Volvo Penta 22 Series Instruction Book

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INSTRUCTION BOOK

22 Series

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Safety Information ............................................... 3–7

General ................................................................... 3

Voyages ................................................................. 4

Maintenance and service ........................................ 6

Introduction ....................................................... 8–10

Running-in ............................................................... 8

Fuel and oil types ................................................... 8

Certified engines ..................................................... 9

Warranty and Guarantee information ....................... 9

Identification numbers ........................................... 10

Orientation ....................................................... 11–13

MD22L/120S ......................................................... 11

MD22P/MS25 ....................................................... 12

TMD22/MS2 .......................................................... 12

TMD22P/HS25 ...................................................... 12

TAMD22P/SX ....................................................... 13

Instrumentation ............................................... 14–15

Instrument panels ................................................. 14

Starting lock.......................................................... 15

Controls ................................................................ 16

Disengaging the shift function. .............................. 16

Friction brake ........................................................ 16

Power Trim ........................................................... 17

Trim control ........................................................... 17

Trim instrument ..................................................... 17

Starting the engine .......................................... 18–19

Before starting the engine ..................................... 18

Starting ................................................................. 18

Starting the engine using auxiliary batteries .......... 19

Operation ......................................................... 20–24

Cruising speed ...................................................... 20

Maneuvering ......................................................... 20

Trolling operation valve ......................................... 21

When sailing ......................................................... 21

Checking instruments ........................................... 21

Operating with Power Trim .................................... 22

Stopping the engine ....................................... 25–26

After stopping the engine ...................................... 25

Cold weather precautions ...................................... 26

Laying up .............................................................. 26

Transporting on a trailer ........................................ 26

Laying up on land .................................................. 26

Maintenance schedule .................................... 27–28

Maintenance and care ..................................... 29–57

Engine, general ..................................................... 29

Lubrication system................................................ 31

Cooling system ..................................................... 32

Fuel injection system ............................................ 38

Electrical system .................................................. 41

Wiring diagram ...................................................... 45

S-drive and reverse gear ....................................... 47

SX-drive: ............................................................... 52

Laying up/Launching ...................................... 58–60

Inhibiting ............................................................... 58

Bringing out of storage .......................................... 59

”Painting the drive and underwater hull”. ................ 60

Fault-tracing ......................................................... 61

Technical Data ................................................. 62–63

Engine .................................................................. 62

Cooling system ..................................................... 62

Electrical system .................................................. 62

Lubricating oil recommendations ........................... 62

Fuel specification .................................................. 62

S-drive and reverse gear ....................................... 63

Contents

All rights to changes or modifications reserved. Printed on enviornmentally friendly paper.

(Cover: Department of transport (shipping), license 9809095)

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Read this chapter carefully. It concerns your safety. This chapter describes how safety information is presented in the Instruction Manual and on the engine itself. It also gives a general account of basic safety precautions to be taken when operating the boat and maintaining the engine.

Check that you have the correct Instruction Manual before you read on. If this is not the case please contact your Volvo Penta dealer.

If operations are performed incorrectly this could result in personal injury, or damage to property or the engine. Read the Instruction Manual carefully before operating or servicing the engine. If anything is unclear please contact your Volvo Penta dealer for assistance.

This symbol is used in the book and on the engine to make you aware of safety information.

Always read these safety precautions very carefully.

In the Instruction Manual warning texts have the following priority:

WARNING! If these instructions are not followed there is a danger of personal injury, extensive damage to the product or serious mechanical malfunction.

IMPORTANT! Used to draw your attention to something that can cause damage, product malfunction or damage to property.

NOTE! Used to draw your attention to important information that will facilitate work or operations.

This symbol is used in certain cases on our products and refers to important information in

the Instruction Manual. Ensure that warning and information symbols on the engine and transmission are always visible and legible. Replace symbols that have been damaged or painted over.

Safety Precautions

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Safety precautions to be taken when operating the boat

Your new boat

Read Instruction Manuals and other information supplied with your new boat. Learn to operate the engine, controls and other equipment safely and correctly.

If this is your first boat, or is a boat type with which you are not familiar, we recommend that you practice controlling the boat in peace and quiet. Learn how the boat behaves at different speeds, weather conditions and loads before casting off for your “real” maiden voyage.

Remember that the person driving a boat is legally required to know and follow the current rules regarding traffic and safety at sea. Make sure you know the rules that apply to you and the waters you are sailing in by contacting the relevant authorities or organization.

A good piece of advice is to take a course in seamanship. We recommend that you contact your local boating organization to find a suitable course.

Accidents

Statistics show that poor maintenance of boats and engines and a lack of safety equipment are often the cause of accidents at sea.

Ensure that your boat is maintained in accordance with the relevant Instruction Manual and that the necessary safety equipment is on-board and is serviceable.

Daily checklist

Make a habit of checking the engine and engine compartment visually before operating the boat (before the engine is started) and after operating the boat (after the engine has been stopped). This will help you to quickly detect fuel, coolant and oil leaks and spot anything else unusual that has, or is about to happen.

Maneuvering

Avoid violent and unexpected changes in course and gear engagement. This could cause someone on the boat to lose their balance and fall over or overboard.

A rotating propeller can cause serious injury. Check that nobody is in the water before engaging ahead or astern. Never drive near bathers or in areas where people could be in the water.

Avoid trimming an outboard drive too much, as steering will be severely reduced.

Refueling

When refueling there is always a danger of fire and explosion. Smoking is forbidden and the engine must be switched off.

Never overfill the tank. Close the fuel tank filler cap properly.

Only use the fuel recommended in the Instruction Manual. The wrong grade of fuel can cause operating problems or cause the engine to stop. On a diesel engine poor quality fuel can cause the control rod to seize and the engine to overrev with a resultant risk of damage to the engine and personal injury.

Safety breaker

We recommend that you install and use a safety breaker (accessory), especially if you boat can travel at high speeds. The safety breaker stops the engine if the driver falls down and loses control over the boat.

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Carbon monoxide poisoning

When a boat is moving forward backwash is caused behind the boat. Sometimes this backwash can be so powerful that exhaust gases can be sucked into the cabin or seating well on the boat with the resulting risk of carbon monoxide poisoning for those on boar d.

The backwash problem is greatest with high, broad boats with a squared stern. But other types of boat can also have backwash problems under certain conditions, for example when running with an awning rigged. Among other factors that can increase the backwash effect are wind conditions, load distribution, the sea running, trim, open hatches and valves.

Most modern boats are designed in such a way that problems with backwash are extremely unusual. Should a backwash problem occur do not open hatches or valves in the forward part of the boat. This will only increase backwash. Try changing speed, trim or load distribution in the boat instead. In addition take down, open or change the rigging of the awning in some other way if an awning is rigged. Contact the dealer where the boat was purchased to get more information on how to solve this problem should it occur on your boat.

Checklist

● Safety equipment: Life jackets for all passengers, communication equipment, emergency rockets,

approved fire extinguisher, first-aid equipment, life belt, anchor, paddle, torch etc.

● Replacement parts and tools: impeller, fuel filters, fuses, tape, hose clamps, engine oil, propeller

and tools for any repairs that might have to be carried out.

● Get out your charts and go over the planned route. Calculate distance and fuel consumption.

Listen to the weather reports

● Make sure that relations or contact persons are informed when planning a longer voyage.

Remember to inform them if your plans have changed or been delayed.

● Tell your passengers and crew where the safety equipment is stored and how to operate it. Make

sure you are not the only person on board who knows how to start the boat and operate it safely.

The list should be supplemented because the requirement for safety equipment varies depending on the boat type and how it is used etc.. We recommend that you contact a local boating or maritime safety organization for more detailed marine safety information.

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Safety precautions for maintenance and service operations

Preparations

Knowledge

The Owner’s Manual contains instructions on how to carry out general maintenance and service operations safely and correctly. Read the instructions carefully before starting work.

Service literature covering more complicated operations is available from your Volvo Penta dealer.

Never carry out any work on the engine if you are unsure of how it should be done, contact your Volvo Penta dealer who will be glad to offer assistance.

Stop the engine

Stop the engine before opening or removing engine hatches. Unless otherwise specified all maintenance and service must be carried out with the engine stopped.

To prevent accidental start of the boat engine remove the ignition key, turn off the power supply to the engine at the main switch and lock it in the OFF position before starting work. Put up a warning sign in the control position that work on the engine is being carried out.

Approaching or working on an engine that is running is a safety risk. Loose clothing, hair, fingers or a dropped tool can be caught in the rotating parts of the engine and cause serious personal injury. Volvo Penta recommend that all servicing with the engine running be undertaken by an authorized Volvo Penta workshop.

Lifting the engine

When lifting the engine use the lifting eyes installed on the engine (reverse gear where installed). Always check that lifting equipment is in good condition and is strong enough for the lift (engine weight with any extra equipment). For safety’s sake lift the engine using an adjustable lifting beam. All chains and cables should run parallel to each other and as perpendicular as possible in relation to the top of the engine. Bear in mind that extra equipment installed on the engine may alter its center of gravity. Special lifting equipment may then be required in order to maintain the correct balance and make the engine safe to handle. Never carry out work on an engine suspended on a hoist.

Before starting the engine

Reinstall all guards removed during service operations before starting the engine. Check that no tools or other items have been left on the engine.

Never start a turbocharger engine without installing the air cleaner (ACL). The rotating compressor in the turbocharger can cause serious personal injury. Foreign objects can also be sucked in and cause mechanical damage to the unit.

Fire and explosion

Fuel and lubrication oil

All fuel, most lubricants and many chemicals are inflammable. Read and follow the instructions on the packaging.

When carrying out work on the fuel system make sure the engine is cold. A fuel spill onto a hot surface or electrical components can cause a fire.

Store fuel soaked rags and other flammable material so that there is no danger of them catching fire. In certain conditions oil-soaked rags can spontaneously ignite.

Do not smoke when filling fuel, oil or in proximity of a filling station or in the engine room.

Non-original components

Components used in the fuel and ignition system (gasoline engines) and electrical systems on Volvo Penta products are designed and constructed to minimize the risk of fire and explosion.

Using non-original Volvo Penta parts can result in fire or explosion on board.

Batteries

The batteries contain and give off oxyhydrogen gas, especially during charging. This gas is easily ignited and highly flammable.

Do not under any circumstances smoke or use naked flame or allow sparks in the vicinity of the batteries or battery compartment.

Incorrectly connecting a battery terminal cable or jump-start cable can cause a spark which in turn can be sufficient to cause an explosion.

Start spray

Never use start spray or similar agents to start an engine equipped with air pre-heating (glow plugs/ starter element). The starter element may cause an explosion in the inlet manifold. Danger of personal injury.

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Hot surfaces and fluids

There is always a risk of burns when working with a hot engine. Beware of hot surfaces. For example: the exhaust pipe, turbocharger (TC), oil pan, charge air pipe, starter element, hot coolant and hot oil in oil lines and hoses.

Carbon monoxide poisoning

Start the engine only in a well-ventilated area. If operating the engine in an enclosed space, ensure that there is proper ventilation in order to remove exhaust gases and crankcase ventilation emissions from the working area.

Chemicals

Most chemicals such as anti-freeze, rustproofing agent, inhibiting oil, degreasing agent etc. are hazardous to health. Read and follow the instructions on the packaging.

Some chemicals such as inhibiting oil are inflammable and dangerous if breathed in as well. Ensure good ventilation and use a protective mask when spraying. Read and follow the instructions on the packaging.

Store chemicals and other hazardous materials out of the reach of children. To protect the environment please dispose of used or leftover chemicals at a properly designated disposal site for destruction.

Cooling system

There is a risk of water penetration when working on the seawater system. Turn off the engine and close the sea cock before starting work on the system.

Avoid opening the coolant filler cap when the engine is hot. Steam or hot coolant can spray out and cause burns.

If work must be carried out with the engine at operating temperature and the coolant filler cap or a cock open or a coolant hose disconnected, open the coolant filler cap carefully and slowly to release pressure before removing the cap completely. Note that the coolant may still be hot and can cause burns.

Lubrication system

Hot oil can cause burns. Avoid skin contact with hot oil. Ensure that the lubrication system is not under pressure before commencing work on it. Never start or operate the engine with the oil filler cap removed, oil can spray out.

Fuel system

Always use protective gloves when tracing leaks. Liquids ejected under pressure can penetrate body tissue and cause serious injury. There is a danger of blood poisoning.

Always cover the generator if it is located under the fuel filter. The generator can be damaged by spilled fuel.

Electrical system

Cutting off power

Always stop the engine and break the current using the main switches before working on the electrical system. Isolate shore current to the engine block heater, battery charger, or accessories mounted on the engine.

Batteries

The batteries contain an extremely corrosive electrolyte. Protect your skin and clothes when charging or handling batteries. Always use protective goggles and gloves.

If battery electrolyte comes into contact with unprotected skin wash off immediately using plenty of water and soap. If battery acid comes into contact with the eyes, flush immediately with plenty of water and obtain medical assistance without delay.

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Introduction

This Instruction Manual has been compiled to help you get the most from your Volvo Penta engine. It contains all the information you need in order to operate and maintain your engine safely and correctly. Please

read the Instruction Manual carefully and learn how to operate the engine, controls and other equipment safely.

Always have the Instruction Manual available. Keep it in a safe place and do not forget to give it to the new owner if you sell your boat.

Responsibility for the environment

We all want to live in a clean environment. Where we can breathe clean air, see healthy trees, have clean water in our lakes and oceans and enjoy the sunshine without worrying about our health. Unfortunately this is no longer something we can take for granted, we must work hard together for the environment.

As a manufacturer of marine engines Volvo Penta has a particular responsibility. This is why concern for the environment is one of the cornerstones of our product development. Today great advances have been made in reducing exhaust emissions, fuel consumption and engine noise in Volvo Penta’s wide range of engines.

We hope that you will take care to maintain these properties. Always follow the advice in the Instruction Manual about fuel grades, operation and service and you will avoid unnecessary negative impact on the environment. If you notice changes such as increased fuel consumption or exhaust smoke, please contact your Volvo Penta dealer.

Adapt speed and distance so that swell and noise generated by the boat do not disturb or harm wildlife, moored boats, landing stages etc. Leave islands and harbors in the same condition you would like to find them. Always dispose of environmentally harmful waste such as engine and transmission oil, coolant, old paint, degreasing agents, paint and cleaning residue and old batteries at designated disposal areas for destruction.

Together we can work to make a valuable improvement to the environment.

Running-in

The engine must be run in for its first 10 operating hours as follows:

Operate the engine normally. Do not operate it at full load except for short periods. Never run the engine at a constant engine speed for long periods during the running-in period.

The engine can be expected to use more engine oil during the running-in period than would otherwise be normal. Check the oil level more often than is normally recommended.

A First Service Inspection must be carried out after 20-50 running hours. For further information: See the Warranty and Service Book.

Fuel and oils

Only use the fuel and oils recommended in the chapter Technical Data. Other grades of fuel and oil can cause operating problems, increased fuel consumption and, in the long-term, a shorter engine service life.

Always change oil, oil filters and fuel filters at the recommended intervals.

Service and replacement parts

Volvo Penta engines are designed for maximum service life and reliability. They are built to survive in a tough marine environment, but also to cause as little environmental impact as possible. Regular service and the use of Volvo Penta Genuine parts will maintain these properties.

The Volvo Penta worldwide network of authorized dealers are at your service. They are specialists in Volvo Penta products and have accessories and the original replacement parts, test equipment and special tools necessary for high quality service and repair work.

Always follow the service intervals contained in this Instruction Manual and remember to quote the engine/transmission identification number when ordering service and replacement parts.

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Certificated engines

If you own an engine certificated for any area where exhaust emissions are regulated by law, the following is important:

Certification means that an engine type is inspected and approved by the authorities. The engine manufacturer guarantees that all engines manufactured of that type correspond to the certified engine.

This places special requirements for maintenance and service as follows:

● The maintenance and service intervals

recommended by Volvo Penta must be observed.

● Only genuine Volvo Penta replacement parts may

be used.

● The service of injection pumps and injectors or

pump settings must always be carried out by an authorized Volvo Penta workshop.

● The engine must not be modified in any way except

with accessories and service kits approved by Volvo Penta.

● No modifications to the exhaust pipes and air

supply ducts for the engine may be undertaken.

● Seals may only be broken by authorized personnel.

Otherwise the general instructions contained in the Instruction Manual concerning operation, service and maintenance must be followed.

IMPORTANT! Late or inadequate maintenance/ service or the use of spare parts other than Volvo Penta original spare parts will invalidate AB Volvo Penta’s responsibility for the engine specification being in accordance with the certificated variant.

Volvo Penta accepts no responsibility or liability for any damage or costs arising due to the above.

Warranty

Your new Volvo Penta marine engine is covered by a limited warranty according to the conditions and instructions contained in the Warranty and Service book.

Note that AB Volvo Penta’s liability is limited to that contained in the Warranty and Service Book. Read this book as soon as you take delivery of the engine. It contains important information about warranty cards, service and maintenance which you, the owner, must be aware of, check and carry out. Liability covered in the warranty may otherwise be refused by AB Volvo Penta.

Contact your Volvo Penta dealer if you have not received a Warranty and Service Book and a customer copy of the warranty card.

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Identification number

Your engine and transmission has identification plates with identification numbers. This information should always be quoted when ordering service and replacement parts. There are probably similar plates on your boat and its equipment. Make a note of the details below, make a copy of the page and keep it so that you have a copy should the boat be stolen.

The appearance and location of identification plates is shown below. The figures in brackets refer to the location of the identification numbers on the identification plate.

Engine

Product designation (1) ......................................................................................................

Serial number (2) ...............................................................................................................

Product number (3) ............................................................................................................

Certification number (4) .....................................................................................................

Drive/Shield/Reverse gear

Product designation (5) .......................................................................................................

Serial number (6) ................................................................................................................

Product number (7) .............................................................................................................

Gear ratio (8) ..................................... Propeller designation ..............................................

Engine and transmission decal

xxx (5) (8) xxxxxx (7)

. xxxxxxxxxx (6)

XXXXXX (7)

XXX (5)

XXXXXXXXXX (6)

XX (8)

xxxx (1) xxxxxx (3)

. xxxxxxxxxx (2)

SX-drive and shield

Reverse gear MS25/HS25

S-drive/Reverse gear MS2

Certification plate

Engine plate

xxxxxxxxxx (4)

EMISSION APPROVED IN ACCORDANCE TO THE BODENSEE SCHIFFAHRTS ORDNUNG ANLAGE C. APPROVAL NO:

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1 2

MD22L/120S

Orientation

The orientation illustrations do not illustrate all combinations of engines and reverse gears respectively drives It is therefore possible that information about your reverse gear or drive is with another engine model than the ones covered here.

1. Coolant filler cap

2. Heat exchanger

3. Oil scavenging/bilge pump pipe

4. Oil filter

5. Starter motor

6. Generator

7. Injection pump

8. Fuel feed pump

9. Dipstick (engine)

10. Oil filler cap (engine)

11. Fuel filter

12. Seawater pump

13. Central electronics module

14. Oil filler (drive)

15. Oil dipstick (drive)

16. Seacock

17. Sacrificial anode

18. Oil draining (drive)

19. Seawater intake

516

MD22L/120S

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MD22P/MS25

18, 19

TMD22/MS2

TMD22P/HS25

18, 19

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1 2 3 4

11 12 13 14 15 16 17

TAMD22P/SX

1. Turbo (TMD, TAMD)

2. Coolant filler cap

3. Heat exchanger

4. Oil cooler

5. Oil scavenging/bilge pump pipe

6. Charge air cooler (CAC) (TAMD)

7. Oil filter

8. Starter motor

9. Generator

10. Injection pump

11. Fuel feed pump

12. Dipstick (engine)

13. Oil filler cap (engine)

14. Fuel filter

15. Seawater pump

16. Seawater filter (SX)

17. Central electronics module

18. Oil dipstick (reverse gear/SX)

19. Oil filler, reverse gear/SX

20. Oil cooler (reverse gear)

21. Seawater intake

22. Trim cylinder (SX)

23. Oil draining (SX)

24. Servo pump (SX)

25. Sacrificial anode (SX)

26. Sacrificial anode (SX)

27. Trim fin (SX)

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Instrumentation

This chapter only describes the instrument panels available from Volvo Penta as standard alternatives for your engine. Note that in certain boats instruments, alarm panels, key switches etc. may be installed separately without the instrument panels shown here.

If you want to install additional instrumentation, or your boat is equipped with instruments not described here, please contact your Volvo Penta dealer.

Instrument panel

1. Tachometer and hour counter (accessory). Displays engine speed. Multiply this value by 100 for revolutions per minute. The hour counter displays engine operating time in hours and tenths of an hour.

2. Siren for acoustic alarm.

3. Warning display. See 10-13.

4. Switch for instrument lighting.

5. Alarm test/acknowledgment switch.

To test alarm: Press the switch. All warning lights light and the acoustic alarm sounds.

Alarm acknowledgment: Press the switch if there is an alarm. The acoustic alarm stops but the relevant warning lamp continues to flash until the malfunction is corrected.

6. Temperature gauge. Displays the engine coolant temperature.

7. Oil pressure gauge. Displays the oil pressure in the engine.

8. Voltmeter. Displays the charge voltage from the generator.

9. Ignition switch. See illustration on next page.

394

152

6738

15249

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Warning display

If the acoustic alarm sounds, one of the three warning lamps (10-12) on the instrument panel starts to flash to indicate the source of the alarm.

10. Engine coolant temperature too high.

11. Low oil pressure.

12. Generator not charging.

13. Indicator lamp Comes on when the glow plugs are activated.

IMPORTANT! Read “check the instruments” in the chapter Operation.

11 12

10 13

Ignition switch

The starting lock has an integrated starter motor protection, which means that a new start attempt can only be made when the ignition key has been returned to the “0” position.

S = Stop position The stop solenoid is connected

and cuts off the fuel supply to the engine.

0 = The key can be inserted and removed.

I = Operating position.

II = Glow plug position. The glow plugs are

connected and pre-heating the engine.

III = Start position. The starter motor is engaged.

IMPORTANT! Read the starting instructions in the chapter Starting the engine.

A tag with the key code is supplied with the ignition key for use when ordering extra ignition keys. Keep the code where it is not available to unauthorized persons.

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Controls

This chapter only describes the controls available from Volvo Penta as standard alternatives for your engine. If your boat is equipped with controls which are not described here and you feel uncertain about the functions, contact your Volvo Penta dealership.

Top mounting controls

Side mounting controls

Maneuvering

Shifting and engine speed are controlled with the same lever (1).

N = Neutral position. Drive/reverse gear disengaged.

F = Drive/reverse gear engaged for movement ahead.

R = Drive/reverse gear engaged for movement astern.

T = Engine speed control

A neutral position switch is available as an accessory, this will only permit the engine to be started with the drive/reverse gear disengaged.

Friction brake

The friction brake only affects the engine speed control movements.

1. Lift the cover over the control. For side-mounted controls the lever must first be removed.

2. Set the lever to the half-open throttle/reverse position.

3. Adjust the friction brake. Turning the screw clockwise (+) makes the lever movement stiffer, while turning counterclockwise (–) makes it easier to move the lever.

4. Reinstall the cover and lever.

Disengaging the shift function

Move lever (1) to the neutral position (N). Press in button (2), move the lever slightly forward and release the button. The shift function is now disengaged and the lever affects only engine speed.

When the lever is moved back to the neutral position it will automatically re-engage.

IMPORTANT! Take care not to engage the drive/reverse gear by mistake.

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Power Trim

The SX propulsion system is equipped with a Power Trim hydraulic trim system which makes it possible to adjust the angle of the drive in relation to the stern of the boat. This adjusts the boat’s trim to obtain maximum comfort and fuel economy in different operating conditions. Power Trim settings and adjustment are controlled from the helm position using the controls and instruments described below. The section on Operation provides more information on use of the Power Trim system when operating the boat.

WARNING! Extreme trimming of the drive system can have severely adverse effects on the steering of the boat. Read the information on “Power Trim during operation” in the chapter Operation.

Trim controls

Trimming and raising the drive can be done either using the separate control panel or using the button in the control lever (accessory).

Trimming the drive away from the stern of the boat raises the bow in relation to the horizontal, while moving it towards the stern will lower the bows.

● Press the “down button” (1) to lower the bow of the boat (drive

is trimmed inward).

● Press the “ Up button” (2) to raise the bow of the boat (drive is

trimmed out).

● Button (3) has no function.

● Press the button in the control lever (4) upwards to raise the

bow and downwards to lower the bow.

Trim instrument

The current trim position of the drive is shown on the trim instrument. There are three ranges:

1. Trim-range

The Trim range is used to achieve maximum comfort under normal operation at all speeds from start to maximum speed.

2. Beach range (Red)

The beach range is used for operation at reduced speed in shallow water or where water depth is uncertain.

3. Lift range (Red)

Lift range is used when the drive must be lifted to the maximum height, for example when trailering. The drive stops automatically when the end position is reached. Lift range may only be used

when the engine is stopped; never when it is in operation.

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Starting the engine

Make a habit of checking the engine and engine compartment visually before starting the engine. This will help you to quickly detect anything unusual that has or is about to happen. Also check that instruments and the warning display are indicating normal values when you have started the engine.

WARNING! Never use start spray or similar to start the engine. Danger of explosion!

Before starting the engine

● Open fuel cock.

● Open the seacock (if installed)

● Check that there are no fuel, engine coolant or oil leaks.

● Check the oil and water levels in the engine (See the chapter

Maintenance, under the headings lubrication and cooling system respectively).

● Switch on the main switch.

IMPORTANT! Never break the circuit with the main switches while the engine is running. This could damage the generator.

● Check there is sufficient fuel for the planned journey

● Lower the SX-drive if it was raised. Check there are no obstacles in

the water near the propellers.

Starting the engine

1. Move the control lever to the neutral/idle position.

2. Turn key to the ”I” position. The three warning lamps come on and can be checked. Check that the acoustic alarm is functioning by pressing the ”Alarm Test” button.

3. If the engine is hot: Proceed to operation 4.

If the engine is cold: Turn key to the ”II” position. The indicator light comes on and the glow plugs are connected to pre-heat the engine.

IMPORTANT! Preheating should be engaged for approx. seven seconds, no longer!

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4. Turn the key to position ”III” to start. Release the key as soon as the engine has started, the key will automatically spring back to the ”I” position. If the engine did not start the key must first be turned to the ”0” position before trying again.

IMPORTANT! If the starter motor is engaged for its maximum

engagement time (20-30 seconds) let it cool down for five minutes before trying to start the engine again.

5. Warm up the engine at low speed and low load.

IMPORTANT! Do not race the engine while it is cold.

Starting using auxiliary batteries

WARNING! Ensure that the ventilation is good. Batteries

generate oxyhydrogen which is highly flammable and explosive. A short-circuit, naked flame or spark can cause a large explosion.

Never mix up battery positive and negative terminals. This may cause sparks and an explosion.

1. Check the auxiliary batteries have the same rated voltage as the engine’s system voltage.

2. First connect the red jump lead to the discharged battery’s + terminal (A) and then to the auxiliary battery’s + terminal (B).

3. Then connect the black jump lead to the auxiliary battery - terminal

(C) and then to a spot a short distance from the discharged batteries, for example at the main switch on the negative cable or at the negative cable’s connection (D) to the starter motor.

WARNING! The black jumper cable (-) must under no

circumstances come in contact with the positive connection of the starter motor.

4. Start the engine and run it at a fast idle for approximately ten minutes to charge the battery.

WARNING! Approaching or working on a running engine is dangerous. Watch out for rotating components and hot surfaces.

Do not touch the connections while trying to start the engine: This may cause sparks. Do not lean over the batteries.

5. Stop the engine. Remove the jump leads in exactly the opposite order to which you put them on.

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Operation

It is important to learn how to operate the engine, controls and other equipment safely and properly before setting off on a maiden voyage. Avoid violent and unexpected changes in course and gear engagement. There is a risk that someone aboard will fall over or overboard.

WARNING! A rotating propeller can cause serious injury. Check that nobody is in the water before engaging ahead or astern. Never drive near bathers or in areas where people could be in the water.

Cruising speed

Operating the engine at wide open throttle (WOT) should be avoided since it is both uneconomical and uncomfortable. Volvo Penta recommends a cruising speed in the range 300 - 500 rpm lower than maximum rpm at WOT. Depending on hull type, choice of propeller, load and conditions etc. the maximum engine speed at top speed can vary, but it should be within the WOT range.

Wide Open Throttle (WOT) range:

MD22L ............ 2,700-3,000 rpm TMD22 ............ 3,500-4,500 rpm

MD22P ...........3,500-4,000 rpm TAMD22P ....... 3,500-4,500 rpm

If the engine does reach the wide open throttle range it may be due to one of the reasons covered in the chapter: Fault-tracing. If the engine speed exceeds wide open throttle range a propeller with a higher pitch should be selected. Ask your Volvo Penta service dealer for advice.

Maneuvering

All shifting between ahead and astern must be done at engine idle speed. Shifting at higher speeds may damage the drive or reverse gear and will also be uncomfortable for those on board. There is a risk that

someone aboard will fall over or overboard.

1. Reduce engine speed to idling and, if possible, let the boat lose most of its speed.

2. Move the reverse gear control lever quickly and firmly into the neutral position. Wait for a moment.

3. Move the gear control lever quickly and firmly into astern, then increase the speed.

IMPORTANT! Never change to reverse when the boat is planing, there is a risk of water penetrating the engine via the exhaust outlet. If the boat has two engines, it is important that they are both running during maneuvers astern (rearward movement), otherwise water might get into the exhaust of the engine which is not running.

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BAC

Trolling operation valve

HS25 reverse gear can be equipped with a trolling operation valve which makes it possible to steplessly reduce the boats lowest speed by 1-80% at engine speeds up to 1200 rpm.

IMPORTANT! At higher speed the reverse gear may overheat.

When sailing

When sailing the control lever should be in the neutral position if the boat is equipped with HS25 reverse gear. If the boat is equipped with S- drive or MS2/MS25 reverse gear the control lever should be the reverse position if a folding propeller is used and in neutral position if a fixed propeller is used.

IMPORTANT! S-drive and MS2 with fixed propeller: When sailing long distances the engine should be started for five minutes

every 10 hours to cool the drive/reverse gear. If this is not possible then a propeller shaft brake must be installed.

Checking instruments

Check the instruments and warning display directly after starting the engine and then at regular intervals while driving the boat.

Oil pressure (A)

Normal operating oil pressure is between 150-500 kPa (21-71 psi). At engine idle this is normally lower. The acoustic alarm will automatically go off and the warning lamp will light up if the oil pressure is too low.

IMPORTANT! At the alarm the engine should be stopped immediately. Investigate and correct the malfunction.

Engine coolant temperature (B)

Normal operating temperature is between 75-90°C. The acoustic alarm will automatically go off and the warning lamp will light up if the coolant temperature is too high.

IMPORTANT! At the alarm the engine speed should be reduced to idle (neutral). Stop the engine if the temperature does not drop.

Investigate and correct the malfunction.

Charging (C)

During operation the charge voltage should be around 14 V. With the engine stopped voltage is approximately 12 V. In event of charging failure the alarm sounds at the same time as the warning lamp is lit.

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Power Trim while running

The SX propulsion system is equipped with a Power Trim hydraulic trim system which makes it possible to adjust the angle of (trim) the drive in relation to the stern of the boat. This adjusts the boat’s trim to obtain maximum comfort and fuel economy in different load, speed, wind and sea conditions.

Power Trim settings and adjustment are controlled from the helm position using the controls and instruments described in the Power Trim chapter..

Trimming the drive away from the stern of the boat raises the bow in relation to the horizontal, while moving it towards the stern will lower the bows.

The current trim position of the drive is shown on the trim instrument. There are three ranges: “Trim range” (1), “Beach range” (2) and “Lift range” (3). The “lift range” (3) must never be used when operating.

WARNING! Extreme trimming of the drive system can have severely adverse effects on the steering of the boat.

“Trim range”

The trim range is used to achieve maximum comfort under normal operation at all speeds from start to maximum speed.

Since every boat has its own unique characteristics and will be effected in different ways by the load, wind, etc. only general advice is given here on how to get the best trimming angle for your boat. It can generally be said that when the boat feels well-balanced, easy to steer and pleasant to operate, then that is the optimal trim angle for the boat.

WARNING! Take care to observe the instruments when trimming the drive out so that the drive does not enter the Beach range. Extreme trimming of the drive system can have severely adverse effects on the steering of the boat.

IMPORTANT! Avoid running with the drive fully trimmed for long periods (when planing). Apart from excessive fuel consumption this can cause cavity damage to the propeller(s).

When starting and accelerating

Trim the drive. The bow will be pressed down and the boat accelerates faster. This gives improved running and steering characteristics at speeds below the planing threshold.

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At planing speed

Trim the drive out to the operating position which provides the most stable and comfortable running.

If the boat has twin motors the drives can be trimmed with different angles to compensate for side winds and to a certain extent compensate for uneven loading on one side of the boat or the other.

For maximum fuel economy

Operate engine at a steady throttle opening. Trim the drive out/in a little. The boat is most easily propelled and speed will increase in the position that gives the highest engine speed. The throttle opening can then be slightly reduced to retain the original speed.

In choppy seas or running against a heavy sea

Trim drive so the bows drop. This will provide more comfortable running.

“Beach range”

The beach range is used for operation at reduced speed in shallow water or where water depth is uncertain.

IMPORTANT! Max. permitted engine speed (rpm) when running in the ”Beach range” is 1,000 rpm. Check that the cooling water intake for the drive is never trimmed out of the water.

“Lift range”

Lift range may only be used when the engine is stopped, never when it is in operation. The lift range is used for lifting the drive to its

maximum angle, when trailering for example.

WARNING! Extreme trimming of the drive system can have severely adverse effects on the steering of the boat. The engine must not be run with the drive in the ”Lift” range.

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Running aground

The automatic Kick-up function releases the SX-drive if it grounds or hits an object in the water. If the function has been tripped and the drive released it must be trimmed back to the original position using the control buttons.

IMPORTANT! The Kick-up function only protects the drive when running ahead (forwards). There is no protection for the drive while running astern (backward).

Check after running aground that the drive or propeller are not damaged or if there are vibrations from the drive. If this is the case then the boat (if possible) should be run to harbor at reduced speed and taken out of the water.

IMPORTANT! Damaged propellers should be replaced immediately. Operating the boat with a damaged propeller should be undertaken with extreme care and only at reduced engine speeds.

Take the boat out of the water. Check the oil level in the drive. If it is colored gray then water has entered the drive. If this is the case or if other damage has occurred to the drive it must be inspected at an authorized Volvo Penta workshop. If only the propeller has been damaged it must be replaced. Launch the boat and test drive. If there are still vibrations it must be inspected by an authorized Volvo Penta workshop.

IMPORTANT! To prevent galvanic corrosion any damage to the paintwork on the drive and propeller must be repaired before launching the boat: See section “Laying up/Launching”.

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Stopping the engine

The engine should be run for a few minutes at idle (in neutral) before turning it off. This will avoid boiling and even out the temperature. This is especially important if the engine has been operated at high engine speeds and loads.

Stopping

Turn the key to stop position ”S”. Keep key in this position until the

engine stops. The key will automatically spring back to the ”0” position when it is released and can then be removed.

After stopping the engine

● Inspect the engine and engine compartment for any leaks.

● For boats with SX-drive: The drive must be trimmed in to its

maximum to protect the trim cylinders untreated surfaces from fouling.

IMPORTANT! If there is a risk that the drive can run aground, it must instead be trimmed out to its maximum lift position.

● Shut the fuel cock and the seacock (not standard on SX-drive).

IMPORTANT! Do not forget to open the cocks before the engine is started again.

● Switch off the main switch if the boat is not to be used for some

time.

IMPORTANT! Never break the circuit with the main switches while the engine is running. This could damage the generator.

Emergency stop

If there is a malfunction in the engine’s electrical system and the engine will not stop when the ignition key is used, an emergency engine stop can be carried out using the lever on the injection pump. Twist the lever (1) backwards until the engine stops.

WARNING! Approaching or working on a running engine is

dangerous. Watch out for rotating components and hot surfaces.

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Cold weather precautions

To prevent freezing damage, the seawater system must be drained and the freshwater system coolant must have sufficient antifreeze protection. See chapter Maintenance ”Cooling systems”.

IMPORTANT! A poorly charged battery may burst as a result of

freezing.

Laying up

If the boat is not going to be used for some time but is being left in the water, the engine must be run to operating temperature at least once every 14 days. This prevents corrosion in the engine. If the boat will not be used for more than two months then inhibiting should be carried out: See chapter on Laying up/Launching.

Transporting on a trailer

Check local legislation for transporting boats on trailers, there are differences between different countries’ trailer laws. For boats with SX-drive: Lift the drive to the highest position when the boat is put on the trailer (the drive is stopped automatically at the highest position).

IMPORTANT! The engine must not be run with the SX-drive is in the lift range. Before transporting the boat by trailer always secure the drive in the lift position with a Trailer Kit (accessory) or similar, so that it cannot drop down.

IMPORTANT! Boats with reverse gear/S-drive: Drain water out the exhaust pipes to prevent water entering the engine when transporting the boat by trailer.

Laying up on land

Where boats are kept laid up on land when not in use there is a lower level of galvanic corrosion protection due to the oxidation on the sacrificial anodes. Before launching the boat the sacrificial anodes on the drive and shield must be cleaned with emery paper to remove any oxidation.

IMPORTANT! Do not use a wire brush or other steel tools when cleaning, as these may damage the galvanic protection.

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Maintenance schedule

Your Volvo Penta engine and its equipment is designed for maximum service life and reliability. They are built to survive in a tough marine environment, but also to cause as little environmental impact as possible. Regular maintenance according to the following schedule is necessary if the engine and transmission are to operate without problems.

WARNING! Read the chapter on Maintenance carefully before starting work. It contains instructions on how to carry out the work safely and correctly.

IMPORTANT! Service operations marked must be carried out by an authorized Volvo Penta Service workshop.

DAILY BEFORE STARTING FOR FIRST TIME

● Engine oil. Checking level .............................................................................. page 31

● Coolant. Checking level ................................................................................. page 33

EVERY 14 DAYS

● Fuel filter. Drain water .................................................................................... page 39

● Fuel pre-filter. Drain water .............................................................................. page 39

● Generator and circulation pump drive belts. Check ........................................ page 30

● Servo pump drive belt (SX). Check ................................................................ page 30

● Servo pump (SX). Check oil level .................................................................. page 29

● Seawater filter. Cleaning ................................................................................ page 37

● Battery. Check electrolyte level ..................................................................... page 42

● Reverse gear. Check oil level ................................................................... page 47–48

● S-drive. Check oil level ..................................................................................page 47

● SX-drive. Check corrosion protection ............................................................. page 52

● SX-drive. Check oil level in trim pump ........................................................... page 54

AFTER THE FIRST 20–50 OPERATING HOURS

First Service inspection .......................................................................... not shown

A first Service Inspection must be carried out in accordance with the instructions in the Warranty and

Service Book.

EVERY 100 OPERATING HOURS OR AT LEAST ONCE A YEAR

● S-drive. Checking/Replacing corrosion protection ........................................... page 49

● S-drive. Check rubber seal (hull/drive) ............................................................ page 50

● SX-drive. Checking aluminum anode .............................................................. page 52

● SX-drive. Oil change ......................................................................................page 53

● SX-drive. Grease CV joint and primary shaft bearing ............................... page 56–57

● SX-drive. Checking CV joint and exhaust bellows. ......................................... page 56

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EVERY 200 OPERATING HOURS OR AT LEAST ONCE A YEAR

● Engine oil and oil filter. Replace ..................................................................... page 31

● Timing gear belt. Check .................................................................................page 29

● Fuel filter. Replace ......................................................................................... page 39

● Fuel pre-filter. Replace ................................................................................... page 40

● Fuel feed pump. Cleaning .............................................................................. page 38

● Coolant. Replacing 1)...................................................................................... page 34

● Seawater pump. Check belt tension ............................................................... page 30

● Seawater pump. Check impeller ..................................................................... page 34

● Vacuum valve. Cleaning ................................................................................ page 37

● Reverse gear. Oil change ........................................................................ pages 47-49

● Reverse gear (HS25) Cleaning the oil filter ..................................................... page 48

● S-drive. Oil change ........................................................................................ page 47

If the freshwater system is filled with an anti-corrosion agent mixture it must be changed every year. If the freshwater system is filled with an antifreeze (glycol) mixture it must be changed every other year.

EVERY OTHER YEAR

● Coolant. Replacing 1)...................................................................................... page 34

SX-drive. Replace universal joint and exhaust bellows ............................... not shown

EVERY 500 OPERATING HOURS OR AT LEAST EVERY FIFTH YEAR

Reverse gear. Replacing propeller shaft seal .............................................. not shown

EVERY SEVENTH YEAR

S-drive. Replacing rubber seal between drive and hull ................................ not shown

EVERY 600 OPERATING HOURS

Injectors. Test pressure ............................................................................. not shown

EVERY 2000 OPERATING HOURS

Timing gear belt. Replace .......................................................................... not shown

Valve clearance. Adjustment ..................................................................... not shown

Crankcase ventilation. Cleaning ................................................................. not shown

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Maintenance

This chapter contains instructions regarding how the above maintenance points should be carried out together with general technical information. Read the instructions carefully before starting work. Maintenance intervals are contained in the chapter: Maintenance schedule

WARNING! Read the safety precautions for maintenance and service in the chapter: Safety Precautions, before starting work.

WARNING! Unless otherwise specified all maintenance and service must be carried out with the engine

stopped. Stop the engine before opening or removing engine hatches. Immobilize the engine by removing the ignition key, turning off the power supply with the main switch.

Camshaft belt

Check the camshaft belt every year. If must be changed every 2000 hours of operation or earlier if it appears worn or cracked. Replacement should be left to authorized service personnel.

Wastegate (TMD22, TAMD22)

If the engine is not used for a longer period of time there is a risk that the turbocharger boost pressure valve may stick. Check that the shaft turns.

Servo pump (SX). Oil level

Turn the filler cap counterclockwise and remove. Check the oil level is between the MAX and MIN markings on the dipstick. Top up if necessary using ATF oil.

Engine

The engine is a four-stroke, 4 cylinder marine diesel engines with overhead camshaft. The engine block is of high grade cast iron and the cylinder head is of aluminum. TMD22 and TAMD22 are equipped with a turbocharger. In addition the TAMD22 is equipped with a charge air cooler (CAC).

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Drive belts. General

WARNING! Always turn the engine off before

starting maintenance work.

Check the tension and condition of the belts regularly. A belt that is too tight can damage the bearings and a belt that is too loose can result in slippage. Check and adjust as necessary after operating the engine when the belts are warm.

IMPORTANT! Always replace belts which are

worn or have cracks. Check the tension of the new belt after several hours of operation.

Generator and circulation pump

It should be possible to depress a belt at the correct tension approx. 10 mm (0.4") down between the pulleys.

Adjustment: Unscrew the screws (1) and if necessary (2). Adjust to correct tension. Tighten the screws.

Replacing: Unscrew the screws (1 and 2) so the belt can be removed. Clean off the pulley grooves. Install the new belt. Adjust as above.

Seawater pump

It should be possible to depress a belt at the correct tension approx. 5 mm (0.4") down between the pulleys.

A torque wrench is required for adjustment. Unscrew the screws (1 and 2). Locate the torque wrench’s square plug in the hole (3). Tighten to 60 Nm. Tighten the screws.

Servo pump (SX)

It should be possible to depress a belt at the correct tension approx. 10 mm (0.4") down between the pulleys.

Adjustment: Unscrew the screws (1 and 2). Adjust to correct tension. Tighten the screws.

Replacing: Unscrew the screws (1 and 2) so the belt can be removed. Clean off the pulley grooves. Install the new belt. Adjust as above.

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Lubrication system

IMPORTANT! With a new or reconditioned engine, the oil and oil filters must be changed after 20-50

hours of operation. After that they should be changed every 200 operating hours or at least once a year. Use only the recommended grades of oil: see the chapter ”Technical Data”.

Oil level. Checking and topping up

The oil level should be within the marked area on the dipstick (1) and should be checked every day the first time the engine is started. Topping up is done through the oil filler pipe (2). Wait a few minutes before checking the oil level again, so the oil has time to run down to the oil pan. Use only the recommended grades of oil: See the chapter ”Technical Data”.

IMPORTANT! Do not fill the oil above the MAX level.

Oil and oil filters. Changing

1. Run the engine to operating temperature so that the oil is easier to suck out. Stop the engine.

2. Suck out the oil using an oil drain pump through oil drain pipe (1).

WARNING! Hot oil and hot surfaces can

cause burns.

3. Unscrew the old filter. (To avoid oil spills put a plastic bag over the filter before it is unscrewed).

4. Check that the engine mating surface is clean.

5. Moisten the filter rubber gasket with a little oil. Screw on the new filter by hand until it is in contact with the mating surface. And then a further half turn but no more!

6. Top up oil to correct level. Start the engine and let it idle. Check that the warning lamp for low oil pressure goes out.

7. Stop the engine. Wait for approx. 10 minutes before checking the oil level. Top up if required. Check that there are no leaks round the oil filter.

NOTE! Collect up the old oil and filter for deposit at a proper disposal site.

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Cooling system

The cooling system is divided into a freshwater and a seawater system. The seawater pump sucks water into the seawater system through the drive/reverse gear. The seawater is then pumped through the charge air cooler (CAC) (TAMD22), heat exchanger and the oil cooler (not MD22L), and then into the exhaust elbow pipe where it is mixed with the exhaust gases. The freshwater system is the engines internal cooling system. It is a closed system driven by a circulation pump. When the thermostat opens (at operating temperature) the freshwater system coolant flows through the heat exchanger, where it is cooled by the seawater.

WARNING! There is a risk of water penetration when working with the seawater system ( if the boat is in the water). If a plug, pipe or similar below the waterline is removed water can flow in. Therefore always close the seacock. If the boat does not have a seacock (boats with SX-drive for example) the water intake must be completely blocked, if this is not possible the boat must be taken out of the water before work begins.

Coolant. General

The freshwater system must be filled with a coolant that protects the engine against internal corrosion and from freezing, if the climate requires it.

IMPORTANT! Never use water alone.

We recommend that a mixture of water and Volvo Penta antifreeze is used all year round, regardless of the climate.

Water quality

To avoid the risk of blocking the cooling system the coolant should be mixed with clean water. If there is any doubt over the water quality distilled water or

premixed coolant should be used.

In event of frost risk

Use a mixture of Volvo Penta antifreeze and pure water (the mixing ratio is on the packaging). Mix the coolant in a separate container before filling.

IMPORTANT! Always mix so that full anticorrosion protection is retained.

WARNING! Glycol is harmful to health (dangerous if ingested).

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No risk of freezing

When there is never a risk of freezing water may be used as coolant with addition of Volvo Penta anti corrosion agent.

Mix according to the instructions on the packaging. Warm up the engine after filling to allow the additive to work as efficiently as possible.

If operating hours exceed 600 hours per annum the coolant anti corrosion must be complemented with ½ liter anti corrosion agent every 600 hours.

WARNING! Anti-corrosive agents are harmful to health (dangerous if ingested).

IMPORTANT! Never mix antifreeze (glycol) and anti-corrosive agents. The two combined can produce foam and drastically reduce the coolant’s effectiveness.

Coolant. Filling

WARNING! Do not open the pressurized engine

coolant system filler cap when the engine is still hot. Steam or hot coolant may spray out.

Turn the pressure cap (1) to the first stop and let any pressure escape from the system before removing the cap. Top up coolant so that the level reaches the lower edge of the filler pipe. Reinstall the cap. NOTE!

IMPORTANT! The coolant level must not be below the level spur (2) in the heat exchanger.

Fill with the same sort of coolant already in the system.

Never fill a hot engine with cold coolant.

When filling a completely empty coolant system or when the coolant level has for some reason dropped below the level spur, the venting plug (3) must be unscrewed before starting to fill the system. Fill with coolant to correct level. Tighten the venting plug and reinstall pressure cap. Start engine and let it idle until it reaches normal operating temperature. Stop engine and let it cool down. Top up coolant to correct level.

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Coolant. Replacing/Draining

The antifreeze additive rust-proofing properties diminish with time. It is therefore important that the coolant is replaced according to the service schedule below.

To avoid reduced cooling performance caused by scaling in the coolant system it should be flushed when it has been drained.

Draining: Remove heat exchanger filler cap. Position a container under the drain cock (1) on the starboard side of the cylinder block. Open the drain tap and allow the coolant to drain out.

Flushing: Insert a hose in the filler pipe on the heat exchanger and flush with freshwater. Flush until the water which runs out of the drain cocks is clean. Close the drain cock when all the water has run out. Fill with new coolant.

NOTE! To protect the environment please dispose of used coolant at a properly designated disposal site.

Impeller. Check/Replace

WARNING! If the engine is installed so that the

seawater pump is located under the water line there is a risk of water penetration (if the boat is in the water). Close the seacocks.

1. Remove the cover and sealing plate on the seawater filter (if installed).

2. Remove the cover from the seawater pump (1) and remove the impeller (2). If there are cracks or other defects the impeller must be replaced.

3. Lubricate the pump housing and the inside of the cover with a little waterproof grease which is suitable for rubber.

4. Reinstall the impeller using a clockwise rotating movement. Install sealing washer in the outer end on the impeller center. Install the cover together with a new gasket.

5. Open sea cock.

IMPORTANT! Always carry a spare impeller on board.

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Seawater system. Draining

To prevent freezing damage the seawater system must be drained in cold weather where there is a risk of frost.

IMPORTANT! If the boat does not have a seacock (boats with SX for example) the boat must be standing on dry land in order to drain the entire seawater system.

An alternative to draining is to keep the engine compartment free of frost using an approved heater fan.

Draining (with the boat out of the water):

1. Check that the seacock is open.

2. Remove the cover from the seawater pump and let the water run out.

3. MD/TMD22: Drain the water from the heat exchanger by opening the cock/plug (1).

TAMD22: Drain the water from the heat exchanger and charge air cooler (CAC) by opening the cock/ plug (2) on the charge air cooler (CAC).

4. Engines with seawater filter: Remove the cover (3) and sealing plate (4) on the sea water filter. Detach the hose on the seawater pump inlet side (5) and empty it of water.

5. MS25/HS25: Drain the water from the oil cooler by opening the plug (6).

6. SX-drive: Trim drive out to max. raised position. Remove drain plug (7). Trim drive in max. and let the water run out.

7. Connect all hoses and close/install all drain cocks and plugs before you leave the boat.

Draining (with the boat in the water:

WARNING! Risk for water penetration.

1. Close the seacocks. Then remove the hose by the seacock (8) and allow the water to run out into a container.

2. Carry out points 2-5 and point 7 in the previous paragraph.

MS25

HS25

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Seawater system. Cleaning and inhibiting

To prevent the build up of deposits and salt crystals in the seawater system it must be flushed with freshwater. When the boat is laid up it must also be inhibited.

WARNING! There is a risk of water penetration. Cleaning and inhibiting the seawater system should be carried out with the boat on land.

1. Open the seacock (not standard with SX-drive).

2. S-drive/Reverse gear: Disconnect the hose (1) at the bottom cock and insert the free end in a container of fresh water.

SX-drive: Detach the hose from the seawater filter (2) at the seawater pump inlet side. Connect a hose (3) to the pump and insert the free end in a container of fresh water.

3. Refill the container and ensure that there is not a risk of some shut in behind the exhaust outlet.

IMPORTANT! The impeller will be damaged if it runs dry.

4. Set the gear control lever in the neutral position. Check that nobody is near the propellers. Start the engine. Let it run at idle a few minutes. Stop the engine.

WARNING! Approaching or working on a

running engine is dangerous. Watch out for rotating components and hot surfaces.

5. Empty and clean the seawater filter if installed according to the description on the next page.

The seawater system is now cleaned. Continue with points 6-8 to preserve it.

6. Fill container with an antifreeze mixture of 50% Volvo Penta glycol and 50% freshwater.

7. Collect mixture from system in a suitable container.

8. Start the engine and let it idle. Stop the engine just before the mixture is finished.

The antifreeze mixture should be left in the system while the boat is laid up. Drain the mixture just before the boat is launched. Reuse the antifreeze mixture next season or deposit it at a properly designated disposal site.

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Vacuum valve. Cleaning

Some engines have a vacuum valve installed in the seawater piping. Disassemble the valve. Unscrew the hexagonal cover. In the cover there is a membrane and a gasket. Clean all the parts. Turn the cover upside down. Install the membrane first and then the gasket. Turn the valve housing upside down as well. Screw the cover into position, but not too hard (0.2 kpm), or the valve may stop working.

WARNING! Risk for water penetration. Close the seacocks.

Seawater filter. Cleaning

The seawater filter is only standard on engines with SX-drive.

If the boat is used in water that has a lot of contaminants, seaweed etc. the filter must be checked more frequently than indicated in the maintenance schedule. Otherwise there is a risk the filter will clog and the engine will overheat.

WARNING! Stop the engine before removing the cover on the seawater filter.

Screw off cover (1) and remove seal plate (2). Lift out and clean the insert (3).

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Fuel injection system

The fuel feed pump sucks fuel from the fuel tank and pumps it through the fuel filter on to the fuel injection pump where the pressure is increased before the fuel is pumped out to the injectors. When the injectors open the fuel is sprayed in to the cylinders. Any excess fuel is passed through the return line back to the fuel tank.

All work on the engine injection pump or injectors must be carried out at an authorized workshop. Use only the recommended grade of fuel: See the chapter ”Technical Data”.

WARNING! Fire risk. When carrying out work on the fuel system make sure the engine is cold. A fuel spill onto a hot surface or an electrical component can cause a fire. Store fuel soaked rags and other flammable material in fireproof conditions.

Venting the fuel system

The fuel system must be vented after fuel filters have been replaced or after refilling the fuel tank after it has been run dry.

1. Open vent screw (1) on the filter mounting approx. three turns. Avoid fuel spillage. Use rags around the venting point.

2. Pump the fuel using hand pump (2) until there are no more air bubbles visible in the fuel. Continue pumping and at the same time tighten the venting screw.

If the pump effect is poor, turn the engine over slightly so that the pump drive cam changes position.

3. Turn the engine using the starter motor until it starts. Allow it to idle for several minutes so that the system bleeds automatically.

WARNING! Approaching or working on a running engine is dangerous. Watch out for rotating components and hot surfaces.

4. Stop the engine and check for leaks.

Fuel feed pump. Cleaning

Remove the cover. Remove the filter. Clean filter and filter housing carefully. Reinstall in reverse order. Bleed fuel system.

IMPORTANT! Start the engine and check for leaks.

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Fuel filter. Draining

Open vent screw (1) on the filter mounting approx. 3 turns. Then undo the drain screw (2) a few turns. Let any water in the filter run off into a container. Tighten the screws.

IMPORTANT! Wait a few hours after the engine has been turned off before draining the filter.

Fuel filter. Replacement

Clean the filter console and locate a container underneath the filter. Remember to dispose of the old filter at a proper disposal site.

1. Unscrew the filter. Check that the nipple (1) is located securely in the filter mounting.

2. Moisten the new filter’s rubber gasket with a little fuel.

3. Screw on the new filter by hand until it is in contact with the mating surface. And then a further half turn but no more!

4. Bleed fuel system.

5. Start the engine and check for leaks.

WARNING! Approaching or working on a running engine is dangerous. Watch out for rotating components and hot surfaces.

Fuel pre-filter. Draining

Fuel pre-filters and water separators are accessories and are available in two variants.

Position a container under the fuel filter. Drain off water and contaminants using the cock/plug (1) at the bottom of the glass.

IMPORTANT! Wait a few hours after the engine has been turned off before draining the filter.

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Fuel pre-filter. Replacement

Fuel pre-filters and water separators are accessories and are available in two variants.

Filter insert replacement

Close fuel cock at the fuel tank. Position a container under the fuel filter. Remember to dispose of the old filter at a proper disposal site.

Fuel pre-filter type A: Remove the glass bowl by slackening off screw (2). Empty and clean glass. Replace insert and reinstall glass. Open fuel cock. Undo the screw (3) a few turns and the glass will fill with fuel. Bleed fuel system.

Fuel pre-filter type B: Remove cover (2) and lift up the insert. Drain water and contaminants through the drain cock (1). Install new filter insert and fill container with clean diesel oil. Screw on cover and tighten by hand. Open fuel cock. Bleed fuel system.

WARNING! Approaching or working on a running engine is dangerous. Watch out for rotating components and hot surfaces.

IMPORTANT! Start the engine and check for leaks.

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Electrical system

The electrical system is 2 poled and has a system voltage of 12V. For effective charging the generator is equipped with a charge regulator and for reliable cold starts the engine has glow plugs.

WARNING! Always stop the engine and break the current using the main switches before working on the electrical system. Isolate shore current to the engine block heater, battery charger, or accessories mounted on the engine.

Main switch

The main switch must never be turned off before the engine has stopped. If the circuit between the generator and the battery is cut off when the engine is running the generator can be seriously damaged. For the same reason charging circuits must never be switched over while the engine is running.

IMPORTANT! Never break the circuit with the main switches while the engine is running.

Fuses

If the engine cannot be started or if all instruments read zero, an engine fuse can have blown. Always investigate the reason! The engine has two semiautomatic fuses which will cut off the current if there is an overload. Reset the fuses by pressing in the two reset buttons (1). The engine also has a 55 A ground protection fuse (2) attached to the cable harness. If this has blown then it must be replaced. Always carry

a spare fuse on board.

NOTE! The Power Trim equipment also has fuses.

See under heading: SX-drive.

Electrical connections

Also check that all electrical connections are dry and free of oxidation and that there are no loose connections. If necessary, spray these connections with a water-repellent spray (Volvo Penta Universal oil).

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Battery. Maintenance

WARNING! Risk of fire and explosion. Never

allow an open flame or electric sparks near the battery or batteries.

WARNING! Never mix up battery positive and negative terminals. This may cause sparks and an explosion.

WARNING! The battery electrolyte contains extremely corrosive sulfuric acid. Protect your skin and clothes when charging or handling batteries. Always use protective goggles and gloves. If battery electrolyte comes into contact with unprotected skin wash off immediately using plenty of water and soap. If battery acid comes into contact with the eyes, flush immediately with plenty of water and obtain medical assistance without delay.

Connecting and disconnecting

First connect the red battery lead + to the battery + terminal. Then connect the black battery lead - to the battery - terminal.

When disconnecting the battery, disconnect the -lead (black) first and then the + lead (red).

Cleaning

Keep batteries dry and clean. Oxidation or dirt on the battery and battery terminals can cause short-circuits, voltage drop and discharge especially in damp weather. Clean the battery terminals and leads to remove oxidation using a brass brush. Tighten the cable terminals well and grease them with terminal grease or petroleum jelly.

Electrolyte level

The electrolyte should be 5 - 10 mm over the plates in the battery. Top up using distilled water if necessary. After topping up charge the battery for at least 30 minutes by running the engine at fast idle. NOTE! Certain maintenance-free batteries have special instructions which must be followed.

IMPORTANT! Never mix up battery positive and negative terminals.

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Battery. Charging

WARNING! Danger of explosion! The batteries

give off hydrogen gas during charging which when mixed with air can form an explosive gas oxyhydrogen A short-circuit, naked flame or spark can cause a large explosion. Ensure that the ventilation is good.

If the battery has discharged it must be charged. f the boat has not been used for some time charge the battery and then trickle charge it (see manufacturer’s recommendations). A poorly charged battery will be damaged and may burst in cold weather.

IMPORTANT! Follow the instructions supplied with the battery charger carefully. To avoid electrolytic corrosion when an external charger is connected, always disconnect the battery leads before connecting the charger.

When charging, unscrew filler plugs but leave them in their holes. Ventilation should be good, particularly if the batteries are being charged in an enclosed area.

WARNING! Always switch off the charging circuit before removing the battery charger connectors. Never mix up battery positive and negative terminals. This may cause sparks and an explosion.

Special instructions apply when boost charging the batteries. Avoid boost charging the batteries as it will shorten their service life.

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Electrical installations

Leakage current from the electrical system can be caused by incorrect installation of electrical equipment. Leakage current can in turn damage the galvanic protection of components such as the drive, propeller, propeller shaft, rudder stock and keel and cause damage by electrolytic corrosion.

IMPORTANT! Work on the boat’s low tension circuit should only be carried out by qualified or experienced persons. Installation or work on the shore power equipment must only be carried out by electricians authorized to work with high-voltage installations.

The following should always be observed:

1. If shore power is connected, the protector ground should be ashore, never in the boat. Shore power should always have a ground fault circuit breaker.

Shore power units (transformer, rectifier, battery chargers etc.) must be intended for marine usage

and the high tension circuit must be galvanically separated from the low tension circuit.

2. Route and clamp electric cables so that they will not be exposed to rubbing, damp or bilge water in the keelson.

3. Protective grounds for the radio, navigational equipment, rudder, bathing steps or other equipment with separate ground leads must be connected to a common ground terminal which is not connected to the engine, drive or reverse gear.

IMPORTANT! Engine, drive or reverse gear

must never be used as a ground point.

4. There must be a main switch connected to the starter battery positive (+) terminal. The main switch should cut off power to all power consuming equipment and should be switched off when the boat is not in use.

5. If an auxiliary battery is in use, a main switch (1) should be connected between the battery (+) terminal and the electrical system fuse block. The main switch for the auxiliary battery must cut off all power consuming equipment connected to that battery and be turned off when power is no longer needed. All equipment connected to the auxiliary battery should have separate switches.

To simultaneously charge two independent battery circuits, fit a Volvo Penta charge distributor (accessory) to the regular generator.

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Wiring diagram

Engine

PU = Purple GN = Green W = White BL = Blue LBL = Light-blue OR = Orange

Color code

GR = Gray SB = Black BN = Brown LBN = Light-brown R = Red

Engine

1. Engine coolant temperature (ECT)

2. Engine coolant temperature (ECT) switch

3. Oil pressure sensor/switch

4. Glow plugs

5. Relay

6. Ground fault fuse 55 A

7. Automatic fuse

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“De Luxe”

Instrument panels

Spring loaded

Cable areas (mm

are indicated as in the color codes

in the wiring diagrams.

Instrument panels

1. Instrument lighting

2. Voltmeter

3. Oil pressure gauge

4. Engine coolant temperature gauge

5. Connection for extra warning display

6. Electronics module (alarm)

7. Engine coolant temperature warning lamp

8. Oil pressure warning lamp

9. Charge warning lamp

10. Control lamp, pre-heating

11.Switch, instrument panel lighting

12.Switch, alarm test

13.Tachometer

14.Ignition switch

15.Alarm

16.Neutral position switch terminal

17.16-pin connector

18. 2-pin connector for auxiliary panel

“Standard”

Color code

GR = Gray

SB = Black

BN = Brown

LBN = Light-brown

R = Red

PU = Purple

GN = Green

W = White

BL = Blue

LBL = Light-blue

OR = Orange

VO = Violet

Y = Yellow

Spring loaded

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S-drive and reverse gear

The S-drive and in certain cases the propeller (reverse gear) is equipped with a sacrificial anode which prevents galvanic corrosion. Faulty electrical installation can also cause the break down of the galvanic protection. Damage due to electrolytic corrosion occurs rapidly and is often extensive. For further information see the chapter: ”Electrical system”

IMPORTANT! Improperly applied paint or the wrong type of paint on the keel can put the corrosion protection

system out of action. For further information on painting see the chapter: Laying up/Launching

Oil level. S-drive and MS2

Remove the dipstick by turning/screwing it anti clockwise. Dry off the dipstick and reinstall it in the drive, without screwing it into place. Remove again and check that the oil level is between the MAX and MIN markings on the dipstick. Top up oil if necessary.

IMPORTANT! The oil level should always be within the MAX and MIN range marked on the dipstick.

Oil change. S-drive

Remove the oil dipstick. Remove the plug on the propeller gear housing and let the oil run out. Check that the plug o-ring is intact. Replace if necessary. Install the plug and o-ring. Top up oil to correct level. For oil quality and capacity: See the chapter ”Technical Data”.

IMPORTANT! If the oil is colored gray then water has entered the drive. Please contact your authorized Volvo Penta dealer.

Oil change. MS2

Remove the oil dipstick. Suck up oil using an oil pump through the hole for the dipstick. Top up oil to correct level. For oil quality and capacity: See the chapter ”Technical Data”.

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2 3

MS25 HS25

Oil level. MS25 and HS25

Remove the dipstick by turning/screwing it anti clockwise. Dry off the dipstick and reinstall it in the reverse gear, without screwing it into place. Remove the oil dipstick again and check the oil level. The correct oil level is between MAX and MIN marking for the HS25 and at the level marking for the

MS25.

If necessary the oil is filled through the hole for the dipstick. For oil quality and capacity: See the chapter ”Technical Data”.

IMPORTANT! Never overfill reverse gear. The oil level should always lie within/at the recommended level.

Oil change and filter cleaning. HS25

1. Clean around the cover (2) so that there is no risk

of the dirt falling into the filter housing.

2. Undo the screws (1). Remove the cover (2) and

gasket (3).

3. Carefully remove the filter (4). Clean the filter in

kerosene (leave the gasket (5) in place). Clean the filter housing.

4. Suck up oil using an oil pump through the hole for

the dipstick.

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

through the hole for the oil dipstick or filter housing. For oil quality and capacity: See the chapter ”Technical Data”.

IMPORTANT! Never overfill reverse gear.

6. Reinstall the filter (4) with gasket (5) in the filter

housing. Check that the filter bottoms correctly.

IMPORTANT! If the filter does not sit flat there is a risk of breaking it when the cover (2) is installed.

7. Center the gasket (3) above the filter. Install the

cover.

8. Move the control lever to the neutral position. Start

engine and run at 1500 rpm for a few minutes so the reverse gear oil cooler is filled with oil.

9. Stop engine and check oil level. Top up if required.

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Oil change. MS25

Remove the dipstick. Suck up oil using an oil pump through the hole for the dipstick. Measure out the correct amount of oil and fill up through the hole for the oil dipstick. For oil quality and capacity: See the chapter ”Technical Data”.

IMPORTANT! Never overfill reverse gear. The oil level should always lie at the recommended level.

Corrosion protection. Check

Check the sacrificial anode. Replace the sacrificial anode when 50% of the material has been worn away or at least once a season. Remedy any paintwork damage on the drive according to the instruction in the chapter: Laying up/Launching.

IMPORTANT! Use zinc sacrificial anodes for salt water and magnesium anodes for freshwater.

Replacing sacrificial anodes

Folding propellers for the S-drive have three sacrificial anodes (1) installed on the propeller hub. To replace the sacrificial anodes (2) on the S-drive the propeller must first be removed (see separate description).

Remove the sacrificial anode. Thoroughly scrape the mating surfaces. Install and tighten the new anodes so that there is a good metal contact.

The sacrificial anodes oxidize in contact with air, which diminishes the galvanized protection. Even a new anode can be oxidized on the surface. Therefore

always clean the sacrificial anodes before launching the boat.

IMPORTANT! Use emery paper. Do not use a

wire brush or other steel tools when cleaning, as these may damage the galvanic protection.

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Rubber seal. S-drive

Check the rubber seal (1) between the drive and the hull regularly for cracks and wear.

WARNING! The seal must be changed every seven years or earlier if it is defective. This work should be carried out by an authorized workshop.

Propeller shaft seal. Reverse gear

If the boat has a water lubricated shaft seal, the seal must be vented and lubricated directly after launching.

Vent the propeller shaft seal by pressing it together while pressing it down onto the shaft until water appears. Then press in approx. 1 cm3 (0.06 cu.in.)

water repellent grease into the seal.

IMPORTANT! The seal must be replaced every

500 running hours or every 5th year.

Folding propeller. Maintenance

The propeller should be disassembled once a year for cleaning and lubrication. Clean carefully. Apply waterproof grease to the propeller blade teeth and bearing surfaces so that the propeller can fold easily. Also apply waterproof grease to the studs (1), propeller shaft and hub.

WARNING! The line cutter (2) has very sharp edges and must be handled with care.

IMPORTANT! The tab washer (3) must be replaced every fourth year. Only a Volvo Penta original locking screw (4) may be used.

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3-blade folding propeller (reverse)

2-blade folding propeller (drive)

3-blade folding propeller (drive)

Removing and installing

1. Set the control lever in the ”Ahead” position.

WARNING! Immobilize the engine before

starting work.

2. Remove the propeller blade by first undoing the locking screws (5) completely and then pressing out the shaft studs (1).

3. Drive: Bend down the tabs of the tab washer (3) and remove the locking screw (4), tab washer and nut (6).

Reverse gear: Remove the nut (7), washer (8) and then the locking screws (9).

4. Pull off the propeller hub. Clean and lubricate the propeller and propeller shaft as described.

5. Reinstall the propeller hub on the shaft.

6. Drive: Install the nut (6) and tighten to 70 Nm.

Reverse gear: Install the washer (8) and tighten the nut (7) to 220 Nm. Apply thread sealant to the locking screws (9). After the locking screws have been tightened apply thread sealant to the screw heads as well.

7. Drive: Locate the tab washer (3) on the nut. Install and tighten the locking screw (4) to 20 Nm and bend one of the tab washer tabs to the screw head.

8. Install one propeller blade in the propeller hub and push in the stud (1) in such a position so the groove in the stud is exactly centered in the hole for the locking screw (5). Apply thread sealant to the locking screw and tighten to 20 Nm.

IMPORTANT! The locking screw (5) must be

replaced every fourth year.

9. Install the other blades in the same way. Check the blades are at the same angle to the propeller shaft and that they move easily.

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SX-drive

The drive alloy components are protected against galvanic corrosion. This protection consists of five layers of paint, sacrificial anodes and ground braids.

IMPORTANT! Check the corrosion protection regularly. Used, overpainted or oxidized sacrificial anodes, a

broken ground braid or a paintwork damage can result in corrosion. The corrosion protection may also be inadequate due to a faulty electrical or faulty painting (for more information see “Electrical system” and Painting the drive and hull).

Sacrificial anodes. Checking

Check the sacrificial anodes at the front edge of the drive (1) and under the shield (2) every 14 days and the aluminum anode (3) in the lower transmission housing once a year. Replace with new anodes

when approximately 30% of the anode has been eroded. Note that most stainless steel propellers

(accessories) use the sacrificial anodes faster than normal.

IMPORTANT! Tighten the new anodes so that there is a good metallic contact is retained.

IMPORTANT! Use zinc sacrificial anodes for

salt water and magnesium anodes for freshwater.

The sacrificial anodes oxidize in contact with air, which diminishes the galvanized protection. Even a new anode can be oxidized on the surface. Therefore

always clean the sacrificial anodes before launching the boat.

IMPORTANT! Use emery paper. Do not use a

wire brush or other steel tools when cleaning, as these may damage the galvanic protection.

Ground braids. Check

The ground braids join the drive and shield separate components at a common ground point on the engine. Check that the ground braids are not broken and have

good contact.

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Oil level. Check

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

IMPORTANT! The dipstick must always be screwed in completely before it is pulled up for

reading the oil level.

Oil. Draining and filling

1. Trim the drive to normal operating position and

remove the dipstick.

2. Position a suitable container under the drain hole.

Remove the plug (1) and the gasket.

3. Allow all the oil to run out. Deposit the used engine

oil at a properly designated disposal site.

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

bad).

IMPORTANT! If the oil is colored gray then

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

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

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

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

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

7. Install the plug and gasket.

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

approx. 15 minutes to give the oil time to run down. The dipstick should not be installed

during the waiting time.

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

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Fuses. Power Trim

On the trim pump motor “A” is a 10 A automatic fuse which is reset with the button (3). On trim pump motor “B” there is a fuse holder with a 10 A blade fuse (4).

There is a 50 A automatic fuse located on the engine port side (on the injection pump). Reset the fuse by pressing in the button (5).

The control handle with integrated Power Trim controls (Volvo Penta control) has a 5 A fusible link (6) in the harness.

IMPORTANT! Always investigate the reason for the fuse activating. Always carry spare fuses.

Trim pump. Oil level

When checking and topping up the oil it is important that no dirt gets into the oil. Keep everything very clean.

Trim pump ”A”

WARNING! The hydraulic system is under

pressure. Before removing the filler plug the drive must be trimmed up completely so that the system is not under pressure. Always use a rag over the filler hole when the plug is being removed so that should the system still be under pressure the oil does not spray out.

Trim the drive to the maximum up position. Remove the oil filler plug (1) and check that the oil level reaches the bottom edge of the hole. Top up if necessary using ATF oil. Tighten the filler plug.

Trim pump ”B”

Trim the drive to the maximum down position. Check the oil level is between the MAX and MIN markings on the oil container. Remove the oil filler cover (2) to fill with oil. Use automatic transmission fluid.

After filling a completely drained reservoir the system should be bled by trimming the drive in and out approximately 10 times. Top up if required.

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Propellers

The propeller shaft should be smeared with a water resistant grease once a year. Remove and install according to the instructions on the next page.

Ask your Volvo Penta dealership for advice if you wish to change to a propeller with another pitch or diameter.

For twin installations one propeller must be right rotating and the other left rotating. Both should have the same pitch and diameter.

WARNING! Prevent an unwanted start. Remove the ignition key or turn off power at main switch before working on the propeller.

Removing and installing

1. Set the control lever in the neutral position.

Remove the split pin (1) and the locking tab washer (2)

2. Put a wooden block between the propeller blade

and the cavitation plate.

3. Remove the nut (3), spacer (4), propeller (5) and

the bushing (6).

4. Grease the propeller shaft using water repellant

grease.

5. Install the bushing (6) with the inner cone turned

toward the propeller shaft cone.

6. Install the propeller (5). Press the propeller against

the bushing until the spline edges can be seen and install the spacer (4) on the splines.

7. Put a wooden block between one propeller blade

and the cavitation plate. Install the nut (3) and tighten using a torque of 96-108 Nm.

8. Install the locking tab washer (2) so the split pin

can be inserted in the hole on the shaft. Install split pin (1).

IMPORTANT! Always use a new split pin, do not reuse the old one.

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Trim fin. Setting

No adjustment is required if the boat has power steering. If the boat is not equipped with the power steering the trim fin should be set depending on the propeller rotation.

WARNING! Immobilize the engine before starting work.

The following initial setting applies for both double and single installations:

With a left-rotating propeller (B) the measurement D is 83 mm (E = 5°). With a right-rotating propeller (A) the measurement F is 57 mm (G = 30°). Tighten the trim fin using 38-44 Nm.

If the steering wheel still feels heavy further adjustment may be required.

Bellows. Check

Remove the drive from mounting fork. Check the condition on the universal joint and the exhaust bellows every year. If there are cracks or other defects they must be replaced. Otherwise replace every other year.

WARNING! Removal of the drive requires special knowledge and tools. A falling drive can cause serious personal injury. Please contact your nearest authorized Volvo Penta dealer for assistance.

Lubrication. CV joint

Remove the drive from mounting fork. The CV joint is lubricated by the two lubricating nipples (1). Press in grease until it is forced out of the bearing. Use an EP wheel bearing grease. NOTE! The splined joint on the shaft (2) must be greased using molybdenum grease. Lubricate the two O rings (3) with a little engine oil.

WARNING! Removal of the drive requires special knowledge and tools. A falling drive can cause serious personal injury. Please contact your nearest authorized Volvo Penta dealer for assistance.

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Lubrication. Primary shaft bearing

Remove the drive from mounting fork. Grease the primary shaft bearing via the nipple (1) using a grease gun. Use an EP wheel bearing grease. Press in grease until it is forced out of the bearing. If the old grease indicates water contamination the bearing must be inspected and replaced if damaged.

WARNING! Removal of the drive requires special knowledge and tools. A falling drive can cause serious personal injury. Please contact your nearest authorized Volvo Penta dealer for assistance.

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Laying up/Launching

Before taking the boat out of the water for winter/out-of-season storage have an authorized Volvo Penta workshop inspect the engine and other equipment.

Inhibition should be carried out to ensure that the engine and transmission are not damaged while out of commission during the winter/off-season. It is important this is done properly and than nothing is forgotten. We have therefore provided a checklist covering the most important points.

WARNING! Read the chapter on Maintenance carefully before starting work. It contains instructions on how to carry out the work safely and correctly.

Inhibiting

● Change engine oil and replace oil filter.

● Change oil in the reverse gear.

● Replace fuel filter. Replace fuel pre-filter if

installed.

● Run engine to normal operating temperature.

● Take the boat out of the water:

The following should be carried out with the boat out of the water:

● Clean the hull and drive directly after taking up the

boat (before it dries).

IMPORTANT! Be careful when cleaning with a

high pressure water spray. Never direct the jet at seals, rubber bellows and hoses (for example the propeller shaft seal, exhaust or drive joint bellows and the trim cylinder seals).

● Check the condition of the engine coolant

antifreeze. Top up if required. Replace the coolant according to the maintenance schedule.

IMPORTANT! An anti-corrosion mixture in the

engine coolant system provides no protection against freezing. If there is any possibility the engine will be subjected to freezing temperatures then the system must be drained.

● Open the seacock (not standard with SX-drive).

● Clean and inhibit the seawater system.

● Remove the impeller from the seawater pump.

Store the impeller in a sealed plastic bag in a cool place.

● If a vacuum valve is installed on the seawater

circuit it must be cleaned.

● Drain any water and contaminants from the fuel

tank. Fill the tank completely with fuel to avoid condensation.

● Clean and charge the batteries. Keep the batteries

charged while the boat is in storage. NOTE! A poorly charged battery may burst as a result of freezing.

● Clean the outside of the engine. Do not use a high

pressure spray to clean the engine. Touch up any damaged areas of paintwork with Volvo Penta original paint.

● Spray electrical system components with moisture

repellent spray.

● Check all control cables and treat with rust

inhibitor.

● Change oil in the drive/reverse gear.

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● Touch up any damaged areas of paintwork with

Volvo Penta original paint. NOTE! Read the special instructions on painting the drive under the heading: Painting the drive and underwater hull

● Remove the propeller for storage. Grease the

propeller shaft using water repellent grease. Disassemble folding propellers, clean and grease.

● SX-drive. Check the universal joint and exhaust

bellows. Replace every other year.

● SX-drive. Grease the primary shaft bearing and CV

joint.

● S-drive. Check the rubber seal between the S-drive

and hull carefully. The seal must be changed every seven years or if it is defective. Leave this job to an authorized workshop.

● Close/tighten drain cocks/plugs.

● Check drive belts.

● Check the condition of rubber hoses and check

tighten hose clamps.

● Check engine coolant level and antifreeze

protection. Top up if necessary.

● Connect the fully charged batteries.

● Check that the Turbos boost pressure valve is not

stuck (TMD and TAMD 22).

● Paint the drive and hull: See following section.

● The drive’s sacrificial anodes must be cleaned off

with emery paper immediately before launching. If there is less than 50% of the anode left it must be replaced.

IMPORTANT! Do not use steel brushes or any

steel tools for cleaning the anodes. This can result in reduced galvanic protection.

● Reinstall the propeller.

● Launch the boat.

● Check that there is no fuel, water or exhaust

leakage. Check that all control functions are operating normally.

● Vent the rubber propeller shaft seal after launching

(reverse gear).

Bringing out of storage

● Check the engine oil level. Top up if necessary. If

there is inhibiting oil in the system drain and fill with new oil, change oil filter. For correct oil grade: See the chapter ”Technical Data”.

● Check the oil level in the drive and reverse gear.

Top up if necessary. For correct oil grade: See the chapter ”Technical Data”.

● Install the impeller in the seawater pump.

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Painting the drive and underwater hull

General

Most countries have introduced legislation controlling the use of anti-fouling agents. In some cases these agents are completely forbidden for use on leisure craft. In these cases ask your Volvo Penta dealer

for advice about alternative methods.

IMPORTANT! Find out what regulations apply to

the use of anti-fouling agents.

Drive

The paintwork is part of the drive’s anti-corrosion protection and it is therefore important that any paintwork damage is remedied.

Sand down metal surfaces lightly using a 120 grade paper and a finer grade for painted surfaces. Wash off using thinners or similar. Any pores in the surface should be filled and sanded down. Paint using Volvo Penta original primer and topcoat. Let the paint dry.

The drive should be painted with Volvo Penta antifouling to prevent fouling. Apply according to the instructions on the packaging.

IMPORTANT! The sacrificial anodes on the drive must not be painted.

Underwater hull Anti fouling agent containing copper oxide can increase the risk of galvanic corrosion and therefore should never be used.

IMPORTANT! SX-drive: Never paint all the way

forward to the shield, this can increase the risk of galvanic corrosion. Leave an area of 10 mm around the shield unpainted.

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Symptoms and possible causes

Engine cannot be stopped 1, 2, 3

Starter motor not turning or slow 1, 2, 3

Engine will not start 4, 5, 6, 7, 8

Engine starts but stops again 6, 7, 8, 13

Engine difficult to start 6, 7, 8, 13

Engine does not reach correct speed at wide open throttle (WOT) 6, 7, 8, 9, 10, 11, 12, 13, 18

Engine knocks 14

Engine runs unevenly 6, 7, 8, 13, 14

Engine vibrates 18, 19

High fuel consumption 9, 10, 13, 15

Black exhaust smoke 4, 13, 15, 18

Blue or white exhaust smoke 14, 15, 26

Low oil pressure 16, 17

Engine coolant temperature too high 20, 21, 22, 23, 24, 25, 26

No or poor charging 2, 27

Fault-tracing

A number of symptoms and possible reasons for engine problems are described in the table below. In case of

faults or mishaps which you cannot solve, always contact the Volvo Penta dealership.

WARNING! Read the safety precautions for maintenance and service in the chapter: Safety Precautions,

before starting work.

1. Discharged battery

2. Loose connection/open-circuit

3. Ground protection fuse or one of the semi-automatic fuses in the terminal box has blown/been triggered

4. Preheating insufficient

5. Lack of fuel

6. Blocked fuel filter/supply pump

7. Air in the fuel injection system

8. Water/contaminants in the fuel

9. Boat abnormally loaded

10. Fouling on underwater hull/drive/propeller

11. Limited speed control lever movement

12. The boost pressure control (BPC) valve sticks (TMD, TAMD)

13. Insufficient air supply

14. Engine coolant temperature too high

15. Engine coolant temperature is too low

16. Lubricating oil level too low.

17. Blocked fuel filter

18. Defective/incorrect propeller

19. Defective engine mounting

20. Too little coolant

21. Air in the freshwater cooling system

22. Blocked seawater intake/pipe/filter

23. Seawater/circulation pump drive belt slipping

24. Defective impeller

25. Defective/incorrect thermostat

26. Lubricating oil level too high

27. Generator drive belt slipping

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Engine

Engine designation .......................................... MD22L-B, MD22P-B, TMD22-B, TMD22P-C, TAMD22P-B

No. of cylinders ............................................... 4

Cylinder bore/stroke ........................................ 84.5/88.9 mm

Cylinder volume ............................................... 2 liters

Max. bhp .......................................................... See sales literature

Idling speed ..................................................... 800 ± 25 rpm

Wide Open Throttle (WOT) range ................... See chapter ”Operation”

Injection order .................................................. 1-3-4-2

Rotational direction, viewed from in front ............. Clockwise

Max. permitted rake backwards (while running) 20°

Max. list (while running) .................................. 30°

Valve clearances cold engine: Intake ............. 0.20-0.40 mm (adjustment play=0.25-0.35 mm)

Valve clearances cold engine: Exhaust ......... 0.30-0.50 mm (adjustment play=0.35-0.45 mm)

Weight of engine without water and oil ........... MD22L=220kg, MD22P=223kg, TMD22=225kg, TAMD22=235kg

Cooling system

Freshwater coolant system capacity .............. 7,5 liters

Thermostat: Starts opening at ........................ 81°C ± 4°C

Thermostat: Fully open at ............................... 95°C ± 3°C

Electrical system

System voltage ............................................... 12 V

Starter battery (capacity) ................................ 70 Ah

AC generator .................................................... 14V/60A

Lubricating oil recommendations

Oil volume (including oil filter) ......................... 6.0 liters

Oil quality according to

API* ........................................................... CD, CF, CF–4, CG–4

ACEA* ....................................................... E1, E2, E3

VDS*.......................................................... VDS, VDS–2

Viscosity is selected from the table** ............

* API= American Petroleum Institute, ACEA= Association des Constructeurs Européenne d’Automobiles, VDS=Volvo Drain Specification ** Temperature based on constant outside air temperature.

Technical data

Fuel specification

Fuel must meet national and international standards at least. For example:

EN 590 (with national environmental and cold standards) ASTM D 975 No 1-D and 2-D JIS KK 2204 Sulphur content: According to statutory requirements.

Fuels with extremely low sulphur contents (“urban diesel” in Sweden and “city diesel” in Finland) can cause a drop in output of 5% and an increase in fuel consumption of 2-3%.

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S-drive

Type designation ............................................. 120S–E

Gear ratio ......................................................... 2,2:1

Oil quality/Viscosity ........................................ API GL5/SAE 75W/90 (synthetic)

Oil capacity, approximately ............................ 2,8 liters

Difference between MIN and MAX markings . 0,07 liters

Weight .............................................................. 28 kg

Reverse gear

MS2

Type designation ............................................. MS2L–E MS2A–E

Gear ratio ......................................................... 2,3:1 2,4:1/3,0:1

Angle (output shaft) ......................................... 0° 7°

Oil quality/Viscosity ........................................ API GL5/SAE 75W/90 (synthetic)

Oil capacity, approximately ............................ 0,8 liters 0,8 liters

Weight .............................................................. 17 kg 17 kg

MS25

Type designation ............................................. MS25L

Gear ratio

Left rotating (Position B) ........................... 2,1:1/2,72:1

Right rotating (Position A) ......................... 2,3:1/2,74:1

Angle (output shaft) ......................................... 0°

Oil grade .......................................................... ATF (Dexron II)

Oil capacity, approximately ............................ 0.75 liters

Weight .............................................................. 18 kg

HS25

Type designation ............................................. HS25A

Gear ratio ......................................................... 2,29:1/2,71:1

Angle (output shaft) ......................................... 8°

Oil grade .......................................................... ATF (Dexron II)

Oil capacity, approximately ............................ 1,8 liters

Weight .............................................................. 24 kg

SX-drive

Type designation ............................................. SX-R

Gear ratio ......................................................... 2,18:1

Oil grade .......................................................... API GL5

Viscosity .......................................................... SAE 75W/90 (synthetic)

Oil capacity ...................................................... 2,1 liters

Weight (including shield) ................................. 91 kg

Power Trim hydraulic system

Oil grade .......................................................... ATF

Oil capacity ...................................................... 1,6 liters

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________________________________________________

Notes

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7738666-2 English 11-1998

AB Volvo Penta

SE-405 08 Göteborg, Sweden

www.volvopenta.com