Page 1
OPERATOR’S MANUAL
D12
Page 2
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
This operator’s manual is also available in the following languages:
Diese Betriebsanleitung ist auch auf
Deutsch erhältlich.
Ein Bestellcoupon ist am Ende der Betriebsanleitung zu finden.
Ce manuel d’instructions peut être
commandé en français.
Vous trouverez un bon de commande à la fin
du manuel d’instructions.
Este libro de instrucciones puede solicitarse en español.
El cupón de pedido se encuentra al final del
libro.
Den här instruktionsboken kan beställas på svenska.
Beställningskupong finns i slutet av instruktionsboken.
Questo manuale d’istruzioni può essere ordinato in lingua italiana.
Il tagliando per l’ordinazione è riportato alla
fine del manuale.
Dit instructieboek kan worden besteld
in het Nederlands.
De bestelcoupon vindt u achter in het instructieboek
Denne instruktionsbog kan bestilles
på dansk.
Bestillingskupon findes i slutningen af instruktionsbogen.
Tämän ohjekirjan voi tilata myös suomenkielisenä.
Tilauskuponki on ohjekirjan lopussa.
Este manual de instruções pode ser
encomendado em português.
O talão de requerimento encontra-se no fim
do manual.
Бхфь фп егчейсЯдйп чсЮузт
дйбфЯиефбй уфзн бгглйкЮ глюууб.
Гйб нб рбсбггеЯлефе Энб бнфЯфхрп,
ухмрлзсюуфе фз цьсмб рпх всЯукефбй уфп
фЭлпт бхфпэ фпх егчейсйдЯпх чсЮузт.
Данное руководство оператора
имеется на русском языках.
Для получения инструкции на нужном
языке заполните форму в конце
инструкции.
Bu kullanýcý el kitabý Türkçe dillerinde mevcuttur.
Birnüshasýný sipariþ etmek için kullanýcý el
kitabýnýn sonundaki formu doldurun.
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Welcome aboard
Volvo Penta marine engines are used all over the world. They are used in all possible operating
conditions for professional as well as leisure purposes. That’s not surprising.
After 100 years as an engine manufacturer the Volvo Penta name has become a symbol of reliability, technical innovation, top of the range performance and long service life. We also believe
that this is what you demand and expect of your Volvo Penta engine.
We would like you to read this operator’s manual thoroughly and consider the advice we give on
operation and maintenance before your maiden voyage so that you will be ensured of fulfilling
your expectations. Please pay attention to the safety instructions contained in the manual.
As owner of a Volvo Penta marine engine, we would also like to welcome you to a worldwide
network of dealers and service workshops to assist you with technical advice, service requirements and replacement parts. Please contact your nearest authorized Volvo Penta dealer for
assistance.
We also invite you to visit our home page on the Internet at www.volvopenta.com
With warm regards
AB VOLVO PENTA
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2
© 2006 AB VOLVO PENTA
We reserve the right to make modifications without prior notice. Printed on environmentally compatible paper.
(Cover: Department of transport (shipping), license 9809095)
Contents
Stopping the engine ........................................... 50
Stop ..................................................................... 50
Cold weather precautions .................................... 51
Laying up ............................................................. 51
Maintenance schedule ....................................... 52
Maintenance ........................................................ 54
Engine, general ................................................... 54
Lubrication system .............................................. 57
Freshwater system .............................................. 61
Seawater system ................................................. 66
Fuel system ......................................................... 70
Electrical system ................................................. 76
Reverse gear ....................................................... 81
Accessoties ......................................................... 83
Laying up/ Launching ......................................... 84
Inhibiting .............................................................. 84
Bringing out of storage ........................................ 85
In case of emergency ......................................... 86
Starting with auxiliary batteries ........................... 86
Emergency shifting .............................................. 87
Fault-tracing ......................................................... 88
Diagnostic function .............................................. 89
Fault register ....................................................... 92
Technical data ..................................................... 100
Engine ................................................................. 100
Reverse gear ....................................................... 102
Safety information .............................................. 3
General information ............................................ 3
Boat trips ............................................................. 4
Care and maintenance ........................................ 6
Introduction ......................................................... 8
Running in ........................................................... 8
Fuel and oils ........................................................ 8
Certified engines ................................................. 9
Warranty information ........................................... 9
Identification number .......................................... 10
Presentation ........................................................ 11
Technical description ........................................... 11
Orientation ........................................................... 12
Instruments ......................................................... 13
Instruments .......................................................... 13
Ignition lock .......................................................... 13
Start/stop panel ................................................... 13
Alarm display (optional extra) .............................. 14
EVC control panel................................................ 17
EVC system tachometer ...................................... 18
EVC system display (optional extra) .................... 27
Controls ............................................................... 35
Single lever control .............................................. 35
Two lever control .................................................. 37
Starting the engine ............................................. 38
Before starting ..................................................... 38
General information about starting ...................... 38
Starting method ................................................... 39
Operation ............................................................. 41
Reading instruments ........................................... 41
Alarm ................................................................... 42
Cruising speed .................................................... 42
Synchronising engine speed ............................... 43
Changing the helm station ................................... 43
Operation ............................................................. 45
Low speed ........................................................... 46
Trolling ................................................................. 47
Propeller shaft brake ........................................... 48
Extra equipment .................................................. 49
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Safety information
Read this chapter very carefully. It has to do with your safety. This describes how safety information is presented
in the instruction book and on the product. It also gives you an introduction to the basic safety rules for using and
looking after the engine.
Check that you heave received the correct instruction book before you read on. If not, please contact
your Volvo Penta dealer.
Incorrect operation can lead to personal injury and damage to products or property. So
read the instruction book through very carefully before you start the engine or do any
maintenance or service work. If there is still something which is unclear or if you feel unsure about it, please contact your Volvo Penta dealer for assistance.
This symbol is used in the instruction book and on the product, to call your attention to the
fact that this is safety information. Always read such information very carefully.
Safety texts in the instruction book have the following order of priority:
WARNING! Warns for the risk of personal injury, major damage to product or property, or
serious malfunctions if the instruction is ignored.
IMPORTANT! Is used to call attention to things which could cause damage or malfunctions
to product or property.
NOTE! Is used to call attention to important information, to facilitate work processes or operation.
This symbol is used on our products in some cases and refers to important information in
the instruction book. Make sure that warning and information symbols on the engine are
clearly visible and legible. Replace symbols which have been damaged or painted over.
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Safety information
Safety advice for boat operation
Your new boat
Read the instruction books and other information
carefully, which came with your new boat. Learn to
handle the engine, controls and other equipment in a
safe and correct manner.
If this is your first boat, or a type of boat you are not
experienced in using, we recommend that you practice operating the boat in peace and quiet. Get to know
the way the boat reacts to sea and to the controls
under different speed, sea and loading conditions before you cast off for your first “real” maiden voyage.
Remember that the captain of every boat is required
by law to know and to observe applicable rules for
traffic and safety at sea. Get to know the rules which
apply to you and your waters, by contacting the relevant authority or sea safety organisation.
It is a good idea to go on some kind of boat operation
course. We recommend that you contact a regional
boat or sea safety organisation to find a suitable course.
Accidents and near misses
Life saving statistics show that inadequate care of
boats and engines, and deficiencies in safety equipment are frequent causes of accidents and near misses
at sea.
Make sure that your boat and engine are maintained
in accordance with the advice in each instruction
book, and that the necessary safety equipment is on
board, and is in working condition.
Daily checks
Make it a habit to give the engine and engine bay
a visual check before driving (before starting the
engine) and after operation (when you have stopped the engine). This helps you to quickly discover
whether any leakage of fuel, coolant, oil or any other
abnormal event has happened, or is about to happen.
Manoeuvring
Avoid sudden or surprising rudder movements and
gear shifting. There is a risk that passengers could
fall over, or overboard.
A rotating propeller can cause severe injury. Check
that there is nobody in the water before you engage
forward / astern (reverse) drive. Never drive close to
bathers or in areas where you could reasonably expect that people could be in the water.
Fuel filling
There is always a risk of fire and explosion during
fuel filling. Smoking is not permissible, and the engine should be stopped.
Never over-fill the tank.
Shut the tank cap securely. Only use the fuel recommended in the instruction book. The wrong grade of
fuel can cause malfunctions or stop the engine. In a
diesel engine, it can also cause the regulation rod to
bind and the engine will over-rev, entailing a strong
risk of personal injury and machinery damage.
Do not start the engine.
Do not start the engine if you suspect a fuel or LPG
leak in the boat, close to explosive media, or if there
is a spillage of explosive media. An explosive environment entails a risk of fire and/or explosion.
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Safety information
Carbon monoxide poisoning
When a boat moves forwards, an area of low pressure air forms behind the boat. In adverse conditions,
this low pressure can be so strong that the boat’s
own exhaust fumes are sucked into the cockpit or
cabin, which entails a risk of carbon monoxide poisoning for all aboard.
The problem of low-pressure suction is worst in high,
wide boats with a square transom. But even in other
types of boats, low-pressure suction can be a problem in some conditions, such as if you drive with the
hood up. Other factors which increase the low-pressure effect are wind conditions, load distribution, pitching, trimming, open windows and ventilators etc.
Most modern boats are designed so that the problem
of low-pressure suction is very rare, however. If lowpressure suction does occur anyway, do not open
hatches or ventilators in the forward part of the boat.
Strangely enough, this makes the problem worse. Try
changing speed, trimming or load distribution instead.
Also try taking down/opening the hood or modifying
it in some other manner. Ask your boat dealer for advice about the best solution for your particular boat.
Remember
● Safety equipment: Life jackets for everybody aboard, communication equipment, emergency
rockets, approved fire extinguisher, first aid kit, life buoy, anchor, paddle, torches etc.
● Spare parts and tools: Impeller, fuel filters, fuses, tape, hose clamps, engine oil, propeller and
tools for the jobs you could be expected to have to do.
● Take your chart out and study your planned route. Calculate distance and fuel consumption.
Listen to weather reports.
● Tell your friends/relatives about route plans if you undertake a long journey. Remember to notify
changed plans or delays.
● Inform everybody aboard about where the safety equipment is located, and how it works. Make
sure that there is more than one person aboard who can start and operate the boat safely.
This list can be extended, since the need for safety equipment varies with the type of boat, and
where or how it is used etc. We recommend that you ask a regional boat or sea safety organisation
for more detailed maritime safety information.
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Safety information
Safety advice for care and maintenance work
Preparations
Knowledge
The Instruction Book contains instructions for doing
the most common service and maintenance tasks in
a safe and correct manner. Read them carefully before starting work.
Literature for more major tasks is available from your
Volvo Penta dealer.
Never do a job if you are not entirely sure about how to
do it. Contact a Volvo Penta dealer for assistance instead.
Stop the engine.
Stop the engine before opening or removing the engine
hatch/hood. Care and maintenance work should be
done with the engine stopped unless otherwise specified.
Prevent the engine from being started by cutting the
current with the battery isolator, or remove the cable
from the battery positive pole before you start service
work. Fix a notice by the helmsman’s seat to say that
work is in progress.
Working with, or going close to a running engine
is a safety risk. Loose clothes, long hair, fingers or
dropped tools can catch on rotating components and
cause severe injury. Volvo Penta recommends that all
service work which requires the engine to be running
should be done by a Volvo Penta authorised workshop.
Lifting the engine
The existing lugs on the engine (or reverse gear)
should be used for lifting. Always check that the lifting
devices are in good condition and that they have the
correct capacity for the lift (engine weight together
with reverse gear and auxiliaries, if fitted). The engine
should be lifted with an adjustable lifting boom for
safe handling. All chains or cables should be parallel
to each other and should be as square as possible
to the top of the engine. Please note that auxiliary
equipment installed on the engine could change its
centre of gravity. Special lifting devices may then
be needed to obtain the correct balance and safe
handling. Never do any work on an engine which just
hangs from a lifting device.
Before starting
Re-install all guards which have been removed
during service work, before re-starting the engine.
Make sure that there are no tools or other objects left
behind on the engine.
Never start a turbocharged engine without the air
filter in place. The rotating compressor turbine in the
turbocharger can cause severe injury. There is also a
risk that foreign bodies could be sucked in and cause
machinery damage.
Fire and explosion
Fuel and lubrication oil
All fuel, most lubricants and many chemicals are
flammable. Always read and observe the advice on
the packages.
Work on the fuel system must be done with the engine cold. Fuel leakage and spills on hot surfaces or
electrical components can cause fires.
Store oil and fuel soaked rags and other flammable
material in a fire-proof manner. Oil soaked rags can
self-ignite in certain circumstances.
Never smoke when filling fuel, lubrication oil or close
to fuel filling stations or the engine bay.
Non-original spare parts
Components in fuel systems and electrical systems
on Volvo Penta engines are designed and manufactured to minimise the risk of explosions and fire, in accordance with applicable legal requirements.
The use of non-original spare parts can cause a fire.
Batteries
Batteries contain and give off an explosive gas, especially when charged. This gas is very flammable and
highly explosive.
Smoking, open flames or sparks must never occur in
or near to batteries or the battery locker.
Incorrect connection of a battery cable or start cable
can cause a spark which can be sufficient, in its turn,
to make the battery explode.
Start spray
Never use start spray or similar products as a starting aid. Explosions could occur in the inlet manifold.
Danger of personal injury.
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Safety information
Hot surfaces and fluids
A hot engine always offers the risk of burns. Be on
your guard against hot surfaces, such as the exhaust manifold, turbocharger, sump, charge air pipe,
starting heater, hot coolant and hot lubricating oil in
pipes and hoses.
Carbon monoxide poisoning
Only start the engine in a well-ventilated area. When
operated in a confined space, exhaust fumes and
crankcase gases must be ventilated.
Chemicals
Most chemicals, such as glycol, rust preventer, conservation oils, degreasers etc. are hazardous. Always
read and observe the advice on the packages.
Some chemicals, such as conservation oils, are flammable and also hazardous to breathe. Ensure good
ventilation and use a protective mask for spraying. Always read and observe the advice on the packages.
Store chemicals and other hazardous material out of
the reach of children. Hand in surplus or used chemicals to a recycling station for destruction.
Cooling system
There is always a risk of water entry when any work
is done on the seawater system. For this reason,
stop the engine and close the sea cocks before you start
work.
Avoid opening the coolant filling cap when the engine
is hot. Steam or hot coolant can spray out and cause
scalding.
If the filler cap, coolant hose etc., still has to be opened or removed when the engine is hot, undo the
filler cap slowly and carefully, to let the pressure out
before removing the filler cap completely and starting
work. Note that the coolant can still be hot and cause
scalding.
Lubrication system
Hot oil can cause burns. Avoid skin contact with hot
oil. Make sure that the oil system is de-pressurised
before starting work. Never start or run the engine with
the oil filler cap removed, because of the risk of oil spillage.
Fuel system
Always protect your hands when searching for leaks.
Fluids which leak under pressure can force their way
into body tissue and cause severe injury. Risk of
blood poisoning (septicaemia).
Always cover the alternator if it is located beneath the
fuel filters. Fuel spillage can damage the alternator.
Electrical system
Cut the current
Before any work is done on the electrical system,
the engine must be stopped and the current cut by
switching off the battery isolator. Shore current for
engine heaters, battery chargers or other auxiliary
equipment connected to the engine must be disconnected.
Batteries
Batteries contain a highly corrosive electrolyte. Protect your eyes, skin and clothes during charging and
other handling of batteries. Always use protective
goggles and gloves. If this comes into contact with
your skin, wash at once with soap and a lot of water.
If you get battery acid in your eyes, flush at once with
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Introduction
This instruction book has been prepared to give you the greatest possible benefit from your Volvo Penta marine
engine. It contains the information you need to be able to operate and maintain the engine safely and correctly.
Please read the instruction book carefully and learn to handle the engine, controls and other equipment in a
safe manner before you cast off on your maiden voyage.
Always have the instruction book available. Store it safely and do not forget to hand it over to the next owner if
you sell your boat.
Environmental care
All of us want to live in a clean, healthy environment.
Where we can breathe clean air, see healthy trees,
have clean water in lakes and seas, and be able to
enjoy the sunlight without fearing for our health. Unfortunately, this is not self-evident these days, it is
something all of us must work hard for.
As a manufacturer of marine engines, Volvo Penta
has particular responsibility and for this reason, environmental care is a core value in our product development. Volvo Penta has a wide engine programme
these days, where considerable progress has been
made in reducing exhaust fumes, fuel consumption,
engine noise etc.
We hope that you will be want to preserve these
values. Always observe the advice in the instruction
book about fuel grades, operation and maintenance,
to avoid unnecessary environmental impact. Please
contact your Volvo Penta dealer if you notice any
changes such as increased fuel consumption or increased exhaust smoke.
Moderate your speed and distance so that wake and
noise do not disturb or damage animal life, moored
boats, jetties etc. Leave the archipelago and harbours
in the same state you would like to find them. Remember to always hand in drained oil, coolant, paint
and wash residue, used batteries etc. for destruction
at a recycling station.
If we all pull together, we can make a valuable contribution to the environment together.
Higher oil consumption is normal during the running
in period. For this reason, check the oil level more
frequently than normally recommended.
After the first period of operation, the specified warranty inspection “First service inspection” can be
done. For more information: Please refer to the Warranty and Service book.
Fuel and oils
Only use the fuels and oils recommended in the instruction book. Other grades can cause malfunctions,
increased fuel consumption and eventually even
shorten the life of the engine.
Always change the oil, oil filter and fuel filter at the
specified intervals.
Running in
The engine must be “run in” during its first 10 hours,
as follows:
Use the engine in normal operation. Full load should
only be applied for short periods. Never run the engine
for a long period of time at constant speed during this
period.
Service and spare parts
Volvo Penta marine engines are designed for high
reliability and long life. They are built to withstand
a marine environment, but also to have the smallest possible environmental impact. Through regular
service and use of Volvo Penta original spare parts,
these qualities are retained.
Volvo Penta’s world-wide network of authorised dealers is at your service. They are Volvo Penta product
specialists, and have the accessories, original spares, test equipment and special tools needed for high
quality service and repair work.
Always observe the maintenance intervals in the
instruction book, and remember to note the engine/
transmission identification number when you order
service and spare parts.
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Introduction
Certified engines
If you own or operate an emission certified engine it
is important to be aware of the following:
Certification means that an engine type has been
checked and approved by the relevant authority. The
engine manufacturer guarantees that all engines
made of the same type are equivalent to the certified
engine.
This makes special demands on the care and
maintenance you give your engine, as follows:
● Maintenance and service intervals recommended
by Volvo Penta must be complied with.
● Only Volvo Penta original spares may be used.
● Service on injection pumps, pump settings and
injectors must always be done by an authorised
Volvo Penta workshop.
● The engine must not be converted or modified,
except for the accessories and service kits which
Volvo Penta has approved for the engine.
● Installation changes to the exhaust pipe and engi-
ne air inlet ducts must not be done.
● No seals may be broken by unauthorised personnel.
The general advice in the instruction book about operation, care and maintenance apply.
IMPORTANT! Late or inadequate maintenance/
service or the use of spare parts not approved
by Volvo Penta will invalidate AB Volvo Penta’s
responsibility for the engine specification being
in accordance with the certificated variant.
Volvo Penta accepts no responsibility or liabi-
lity for any damage or costs arising due to the
above.
Warranty
Your new Volvo Penta marine engine is covered by a limited warranty, under the conditions and instructions compiled in the Warranty and Service book.
Please note that AB Volvo Penta’s liability is limited to the specification in the Warranty and Service
book. Read it carefully, as soon as possible after delivery. It includes important information about warranty cards, service, maintenance, which it is the responsibility of the owner to know, check and carry
out. If this is not done, AB Volvo Penta may fully or partly refuse to honour its warranty undertakings.
Please contact your Volvo Penta dealer if you have not received a Warranty and Service book, or
a customer copy of the warranty card.
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Introduction
Identification numbers
There are type plates on the engine and transmission, marked with identification numbers. This information must
always be used a reference when service and spare parts are ordered. You will probably find similar plates on
your boat and its equipment. Note this information below, make a copy of the page and store it in a safe place,
so that you can have the information available if the boat is stolen.
The appearance and location of the type plates is shown below. The figures in brackets refer to the location of
the identification number on the type plate.
Engine
Product designation (1) D12D-C MH
Serial and base engine number (2) .................................................................................
Product number (3) ..........................................................................................................
Control unit
“Dataset” (parameter file) (4) ...........................................................................................
Main software (5) .............................................................................................................
Certification, IMO
Reverse gear
Product designation (6) ..................................................................................................
Serial number (7) .............................................................................................................
Product number (8) ..........................................................................................................
Reverse gear plate
Engine plate
Warranty decal
Decal, control unit
6, 7, 8
THIS ENGINE TYPE IS CERTIFIED
ACC. TO IMO NOx TECHNICAL
CODE ANNEX VI
Certification decal
D12D-C MH
RATED POWER: xxx kW
RATED SPEED: xxxx RPM
MSW: xxxxxxx (5)
DST 1: xxxxxxxx (4)
DST 2: xxxxxxxx (4)
SPEC. NO: xxxxxx (3)
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Presentation
The D12D-C MH is an in-line, direct injection 6-cylinder marine diesel engine.
The engine has electronically controlled fuel injection, a turbocharger, aftercooler, heat exchanger and thermostatically controlled freshwater cooling, electronically controlled engine speed control and shifting.
The exhaust manifold and turbocharger are freshwater cooled to reduce heat radiation to the engine room
Technical description
Engine and cylinder block
– The cylinder block and cylinder head are manu-
factured of alloyed cast iron
– Induction hardened crankshaft journalled in seven
main bearings
– Replaceable wet cylinder liners
– Gallery oil cooled cast aluminium pistons
– Three piston rings, including a “keystone” type top
ring
– Induction hardened overhead camshaft with roller
rocker arms
– Four valves per cylinder
– Replaceable valve seats and valve guides
Fuel system
– Microprocessor based fuel supply control unit
– Gear driven fuel feed pump
– Centrally located unit injectors with electromag-
netically controlled fuel valves
– Spin-on fine fuel filter with water trap
Lubrication system
– Freshwater cooled oil cooler
– Gear driven oil pump
– Side mounted or rear mounted full flow and by-
pass oil filters of spin-on type
Turbocharging system
– Turbocharger with freshwater cooled turbine hous-
ing
Cooling system
– Tube heat exchanger ( or 1- circuit keel cooling)
with expansion tank
– Plate type freshwater cooled aftercooler
– Gear driven seawater pump
Electrical system
– 24V electrical system, alternator (60A) with
charge sensor
– Engine mounted emergency stop button
– Power modul
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Presentation
D12D-C MH
1. Alternator
2. Expansion tank
3. Level glass, coolant
4. Coolant filler cap
5. Charge air cooler (located beneath
cover)
6. Air filter
7. Oil cooler, reverse gear
8. Crankcase breather filters
9. Heat exchanger
10. Control unit (located behind heat
exchanger)
11. Seawater pump
D12D-C MH
1. Exhaust pipe, dry
2. Turbocharger
3. Fine fuel filter with water trap
4. Emergency stop button
5. Oil filler cap
6. Coolant pump
7. Oil sump
8. Oil cooler, engine (loc. in engine
block)
9. Lubrication oil filter
10. By-pass filter for lubrication oil
11. Coolant filter
12. Oil dipstick, engine
13. Oil filler cap
14. Oil drain pump (optional)
15. Starter motor
16. Reverse gear Twin Disk MG5114 DC
1 2 3 4 5 6
7
891011
1 2 3 4
5
679
10
11
12
131516
14
8
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Instruments
This chapter describes the instrument and control panels sold by Volvo Penta for your engine.
If you want to supplement the instrumentation, or if your boat is equipped with instruments not described here,
or you are not sure about their function, please contact your Volvo Penta dealer.
1. EVC system tachometer (with display)
2. Voltmeter
3. Oil pressure gauge
4. Temperature gauge
Ignition lock
A tab with the key code accompanies the ignition
keys, and is used to order extra ignition keys. Do not
store the code where it is accessible to unauthorized
persons.
S = Stop position.
0 = Key can be inserted and removed.
I = System voltage on (drive position).
II = Not used.
III = Start position.
IMPORTANT! Read the starting instructions in
the “Starting the engine” chapter.
2.
3.
4.
1.
Instruments
Start/stop panel
The start/stop panel is used to start or stop the engine. The starter key in the main control panel must be
in position “I” (driving position) for the engine to start.
The engine can only be stopped if the control panel
is activated.
IMPORTANT! Read the starting instructions in
the “Starting the engine” chapter.
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Instruments
Alarm display (optional extra)
The following warning lamps should never light up during operation. On the other hand, the warning lamps light
up when the starter key is first turned to the drive position. Check that all lamps function. When the engine has
started, all lamps should have gone out. The lamps flash if the diagnostic function has registered malfunction.
When the fault has been acknowledged, the lamp gives continuous light.
NOTE! Warning lamps should never light up during operation
Oil pressure (red indication)
If the oil pressure lamp lights up during operation, the
oil pressure in the engine is too low. Stop the engine
at once.
Check the oil level in the engine. Please refer to
“Maintenance: Lubrication” to check and top the oil
up.
Also check that the oil filters are not blocked.
Please refer to “Maintenance: Lubrication system”
Please refer to the “If something happens” chapter,
and you will find detailed information about recommended action in the “Diagnostic function” section.
WARNING! Continued operation when the oil
pressure is too low can cause serious engine
damage.
Water in fuel filter (orange indication)
If the lamp lights up, there is too much water in the
water trap in the fuel filters.
Empty the water trap underneath the secondary
fuel filter. Please refer to “Maintenance: Fuel system”.
Please refer to the “In case of emergency” chapter,
and you will find detailed information about recommended action in the “Diagnostic function” section.
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Instruments
Battery (orange indication)
The battery lamp lights up if the alternator is not
charging. Stop the engine if this lamp lights up during
operation. If the lamp lights up, this can be due to a
fault in the electrical system or because the alternator drive belt is slack.
Check the alternator drive belts. Please refer to
“Maintenance: Engine, general”.
Also check that there is no poor contact/broken wires.
Please refer to the “If something happens” chapter,
and you will find detailed information about recommended action in the “Diagnostic function” section.
WARNING! Do not continue operation if there
is any problem with the alternator drive belts.
This could cause serious engine damage.
Coolant temperature (red indication)
The coolant temperature lamp lights up when the
coolant temperature is too high. Stop the engine if
this lamp lights up during operation.
Check the coolant level. Please refer to “Mainte-
nance: Fresh water system”.
Check that the sea water filter is not blocked.
Please refer to “Maintenance: Sea water system”
Also check the impeller in the sea water pump.
Please refer to “Maintenance: Sea water system”.
Please refer to the “If something happens” chapter,
and you will find detailed information about recommended action in the “Diagnostic function” section.
WARNING! Do not open the coolant filler cap
when the engine is warm, except in emergencies. Steam or hot fluid could spray out.
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Instruments
Coolant level (orange indication)
The coolant lamp lights up when the coolant level is
too low.
Check coolant level. Please refer to “Maintenan-
ce: Lubrication system”.
Please refer to the “If something happens” chapter,
and you will find detailed information about recommended action in the “Diagnostic function” section.
Oil level (orange indication)
The oil level lamp lights up when the oil level is too
low.
Check the oil level. Please refer to “Maintenance:
Fresh water system”.
Please refer to the “If something happens” chapter,
and you will find detailed information about recommended action in the “Diagnostic function” section.
Serious fault (red indication)
The lamp lights up when a serious fault occurs.
Please refer to the “If something happens” chapter,
and you will find detailed information about recommended action in the “Diagnostic function” section.
Fault (orange indication)
The lamp lights up when a fault occurs.
Please refer to the “If something happens” chapter,
and you will find detailed information about recommended action in the “Diagnostic function” section.
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Instruments
Tachometer display selection (twin installa-
tion, port or starboard tachometer)
Is used to select which of the engines menu systems
should be navigable from the control panel. The
menu is shown on the display of the corresponding
engines tachometer. Select port or starboard.
Indication (red/green):
Off: Not possible to navigate in menu.
Lit: Possible to navigate in menu for selected en-
gine, port (red), starboard (green).
Multifunction button
Used to increase or decrease the instrument’s and
panel’s backlighting.
Depress the button for at least 1 second to turn the
backlighting on or off. The backlighting can be adjusted in five stages by pressing the multifunction button.
If the button is pressed on a inactive control panel,
operating information is shown on the display(s) and
it is possible to navigate in the menus.
Back button
Used to back a step in the menu.
IMPORTANT! Always press the buttons firmly,
and for at least one second each time.
Activation button
Used to activate and lock the control panel and helmstation.
Indication (red):
Off: Control panel not activated.
Lit: Control panel activated.
Flashes: Control panel not activated due to the con-
trol lever not being in neutral or the system has been
locked from another control panel.
Padlock
The padlock symbol lights if the control panel is
locked manually by depressing the -button, or if
exchange has been activated by routine ”Change of
control panel during journey”.
Lit: The system is locked and the engine can only be
controlled from the activated control panel.
Neutral button
Used to disengage the drive so that the engine speed
can be increased without driving (warming up).
Indication (green):
Off: Drive engaged.
Lit: Control lever in neutral position.
Flashes: Drive disengaged or system in calibration
mode.
Navigation wheel
Used to navigate through the menus shown on the
tachometer EVC system display. Navigate through
the menus by turning the wheel. Depress the wheel
to confirm a selection.
EVC control panel
The control panel is used in combination with the EVC system tachometer. The tachometer display shows operating information and menus that can be navigated from the control panel.
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Instruments
EVC System Tachometer
Introduction
Volvo Penta EVC System Tachometer presents relevant boat and engine information to the helmsman.
Information is presented on a display in the tachometer.
Information is depending on engine model, number
of sensors and type of accessories.
Using the instrument
Start-up screen
This is the start-up screen for the EVC System Tachometer. After a few seconds the first item in MAIN
MENU will appear.
Main menu
Navigating the menus
Navigate the menus by turning NAVIGATION WHEEL
clockwise or counter-clockwise. Views with a POINTING HAND-symbol indicates a SUB-MENU. To enter
a SUB-MENU, push NAVIGATION WHEEL.
Speed (Optional)
Boat speed. Requires multisensor or GPS.
Water temp (Optional)
Water temperature. Requires multisensor.
Depth (Optional)
Water depth. Requires multisensor.
Trip menu (Optional)
Shows trip information. Requires the following:
- Multisensor or NMEA 0183/NMEA 2000 compatible component (plotter, GPS, paddle wheel etc)
- Fuel level sender
- Trip computer software
Gauges menu
Shows data parameters.
Settings menu
The SETTINGS MENU allows the user to set various
options for the EVC System and to calibrate various
parameters.
Faults list
Number after word FAULTS indicates number of
faults stored in FAULTS LIST. List is reset when system is rebooted.
NOTE! Faults list is not shown if no faults are registered.
Main menu structure
Trip menu
Gauges menu
Settings menu
Faults list
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Instruments
Trip menu (extra optional)
In the TRIP MENU the user gets trip information from the EVC System and the user is allowed to select which
view that should be presented in the EVC System Tachometers MAIN MENU as trip information. To get trip information following are required:
- Multisensor or NMEA 0183/NMEA 2000 compatible component (plotter, GPS, paddle wheel etc)NMEA 0183/NMEA 2000 compatible component (plotter, GPS, paddle wheel etc) compatible component (plotter, GPS, paddle wheel etc)
- Fuel level sender
- Trip computer software
NOTE! The accuracy of trip information concerning, and based on, remaining fuel volume depends on which
method the user has choosen for calibrating the fuel tank.
When in TRIP MENU, select view by turning NAVIGATION WHEEL. To select view as favorite, push NAVIGATION WHEEL. System returns to MAIN MENU.
Push BACK BUTTON to return to MAIN MENU without setting a new favorite.
Units are user selectable. See section "Units".
TRIP RESET: Reset all trip data.
FUEL REMAINING: Fuel remaining (l, Gal).
FUEL ECONOMY: Instantaneous fuel rate per dis-
tance (l/nm, l/km, l/mile, Gal/nm, Gal/km, Gal/mile).
FUEL RATE: Instantaneous fuel rate per hour (l/h,
Gal/h).
DISTANCE TO EMPTY: Distance to empty based on
instantaneous fuel rate, remaining fuel and speed
(nm, km, miles).
TIME TO EMPTY: Time to empty based on instantaneous fuel rate and remaining fuel (h).
TRIP DISTANCE: Trip distance since last reset (nm,
km, miles).
TRIP FUEL: Trip fuel used since last reset (l, Gal).
TRIP FUEL ECONOMY: Average fuel rate per dis-
tance since last reset (l/nm, l/km, l/mile, Gal/nm, Gal/
km, Gal/mile).
TRIP FUEL RATE: Average fuel rate per hour since
last reset (l/h, Gal/h).
TRIP TIME: Trip engine hours since last reset (h).
Trip menu structure
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Instruments
Gauges menu
In GAUGES MENU the user gets information from analogue senders, placed on the engine. If the data is not
available the parameter will not be displayed.
When in GAUGES MENU, select view by turning NAVIGATION WHEEL. To select view as favorite, push NAVIGATION WHEEL. System returns to MAIN MENU.
Push BACK BUTTON to return to MAIN MENU without setting a new favorite.
VOLTAGE: (V)
ENGINE HOURS: (h)
ENGINE RPM: (RPM)
COOLANT TEMP: (°C, °F)
ENGINE OIL PRESSURE: (kPa, PSI)
EXHAUST TEMP: (°C, °F)
TURBO PRESSURE: (kPa, PSI)
TRANSMISSION OIL TEMPERATURE: (°C, °F)
RUDDER ANGLE: (°)
FUEL LEVEL: (%)
FRESH WATER LEVEL: (%)
Gauges menu structure
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Instruments
Settings menu
In the SETTINGS MENU the user is allowed to set various options for the EVC system and to calibrate various
parameters.
IMPORTANT! For all settings and calibration procedures: Activate helm station by pushing the ACTIVA-
TION BUTTON.
NOTE! For twin installations always perform the settings on the port side system. Port side is the master side.
When in SETTINGS MENU, select view by turning NAVIGATION WHEEL. Views with a POINTING HAND-symbol indicates a SUB-MENU. To enter a SUB-MENU, push NAVIGATION WHEEL.
Push BACK BUTTON to return to MAIN MENU.
INFO BEEP: Set info beep sound level for the built-in
buzzer in EVC tachometer.
DEPTH ALARM: Settings for depth alarm functions.
UNITS: Choose which units to display. Set US or
metric and units for distance, nm, km, miles.
FUEL TANK CALIBRATION: Calibration of the fuel
tank.
CHASSIS ID: Shows information about the EVC system and the VIN (Vehicle Identification Number).
SEL LANGUAGE: Select language (10 different)
DISPLAY CONTRAST: Adjust the contrast of the
display.
SPEED FACTOR: Set the calibration factor for the
boat´s paddle wheel speed sensor.
Settings menu structure
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Instruments
DEPTH ALARM, ON/OFF
Depth alarm can be switched ON/OFF.
SET DEPTH
Adjust the depth alarm value by turning the NAVIGATION WHEEL. The value can be adjusted at a resolution of 0.1 m or 1 ft.
Once adjustment value is reached, the data is stored
by pushing NAVIGATION WHEEL.
DEPTH OFFSET
The depth sounder can be placed somewhere on the
hull that gives another depth than the desired depth.
You can then add or subtract a distance so that the
display shows the depth from, for example, the lowest
point on the boat, or from the surface.
Adjust the depth offset value by turning the NAVIGATION WHEEL. The value can be adjusted at a resolution of 0.1 m or 1 ft.
Once adjustment value is reached, the data is stored
by pushing NAVIGATION WHEEL.
Depth alarm pop-up
The depth alarm pop-up will appear when the depth
is less than the depth alarm setpoint. The pop-up
shows the actual depth.
Acknowledge depth alarm by pushing NAVIGATION
WHEEL.
The depth alarm pop-up will re-appear every 30 seconds until the depth increases and exceeds the depth
alarm setpoint.
Depth alarm (extra optional)
All depth alarm functions are accessed through this menu. A multisensor needs to be installed.
Depth alarm signal loss
If the depth alarm is enabled and the depth signal is
lost, for instance in the case of sensor malfunction,
the depth alarm signal loss pop-up will appear.
Depth sounder
Waterline
Lowest point
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Instruments
Select units and language
Choose which units and languages to display.
NOTE! Language and unit settings must be performed in all EVC system tachometers.
US or METRIC
1. Activate helm station by pushing the ACTIVATION
BUTTON.
2. Select SETTINGS from MAIN MENU by turning NAVIGATION WHEEL. Push NAVIGATION
WHEEL to enter SETTINGS MENU.
3. Select UNITS and push NAVIGATION WHEEL.
4. Select US OR METRIC and push NAVIGATION
WHEEL.
5. Set US or METRIC units by turning NAVIGATION
WHEEL and confirm by pushing NAVIGATION
WHEEL.
DISTANCE
1. Activate helm station by pushing the ACTIVATION
BUTTON.
2. Select SETTINGS from MAIN MENU by turning NAVIGATION WHEEL. Push NAVIGATION
WHEEL to enter SETTINGS MENU.
3. Select UNITS and push NAVIGATION WHEEL.
4. Select DISTANCE and push NAVIGATION
WHEEL.
5. Set distance unit: km, nm or miles and confirm by
pushing NAVIGATION WHEEL.
LANGUAGE
1. Activate helm station by pushing the ACTIVATION
BUTTON.
2. Select SETTINGS from MAIN MENU by turning NAVIGATION WHEEL. Push NAVIGATION
WHEEL to enter SETTINGS MENU.
3. Select SEL LANGUAGE and push NAVIGATION
WHEEL.
4. Select language and confirm by pushing NAVIGATION WHEEL.
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Instruments
Fuel tank calibration
There are two possible calibration methods for the fuel tank. One approximative, FULL TANK CALIBRATION,
and one more precise, FUEL MULTIPOINT CALIBRATION. A fuel level sender need to be installed.
NOTE! If FUEL TANK CALIBRATION is not shown in SETTINGS MENU, please contact your Volvo Penta dealer.
FUEL MULTIPOINT CALIBRATION
When FUEL MULTIPOINT CALIBRATION is selected, the fuel level sender is calibrated in five equally
divided steps; 20% full (pos 1), 40% full (pos 2), 60%
full (pos 3), 80% full (pos 4) and 100% full (pos 5)
NOTE! To perform multipoint calibration, fuel tankTo perform multipoint calibration, fuel tank
must be LESS than 20% full. If calibration skips POS
1 and goes directly to POS 2, the fuel tank contains
to much fuel and the calibration will not be correct.
1. Activate helm station by pushing the ACTIVATION BUTTON.
2. Select SETTINGS from MAIN MENU by turning NAVIGATION WHEEL. Push NAVIGATION
WHEEL to enter SETTINGS MENU.
3. Select FUEL TANK CALIBRATION and push
NAVIGATION WHEEL.
4. Select FUEL MULTIPOINT CALIBRATION by
turning NAVIGATION WHEEL. Push NAVIGATION WHEEL to enter FUEL MULTIPOINT CALIBRATION.
NOTE! The fuel multipoint calibration procedure differs depending on EVC software release.
5A. If the number after “POS” in the display is flashing:
Fill fuel tank with displayed volume (POS 1) and
push NAVIGATION WHEEL. Add fuel (do not reset
the pump) up to displayed volume for each POS
until the tank i filled.
Push BACK BUTTON to return to SETTINGS MENU.
5B. If the number after “POS” is not flashing:
Fill fuel tank with displayed volume (POS 1) and
push NAVIGATION WHEEL. Repeat procedure
for each POS until the tank is filled.
Push BACK BUTTON to return to SETTINGS MENU.
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Instruments
FUEL FULL TANK CALIBRATION
When FUEL FULL TANK CALIBRATION is selected,
the fuel level sender is calibrated in one step. This
only gives an approximated value of the fuel level.
Therefore all trip data concerning and based on,
remaining fuel volume should be recognized as approximated values only.
1. Activate helm station by pushing the ACTIVATION BUTTON.
2. Select SETTINGS from MAIN MENU by turning NAVIGATION WHEEL. Push NAVIGATION
WHEEL to enter SETTINGS MENU.
3. Select FUEL TANK CALIBRATION and push
NAVIGATION WHEEL.
4. Select FUEL FULL TANK CALIBRATION by turning NAVIGATION WHEEL. Push NAVIGATION
WHEEL to enter FULL TANK CALIBRATION.
4. Fill fuel tank and push NAVIGATION WHEEL.
Push BACK BUTTON to return to SETTINGS MENU.
Fuel alarm pop-up
The fuel level alarm pop-up will appear when the fuel
level is lower than fuel alarm setpoint. The pop-up
shows the percentage of fuel remaining.
Acknowledge fuel alarm by pushing NAVIGATION
WHEEL.
Fuel level alarm pop-up will re-appear every 10
minutes until the fuel level in tank is higher than fuel
alarm setpoint.
Fuel level signal loss
If the fuel level has been set and the fuel level signal
is lost, for instance in the case of sensor malfunction,
the fuel level alarm signal loss pop-up will appear.
Approximated trip data
This pop-up will be shown every time after start-up ifstart-up ifif
FUEL FULL TANK CALIBRATION is performed.
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Instruments
Speed factor
The speed factor for the boat´s paddle wheel speed
sensor can be adjusted at a resolution of 1% and is
used by the EVC to apply a correction to the output
from the speed sensor.
Set speed factor
Set speed factor while driving the boat. Compare
displayed speed with speed data from GPS (or other
boat) and adjust the speed factor until they correspond.
Adjust the speed factor by turning the NAVIGATION
WHEEL.
Once adjustment value is reached, the data is stored
by pushing NAVIGATION WHEEL.
Information message
Start attempt with gear engaged
The engine control lever must always be in neutral
before starting. If not, this pop-up will be shown.
Approximated trip data
This pop-up will be shown every time after start-up ifstart-up ifif
FUEL FULL TANK CALIBRATION is performed.
Retrieving faults
The EVC system is retrieving faults from its nodes.
Monitoring mode (inactive station)
An inactive station can show system information.
Push MULTIFUNCTION BUTTON on the inactive station.
It is possible to navigate the menus when in monitoring mode.
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Instruments
EVC System Display (extra
optional)
Introduction
Volvo Penta EVC system display is an instrument
which displays operating information about the engine and allows you to communicate with the engine’s
electrical system.
Operation information is shown on an LCD display.
The driver can select the display mode operative on
the display with the aid of the five buttons on the front
of the instrument.
The four buttons at the furthest left are used to display operating information in different ways. The button at the furthest right is used to adjust the display
contrast and to access the so-called configuration
menu. Various settings etc. can be done in it. You can
also use the configuration menu to reach the display
mode SYSTEM INFORMATION (which can also be
reached via button 2, please refer to the schedule
below). This display mode functions in the same way
as the display in the tachometer (EVC System Tachometer).
Before the display is used, it may be necessary to
modify the way that the display shows operating information, to comply with user requirements. You can
see the settings that can be changed in the section
about the configuration menu.
Structure of the display functions
Button 1
Engine
(10 different
fuel information)
Button 2
Multi
(display in
several windows)
Button 3
Trip
Button 4
Graph
(display as
graphs)
Fuel
consumption/time
Fuel
consumption
Trip
fuel
consumption
Numerical
display
Instrument
display
Zeroing
of trip information
Button 1 depressed
Button 2
depressed
Button 4 depressed
Graph
display 1
Graph
display 2
Graph
display 3
Button 5
Contrast/Configuration
Button 5
depressed for > 3 sec
Button 5
depressed
1
2
3
4
5
Contrast
Button 3 depressed
Keep button
3 depressed
for 3 sec.
Trip info.
Configuration menu
- System information
- Settings
- System
System information
More fuel info. available
More displays available
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Instruments
Display after starting screen
Display mode ENGINE (button 1) is always shown
after the starting screen when the display is first started up (more information about this display mode can
be found below in the instructions). Once the display
has been used, it will always show the display mode
when it starts up, that was selected when the display
was last switched off.
Figure for single engine
installation
Figure for twin engine
installation
Connection fault
If the display does not register transfer of operating
information from the electrical system, the pop-up
window will flash CONNECTION LOST When operating information has been registered/reset, the popup window disappears.
Start image
This is the starting image that is shown on the display
for a brief period after starting.
If the unit gives a constant audible warning after starting, the self-test has failed. The unit will still work, but
may behave in an unexpected manner.
Symbols for operating information
Turbocharge pressure (current)
Induction air temperature
Exhaust temperature
Voltage
Oil pressure, reverse gear
Oil temperature, reverse gear
Fuel level
Differential pressure, oil filter
Engine speed
Coolant temperature
Engine temperature
Fuel pump pressure
Oil pressure
Coolant temperature
Speed
Fuel consumption/time
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Instruments
Set display contrast
Press button 5 (furthest right) to set display contrast.
Then press the appropriate buttons to adapt the levels, then save the settings by pressing EXIT. The
display unit has 5 contrast settings.
Configuration menu (button 5)
(depressed for longer than 3 s)
The configuration menu is used to:
- access the display mode SYSTEM INFORMATION.
- do various settings for the display.
- reach information and functions for servicing the
display.
Please refer to the configuration menu structure below and read the following section, which explains
each section in the menu.
Note! The port engine or both engines must have the
ignition switched on when display settings are changed.
Configuration menu structure
System
Information
Language (8 available)
Bleep ON, OFF
Engine PORT, STARBOARD
TWIN, SINGLE
Engine series D1/D2, >D2
Settings GLOBAL, LOCAL
Display
Units
Settings
System
Engine [2500 rpm: 9000 r/min] in stages of 500 rpm
Speed On, off
Speed [10 KNOT: 100 KNOT] in stages of 10 (in appropriate units)
Graph interval 2MIN, 10MIN, 30MIN, 60MIN, 2 H, 4 H, 8 H
Read more about this display mode
on the next page
Speed Knots, mph, km/hr
Distance NM, Miles, km
Oil pressure kPa, psi
Turbo pressure kPa, psi
Fuel consumption Liter/hr, Gal(US)/hr, IGal/hr
Temperature degrees C, degrees F
Volume Liter, Gal(US), Imperial Gallons
Depth (std distance) m, ft
Menu SYSTEMis for service technicians
The UNITS menu is
only available if LOCAL
has been selected in
the menu SETTINGS
Demo
Com Viewer
Prog. tx
About
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Instruments
Settings
Menu SETTINGS is used to do various settings for
the display.
- Language: This is where you select the language
that the display should use (8 different languages
are available).
- Bleep: This is where you select whether a beep
should be heard when any button is depressed.
ON/OFF.
- Engine: This is where you select the engine for
which operating data will be displayed. SINGLE,
PORT, STARBOARD or TWIN.
- Engine series: This is where you select the engi-
ne for which the display has been installed D1/D2,
>D2. The display is pre-set for use with engines
larger than D2.
Display mode System Information
SYSTEM INFORMATION is a display mode that
functions in the same way as the display in the tachometer (EVC System Tachometer). You navigate round
these functions, using the buttons on the free-standing control panel.
In display mode SYSTEM INFORMATION there are
several functions:
- Display of operating information, information messages and alarm (note! The display is adapted to
suit the size of the panel in the tachometer).
- Settings for displaying operating information in this
display mode.
- All calibrations.
Detailed instructions for the functions in display mode
SYSTEM INFORMATION are found in the section
about the tachometer in this owner’s manual .
Information message and alarm
The display automatically switches to display mode
SYSTEM INFORMATION when the electrical system needs to show information messages or alarms.
Instructions about how information messages and
alarms should be handled are found in the section
about the tachometer and in the section ”In case of
emergency” in this owner’s manual.
SYSTEM INFORMATION display mode for
twin engine installations
Control panel
SYSTEM INFORMATION display mode for single engine installations
Alarm example
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Instruments
- Display: This is where you set the measurement
intervals of the speedometers and tachometers.
Rpm engine: [2500 rpm: 9000 r/min] in stages of
500 rpm
- Speed: Change speed display (on/off)
- Speed: [10 KNOT: 100 KNOT] in states of 10 (in
the appropriate speed intervals)
- Graph interval: 2 MIN,10 MIN, 30 MIN, 60 MIN,
2 H, 4 H, 8 H
- Units: (This menu is only displayed if LOCAL has
been selected in menu SETTINGS). This is where
you select the measurement units to be used to
display operating information. (GLOBAL is preset, which means that the units of measurement
are pre-set, but they can be changed if LOCAL is
selected in menu UNITS).
- Speed: KNOT, MPH, KM/H
- The distance is adjusted to suit the speed unit:
NM, MILE, KM
- Oil or Turbo pressure: kPa, PSI
- Volume: LITER, GAL, Imperial GAL
- Fuel consumption / time: is adjusted to suit the
volume unit: L/H, GAL/H, IGAL/H
- Temperature: °C (CELSIUS), °F (Fahrenheit)
System
Menu SYSTEM is intended to provide the necessary
functions and information for service technicians.
- Demo: Switches between demo mode ON/OFF
The unit is in normal operation mode when Demo
is OFF.
- Com Viewer: Shows the latest messages recei-
ved on the communication inputs
- Prog tx: Transfers the contents of the application
program in the flash memory to other CANtrak
units on the same CANbus link
- About : Shows the following information:
ID no: Display serial number
Eeprom: No. of writes to the EEPROM
Vers: Software version number
Chk: Flash memory checksum
Part no: Volvo’s part number for the software
Source: Shows the source of the received data
Label: Label allocated on the bus. Each unit on
the same bus must have its own unique label
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Instruments
Menu, trip computer
Fuel consumption (L/N.M.) -
If information about speed is available > 2 knot
Trip fuel consumption (L)
Button 1
Changes display each time the button is pressed
Remaining fuel (until the tank is empty) ( L) –
If there is a tank sensor
Trip hours (hr)
Remaining distance (until the tank is empty) (L) –
If there is a tank sensor
Trip fuel consumption/time (L/hr)
Remaining time (until the tank is empty) (hr)
Fuel consumption/time (L/hr)
Trip distance (N.M)
Figure for twin engine installation
Figure for single engine installation
Display mode Engine (Button 1)
This display mode shows the engine speed and boat
speed in the form of standard instruments, together
with a trip computer and fuel level gauge. The fuel
level gauge are displayed if there is a tank sender
installed.
Note! Trip information is only displayed if following
are installed:
- Multisensor or NMEA 0183/NMEA 2000 compa-Multisensor or NMEA 0183/NMEA 2000 compatible component (plotter, GPS, paddle wheel etc)
- Fuel level sender
- Software for trip computer (order and download
from VODIA website)
The trip computer shows various types of information
if you repeatedly press the button ENGINE (ENGINE)
(button 1). Please refer to the trip computer menu
below.
Note! Only metric values are displayed, but other
units can be displayed if they have been chosen in
the configuration menu.
The scale values for maximum engine speed and
maximum speed can be set in the configuration
menu.
If information about boat speed is not available, the
display shows coolant temperature instead.
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Instruments
Display mode Multi (button 2)
This display mode shows operating information in
four different windows (see below). The user can
choose the operating information to be displayed in
each window.
The information can be displayed as figures or as
standard instruments. Display indication shifts between the two modes when you press button 2 repeatedly.
If an item of operating information is not available, the
unit displays ”—” and the analogue gauge needle is
not shown.
From this display mode MULTI , you can also reach
display mode that functions in the same way as the
smaller display in the tachometer. Read more about
this display mode SYSTEM INFORMATION in the
configuration menu section.
Set the appearance of the display mode Multi
Display mode MULTI has a mode to set the operating
information to be displayed in each window.
The setting mode is reached by pressing button 5
(furthest right), when you are in the display mode
MULTI. Please refer to the illustrations below.
Note! The type of operating information available
depends on the electrical system in the boat and the
sensors that the boat is equipped with. Optional sensors include depth gauge, water temperature, speed,
trim angle and rudder angle.
Note! This applies to the graphic display:
The maximum engine speed range can be set on the
configuration menu.
The voltage interval can be [8V: 16V] or [16V: 32V]
and is changed automatically, depending on the latest data value.
Example of display in several windows for
twin engine installation
Example of display in several windows for
single engine installation
Press button 5 to choose setting mode
Buttons 1 to 4 are used to adjust the corresponding window
(please refer to the black markings)
Figure for single engine
installation
Figure for twin engine
installation
Figure for twin engine
installation
Figure for single engine
installation
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Instruments
Window with curve for single engine installation
(shows engine speed)
Window with curve for twin engine installation
(shows engine speed)
Figure for single engine installation
Figure for twin engine installation
Display mode Graph (button 4)
In this display mode, operating information is displayed in the form of a histograph. Press button 4 repeatedly to show different operating information.
If an item of operating information is not available,
that window can not be chosen.
If contact with the relevant information is lost during
display, the curve will no longer be drawn, but the line
will continue to scroll across the window.
Data for the port engine or single engine information
is drawn with a black line.
Data for the starboard engine information is drawn
with a gray line.
The maximum time interval can be set to one of the
following values in the configuration menu: 2 min, 10
min, 30 min, 1 h, 2 h, 4 h, 8 h.
The interval on the Y axis is automatically adjusted
for best indication.
Display mode Trip (button 3)
This display mode shows:
- Fuel used after last zeroing
- Instantaneous fuel consumption (amount of fuel
used per hour) (If speed information is available,
instantaneous fuel consumption can also be calculated in relation to distance.)
- Operation time after last zeroing
- Total operating time (can not be zeroed)
If you want to zero the trip values (trip fuel consumption and trip operating time), keep button 3 depressed for 1 second. The unit beeps and the values are
zeroed.
Note!
When the display is set for a twin engine installation,
the information displayed for each engine will be
the sum of the values from both engines, apart from
operating time. Operation times for twin engines are
shown separately.
The size of the operating hours figures shown on the
display is reduced if the number does not fit in the
window.
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35
Controls
This chapter describes the instrument panels sold by Volvo Penta for your engine. If your boat is equipped with
controls which are not described here and you feel uncertain about the function, please contact the dealer you
purchased the boat from.
Disengaging the shift function
The shift function can be disengaged so that the control lever only affects the engine speed.
1. Move the lever to the neutral position (N)
2. Press the neutral button (N) in and hold it down
while moving the control lever forward to the shift
position (F).
3. Release the neutral button. The green indicator
begins to flash to acknowledge that the shift function is disengaged.
The lever now only controls engine speed.
When the lever is moved back to the neutral position
it will automatically re-engage. This is confirmed by
the green indication which gives constant light.
WARNING! Take care not to engage the rever-
sing gear/stern drive unintentionally.
Single lever control. Electronic
Operation
Both the shift function and engine speed control are
controlled using the single lever control.
N = Neutral position (reverse/stern drive is disenga-
ged and the engine runs at idle speed).
F = Reversing gear/stern drive engaged for move-
ment ahead.
R = Reversing gear/stern drive engaged for move-
ment astern.
T = Adjustment of engine speed.
NOTE! The engine can only be started if the Control
lever is in the neutral position.
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36
Controls
Friction brake
The control is also equipped with a friction brake which
can be adjusted for easier or stiffer lever movement as
necessary.
Friction brake adjustment:
1. Stop the engine.
2. Move the control lever forwards to make the groove
in the control lever hub accessible.
3. Put a screwdriver in the groove and disassemble
the plug.
4. Adjust the friction brake (spanner size 8 mm):
Clockwise = stiffer lever movement
Anti-clockwise = easier lever movement
5. Install the plug.
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37
Controls
Two lever control. Mechanical
Operation
The two lever control has separate levers for shifting
(1) and speed control (2).
The control has a neutral position switch that only allows the engine to be started with the reversing gear
in neutral.
Black lever (1):
N = Neutral position. Reversing gear is disengaged.
F = Reversing gear engaged for movement ahead.
R = Reversing gear engaged for movement astern.
Red lever (2):
Engine speed control.
A
B
A
Friction brake
The control has an adjustable friction brake for speed
control.
Adjust the friction brake by turning the screw (control
A) or lever (control B).
Turn clockwise (+) for heavier lever movement or
anti-clockwise (–) for lighter lever movement.
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38
Starting the engine
Make it a habit to give the engine and engine bay a visual check before starting. This will help you to discover
quickly if anything abnormal has happened, or is about to happen. Also check that instruments and warning displays show normal values after you have started the engine.
To minimize starting smoke in cold starting, we recommend that a heater should be installed to warm the engine
bay at temperatures below +5°C.
WARNING! Never use start spray or similar products as a starting aid. Explosion risk!
Before starting
● Open the fuel tap
● Open the sea cock (reverse gear)
● Do the tasks under the “Daily before first start”
heading in the maintenance schedule.
● Turn the main switches on.
IMPORTANT! Never disconnect the current
with the main switches when the engine is
running. This can damage the alternator.
● Start the engine bay fan, if one is installed, and let
it run for at least four minutes.
● Check that the amount of fuel aboard is enough
for your planned voyage.
General information about starting
The engine control lever must always be in neutral
before starting. The engine management system ensures that the engine receives the correct amount of
fuel - even when the engine is cold.
The idling speed is also governed by engine temperature, and is somewhat raised after a cold start.
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39
Starting the engine
Starting method
Put the reversing gear in neutral
Put the reversing gear in neutral by moving the control lever(s) to neutral at all control positions.
Two lever control: Also check that the engine
speed lever is in the idling position.
Turn the ignition on
Turn the starter key to position I to switch the ignition on.
Check the warning lamps and LEDs
Each time the ignition is turned on, all bulbs and
LEDs are illuminated on the main control panel.
Check that all bulbs and LEDs function.
If the boat has more than one control panel, the
lamps on the other panel(s) are not checked until the
control panel(s) is(are) activated.
Activate the control position and lock the
system.
Press the activation button for at least one second.
When the button is released, the indication lights up
to confirm that the control position is activated.
NOTE! If the indicator flashes, the control position
has not been activated because the control lever(s)
are not in the neutral position or the system has been
locked from another control panel.
If the boat has more than one control panel, the system can be locked, so that the engine can only be
controlled from the activated control board. Press the
activation button for a further second to lock the system. The padlock sign lights up in confirmation.
Unlock the system by pressing the activation button
for one second. This can only be done from an activated control panel.
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40
Starting the engine
Start the engine
Start using the ignition switch
Turn the key to position III. Release the key and let it
key spring back to position I as soon as the engine
has started.
NOTE! If repeated start attempts are needed, the
key must be turned back to position 0 first.
Starting with the starter button
Press the starter button. Release the button as soon
as the engine has started. Please note that if you
start from an alternative control station, the starter
key at the main control station must be in position I.
Overheating protection
If the starter motor is engaged for its maximum activation time (30 seconds), the starter motor circuit
is cut automatically to protect the starter motor from
overheating. Leave the starter motor to cool for at
least five minutes (if possible) before making a new
start attempt.
Read the instruments and warm the
engine up
Allow the engine to idle for the first ten seconds, and
check that instruments and warning displays show
normal values. Check that no alarms are displayed
and that no warning lamps are flashing.
Then warm the engine up at low speed and low load,
so that reaches normal operating temperature before
full power is used.
IMPORTANT! Never race the engine when it is
cold.
Check the oil level in the reverse gear
Check the oil level when the reversing gear has
reached operating temperature (please refer to the
description in the “Maintenance” chapter under the
“Reversing Gear” heading)
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41
Operation
Learn to handle the engine, controls and other equipment in a safe and correct manner before you cast off on
your maiden voyage. Remember to avoid sudden or surprising rudder movements and gear shifting. There is a
risk that passengers could fall over, or overboard.
WARNING! A rotating propeller can cause severe injury. Check that there is nobody in the water before
you engage forward / aft drive. Never drive close to bathers or in areas where you could reasonably expect
that people could be in the water.
Reading the instruments
Read all instruments and alarm displays directly after
starting, and then regularly during your voyage.
Oil pressure
The oil pressure gauge should normally indicate
between 4-5.5 bar. It will indicate a somewhat lower
value when idling.
If the oil pressure is too low, the audible warning will
sound automatically at the same time as the lamp in
the warning display will flash.
Coolant temperature
The temperature gauge should normally indicate between 75– 95°C (167-203°F) in normal operation.
If the coolant temperature is too low, the audible warning will sound automatically at the same time as the
lamp in the warning display will flash.
Charging
During operation, system voltage should be about 28
V for 24 Volt system voltage.
If there is a charge failure, the audible warning will
sound automatically at the same time as the lamp in
the warning display will flash.
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42
Operation
Alarm
If a fault occurs, the audible warning will sound and
the relevant warning lamp on the alarm panel will
start to flash and the display will show a alarm pop-up.
1. Reduce engine speed to idling.
2. Acknowledged the larm by pressing the naviga-
ton wheel on the control panel once.
When the fault has been acknowledged, the lamp
concerned gives constant light and the audible warning will become silent.
Please refer to the “In case of emergency” chapter,
and you will find detailed information about recommended action in the “Diagnostic function” section.
The fault will also be stored in the form of a fault code
for as long as the malfunction remains. It is possible
to read the fault code during a subsequent service.
Cruising speed
Avoid operation at full throttle, for best fuel economy.
We recommend a cruising speed which is at least
10% below the maximum engine speed at full speed
(full throttle). The maximum engine speed will vary
due to propeller choice, load and sea conditions, but it
should be in the full throttle range.
Full throttle range:
D12D-C MH rating 1 .......... 1800–1850 rpm.
rating 2 .......... 1900–1950 rpm.
If the engine does not reach the full throttle range,
this could be caused by a number of factors which
are noted in the “Fault tracing” chapter. If the engine
speed exceeds the full throttle range, select a coarser pitch propeller. Ask your Volvo Penta dealer for
advice.
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43
Operation
Synchronizing engine speed
When driving with twin engines, both the operating
economy and comfort will be increased when the
engines are operating at the same engine speed
(rpm).
When the synchronization function is activated, the
engine speed (rpm) of the starboard engine is automatically adjusted to that of the port engine. The
synchronization function is activated automatically if
the following conditions are met.
1. The engine speed levers for both engines are in
(approximately) the same position.
2. The engine speed on both engines must exceed
800 rpm.
NOTE! The synchronizer is disengaged as soon as
the conditions are no longer met.
1
Changing the helm station
The first time you change control panel after starting
the EVC system, a bulb check is done automatically.
All LEDs and bulbs light up for 2 seconds.
1. Check that the control lever(s) is (are) in neutral
on both the control panel you leave and on the
new control panel.
2. Check that the EVC system is not locked.
3. Press the activation button (1) for at least one se-
cond. When the button is released, the indication
lights up to confirm that the control position is activated.
4. Press the activation button (1) for a further second
to lock the EVC system. The padlock sign lights
up in confirmation. Unlock the system by pressing
the activation button for one second. This can only
be done from an activated control panel.
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44
Operation
Changing helm station while cruising
(optional)
This function must be enabled to permit the control
panel to be changed during operation. The function
can only be enabled by authorized Volvo Penta personnel. Please contact your Volvo Penta dealer.
1. Press the activation button (1) to unlock the system. The padlock sign goes out on all control panels to indicate that it is possible to change control
panel.
2. The control lever on the alternative control panel
must be in neutral before it is possible to change
control panel.
3. Press the activation button (1) on the alternative
control panel. The activation button indication flashes on the alternative control panel, and on the
main control panel it gives constant light.
4. The alternative control panel becomes active
when the correct gear and approved engine
speed is demanded. The activation button (1) gives constant light to confirm that the control panel
is activated. The system is now locked, which is
indicated by the padlock sign, which lights up.
NOTE! If the correct gear or engine speed is
not demanded within 15 sec, the system ramps
engine speed down to neutral and the gearbox
engages neutral.
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45
Operation
Operation
Shifting between forward and reverse should be done
at idling. Shifting at higher engine speeds can be uncomfortable for passengers and cause unnecessary
stress on the stern drive/reversing gear, or cause the
engine to stop.
If you attempt to shift gear at an excessive engine
speed, a safety function cuts in automatically, and
delays shifting until engine speed has fallen to 1000
rpm.
Always do a forwards/reverse operation as follows:
1. Reduce engine speed to idle and let the boat
more or less lose way.
WARNING! Never shift to reverse when the
boat is planing.
2. Move the control lever to neutral with a rapid, dis-
tinct movement. Make a brief pause.
NOTE! A beep will sound to indicate that the con-
trol lever is in neutral.
3. Then move the control lever to reverse with a
rapid, distinct movement and increase engine
speed.
IMPORTANT! If the boat has twin engines,
it is important that both should be running
during reversing maneuvers, to avoid the risk
of water entry (via the exhaust pipe) into the
stationary engine.
1
2
3
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46
Operation
Lowspeed (option)
The Lowspeed function is only available for engines
with hydralic reverse gear.
For boats with powerful engines, where the boat
speed at idle is too high, Lowspeed is used to reduce
boat speed by reducing propeller rpm - compared to
normal at engine idle speed.
N = Neutral idling (reverse gear disengaged, engine
runs at idle speed)
F = Forward idling (reverse gear engaged for move-
ment ahead, engine runs at idle speed), maximum slip in reverse gear.
R = Reverse idling (reverse gear engaged for move-
ment astern, engine runs at idle speed), maximum slip in reverse gear.
A = Lowspeed active. Propeller rpm is increased with
increase of throttle, engine rpm is not affected.
B = Lowspeed deactivated. Propeller rpm is in-
creased with engine rpm, engine rpm will increase with throttle.
Engaging Lowspeed
1. Move the lever to neutral position.
2. Press the neutral button (N) to activate
Lowspeed. When Lowspeed is engaged a pop-up
(A) is shown on the tachometer display. It is possible to acknowledge pop-up by pushing NAVIGATION WHEEL.
3. Active Lowspeed is indicated by an icon, , on
the tachometer display (D).
IMPORTANT! If Lowspeed initializing pop-up (B)
and then icon, , are shown on the tachometer display (C), Lowspeed is not ready to use.
Normal gear shifting until Lowspeed is activated
(D).
IMPORTANT! Delay in gear shifting may occur
when Lowspeed is active.
Disengaging Lowspeed
1. Move the lever to neutral position.
2. Press the neutral button (N) to deactivate
Lowspeed. A pop-up (E) is shown on the tachometer display. It is possible to acknowledge popup by pushing NAVIGATION WHEEL.
3. The indication in tachometer display goes out.
Lowspeed activated - Function
active.
Lowspeed initializing - Lowspeed is not ready to use.
(Twin disc)
Pop-up when initializing Lowspeed - Lowspeed is not ready
to use.(Twin disc)
Pop-up when Lowspeed is
engaged. It is possible to acknowledge pop-up by pushing
NAVIGATION WHEEL.
Pop-up when Lowspeed is disengaged. It is possible to acknowledge pop-up by pushing
NAVIGATION WHEEL.
(A)
(B)
(C)
(D)
(E)
Page 49
47
Operation
Trolling (option)
The Trolling function is only available for engines with
hydralic reverse gear.
Trolling requires two control levers, one for throttle/
gear, and the other to control the slip function. Trolling
makes it possible to use higher engine power without
increasing boat speed.
WARNING! If engine speed exceeds the maxi-
mum permissible engine speed for trolling (approx. 1000 rpm, depending on reverse gear), the
EVC system automatically disengages trolling
and full propeller effect returns. Depending on
the position that the control lever is in when automatic disengagement occurs, the boat speed
can increase rapidly.
Operation
Move the throttle/gear lever to a position where the
engine speed is within the permissible engine speed
range and move the slip control lever to a slip position. Active Trolling is indicated by an icon, on the
tachometer display (B).
IMPORTANT! If Trolling initializing icon, , is
shown on the tachometer display (A), Trolling is
not ready to use. Normal gear shifting until Trolling is activated.
NOTE! At maximum slip there is no propeller effect.
Move the slip control lever to minimum slip position to
deactivate Trolling. The indication in the tachometer
display goes out.
IMPORTANT! Delay in gear shifting may occur
when Trolling is active.
Trolling initializing - Trolling is
not ready to use. (Twin disc)
Trolling activated - Function
active. Slip control lever in slip
position.
(B)
(A)
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48
Operation
Propeller shaft brake
In certain conditions, the propeller can make the propeller shaft rotate when the engine is stopped. This
parasitic rotation is uncomfortable, and can damage
the reversing gear since its oil pump, which is driven
by the input shaft, is stationary together with the
engine.
The propeller shaft can be permitted to rotate with
a stationary engine for up to 6-8 h. After this, the
engine must be started and run for at least 5 min to
lubricate and cool the reversing gear.
If the shaft is likely to rotate faster than in normal
operation, such as when sailing, a temperature gauge should be installed to monitor the oil temperature.
Maximum permissible temperature is 95°C for the ZF
reversing gear.
When the above-mentioned rules can not be met,
or if you want to stop the shaft for comfort reasons,
a shaft brake has to be installed. On isolated occasions, the propeller shaft flange can be locked mechanically by some suitable means.
Page 51
49
Operation
Extra equipment
Disengageable clutch
The clutch is disengaged when the lever is in position
(N) and engaged in position (F)
IMPORTANT! The engine speed must not ex-
ceed 800 rprm when engaging and disengaging.
The clutch should be given extra attention during the
first period of operation. Adjustment may be required
to compensate for disc wear. Refer to “Maintenance:
Accessories” when adjusting.
Flush and bilge pump
The bilge pump has a vacuum switch (1) that automatically disengages the pump when water is no longer being drawn into the pump.
The flush and bilge pump are engaged and disengaged from a switch that is normally located at the
main control position. The bilge pump can also be engaged manually by holding down the lever 2 for about
20 seconds.
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50
Stopping the engine
Stop
1. Disengage the reversing gear by putting the con-
trol lever in neutral.
2. Turn the key to stop position “S”. Keep the key
turned until the engine stops. The key will automatically return to the “0” position when it is released and can then be removed.
IMPORTANT! Never switch off the main swit-
ches while the engine is running. This could damage the alternator.
IMPORTANT! Never switch off the main swit-
ches before the starter key is turned off (is in
“0” position or removed). This could damage the
electrical system.
After stopping
● Check the engine and engine bay for leakage.
● Shut off the fuel taps and sea cocks.
IMPORTANT! Do not forget to open the taps
next time the engine is started.
● Read off the hours counter and do preventive
maintenance as in the maintenance schedule.
● Turn off the main switches before any long stopp-
age.
IMPORTANT! Never switch off the main swit-
ches before the starter key is turned off (is in
“0” position or removed). This could damage the
electrical system.
Allow the engine to idle (in neutral) for at least three minutes after the end of your journey. This evens out the
temperatures inside the engine, and stops after-boiling.
IMPORTANT! The above is particularly important if the engine has been driven at high speed and/or hea-
vily loaded.
Auxiliary stop
If a fault occurs that prevents you stopping the engine in
the normal way, you can stop it by pressing the emergency button.
If the engine has been stopped using the emergency
stop button, the button locks in the down position. In
order to be able to restart the engine, the button must
be reset to its original position. To do this, pull the
button upwards until you hear a click.
WARNING! Working with, or going close to a
running engine is a safety risk. Watch out for rotating components and hot surfaces.
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51
Stopping the engie
Cold weather precautions
If the engine bay can not be kept frost-free, the seawater system must be drained and the freshwater
system coolant must have enough anti-freeze to prevent frost damage. Please refer to the “Seawater system” and “Freshwater system” maintenance chapters.
WARNING! If the engine bay can not be kept
frost-free, the seawater system must be drained.
Frost damage in the seawater system can make
the boat sink.
IMPORTANT! If the coolant does not have suf-
ficient frost protection, this can cause expensive
engine damage. Check the battery charge. A
poorly charged battery can freeze and burst.
Laying up
If the boat is not used, but left in the water, the engine must be warmed up at least once every fortnight.
This prevents corrosion damage in the engine.
IMPORTANT! If you expect the boat to be unu-
sed for two months or more, it must be laid up:
Please refer to the Laying up chapter.
Page 54
52
MAINTENANCE SCHEDULE
WARNING! Before you start to do any maintenance work, read the “Maintenance”
chapter carefully. This contains instructions for doing work in a safe and correct manner.
IMPORTANT! When both operation and calendar time are specified, do the mainte-
nance job at the interval which is reached first. Maintenance points marked must
be done by an authorised Volvo Penta workshop.
Daily, before first start
● Engine and engine bay. General inspection .................................................. page 54
● Air filter indicator. Inspection
1)
...................................................................... page 55
● Engine oil. Check level ................................................................................... page 58
● Coolant. Check level ...................................................................................... page 63
● Fuel filter. Drain water/contamination ........................................................... page 71
● Reverse gear. Check oil level (after starting) ................................................. page 81
1)
Change the air filter every 12 months.
After the first 50 hours
● Reverse gear. Oil strainer. Cleaning ............................................................. page 81
● Reverse gear. Oil. Change ............................................................................ page 82
Every 50 hours / at least every 12 months
● Reverse gear. Seal. Lubrication.................................................................... page 82
● Disengageable clutch. Lubrication
1)
............................................................ page 83
Every 50-500 hours / at least every 12 months
● Engine oil Change
2)
..................................................................................... page 58
● Oil filter / Bypass filter. Change
3)
.................................................................. page 60
1)
Applies to release bearing when operated more than 15 times a day. Otherwise, every 500 operating hours.
2)
Oil change intervals vary, depending on oil grade and sulphur content of the fuel. Please refer to page 57.
3)
Change the filters during each oil change.
Maintenance schedule
General information
Your Volvo Penta engine and its equipment are designed for high reliability and long life. They are built to
withstand a marine environment, but also to have the smallest possible environmental impact. If given preventive
maintenance, according to the maintenance schedule, and if Volvo Penta original spares are used, these qualities are retained and unnecessary malfunctions can be avoided.
Warranty inspection
During the first period of operation, the specified warranty inspection “First service inspection” must be done by
an authorised Volvo Penta workshop. Instructions about when and where this should be done are found in the
Warranty and service book.
Page 55
53
Maintenance schedule
Every 250 hours / at least every 12 months
● Fuel pre-filter (twin filter). Inspection
1)
............................................................... page 74
1)
Only applies to the double filter: Check the pressure gauge and change the filter as
necessary every 1000 hours of operation, or at least once every 12 months.
Every 500 hours / at least every 12 months
● Crankcase ventilation. Change filter ................................................................... page 55
● Drive belts. Inspection/adjustment ...................................................................... page 56
● Coolant (corrosion protection mixture). Topping up
1)
........................................ page 63
● Zinc anodes. Change ......................................................................................... . page 67
● Seawater pump. Check/change the impeller ...................................................... page 68
● Batteries. Checking the electrolyte ..................................................................... page 77
1)
Top up with ½ litre corrosion protection fluid. IMPORTANT! This only applies if the
cooling system is filled with a corrosion protection mixture (not a glycol mixture).
Every 1000 hours / at least every 12 months
Valve clearance. Inspection/adjustment...........................................................not shown
● Coolant filter. Change
1)
..................................................................................... page 65
Clean the insert in the heat exchanger and in the reverse gear oil cooler ...... not shown
● Seawater filter. Checking/cleaning
2)
.................................................................. page 68
● Fuel pre-filter. Change filter insert ..................................................................... page 74
● Fuel fine filter. Changing. Venting the fuel system .............................................. page 70
● Reverse gear. Oil strainer. Cleaning ................................................................... page 81
● Reverse gear. Oil. Change .................................................................................. page 82
1)
Not at same time as coolant change.
2)
Adjust the time by experience, after a period of operation.
Every 2000 hours
Turbocharger. Inspection ................................................................................. not shown
Every 12 months
EVC system. Inspection with diagnosis tool .................................................... not shown
Engine and reverse gear. General inspection ..................................................not shown
● Air filter insert. Change ..................................................................................... page 55
● Flushing/Bilge pump. Check the impeller ........................................................ not shown
● Engine and reverse gear. Cleaning/painting .................................................... not shown
Every 24 months
Cooling system Inspection/cleaning ................................................................not shown
Coolant. Change ................................................................................................. page 62
Page 56
54
Maintenance
Engine, general
General inspection
Make it a habit to give the engine and engine bay
a “visual” check before driving before starting the
engine and after operation when you have stopped
the engine. This will help you to discover if anything
abnormal has happened, or is about to happen.
Look especially carefully at oil, fuel and coolant leakage, loose screws, worn or poorly tensioned drive
belts, loose connections, damaged hoses and electrical cables. This inspection only takes a few minutes
and can prevent serious malfunctions and expensive
repairs.
WARNING! Deposits of fuel, oils and grease on
the engine or in the engine bay are a fire hazard
and must be removed as soon as they are discovered.
IMPORTANT! If you discover a leakage of oil,
fuel or coolant, investigate the cause and fix the
fault before you start the engine.
IMPORTANT! Observe the following when
cleaning with a high pressure washer: Never
aim the water jet at seals, rubber hoses or electrical components. Never use a high pressure
washer for engine cleaning.
This chapter contains general technical information and instructions for carrying out the specified maintenance
points. Read them carefully before starting work. The times when maintenance points need to be attended to are
given in the previous chapter: Maintenance schedule
WARNING! Read through the safety advice for care and maintenance work in the Safety information
chapter before you start work.
WARNING! Care and maintenance work should be done with the engine stopped unless otherwise spe-
cified. Stop the engine before opening or removing the engine hatch/hood. Make it impossible to start the
engine by removing the start key and cutting the system voltage with the main switches.
Page 57
55
Maintenance. Engine, general
Crankcase ventilation. Changing the filter
If oil and air begin to find their way out of the overpressure valve (2), change the filters (1) earlier than
recommended.
IMPORTANT! Change both filters at the same
time.
1. Remove the old filters by unscrewing them anticlockwise.
2. Check the rubber seals, change as necessary.
Screw the new filters on by hand.
Air filter. Change
1. If indicator is all red after the engine is stopped,
change the filter..
2. Undo the clamps and remove the lid from the filter housing.
3. Remove the old filter. Be careful to ensure that no
contamination gets into the engine.
4. Install a new air filter and tighten the lid.
5. Reinstate the pressure drop indicator by pressing
in the indicator button.
IMPORTANT! Scrap the old filter. It must not be
cleaned.
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56
Maintenance. Engine, general
Drive belts. Inspection/adjustment
WARNING! Stop the engine before doing any
maintenance work.
General information
Check belt tension and condition regularly. A belt
which is to tense can damage the bearings and a belt
which is too loose can slip.
IMPORTANT! Always change a belt which looks
worn or cracked (belts which operate in pairs
must be changed together).
Alternator belt(s)
The standard alternator, plus the extra alternator if
installed, are driven by a Poly-Vee belt each, for best
function and service life. The belts are tensioned in
the same way.
1. Remove the protective cover over the alternator
drive belt.
2. Undo the inner fixing screw (1) and the lock
screws (2) a couple of turns.
3. Tension the belts with tensioner screw (3). It
should be possible to press the belts down about
5 mm (0.2”) between the pulleys when the tension is correct.
4. Tighten lock screw (2) and the inner fixing screw (1).
5. Install the protective cover over the alternator
drive belt.
Other belts
The flushing and bilge pump etc. are driven by traditional drive belts. In general, it should be possible
to press these belts down 10 mm (0.4”) between the
pulleys when the tension is correct.
When you change a drive belt: Clean the belt grooves
before installing the new drive belt.
Page 59
57
Maintenance. Lubrication system
Lubrication system
Oil change intervals can vary from 50 to 500 hours, depending on oil grade and sulphur content of the fuel. Note
that oil change intervals must never exceed a period of 12 months.
If you want longer oil change intervals than given in the table below, the condition of the oil must be checked by
the oil manufacturers through regular oil testing.
SAE5W/30
−−
−−
−30
−−
−−
−20
−−
−−
−10 ±0 +10 20 30 40
−−
−−
−22
−−
−−
− 4
++
++
+14 32 50 68 86 104
−−
−−
−15oC
SAE15W/40
−−
−−
−25oC
SAE10W/30
−−
−−
−10oC
SAE20W/30
±0oC
SAE30
SAE40
+10oC
o
C
o
F
✱✱
✱✱
✱
Viscosity
Select the viscosity from the table below.
Note. The temperature values refer to stable ambient
temperatures.
* Refers to synthetic or semi-synthetic oils.
Oil change volume
Please refer to the “Technical Data” chapter.
Oil grade
1)
Sulphur content in fuel, by weight
up to 0.5% 0.5 – 1.0% more than 1.0%
2)
Oil change interval: Reached first in operation:
VDS-3 500 hr. or 12 months. 250 hr. or 12 months. 125 hr. or 12 months.
VDS-2 and ACEA E7
4)
or VDS-2 and Global DHD-1 500 hr. or 12 months. 200 hr. or 12 months. 100 hr. or 12 months.
or VDS-2 and API CH-4
or VDS-2 and API CI-4
VDS and ACEA E3
2)
300 hr. or 12 months. 150 hr. or 12 months. 75 hr. or 12 months.
or VDS-2 and API CG-4
3)
NOTE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the quality
requirements above.
1)
When oil quality specifications are joined by ”and” the engine oil must fulfill both requirements.
2)
If sulphur content is > 1.0% by weight, use oil with TBN > 15.
3)
ACEA E7 has replaced ACEA E5, but if available ACEA E5 can be used.
4)
ACEA E3 can be replaced by ACEA E4, E5 or E7.
VDS = Volvo Drain Specification
ACEA = Association des Constructeurs Européenne d’Automobiles
API = American Petroleum Institute
TBN = Total Base Number
Global DHD = Global Diesel Heavy Duty
Page 60
58
Maintenance. Lubrication system
Oil level. Checking and filling
The oil level must be inside the marked area on the
dipstick (1) and should be checked daily before the
first start.
Top up the oil through the filling hole on the side of
the engine (2) . Check that the correct level has been
achieved. But wait a few minutes to allow the oil to
run down into the sump.
IMPORTANT! Do not fill up above the maximum
oil level. Only use a recommended grade of oil
(please refer to previous page).
Engine oil. Change
Always observe the recommended oil change interval.
1. Warm the engine up (this makes it easier to suck
the oil up from the sump). Then stop the engine.
WARNING! Hot oil and hot surfaces can
cause burns.
2. Connect the suction pipe of the oil drain pipe to
the drain pipe. Pump up the oil.
3. Change the oil filter and bypass filter at each oil
change (please refer to the instructions on the
next page).
4. Fill up with oil to the correct level through the filling hole on the side of the engine (please refer to
the “Technical Data” chapter for oil volume).
IMPORTANT! Only use a recommended
grade of oil (please refer to previous page).
5. Start the engine and let it idle. Check that the low
oil pressure warning lamp goes out and that no
leakage occurs by the filters.
WARNING! Working with, or going close to
a running engine is a safety risk.Watch out
for rotating components and hot surfaces.
6. Stop the engine. Wait a few minutes before
checking the oil level. Top up as necessary.
NOTE! Hand the old oil in to a re-cycling station.
Page 61
59
Maintenance. Lubrication system
Switchable oil filters
IMPORTANT! Though possible, the switchable
filters should not be replaced during engine operation other than in case of an emergency
1. Clean the filter bracket.
2. Disconnect the left filter by turning the lever to
the right-hand end position. To unlock the lever,
pull the knob beneath the lever downwards.
3. Unscrew the left-hand oil filter and discard it. Use
a filter wrench if necessary.
4. Check that the mating surfaces on the filter
bracket are clean, and that no traces of the seal
from the old filter remain.
5. Oil the rubber seal for the new filter.
6. Screw the filter on by hand until the rubber seal
just touches the mating surface of the filter bracket. Then tighten the filter a further 3/4 of a turn.
7. Turn the lever to the left-hand end position and
change the right-hand oil filter in the same way.
8. Put the lever in operating position (straight up).
9. If necessary, top up the system with lubrication oil at
first stop. Refer to section “Lubrication oil change”.
Page 62
60
Maintenance. Lubrication system
Oil filter and bypass filter. Change
Change the oil filter and bypass filter during each oil
change.
Remember to hand the old filters in to a re-cycling station.
WARNING! Hot oil and hot surfaces can cause
burns.
1. Put a suitable vessel underneath the filters to
avoid oil spillage.
2. Clean the filter bracket.
3. Unscrew the bypass filter (1) and the oil filters (2)
with a suitable extractor.
4. Check that the mating surfaces on the filter brackets are clean, and that no residue from the old
seals remains.
5. Moisten the seals on the new filters with engine
oil.
6. Screw the filters on by hand until the rubber seals
just touch the mating surface on the filter brackets. Then tighten a further 1/2 to 3/4 turn.
7. Start the engine (low idle) and check that no leak-
Page 63
61
Maintenance. Freshwater system
Fresh water system
The fresh water system is the engines’ internal cooling system, which ensures that the engine operates at the
correct temperature. It is a closed circuit system and must always be filled with a mixture of at least 40 % concentrated coolant and 60 % water to protect against internal corrosion, cavitation and damage caused by freezing.
We recommend that you use “Volvo Penta Coolant, Ready Mixed”, alternatively “Volvo Penta Coolant” (con-
centrated) mixed with pure water according to spec, see “Coolant. Mixture”. Only coolant of this quality is suited
too and approved by Volvo Penta.
The coolant should contain ethylene glycol of a good quality with a suitable chemical consistency for an adequate protection of the engine. Using anti-corrosion aditive exclusively is not permitted in Volvo Penta’s engines.
Never use water by itself as coolant.
IMPORTANT! Coolant must be used all year round. This applies even if there is never any risk for frost , to
ensure that the engine has an adequate protection against corrosion.
Future warranty claims on the engine and additional equipment may be rejected if an unsuitable coolant
has been used or if the instructions concerning coolant mixing have not been followed.
NOTE: The anti-corrosive agents become less effective after a time, which means that the coolant must be replaced, see “Service schematic”. The cooling system should be flushed out at the same time as the coolant is
replaced, see “Cooling system. Flushing”.
“Volvo Penta Coolant” is a concentrated coolant
that is to be mixed with water. It has been developed
to function optimally with Volvo Penta’s engines and
provides excellent protection against corrosion, cavitation and frost damage.
“Volvo Penta Coolant, Ready Mixed” is a readymixed coolant, 40% “Volvo Penta Coolant” and 60%
water. This concentration protects the engine against
corrosion, cavitation damage and freezing conditions
down to -28 °C (-18°F).
Page 64
62
Maintenance. Freshwater system
Coolant. Mixture
WARNING! All glycol is hazardous and harmful
to the environment. Do not consume!
Glycol is flammable.
IMPORTANT! Ethylene glycol must not be
mixed with other types of glycol.
Mix:
40 % “Volvo Penta Coolant” (conc. coolant)
60 % water
This mixture protects the engine against internal corrosion, cavitation and frost damage down to -28 °C
(18°F). (Using 60 % glycol lowers the freezing point
to -54 °C (-65°F)). Never mix more than 60 % concentrate (Volvo Penta Coolant) in the cooling liquid,
this will give reduced cooling effect and increase the
risk of overheating, and will give reduced freezing
protection.
IMPORTANT! Coolant must be mixed with pure
water, use distilled - de-ionized water. The
water must fulfill the requirements specified by
Volvo Penta, see “Water quality”.
IMPORTANT! It is extremely important that the
correct concentration of coolant is added to the
system. Mix in a separate, clean vessel before
adding into the cooling system. Ensure that the
liquids mix properly.
Water quality
ASTM D4985:
Total solid particles ........................................ < 340 ppm
Total hardness:............................................... < 9.5° dH
Chloride ......................................................... < 40 ppm
Sulfate ............................................................ < 100 ppm
pH value ......................................................... 5,5– 9
Silica (acc. ASTM D859) ................................ < 20 mg SiO2/l
Iron (acc. ASTM D1068) ................................ < 0.10 ppm
Manganese (acc. ASTM D858) ...................... < 0.05 ppm
Conductivity (acc. ASTM D1125) ................... < 500 µS/cm
Organic content, CODMn (acc. ISO8467) ....... < 15 mg KMnO4/l
Page 65
63
Maintenance. Freshwater system
Coolant level. Inspection
Note. Coolant level can be checked through a level
glass on top of the expansion tank.
The green float must be visible in the level glass.
WARNING! Never open the pressure cap
when the engine is hot. Steam or hot coolant
can spray out at the same time as the pressure
which has built up is lost.
The coolant level should be about five centimetres (2”)
below the pressure cap sealing plane in the expansion
tank.
If a separate expansion tank is installed, the coolant
level must be between the MAX and MIN markings.
Top up the coolant as necessary, following the description below.
Coolant. Filling
WARNING! Stop the engine and let it cool be-
fore filling. Hot fluids and hot surfaces can cause
burns.
IMPORTANT! Top up with the same type of
coolant as already used in the system.
Topping up
Fill up with coolant to the correct level via the filling hole
on the expansion tank. Fill slowly, to allow the air which
is forced out a chance to flow out of the filling hole.
When you fill up an empty system, or if the coolant
has fallen so low for any reason that it is no longer
visible through the filling hole, fill up as in the description for “Filling a completely empty system”.
Filling a completely empty system
1. Mix a sufficient quantity of coolant in a vessel before filling. Please note that a heating system, tap
water heater etc. if connected to the engine cooling system, mean that a correspondingly greater
amount of coolant will be needed.
2. Open the vent tap by the turbocharger.
3. Also ensure that the heating system, tap water
heater etc. if connected to the engine cooling
system, are also vented (open the heater control
valve).
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64
Maintenance. Freshwater system
F F
F F
1
V
4. Fill up with coolant via the filling hole on the expansion tank.
Fill slowly, to allow the air which is forced out a
chance to flow out of the vent tap(s) and filling
hole.
5. Close the vent tap(s) as and when air-free coolant flows out.
6. Fill up with coolant to about 5 cm (2”) below the
filling cap seal plane.
7. Start the engine and let it idle for about 1 hour.
IMPORTANT! Do not start the engine until
the system is vented and completely filled.
8. Stop the engine and let it cool. Check the coolant
level. Top up as necessary.
Coolant. Draining.
WARNING! Stop the engine and let it cool be-
fore draining. Hot fluids and hot surfaces can
cause burns.
WARNING! Glycol is poisonous (dangerous to
drink). Collect the old coolant and hand it to a
re-cycling station for destruction. Drain the coolant via taps (F).
1. Remove the filling cap (1) from the expansion
tank.
2. Open the vent tap (V) by the turbocharger.
3. Connect a suitable hose to each drain tap. Open
the tap and allow the coolant to drain off into a
suitable vessel.
IMPORTANT! Check that all coolant really
does drain out. Deposits may need to be
cleared away, inside the drain plug(s)/tap(s).
4. Continue with all the drain points until all five
have been opened and all coolant has been
drained off.
5. Also drain the heating system, tap water heater
etc., if connected to the engine’s freshwater system.
6. Close all drain taps.
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65
Maintenance. Freshwater system
1
Freshwater system. Flushing
The cooling system should be flushed when the coolant is changed, to avoid loss of cooling performance
due to deposits in the cooling system.
1. Drain the coolant, as in the description on the
previous page.
2. Put a hose into the filling hole in the heat exchanger and flush with fresh water.
3. Flush until the water which runs out of the drain
points is clean.
4. Close all drain points when all coolant has run
out.
5. Fill up with coolant, as in the description on the
previous page.
Coolant filter. Change
IMPORTANT! Do not change the filter when the
coolant is changed. The concentration of rustpreventer in the coolant can become too high,
which would cause foaming and impaired cooling.
WARNING! Hot coolant and hot surfaces can
cause burns.
1. Clean the filter bracket.
2. Close the filter tap (1), (position A).
3. Unscrew the filter with a suitable extractor.
4. Clean the filter mating surface on the filter bracket.
5. Moisten the seals on the new filter with engine oil
and screw the filter on by hand until the rubber
seal just touches the mating surface on the filter
bracket Then tighten a further 1/2 turn.
6. Open the filter tap (1), (position B).
7. Start the engine and check carefully that no leak-
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66
Maintenance. Seawater system
Seawater system
The seawater system is the engine’s external cooling system. The seawater system sucks in water through the
seawater inlet and pumps it through the heat exchanger and the reverse gear oil cooler. The system is protected
from galvanic corrosion by means of zinc anodes located in the heat exchanger and the reverse gear oil cooler.
WARNING! There is a risk of water entry when you do any work on the seawater system (if the boat is in
the water). If any hose, plug etc. located below the waterline is removed, water will flow into the boat.
Always close the sea cocks. If the boat does not have sea cocks, the water flow must be blocked in a
safe manner. If this is not possible, the boat must be drawn up on land before work starts.
Seawater system. Draining.
The seawater system must be drained in cold weather, if there is a risk of frost, to prevent frost damage.
WARNING! Risk of water entry. Close the sea-
water cocks before doing any work on the seawater system.
An alternative to draining is to keep the engine bay
above freezing temperature, by means of a fan heater which is approved for outdoor use.
Draining:
1. Close the sea cock.
2. Connect a hose to each drain tap before opening
the tap (one at a time).
3. Open the drain taps/remove the drain plugs (S)
and allow the water to run out.
Drain points:
– tap on reverse gear oil cooler
– tap at rear of heat exchanger
– tap above seawater pump
– plug below seawater pump
IMPORTANT! Check that all water really
does drain out. Deposits may need to be
cleared away, inside the drain plug/tap.
4. Also drain/empty any auxiliary equipment such
as the seawater filter, flushing/bilge pump etc.
5. Install the lid on the flushing/bilge pump if fitted.
Connect all hoses.
6. Close/install all drain taps and plugs before you
leave the boat.
S
S S S
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67
Maintenance. Seawater system
Zinc anodes. Check/change
WARNING! Risk of water entry. Close the sea
cock before doing any work on the seawater
system.
1. Close the sea cock.
2. Open the drain tap (1) on the reverse gear oil
cooler, and the tap (2) on the heat exchanger,
and drain off the seawater.
3. Remove the zinc anodes (Z) in the heat exchanger (2 pcs.) and in the reverse gear oil cooler (2
pcs).
4. Check the zinc anodes and replace them if more
than 50% of their original size has been used up.
If not, clean the zinc anodes with emery cloth to
remove the oxide layer before re-installing them.
IMPORTANT! Use an emery cloth for clean-
ing. Do not use steel tools, since this could
impair the galvanic protection.
5. Install the zinc anodes. Make sure that good metallic contact is obtained between the anode and
the casting.
6. Close the drain taps (1 and 2).
7. Open the sea cock before starting the engine.
8. Check that no leakage occurs.
1
Z
Z
Z
Z
Z
2
Page 70
68
Maintenance. Seawater system
Impeller. Check/change
WARNING! Risk of water entry. Close the sea
cock before doing any work on the seawater
system.
1. Remove the seawater pump lid, and pull the impeller out with water pump pliers.
2. Check the impeller. If any cracks or other defects
are visible, the impeller must be changed.
3. Lubricate the pump housing and the inside of the
lid with water-resistant grease (which is not aggressive to rubber). The impeller will be easier to
work with if it is put in hot water prior to fitting.
4. Press the impeller in with a circular motion (counter clockwise). The shaft of the pump has an
internal thread (M8). Screw a stud into the end of
the shaft and press the impeller in using a washer
and nut. Fit the cover, using a new O-ring.
5. Open the sea cock.
IMPORTANT! Always carry a spare impeller on
board.
Seawater filter. Inspection/cleaning
The seawater filter is optional equipment.
If the water where the boat is operated contains a
lot of contamination, weed etc., check the filter more
frequently than specified in the maintenance schedule. There is otherwise a risk that the filter would be
blocked, which would make the engine overheat.
WARNING! Risk of water entry. Close the sea-
water cock before doing any work on the seawater system.
1. Close the sea cock.
2. Remove the lid (1) and lift up the insert.
3. Clean the insert and the housing (2).
4. Install the components as in the illustration.
Check the O-ring. Change as necessary.
5. Open the sea cock and check carefully that no
leakage occurs.
Page 71
69
Maintenance. Seawater system
Inlet manifold. Checking the drain hole
Water can condense in the aftercooler during operation. The condensate is drained via a hose connected
to a nipple under the rear of the inlet manifold.
Check that the nipple is not blocked.
WARNING! If a large amount of water flows out
of the drain hole, from the inlet manifold, the aftercooler must be removed and proof tested.
This task must be done by an authorised workshop.
Page 72
70
Maintenance. Fuel system
Fuel system
Only use the grades of fuel recommended in the fuel specification, see Technical Data. Always observe the
greatest cleanliness during re-fuelling and work on the fuel system.
All work on the unit injectors of the engine must be carried out by an authorised workshop.
WARNING! Fire hazard. Work on the fuel system must be carried out when the engine is cold. Fuel spills
on hot surfaces or electrical components can cause fires. Store fuel-soaked rags and other flammable material in fireproof conditions.
WARNING! Hot fuel can cause burns.
Fuel system venting
The fuel system must be vented, e.g. after changing
fuel filter, if the fuel tank has been run dry and after
long stops.
Single filter and Switchable filters
Stationary engine:
1. Put a suitable vessel underneath the fuel filter.
2. Remove the protective cap from the venting nipple (1) on the filter bracket. Connect a transparent
plastic hose to the nipple and lower this into the
vessel.
3. Open the venting nipple and pump up fuel with the
hand pump (2) until air-free fuel flows out. Tighten
the venting nipple while fuel is flowing out. Repeat
with the second switchable filter.
4. Remove the hose and put the protective cap back
on the venting nipple.
5. If the tank has been run dry or if the engine, for
some reason, has been emptied of fuel, open the
venting nipple (3) at the front of the engine block
and vent in the same way.
6. Run the engine at idling speed for a couple of
minutes to allow any remaining air out of the system. Then close the vent (3) on the engine and
make sure there are no leaks.
1 2
1
2
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71
Maintenance. Fuel system
Fuel filter
Drain
WARNING! Hot fuel can cause burns.
Stationary engine:
1. Put a suitable vessel underneath the filter.
2. Open the tap (1) and drain water and contamination from the water trap (2) by pumping with the
hand pump (3) until clean fuel flows out.
Running engine (switchable filters only):
1. Shut off the fuel flow to the filter to be drained (A).
2. Put a suitable vessel underneath the filter.
3. Cautiously open the tap (1).
4. Drain water and contamination from the water
trap by turning the handle to venting position (B).
Tighten the venting nipple when clean fuel flows
out.
5. Repeat with the other filter.
6. Turn the handle to normal operating position (N).
1
2
3
3
2
1
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72
Maintenance. Fuel system
Change the filter elements
Stationary engine:
(Single and switchable filters)
1. Close the fuel valve/valves.
2. Clean the filter bracket and put a suitable vessel
under the filter.
3. Relieve pressure inside the filter by first opening
the drain tap (1) at the bottom of the water trap
and then the venting nipple (2) to drain the filter
of fuel.
WARNING! High pressure, open the tap with
caution. Hot fuel can spray out in any direction.
4. Remove the cables (3) from the water trap (4)
and unscrew the water trap from the filter.
5. Unscrew the filter, use a filter wrench if needed.
6. Clean the sealing surfaces of the filter bracket.
Make sure the filter is absolutely clean and the
sealing surfaces are undamaged. Moisten the
sealing rings with engine oil, including the inner
rubber seal located inside the threaded hole in
the center of the filter.
NOTE! Do not fill the new filter with fuel before
assembly. Contaminations may get into the
system and cause damage and malfunction.
7. Screw the new filter on by hand until the seal
just touches the mating surface. Then tighten a
further 1/2 turn. Reinstall the water trap and the
cables. Close the drain tap.
8. Open the fuel valve.
9. Open the venting nipple and pump up fuel with
the hand pump (5) until air-free fuel flows out.
Tighten the venting nipple while fuel is flowing out.
10. Remove the hose and put the protective cap
back on the venting nipple.
11. Start the engine and check for leakages.
1
3
2
4
5
Page 75
73
Maintenance. Fuel system
Change the filter elements
Running engine (switchable filters only):
WARNING! Hot fuel can cause burns.
1. Clean the filter bracket and put a suitable vessel
under the filter.
2. Remove the protective cap from the venting nipple (1) on the filter bracket. Connect a transparent
plastic hose to the nipple and lower this into the
vessel.
3. Shut off the fuel flow to one of the filters by lifting
the handle (2) and turning it to its end position
(A).
4. Remove the cables (3) from the water trap (4) on
the shut off filter.
5. Relieve pressure inside the filter by first opening
the drain tap (5) at the bottom of the water trap
and then the venting nipple to drain the filter of
fuel.
WARNING! High pressure, open the tap with
caution. Hot fuel can spray out in any direction.
6. Unscrew the water trap and filter, use a filter
wrench if needed.
7. Clean the sealing surfaces of the filter bracket.
Make sure the filter is absolutely clean and the
sealing surfaces are undamaged. Moisten the
sealing rings with engine oil, including the inner
rubber seal located inside the threaded hole in
the center of the filter.
NOTE! Do not fill the new filter with fuel before
assembly. Contaminations may get into the
system and cause damage and malfunction.
8. Screw the new filter on by hand until the seal
just touches the mating surface. Then tighten a
further 1/2 turn. Reinstall the water trap and the
cables. Close the drain tap.
9. Vent by turning the handle (2) to venting position (B). This allows a reduced flow of fuel
through the filter and evacuates air through the
vent. Tighten the venting nipple when air-free fuel
flows out.
10. Remove the hose and put the protective cap
back on the venting nipple.
11. Repeat with the other filter.
12. Turn the handle to normal operating position (N).
Check for leakages.
2 1
3
4
5
Page 76
74
Maintenance. Fuel system
Fuel pre-filter
The fuel pre-filter supplied by Volvo Penta is available
in single and twin versions.
Fuel pre-filter. Inspection
This filter is equipped with a pressure gauge (1)
which indicates when it is time to change the filter
insert.
Change the filer inserts as recommended in the
maintenance schedule, or earlier if the pressure gauge shows a negative pressure of 6-10 (in. Hg) at idle
or 16–20 (in. Hg) at full speed/loaded engine.
WARNING! Working with, or going close to a
running engine is a safety risk. Watch out for rotating components and hot surfaces.
Fuel pre-filter. Changing the filter insert
The fuel pre-filter/water trap supplied by Volvo Penta
is available in single and twin versions. The twin filter
inserts can be changed with the engine running, by
closing off fuel flow to one filter housing at a time.
Fuel flow is controlled by putting the handle (1) in the
following positions:
A: Normal operation (both filters are connected).
B: The left filter insert can be changed.
C: The right filter insert can be changed.
D: Both filters shut off.
Drain
Place a receptacle under the filter. Drain off water
and contaminants through the plug (4).
4
Page 77
75
Maintenance. Fuel system
Change the filter elements
If the engine is not running close the fuel cocks on
the tank before changing filters. If the engine is running cut off the flow of fuel with the handle (1) on the
filter itself.
1. Place a receptacle under the filters and shut off
the filter to be changed.
2. Undo the T-bolt (2) and remove the cover (3).
3. Take out the insert carefully while turning it.
4. Drain off water and contaminants through the
drain plug (4).
5. Fit a new filter insert and fill the container with
clean fuel.
6. Change the gasket on the cover and the O-ring
on the T-bolt. Moisten the gasket and O-ring with
fuel before assembling.
7. Fit the cover and tighten it by hand.
8. Wipe off any fuel from the heat shield.
9. Change the other filter in the same way.
10. Open the fuel cocks and put the handle in posi-
tion for normal running. Make sure there are no
leaks.
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76
Maintenance. Electrical system
Electrical system
The engine is equipped with a 2-pole electrical system and an alternator. System voltage is 24V.
WARNING! Before any work is done on the electrical system, the engine must be stopped and the current
cut by switching off the battery isolator. Shore current for engine heaters, battery chargers or other auxiliary
equipment connected to the engine must be disconnected.
Main switches
The main switches must never be disconnected
before the engine has been stopped. If the circuit
between the alternator and the batteries is disconnected when the engine is running, the alternator and
electronics can be damaged. The charging circuits
must never be re-connected with the engine running,
for the same reason.
IMPORTANT! Never disconnect the current with
the main switches when the engine is running.
Electrical connections
Check that electrical connections are dry, free from
oxide and that they are securely tightened. Spray
these connections as necessary with water-repellent
spray (Volvo Penta universal oil).
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77
Maintenance. Electrical system
Batteries. Maintenance
WARNING! Fire and explosion hazard. Batter-
ies must never be exposed to open flames or
sparks.
WARNING! Never confuse the positive and
negative poles on the batteries. Risk of arcing
and explosion.
WARNING! Battery electrolyte is highly corro-
sive. Always protect your eyes, skin and clothes
when handling batteries. Always use protective
goggles and gloves. If acid comes into contact
with your skin, wash at once with soap and a
lot of water. If you get battery acid in your eyes,
flush at once with a lot of water, and get medical
assistance at once.
Connection and disconnection
When you connect batteries, first connect the + cable
(red) to the + pole on the battery. Then connect the
– cable (black) to the – pole on the battery
When you disconnect batteries, disconnect the – cable (black) first, then the + cable (red).
Cleaning
Keep the batteries dry and clean. Contamination and
oxide on the batteries and battery poles can cause
stray currents, voltage drop and discharge, especially
in wet weather. Clean oxidation from the battery
poles and terminals, using a copper brush. Tighten
the terminals securely and grease them with terminal
grease or Vaseline.
Electrolyte level
The electrolyte level should be 5–10 mm (0.2–0.4”)
above the cell plates in the battery. Top up with battery water as necessary. After topping up, the batteries should be charged by connecting them to a
battery charger, or by running the engine at normal
speed for 30 minutes.
NOTE! Some maintenance-free batteries have special instructions, which must be observed.
IMPORTANT! Never confuse the positive and
negative poles on the batteries.
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Maintenance. Electrical system
Batteries. Charging
WARNING! Explosion risk! Hydrogen is given
off when batteries are charged. This forms an
explosive mixture with air. A short circuit, open
flame or spark could cause a violent explosion.
Ventilate well.
WARNING! Battery electrolyte is highly corro-
sive. Protect your eyes, skin and clothes. Always
use protective goggles and gloves. If acid comes
into contact with your skin, wash at once with
soap and a lot of water. If you get battery acid in
your eyes, flush at once with a lot of water, and
get medical assistance at once.
Charge batteries if they have become discharged.
If the boat is not used for a longer period of time,
the batteries should be fully charged, then trickle
charged (please refer to the battery manufacturer’s
recommendations). Batteries are damaged by being left
discharged, and can also freeze and burst easier in cold
weather.
IMPORTANT! Observe the instruction manual
for the battery charger carefully. To avoid the risk
of electrochemical corrosion when an external
charger is connected, the battery cables in the
boat should be removed from the batteries before the charger is connected.
During charging, unscrew the cell plugs but leave
them in the plug holes. Ventilate well, especially if the
batteries are charged in an enclosed space.
WARNING! Always switch off the charge cur-
rent before undoing the charging clamps. Never
confuse the positive and negative poles on the
batteries. Risk of arcing and explosion.
Special instructions apply to so-called quick char-
gers. Quick charging can shorten battery life, and
should therefore be avoided.
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79
Maintenance. Electrical system
Electric welding
Remove the positive and negative cables from the
batteries. Then disconnect all cables connected to
the alternator.
Also undo the two connectors for the EVC system
from the control unit. Press the lock tab down and
pull the connector out.
Always connect the welder earth clamp to the component to be welded, and as close as possible to the weld
site. The clamp must never be connected to the engine
or in such a way that current can pass through a bearing.
IMPORTANT! After you have finished welding,
re-connect the EVC connector and the alternator terminals before you connect the battery
cables.
Electrical installations
An incorrectly done electrical installation can generate stray currents from the electrical system. Stray
currents, in their turn, can weaken the galvanic protection of the propeller, propeller shaft, rudder, keel
etc., and cause damage because of electrochemical
corrosion.
IMPORTANT! Work on the low voltage circuits
in the boats should be done by a person with
electrical training or knowledge. Installation or
work on land current equipment must only be
done by a competent electrician, in accordance
with local regulations for mains electricity.
Always consider the following:
1. If land current is connected, its protective earth
must be connected ashore, never to the boat. The
land current installation must also be provided
with an earth fault breaker (RCCB). The land
current installation (transformer, inverter, battery
charger etc. ) must be intended for marine use,
where the high voltage section is galvanically
isolated from the low voltage section.
2. Electrical cables must be installed and clamped
in such a way that they are not exposed to chafing, damp or splashing water in the bilge.
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80
Maintenance. Electrical system
1
3. Protective earth cables for radio, navigation
equipment, rudder, bathing steps etc., or other
equipment which uses protective earthing, shall
be connected to a common earthing point which
is not connected to the engine or reverse gear.
IMPORTANT! The engine and reverse gear
must never be used as earth planes.
4. The starter battery shall have a main switch on
the positive (+) side of the battery. The main
switch must disconnect all loads and shall be
switched off when the boat is not used.
5. If an extra auxiliary battery is used, a main switch
(1) must be connected between the auxiliary
battery positive (+) pole and the fuse box for the
boat’s electrical equipment. The main switch must
disconnect all loads connected to the auxiliary
battery and shall be switched off when the loads
are not used. All equipment connected to the auxiliary battery shall have separate switches.
A charge splitter (optional) should be installed to
charge two independent battery circuits from the
standard alternator.
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81
Maintenance. Reverse gear
Reverse gear
Oil level. Checking and filling
Inspection
Check the oil level when the reverse gear has
reached operating temperature, with the engine idling
and the control lever in neutral.
WARNING! Working with, or going close to a
running engine is a safety risk. Watch out for rotating components and hot surfaces.
Remove the dipstick (1), wipe it off and put it back
into the reverse gear. Remove the dipstick again and
check the oil level. The correct oil level is between the
MAX and MIN marks.
Filling
If necessary, top up with oil through the filler hole
(2) on top of the reverse gear. Oil grade and volume:
Please refer to the “Technical Data” chapter.
IMPORTANT! Never over-fill the reverse gear.
The oil level must always be within the recommended range.
Oil strainer. Cleaning
WARNING! Working with, or going close to a
running engine is a safety risk. Watch out for rotating components and hot surfaces.
1. Remove the lid/plug and carefully remove the
strainer (1) from the housing.
IMPORTANT! Cleanliness! Dirt must not be
allowed to get into the reverse gear.
2. Clean the strainer and other components in paraffin (kerosene).
3. Carefully put the components back again.
4. Tighten the plug/screw.
5. Start the engine and check carefully that no leakage occurs
1
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82
Maintenance. Reverse gear
Oil. Change
1. Remove the dipstick. Connect a hose from the oil
scavenging pump to the dipstick tube.
2. Suck the oil up and put the dipstick back.
3. Fill up with oil to the correct level. Oil grade and volume: Please refer to the “Technical Data” chapter.
IMPORTANT! Never over-fill the reverse
gear.
4. Start the engine and run until the reverse gear
has reached operating temperature.
5. Check the oil level, as in the description on the
previous page.
Seal. Lubrication
Applies only to TwinDisc reverse gear
Lubricate theseal on the output shaft bearing (with
the lubricating nipple) using a hand gun and lithiumbased grease such as Mobilux EP2, Statoil Uniway
EP2N, Texaco Multifak EP2, Q8 Rembrandt EP2.
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83
Maintenance: Accessories
Disengageable clutch. Adjusting
Stop the engine and put the clutch lever in neutral.
Remove the inspection hatch and turn the clutch until
the locking device on the adjusting ring is accessible.
The locking devices have slightly different appearances depending on the make (see illustrations).
Twin Disc (T.D.)
1. Press the locking pin (A) and turn the adjusting ring
(B) to the right enough notches so that a torque of
218 Nm (161 lbf.ft.) is required on the lever for engagement.
2. Screw on the inspection hatch.
Accessories
Disengageable clutch. Lubrication
Use lithium-based grease such as Mobilux EP2,
Statoil Uniway EP2N, Texaco Multifac EP2, Q8 Rembrandt EP2.
Main bearing and clutch mechanism
Lubricate the inner support bearing (with lubricating nipple), the main bearings, release shaft and the
moving parts in the clutch mechanism with grease.
Lubricate sparingly, 20–30 grams (0.6–1.0 oz ) for
the main bearings.
Lubricate the inner link arms with a few drops of oil.
Release bearing
Lubricate sparingly so the grease is not forced out.
Use grease complying with the recommendations
above.
IMPORTANT! If operated more than 15–20
times a day, the release bearing must be lubricated every 50 operating hours. Otherwise, every
500 operating hours.
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84
Laying up/Launching
The boat must be laid up to prevent damage to the engine and other equipment if the boat is not used for two
months or more. It is important that this is done in the correct manner, and nothing is forgotten. For this reason,
we have compiled a check list of the most important points.
Before the boat is taken out of service for a long period of time, an authorised Volvo Penta workshop should over
the engine and other equipment. Have any faults and deficiencies attended to, so that the equipment is in order,
ready for the next start.
WARNING! Before you start to do any maintenance work, read the “Maintenance” chapter carefully. This
contains instructions for doing work in a safe and correct manner.
Some conservation oils are flammable. Some are also dangerous to breathe. Ensure good ventilation. Use
a face mask when spraying.
IMPORTANT! Observe the following when cleaning with a high pressure washer: Never aim the water jet at
seals, rubber hoses or electrical components. Never use a high pressure washer for engine cleaning.
Inhibiting
● Warm the engine up to normal operating tem-
perature and check that the oil level in the reverse
gear reaches the MAX mark on the dipstick. Stop
the engine.
● Max 8 month’s stoppage:
Change the oil and oil filter on the engine, then
warm it up afterwards.
● More than 8 month’s stoppage:
Conserve the lubrication and fuel systems with
conservation oil.Please refer to the instruction
on the next page.
● Check that the coolant offers sufficient frost pro-
tection. Top up as necessary. Alternatively, you
can drain the coolant (also drain the coolant filter).
● Close the sea cock and drain the water from the
seawater system.
● Remove the impeller from the seawater pump.
Store the impeller in a sealed plastic bag, in a
cool place.
● Drain any water and contamination from the fuel
filters and fuel tank. Fill the fuel tank completely,
to avoid condensation.
● Disconnect the battery cables, clean and charge
the batteries. Trickle charge the batteries while
the boat is laid up. A poorly charged battery
can freeze and burst.
● Clean the outside of the battery. Do not use a
high pressure washer for engine cleaning. Touch
up paint damage with Volvo Penta original paint.
● Spray the components of the electrical system
with water-repellent spray (Volvo Penta universal
oil).
● Check and rust-proof any control cables.
● Put a note on the engine with the date, type of
conservation and the conservation oil used.
● Cover over the engine air inlet, exhaust opening
and engine if necessary.
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85
Laying up/Launching
Bringing out of storage
● Remove any covers from the engine, air inlet and
exhaust pipe.
● Top the engine up with the correct grade of oil, if
necessary. Install a new oil filter if the filter was
not changed during conservation.
● Check that there is oil in the reverse gear.
● Install new fuel filters and vent the fuel system.
● Check the drive belt(s).
● Check the condition of all rubber hoses, and re-
tighten the hose clamps.
● Close the drain taps and install the drain plugs.
● Insert the impeller in the seawater pump, using a
rotating movement (anti-clockwise).
● Check the coolant level and anti-freeze. Top up as
necessary.
● Connect the fully charged batteries.
● Open the sea cocks
● Start the engine (if the boat is in the water) and
warm up at a fast idle before loading the engine.
● Check that no oil, fuel or coolant leakage occurs.
● Check the oil level in the reverse gear. Top up as
necessary.
Conservation of the lubrication and fuel systems for more than 8 months’
stoppage:
● Drain the oil from the sump and engine and fill
the engine up with conservation oil* to just
above the MIN marking on the dipstick.
● Connect the fuel supply (1) and return fuel
pipes (2) to a jerrican filled with 1/3 conservation oil* and 2/3 diesel fuel.
● Vent the fuel system.
● Start the engine and run at a fast idle until
about 2 litres (0.5 US gal.) have been used.
Stop the engine and connect the ordinary fuel
pipes.
● Empty the conservation oil out of the engine
● Follow the other instructions on the previous
page.
* Conservation oils are sold by oil companies.
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86
In case of emergency
Despite regular maintenance according to the maintenance schedule and perfect operation, it may occur that a
fault occurs which must be attended to before the boat can travel further. This chapter contains tips for rectifying
some of the possible faults.
There are safety functions which are activated when certain faults occur, to protect the engine. The following can
occur:
● Engine can not be started
● Reversing gear in neutral and engine speed is limited to 1000-1200 rpm, depending on engine.
● The engine stops
If fault occurs, acknowlege any alarm and take the recommended measures. Please refer to this chapter and the
“Fault register” chapter.
Starting with auxiliary batteries
WARNING! Ventilate well. Batteries contain and
give off an explosive gas which is highly flammable and explosive. A short circuit, open flame
or spark could cause a violent explosion.
WARNING! Never confuse the positive and ne-
gative poles on the batteries. Risk of arcing and
explosion.
1. Check that the rated voltage of the help start
battery is the same as the system voltage of the
engine.
2. Connect the red jumper cable to the positive pole
(+) of the flat battery, and then to the positive pole
of the help start battery.
3. Connect the black jumper cable to the negative
pole (–) of the help start battery, and then to a
place some distance from the flat batteries, such
as the negative connection on the starter motor.
WARNING! Under no circumstances may the
black jumper cable (–) come into contact with
the positive connection on the starter motor.
4. Start the engine and run at a fast idle for about
ten minutes to charge the batteries.
WARNING! Working with, or going close to a
running engine is a safety risk. Watch out for rotating components and hot surfaces.
WARNING! Do not touch the connections
during the start attempt: Risk of arcing. Do not
stand bending over any of the batteries either.
5. Stop the engine. Remove the jumper cables in the
exact reverse order from installation.
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87
In case of emergency
Emergency shifting
If a fault occurs which prevents the revers gear from
being operated (shifted) with the control lever, it is
possible to shift manually, using the description below.
Note. The descriptions refer to electrically shifted
revers gear.
WARNING! In emergency shifting, the unit is
locked in forwards operation. Please note that
the revers gear can not then be disengaged
with the control lever. Forward motion can only
be cut off by stopping the engine with the ignition key or stop button.
1. Stop the engine and remove the start key from
the key switch.
2. Note the valve (P or S) to which the cable marked
“Primary” is connected. Then undo the connectors (1 and 2) from the solenoid valves.
3. Remove the cap nut from the valve which was
connected to the “Primary” cable.
4. Press the valve (A) on the valve.
5. Turn the button a 1/2 turn anti-clockwise (the
button is forced out by spring action). The reverse
gear is now connected for forward motion and
cannot be disengaged by the control lever.
1
2
A
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88
In case of emergency
Fault-tracing
A number of symptoms and possible causes of engine malfunctions are described in the table below. Always
contact your Volvo Penta dealer if problems occur which you can not solve by yourself.
WARNING! Read through the safety advice for care and maintenance work in the “Safety information”
chapter before starting work.
1. Flat batteries
2. Poor contact/open circuit in cables
3. Main switch turned off
4. One of the circuit breakers in the distribution box has tripped.
5. Faulty key switch
6. Control lever not in neutral/control position not activated
7. Faulty stop relay
8. Faulty main relay
9. Faulty starter relay
10. Faulty starter motor relay
11. Faulty starter motor/solenoid
12. Lack of fuel:
– fuel taps closed
– fuel tank empty/wrong tank con-
nected
13. Blocked fine fuel filter/pre-filter
(caused by contamination or fuel strati-
fication at low temperature)
14. Air in the fuel system
15. Water/contamination in fuel
16. Boat abnormally loaded
17. Fouling on hull/propeller
18. Faulty injectors (nozzles)
19. Insufficient air supply to engine:
– blocked air filter
– air leakage between turbocharger
and engine inlet pipe.
– fouled compressor section in turbo-
charger
– faulty turbocharger
– poor engine bay ventilation
20. Excessive coolant temperature
21. Too low coolant temperature
22. Too low oil level
23. Faulty / wrong propeller
24. Faulty engine mounting
25. Coolant level too low
26. Air in the freshwater system
27. Faulty circulation pump
28. Closed seawater inlet
29. Blocked seawater inlet/pipe/filter
30. Defective impeller in seawater pump
31. Defective thermostat
32. Blocked heat exchanger insert
33. Blocked aftercooler
34. Too high oil level
35. Alternator drive belt slips
36. Water entry into engine
37. High back pressure in exhaust system
38. Stored fault codes*
39. Check that the emergency stop button
is in the running position (not pressed
down).
* NOTE! The codes can only be read and
erased by a service technician.
Symptoms and possible causes
Pop-ups are shown in the tachometer display See the “Fault register” chapter
Engine can not be stopped 2, 4, 5, 7
Starter motor does not rotate 1, 2, 3, 4, 5, 6, 8, 9, 10, 11, 36, 38, 39
Starter motor rotates slowly 1, 2
Starter motor rotates normally but engine does not start 12, 13, 14, 15, 38
Engine starts but stops again 12, 13, 14, 15, 19, 38
Engine does not reach full operating speed at full throttle 13, 14, 15, 16, 17, 18, 19, 20, 23, 33, 37, 38
Engine runs unevenly 14, 15
Engine vibrates 24
High fuel consumption 16, 17, 21
Black exhaust smoke 19
Blue or white exhaust smoke 20, 21, 34
Lubrication oil pressure too low 22
Coolant temperature too high 25, 26, 27, 28, 29, 30, 31, 32
Coolant temperature too low 31
No charge or poor charge 2, 35
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89
In case of emergency
Diagnostic function
The diagnostic function monitors and checks that the engine, stern drive/reverse gear and EVC system function
normally.
The diagnostic function has the following tasks:
● Discover and localize malfunctions
● Notify that malfunctions have been discovered
● Give advice in fault finding
● Protect the engine and ensure continued operation when serious malfunctions are discovered.
The diagnostic function affects the engine in the
following ways when:
1. The diagnostic function has discovered a minor
malfunction which does not damage the engine.
Reaction: The engine is not affected.
2. The diagnostic function has discovered a serious
malfunction which will not immediately damage
the engine (e.g. high coolant temperature):
Reaction: Engine power is reduced till the rele-
vant value is normalized.
3. The diagnostic function has discovered a serious
malfunction which will cause serious engine damage.
Reaction: Engine power is reduced.
4. The diagnostic function has discovered a serious
malfunction which makes it impossible to control
the engine.
Reaction: The reversing gear/drive is disengaged
and engine speed is cut to 1000 rpm.
It is possible to do an emergency shift: Please re-
fer to the “Emergency shifting” section.
5. The diagnostic function has discovered a serious
malfunction on the sterndrive shift mechanism or
in the engine fuel injection system.
Reaction: Engine is stopped
It is possible to do an emergency shift: Please re-
fer to the ”Emergency shifting” section. In serious
emergency it is also possible to start the engine
with gear engaged after acknowledging the alarm.
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90
In case of emergency
Malfunction message engine and EVCsystem
If the diagnostic function discovers a malfunction, it
warns the driver by showing pop-ups in the tachometer display and the buzzer will sound.
Pop-ups will alternate between “cause of fault” and
“measures to take”.
To acknowledge the alarm, press NAVIGATION
WHEEL. When the fault has been acknowledged, the
buzzer will become silent. Press NAVIGATION WHEEL. The pop-up will disappear and normal display
window will be shown.
NOTE! To enable engine start the alarm must be acknowledged.
Danger pop-up
If the Danger pop-up is shown during operation, a
serious fault has occured.
NOTE! Acknowledge the alarm and stop the engine
at once.
Information regarding “cause of fault” and “measures
to take” is found in chapter “Fault register”.
Warning pop-up
If the Waring pop-up is shown during operation, a
fault has occured.
NOTE! Acknowledge the alarm and stop the engine
at once.
Information regarding “cause of fault” and “measures
to take” is found in chapter “Fault register”.
Caution pop-up
If the Caution pop-up is shown during operation, a
fault has occured.
Acknowledge the alarm.
Information regarding “cause of fault” and “measures
to take” is found in chapter “Fault register”.
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91
In case of emergency
Faults are stored and malfunctions have
been registered
Faults list
A faults list can be viewed from the MAIN MENU, if a
fault is registered.
When in MAIN MENU, select FAULTS by pushing
NAVIGATION WHEEL. Number after FAULTS indicates number of faults stored in faults list. Show faults in
faults list by turning NAVIGATION WHEEL.
Shown fault pop-ups will alternate between “cause of
fault” and “measures to take”.
More information regarding “cause of fault” and “measures to take” is found in chapter “Fault register”.
Erasing faults in faults list
Any fault pop-up in the diagnostic function are automatically erased every time the starter key is turned
to the stop position (S).
NOTE! Stop the engine and check that the ignition
key(s) is(are) in position 0 in all control positions.
When system voltage is switched on again, the diagnostic function checks to see whether there are any
faults in the EVC system. If this is the case, new fault
pop-ups are shown.
This means that:
1. Faults which have been attended to or have dis-
appeared are automatically erased.
2. Faults which have not been attended to must be
acknowledged every time the system voltage is
switched on.
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92
Engine speed R
Explanation: Fault in engine speed sensor.
Reaction: Engine power is reduced.
Action:
• Please contact a Volvo Penta workshop.
Water in fuel O
Explanation: Water in water trap in fuel filters.
Reaction: None
Action:
• Empty the water trap underneath the fuel filters, please refer to
Please refer to “Maintenance: Fuel system”.
• Please contact a Volvo Penta workshop if the fault remains.
Seawater pressure R
Explanation: Seawater pressure too low.
Reaction: Engine power is reduced.
Action:
• Check that the seawater filter is not blocked. Please refer to
"Maintenance: Seawater system".
• Check the impeller in the sea water pump. Please refer to
“Maintenance: Seawater system”.
• Check that no leakage occurs.
• Please contact a Volvo Penta workshop if the fault remains.
Fault register
Description R
Explanation:
Reaction:
Action:
WARNING! Read the safety precautions for maintenance and service in the ”Safety information” chapter
before starting work.
Explanation
Faults are presented with information about reason and proposed measures to be taken.
1. 3.
2.
1. Description of current fault and measures to take.
2. Current warning lamp which flashes during an alarm. O/R means that an orange or red lamp flashes.
3. Audible warning
4. Current fault pop-up which is shown on the EVC tachometer display.
4.
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93
Fault register
Air temperature R
Explanation: Charge air temperature too high.
Reaction: Engine power is reduced.
Action:
• Please contact a Volvo Penta workshop.
Coolant level R
Explanation: Coolant level too low.
Reaction: Engine power is reduced.
Action:
• Check coolant level. Please refer to "Maintenance: Freshwater system".
• Check that no leakage occurs in auxiliary equipment connected to the
engine cooling system.
• Please contact a Volvo Penta workshop if the fault remains.
Coolant pressure R
Explanation: Coolant pressure too low.
Reaction: Engine power is reduced.
Action:
• Check the coolant level. Please refer to "Maintenance: Freshwater system".
• Check that the seawater filter is not blocked. Please refer to
“Maintenance: Seawater system”.
• Check the impeller in the seawater pump. Please refer to
“Maintenance: Seawater system”.
• Check that no leakage occurs.
• Check that no leakage occurs in auxiliary equipment connected to the
engine cooling system.
• Please contact a Volvo Penta workshop if the fault remains.
Coolant temperature R
Explanation: Ccoolant temperature too high.
Reaction: Engine power is reduced.
Action:
• Check coolant level. Please refer to “Maintenance: Fresh water system”.
• Check that the seawater filter is not blocked. Please refer to
“Maintenance: Seawater system”.
• Check the impeller in the seawater pump. Please refer to
“Maintenance: Seawater system”.
• Check that no leakage occurs.
• If the cooling water flow ceases, the exhaust hose should be inspected
internally and replaced if the hose shows signs of damage.
• Please contact a Volvo Penta workshop if the fault remains.
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94
Fault register
Fuel pressure R
Explanation: Fuel pressure too low.
Reaction: Engine power is reduced.
Action:
• Check the fuel level.
• Open the fuel taps and check that no leakage occurs.
• Check that the fuel filters are not blocked. Please refer to
“Maintenance: Fuel system”
• Please contact a Volvo Penta workshop if the fault remains.
Fuel temperature R
Explanation: Fuel temperature too high.
Reaction: Engine power is reduced.
Action:
• Check the fuel level.
• Check fuel cooler.
• Check that no leakage occurs.
• Please contact a Volvo Penta workshop if the fault remains.
Engine oil level R
Explanation: Oil level too low.
NOTE! In rough following seas or head seas, the system can incorrectly sense
that the engine oil level is too low. If this happens, acknowledge the fault, and
check the points below for safety reasons.
Reaction: Engine power is reduced.
Action:
• Check the oil level in the engine. Please refer to
"Maintenance: Lubrication system" to check and top the oil up.
• Check the oil filters. Please refer to "Maintenance: Lubrication system".
• Check that no leakage occurs.
• Please contact a Volvo Penta workshop if the fault remains.
Engine oil pressure R
Explanation: Oil pressure too low.
Reaction: Engine power is reduced.
Action:
• Check the oil level in the engine. Please refer to “Maintenance: Lubrication”
to check and top the oil up.
• Check that the oil filters are not blocked.
• Check that no leakage occurs.
• Please contact a Volvo Penta workshop if the fault remains.
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95
Fault register
Engine oil temperature R
Explanation: Engine oil temperature too high.
Reaction: Engine power is reduced.
Action:
• Check the oil level. Please refer to "Maintenance: Lubrication system".
• Check that the oil filters are not blocked. Please refer to
"Maintenance: Lubrication system".
• Check that no leakage occurs.
• Please contact a Volvo Penta workshop if the fault remains.
Engine oil filter R
Explanation: Oil pressure differential too big.
Reaction: Engine power is reduced.
Action:
• Check that the oil filters are not blocked. Please refer to
"Maintenance: Lubrication system”.
• Please contact a Volvo Penta workshop if the fault remains.
Crankcase pressure R
Explanation: Crankcase pressure too high.
Reaction: Engine power reduced.
Action:
• Check that the crankcase ventilation is not blocked. Please refer to
“Maintenance: Engine, general”.
• Please contact a Volvo Penta workshop if the fault remains.
Exhaust temperature R
Explanation: Exhaust temperature too high.
Reaction: Engine power is reduced.
Action:
• Please contact a Volvo Penta workshop.
Transmission oil pressure R
Explanation: Transmission oil pressure too low.
Reaction: Engine power is reduced.
Action:
• Check oil level. Please refer to “Maintenance: Lubrication system”.
• Check that the oil strainer is not blocked. Please refer to
“Maintenance: Lubrication system”.
• Check that no leakage occurs.
• Please contact a Volvo Penta workshop if the fault remains.
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96
Fault register
Battery voltage O
Explanation: Battery voltage too low.
Reaction:
Action:
• Check battery fluid level.
• Check belt tension.
• Please contact a Volvo Penta workshop if the fault remains.
Auxiliary stop R
Explanation: External stop signal.
Reaction: Engine stops or can not be started
Action:
• Check emergency stop button. Reset if necessary. Please refer to
"Stopping the engine: Emergency stop"
• Please contact a Volvo Penta workshop if the fault remains.
Primary battery R
Explanation: Poor battery or charging.
Reaction:
Action:
• Check battery fluid level.
• Check belt tension.
• Please contact a Volvo Penta workshop if the fault remains.
Secondary battery R
Explanation: Poor battery or charging.
Reaction:
Action:
• Check battery fluid level.
• Check belt tension.
• Please contact a Volvo Penta workshop if the fault remains.
30 V supply fuse R
Explanation: Fuse is broken.
Reaction:
Action:
• Please contact a Volvo Penta workshop.
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Fault register
EMS supply fuse R
Explanation: Fuse is broken.
Reaction:
Action:
• Please contact a Volvo Penta workshop.
Extra supply fuse R
Explanation: Fuse is broken.
Reaction:
Action:
• Please contact a Volvo Penta workshop.
Check control lever O/R
Explanation: Fault in control lever.
Reaction: Engine in emergency mode. Gear to neutral.
Action:
• Restart engine(s).
• If the engine can not be operated from the chosen control panel, use
an alternative control panel.
• Please contact a Volvo Penta workshop if the fault remains.
Lever calibration O
Explanation: Incorrect lever calibration.
Reaction: It is not possible to choose active helm station.
Action:
• Restart engine(s).
• Please contact a Volvo Penta workshop if the fault remains.
Check EVC system O/R
Explanation: Internal fault in the EVC system.
Reaction: Engine power is reduced.
Action:
• Restart engine(s).
• If the engine can not be operated from the chosen control panel, use
an alternative control panel.
• Please contact a Volvo Penta workshop if the fault remains.
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98
Fault register
System failure R
Explanation: Miscellaneous fault.
Reaction:
Action:
• Restart engine(s).
• Please contact a Volvo Penta workshop if the fault remains.
Check joystick O/R
Explanation: Fault in joystick.
Reaction: Engine power is reduced.
Action:
• Restart engine(s).
• If the engine can not be operated from the chosen control panel, use
an alternative control panel.
• Please contact a Volvo Penta workshop if the fault remains.
Check steering wheel O
Explanation: Fault in steering wheel unit.
Reaction: Engine power is reduced.
Action:
• Restart both engines.
• Please contact a Volvo Penta workshop if the fault remains.
Limited engine rpm R
Explanation: Fault in steering system.
Reaction: Engine power is reduced on both sides.
Action:
• Restart both engines.
• Please contact a Volvo Penta workshop if the fault remains.
Limited steering R
Explanation: Fault in steering system.
Reaction: Engine power is reduced on both sides. Limited steering.
Action:
• Restart both engines.
• Please contact a Volvo Penta workshop if the fault remains.
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