Install a new air filter and tighten the lid 5 Reinstate the pressure drop ind...

Страница 58: ...life The belts are tensioned in the same way 1 Remove the protective cover over the alternator drive belt 2 Undo the inner fixing screw 1 and the lock screws 2 a couple of turns 3 Tension the belts with tensioner screw 3 It should be possible to press the belts down about 5 mm 0 2 between the pulleys when the ten sion is correct 4 Tighten lock screw 2 and the inner fixing screw 1 5 Install the pro...

Страница 59: ...y weight up to 0 5 0 5 1 0 more than 1 0 2 Oil change interval Reached first in operation VDS 3 500 hr or 12 months 250 hr or 12 months 125 hr or 12 months VDS 2 and ACEA E7 4 or VDS 2 and Global DHD 1 500 hr or 12 months 200 hr or 12 months 100 hr or 12 months or VDS 2 and API CH 4 or VDS 2 and API CI 4 VDS and ACEA E3 2 300 hr or 12 months 150 hr or 12 months 75 hr or 12 months or VDS 2 and API ...

Страница 60: ... Hot oil and hot surfaces can cause burns 2 Connect the suction pipe of the oil drain pipe to the drain pipe Pump up the oil 3 Change the oil filter and bypass filter at each oil change please refer to the instructions on the next page 4 Fill up with oil to the correct level through the fill ing hole on the side of the engine please refer to the Technical Data chapter for oil volume IMPORTANT Only...

Страница 61: ... Use a filter wrench if necessary 4 Check that the mating surfaces on the filter bracket are clean and that no traces of the seal from the old filter remain 5 Oil the rubber seal for the new filter 6 Screw the filter on by hand until the rubber seal just touches the mating surface of the filter brack et Then tighten the filter a further 3 4 of a turn 7 Turn the lever to the left hand end position ...

Страница 62: ...o avoid oil spillage 2 Clean the filter bracket 3 Unscrew the bypass filter 1 and the oil filters 2 with a suitable extractor 4 Check that the mating surfaces on the filter brack ets are clean and that no residue from the old seals remains 5 Moisten the seals on the new filters with engine oil 6 Screw the filters on by hand until the rubber seals just touch the mating surface on the filter brack e...

Страница 63: ...self as coolant IMPORTANT Coolant must be used all year round This applies even if there is never any risk for frost to ensure that the engine has an adequate protection against corrosion Future warranty claims on the engine and additional equipment may be rejected if an unsuitable coolant has been used or if the instructions concerning coolant mixing have not been followed NOTE The anti corrosive...

Страница 64: ... increase the risk of overheating and will give reduced freezing protection IMPORTANT Coolant must be mixed with pure water use distilled de ionized water The water must fulfill the requirements specified by Volvo Penta see Water quality IMPORTANT It is extremely important that the correct concentration of coolant is added to the system Mix in a separate clean vessel before adding into the cooling...

Страница 65: ...use burns IMPORTANT Top up with the same type of coolant as already used in the system Topping up Fill up with coolant to the correct level via the filling hole on the expansion tank Fill slowly to allow the air which is forced out a chance to flow out of the filling hole When you fill up an empty system or if the coolant has fallen so low for any reason that it is no longer visible through the fi...

Страница 66: ...he engine and let it cool be fore draining Hot fluids and hot surfaces can cause burns WARNING Glycol is poisonous dangerous to drink Collect the old coolant and hand it to a re cycling station for destruction Drain the cool ant via taps F 1 Remove the filling cap 1 from the expansion tank 2 Open the vent tap V by the turbocharger 3 Connect a suitable hose to each drain tap Open the tap and allow ...

Страница 67: ... the previous page Coolant filter Change IMPORTANT Do not change the filter when the coolant is changed The concentration of rust preventer in the coolant can become too high which would cause foaming and impaired cool ing WARNING Hot coolant and hot surfaces can cause burns 1 Clean the filter bracket 2 Close the filter tap 1 position A 3 Unscrew the filter with a suitable extractor 4 Clean the fi...

Страница 68: ...ater system must be drained in cold weath er if there is a risk of frost to prevent frost damage WARNING Risk of water entry Close the sea water cocks before doing any work on the sea water system An alternative to draining is to keep the engine bay above freezing temperature by means of a fan heat er which is approved for outdoor use Draining 1 Close the sea cock 2 Connect a hose to each drain ta...

Страница 69: ...gear oil cooler 2 pcs 4 Check the zinc anodes and replace them if more than 50 of their original size has been used up If not clean the zinc anodes with emery cloth to remove the oxide layer before re installing them IMPORTANT Use an emery cloth for clean ing Do not use steel tools since this could impair the galvanic protection 5 Install the zinc anodes Make sure that good me tallic contact is ob...

Страница 70: ...o the end of the shaft and press the impeller in using a washer and nut Fit the cover using a new O ring 5 Open the sea cock IMPORTANT Always carry a spare impeller on board Seawater filter Inspection cleaning The seawater 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 ...

Страница 71: ...tion The condensate is drained via a hose connected to a nipple under the rear of the inlet manifold Check that the nipple is not blocked WARNING If a large amount of water flows out of the drain hole from the inlet manifold the af tercooler must be removed and proof tested This task must be done by an authorised workshop ...

Страница 72: ...fter long stops Single filter and Switchable filters Stationary engine 1 Put a suitable vessel underneath the fuel filter 2 Remove the protective cap from the venting nipp le 1 on the filter bracket Connect a transparent plastic hose to the nipple and lower this into the vessel 3 Open the venting nipple and pump up fuel with the hand pump 2 until air free fuel flows out Tighten the venting nipple ...

Страница 73: ...pump 3 until clean fuel flows out Running engine switchable filters only 1 Shut off the fuel flow to the filter to be drained A 2 Put a suitable vessel underneath the filter 3 Cautiously open the tap 1 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 with the other filter 6 Turn the handle ...

Страница 74: ...ilter bracket Make sure the filter is absolutely clean and the sealing surfaces are undamaged Moisten the sealing rings with engine oil including the inner rubber seal located inside the threaded hole in the center of the filter NOTE Do not fill the new filter with fuel before assembly Contaminations may get into the system and cause damage and malfunction 7 Screw the new filter on by hand until t...

Страница 75: ...rap and filter use a filter wrench if needed 7 Clean the sealing surfaces of the filter bracket Make sure the filter is absolutely clean and the sealing surfaces are undamaged Moisten the sealing rings with engine oil including the inner rubber seal located inside the threaded hole in the center of the filter NOTE Do not fill the new filter with fuel before assembly Contaminations may get into the...

Страница 76: ...going close to a running engine is a safety risk Watch out for ro tating components and hot surfaces Fuel pre filter Changing the filter insert The fuel pre filter water trap supplied by Volvo Penta is available in single and twin versions The twin filter inserts can be changed with the engine running by closing off fuel flow to one filter housing at a time Fuel flow is controlled by putting the h...

Страница 77: ...move the cover 3 3 Take out the insert carefully while turning it 4 Drain off water and contaminants through the drain plug 4 5 Fit a new filter insert and fill the container with clean fuel 6 Change the gasket on the cover and the O ring on the T bolt Moisten the gasket and O ring with fuel before assembling 7 Fit the cover and tighten it by hand 8 Wipe off any fuel from the heat shield 9 Change ...

Страница 78: ...tches The main switches must never be disconnected before the engine has been stopped If the circuit between the alternator and the batteries is discon nected when the engine is running the alternator and electronics can be damaged The charging circuits must never be re connected with the engine running for the same reason IMPORTANT Never disconnect the current with the main switches when the engi...

Страница 79: ...nnect the cable black to the pole on the battery When you disconnect batteries disconnect the ca ble black first then the cable red Cleaning Keep the batteries dry and clean Contamination and oxide on the batteries and battery poles can cause stray currents voltage drop and discharge especially in wet weather Clean oxidation from the battery poles and terminals using a copper brush Tighten the ter...

Страница 80: ...harged then trickle charged please refer to the battery manufacturer s recommendations Batteries are damaged by being left discharged and can also freeze and burst easier in cold weather IMPORTANT Observe the instruction manual for the battery charger carefully To avoid the risk of electrochemical corrosion when an external charger is connected the battery cables in the boat should be removed from...

Страница 81: ...y currents in their turn can weaken the galvanic pro tection of the propeller propeller shaft rudder keel etc and cause damage because of electrochemical corrosion IMPORTANT Work on the low voltage circuits in the boats should be done by a person with electrical training or knowledge Installation or work on land current equipment must only be done by a competent electrician in accordance with loca...

Страница 82: ...of the battery The main switch must disconnect all loads and shall be switched off when the boat is not used 5 If an extra auxiliary battery is used a main switch 1 must be connected between the auxiliary battery positive pole and the fuse box for the boat s electrical equipment The main switch must disconnect all loads connected to the auxiliary battery and shall be switched off when the loads ar...

Страница 83: ...ssary top up with oil through the filler hole 2 on top of the reverse gear Oil grade and volume Please refer to the Technical Data chapter IMPORTANT Never over fill the reverse gear The oil level must always be within the recom mended range Oil strainer 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...

Страница 84: ...nical Data chapter IMPORTANT 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 EP...

Страница 85: ...ch Accessories Disengageable clutch Lubrication Use lithium based grease such as Mobilux EP2 Statoil Uniway EP2N Texaco Multifac EP2 Q8 Rem brandt EP2 Main bearing and clutch mechanism Lubricate the inner support bearing with lubricat ing nipple the main bearings release shaft and the moving parts in the clutch mechanism with grease Lubricate sparingly 20 30 grams 0 6 1 0 oz for the main bearings ...

Страница 86: ...erse gear reaches the MAX mark on the dipstick Stop the engine Max 8 month s stoppage Change the oil and oil filter on the engine then warm it up afterwards More than 8 month s stoppage Conserve the lubrication and fuel systems with conservation oil Please refer to the instruction on the next page Check that the coolant offers sufficient frost pro tection Top up as necessary Alternatively you can ...

Страница 87: ...es Open the sea cocks Start the engine if the boat is in the water and warm up at a fast idle before loading the engine Check that no oil fuel or coolant leakage occurs Check the oil level in the reverse gear Top up as necessary Conservation of the lubrication and fuel systems for more than 8 months stoppage Drain the oil from the sump and engine and fill the engine up with conservation oil to jus...

Страница 88: ...NING Never confuse the positive and ne gative poles on the batteries Risk of arcing and explosion 1 Check that the rated voltage of the help start battery is the same as the system voltage of the engine 2 Connect the red jumper cable to the positive pole of the flat battery and then to the positive pole of the help start battery 3 Connect the black jumper cable to the negative pole of the help sta...

Страница 89: ...the control lever Forward motion can only be cut off by stopping the engine with the igni tion key or stop button 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 connec tors 1 and 2 from the solenoid valves 3 Remove the cap nut from the valve which was connected to the Primary cable 4 Press the valv...

Страница 90: ...0 Excessive coolant temperature 21 Too low coolant temperature 22 Too low oil level 23 Faulty wrong propeller 24 Faulty engine mounting 25 Coolant level too low 26 Air in the freshwater system 27 Faulty circulation pump 28 Closed seawater inlet 29 Blocked seawater inlet pipe filter 30 Defective impeller in seawater pump 31 Defective thermostat 32 Blocked heat exchanger insert 33 Blocked aftercoole...

Страница 91: ...ly damage the engine e g high coolant temperature 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 engine da mage Reaction Engine power is reduced 4 The diagnostic function has discovered a serious malfunction which makes it impossible to control the engine Reaction The reversing gear dri...

Страница 92: ... start the alarm must be 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 en...

Страница 93: ... to take is found in chapter 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 a...

Страница 94: ...lease refer to Maintenance Seawater system Check the impeller in the sea water pump Please refer to Maintenance Seawater system Check that no leakage occurs Please contact a Volvo Penta workshop if the fault remains Fault register Description R Explanation Reaction Action WARNING Read the safety precautions for maintenance and service in the Safety information chapter before starting work Explanat...

Страница 95: ...cked Please refer 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...

Страница 96: ...ollowing seas or head 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 C...

Страница 97: ...olvo Penta workshop 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 Plea...

Страница 98: ...er to Stopping the 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 ...

Страница 99: ...e chosen control panel 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 po...

Страница 100: ...f the fault remains Check steering wheel O Explanation Fault in steering wheel unit Reaction Engine power is reduced Action Restart both engines Please contact a Volvo Penta workshop if the fault remains Limited engine rpm R Explanation Fault in steering system Reaction Engine power is reduced on both sides Action Restart both engines Please contact a Volvo Penta workshop if the fault remains Limi...

Страница 101: ...s reduced on both sides No steering Action Restart both engines Please contact a Volvo Penta workshop if the fault remains No gear throttle and steering R Explanation Fault in steering system Reaction No steering No propulsion Action Restart both engines Please contact a Volvo Penta workshop if the fault remains ...

Страница 102: ...1000 rpm Nm lbf ft 1461 1078 Max torque 1200 rpm Nm lbf ft 1592 1174 1814 1338 Max torque 1400 rpm Nm lbf ft Engine model D12 450 D12 500 D12 550 Crankshaft power 1800 rpm kW hp 331 450 367 499 Crankshaft power 1900 rpm kW hp 405 550 Max torque 1200 rpm Nm lbf ft 2204 1626 2196 1620 Max torque 1400 rpm Nm lbf ft 2019 1489 General After market designation D12D C MH No of cylinders and configuration...

Страница 103: ...ure Refers to synthetic or semi synthetic oil Cooling system Freshwater system capacity including heat exchanger approx 60 liters 15 9 US gals Electrical system System voltage 24V AC generator voltage max amperage 28V 60A output approx 1700W Alternative generator equipment accessory voltage max amperage 28V 100A output approx 2800W Alternative generator equipment accessory voltage max amperage 14V...

Страница 104: ... 2 1 6 5 kp cm2 2 1 6 5 kp cm2 Oil pressure during operation 1 57 1 63 MPa 1 57 1 63 MPa 16 16 6 kp cm2 16 16 6kp cm2 Weight approx 213 kg 470 lbs 374 kg 825 lbs NOTE Only single grade lubricating oil only one viscosity num ber may be used in the reverse gear At oil temperature 82 C and 1800 rpm Clutch Disengageable clutches at front of engine accessory Twin Disc Type Twin disc clutch over center ...

Страница 105: ...Notes ...

Страница 106: ...r 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 7746216 Name Anschrift Land 42200 615001 155099900192 Notez que l offre est valable pendant 12 ...

Страница 107: ...cación 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 7746218 Nombre Direcci...

Страница 108: ...ller 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 7746221 Navn Adresse Land 42200 615001 155099900192 Huomaa että tarjous on voimassa 12 kuukautta veneen toimituspäivä määräs...

Страница 109: ...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 Department ARU2 Dept 64620 SE 405 08 Göteborg Sweden Fax 46 31 545 772 Ìðïñåßôå åðßóçò íá äþóåôå...

Страница 110: ...u þu adrese posta layýn 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 7746227 Ýsim Adres Ülke 42200 615001 155099900192 ...

Страница 111: ......

Страница 112: ...7746214 English 05 2007 ...

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