OPERATOR’S MANUAL

D2
Welcome aboard
Volvo Penta marine engines are used all over the world today. They are used in all pos-
sible operating conditions for professional as well as leisure purposes. That’s not sur-
prising.
After more than 90 years as an engine manufacturer and after delivering over 500,000
marine engines, the Volvo Penta name has become a symbol of reliability, technical in-
novation, 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 running and maintenance before you cast off on your maiden voyage so that
you will be ensured of fulfilling your expectations.
Best regards
AB VOLVO PENTA


 Contents

Safety Information .................................................. 3 Maintenance schedule ......................................... 34

Maintenance . ........................................................ 36
Introduction ............................................................ 8
Engine, general................................................... 36
Running-in............................................................. 8
Lubrication system.............................................. 39
Fuel and oil types.................................................. 8
Freshwater system.............................................. 40
Certified engines................................................... 9
Seawater system................................................. 43
Warranty information............................................. 9
Fuel system......................................................... 47
Identification numbers......................................... 11
Electrical system................................................. 49
Presentation . ........................................................ 12 S drive and reverse gear..................................... 54
D2-55, D2-75....................................................... 12
Laying up/Launching ........................................... 59
D2-75................................................................... 13
Inhibiting.............................................................. 59
Instrumentation .................................................... 14 Bringing out of storage........................................ 60
Control panel....................................................... 14 Painting the drive and underwater hull................ 61
Tachometer.......................................................... 15
Alarm dispaly (optional extra).............................. 17 In case of emergency ........................................... 62
Display EVC system (optional extra)................... 20 Starting the engine using auxiliary batteries....... 62
Fault tracing......................................................... 63
Controls . ............................................................... 27
Technical Data ..................................................... 64
Starting the engine . ............................................. 28
General................................................................ 64
Before start.......................................................... 28
Cooling and lubrication systems.......................... 64
Starting the engine ............................................. 29
Electrical system................................................. 65
Operation .............................................................. 30 S drive and reverse gear..................................... 65
Checking instruments.......................................... 30 Fuel specification................................................. 65
Cruising speed.................................................... 30
Maneuvering........................................................ 31
When sailing........................................................ 31
Alarm................................................................... 32

Stopping the engine ............................................. 33

After stopping the engine.................................... 33
Laying up............................................................. 33
Cold weather precautions.................................... 33

© 2006 AB VOLVO PENTA

All rights to changes or modifications reserved. Printed on environmentally friendly paper.
 (Cover: Department of transport (shipping), license 9809095)
Safety Precautions
Read this chapter carefully. It concerns your safety. This chapter describes how safety information is presented
in the Operator's Manual and on the engine itself. It also gives a general account of basic safety precautions to
be taken when operating the boat and maintaining the engine.
Check that you have the correct Operator's Manual before you read on. If this is not the case please
contact your Volvo Penta dealer.

If operations are performed incorrectly this could result in personal injury, or damage to
property or the engine. Read the Operator's Manual carefully before operating or servic-
ing the engine. If anything is unclear please contact your Volvo Penta dealer for assist-
ance.
This symbol is used in the book and on the engine to make you aware of safety information.
Always read these safety precautions very carefully.
In the Operator's Manual warning texts have the following priority:
WARNING! If these instructions are not followed there is a danger of personal injury, exten-
sive damage to the product or serious mechanical malfunction.
IMPORTANT! Used to draw your attention to something that can cause damage, product
malfunction or damage to property.
NOTE!Used to draw your attention to important information that will facilitate work or operations.

This symbol is used in certain cases on our products and refers to important information in
the Operator's Manual. Ensure that warning and information symbols on the engine and trans-
mission are always visible and legible. Replace symbols that have been damaged or painted
over.


Safety Information

Safety precautions to be taken when operating the boat

Your new boat Refueling

Read Operator's Manuals and other information When refueling there is always a danger of fire and
supplied with your new boat. Learn to operate the explosion. Smoking is forbidden and the engine must
engine, controls and other equipment safely and cor- be switched off.
rectly.
Never overfill the tank. Close the fuel tank filler cap
If this is your first boat, or is a boat type with which properly.
you are not familiar, we recommend that you prac-
Only use the fuel recommended in the Operator's
tice controlling the boat in peace and quiet. Learn
Manual. The wrong grade of fuel can cause operat-
how the boat behaves at different speeds, weather
ing problems or cause the engine to stop. On a diesel
conditions and loads before casting off for your “real”
engine poor quality fuel can cause the control rod to
maiden voyage.
seize and the engine to overrev with a resultant risk
Remember that the person driving a boat is legally of damage to the engine and personal injury.
required to know and follow the current rules regard-
ing traffic and safety at sea. Make sure you know the
rules that apply to you and the waters you are sailing Do not start the engine
in by contacting the relevant authorities or organiza- Do not start or run the engine with a suspected fuel
tion. or LPG leak in the boat, when you are close to or in a
discharge of explosive media, etc. There is a risk for
A good piece of advice is to take a course in sea- fire and/or explosion in explosive surroundings.
manship. We recommend that you contact your local
boating organization to find a suitable course.

Accidents
Statistics show that poor maintenance of boats and
engines and a lack of safety equipment are often the
cause of accidents at sea.
Ensure that your boat is maintained in accordance
with the relevant Operator's Manual and that the nec-
essary safety equipment is on-board and is service-
able.

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

Maneuvering
Avoid violent and unexpected changes in course and
gear engagement. This could cause someone on the
boat to lose their balance and fall over or overboard.
A rotating propeller can cause serious injury. Check
that nobody is in the water before engaging ahead or
astern. Never drive near bathers or in areas where
people could be in the water.
Avoid trimming an outboard drive too much, as steer-
ing will be severely reduced.


 Safety Information

Carbon monoxide poisoning

When a boat is moving forward backwash is caused Most modern boats are designed in such a way that
behind the boat. Sometimes this backwash can be so problems with backwash are extremely unusual.
powerful that exhaust gases can be sucked into the Should a backwash problem occur do not open
cabin or seating well on the boat with the resulting hatches or valves in the forward part of the boat. This
risk of carbon monoxide poisoning for those on board. will only increase backwash. Try changing speed, trim
or load distribution in the boat instead. In addition
The backwash problem is greatest with high, broad take down, open or change the rigging of the awning
boats with a squared stern. But other types of boat in some other way if an awning is rigged. Contact the
can also have backwash problems under certain dealer where the boat was purchased to get more
conditions, for example when running with an awn- information on how to solve this problem should it
ing rigged. Among other factors that can increase the occur on your boat.
backwash effect are wind conditions, load distribution,
the sea running, trim, open hatches and valves.

Checklist
● Safety equipment: Life jackets for all passengers, communication equipment, emergency rockets,
approved fire extinguisher, first-aid equipment, life belt, anchor, paddle, torch etc.
● Replacement parts and tools: impeller, fuel filters, fuses, tape, hose clamps, engine oil, propeller
and tools for any repairs that might have to be carried out.
● Get out your charts and go over the planned route. Calculate distance and fuel consumption.
Listen to the weather reports
● Make sure that relations or contact persons are informed when planning a longer voyage. Re-
member to inform them if your plans have changed or been delayed.
● Tell your passengers and crew where the safety equipment is stored and how to operate it. Make
sure you are not the only person on board who knows how to start the boat and operate it safely.

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


Safety Information

Safety precautions for maintenance and service operations

Preparations
Knowledge
The Operator's Manual contains instructions on how Never start a turbocharger engine without installing
to carry out general maintenance and service opera- the air cleaner (ACL). The rotating compressor in
tions safely and correctly. Read the instructions care- the turbocharger can cause serious personal injury.
fully before starting work. Foreign objects can also be sucked in and cause
mechanical damage to the unit.
Service literature covering more complicated opera-
tions is available from your Volvo Penta dealer.
Never carry out any work on the engine if you are Fire and explosion
unsure of how it should be done, contact your Volvo Fuel and lubrication oil
Penta dealer who will be glad to offer assistance. All fuel, most lubricants and many chemicals are
inflammable. Read and follow the instructions on the
Stop the engine packaging.
Stop the engine before opening or removing engine
hatches. Unless otherwise specified all maintenance When carrying out work on the fuel system make
and service must be carried out with the engine sure the engine is cold. A fuel spill onto a hot surface
stopped. or electrical components can cause a fire.
To prevent accidental start of the boat engine remove Store fuel soaked rags and other flammable material
the ignition key, turn off the power supply to the en- so that there is no danger of them catching fire. In
gine at the main switch and lock it in the OFF posi- certain conditions oil-soaked rags can spontaneously
tion before starting work. Put up a warning sign in ignite.
the control position that work on the engine is being Do not smoke when filling fuel, oil or in proximity of a
carried out. filling station or in the engine room.
Approaching or working on an engine that is run-
ning is a safety risk. Loose clothing, hair, fingers or Non-original components
a dropped tool can be caught in the rotating parts of Components used in the fuel and ignition system
the engine and cause serious personal injury. Volvo (gasoline engines) and electrical systems on Volvo
Penta recommend that all servicing with the engine Penta products are designed and constructed to
running be undertaken by an authorized Volvo Penta minimize the risk of fire and explosion.
workshop. Using non-original Volvo Penta parts can result in fire
or explosion on board.
Lifting the engine
When lifting the engine use the lifting eyes installed Batteries
on the engine (reverse gear where installed). Always The batteries contain and give off oxyhydrogen gas,
check that lifting equipment is in good condition and especially during charging. This gas is easily ignited
is strong enough for the lift (engine weight with any and highly flammable.
extra equipment). For safety’s sake lift the engine us-
ing an adjustable lifting beam. All chains and cables Do not under any circumstances smoke or use na-
should run parallel to each other and as perpendicu- ked flame or allow sparks in the vicinity of the batter-
lar as possible in relation to the top of the engine. ies or battery compartment.
Bear in mind that extra equipment installed on the Incorrectly connecting a battery terminal cable or
engine may alter its center of gravity. Special lifting jump-start cable can cause a spark which in turn can
equipment may then be required in order to maintain be sufficient to cause an explosion.
the correct balance and make the engine safe to han-
dle. Never carry out work on an engine suspended on Start spray
a hoist. Never use start spray or similar agents to start an
engine equipped with air pre-heating (glow plugs/
Before starting the engine starter element). The starter element may cause an
Reinstall all guards removed during service opera- explosion in the inlet manifold. Danger of personal
tions before starting the engine. Check that no tools injury.
or other items have been left on the engine.


 Safety Information

Hot surfaces and fluids Fuel system

There is always a risk of burns when working with Always use protective gloves when tracing leaks.
a hot engine. Beware of hot surfaces. For example: Liquids ejected under pressure can penetrate body
the exhaust pipe, turbocharger (TC), oil pan, charge tissue and cause serious injury. There is a danger of
air pipe, starter element, hot coolant and hot oil in oil blood poisoning.
lines and hoses.
Always cover the generator if it is located under the
fuel filter. The generator can be damaged by spilled
Carbon monoxide poisoning fuel.
Start the engine only in a well-ventilated area. If op-
erating the engine in an enclosed space, ensure that
there is proper ventilation in order to remove exhaust
Electrical system
gases and crankcase ventilation emissions from the Cutting off power
working area. Always stop the engine and break the current using
the main switches before working on the electrical
system. Isolate shore current to the engine block
Chemicals heater, battery charger, or accessories mounted on
Most chemicals such as anti-freeze, rustproofing the engine.
agent, inhibiting oil, degreasing agent etc. are haz-
ardous to health. Read and follow the instructions on Batteries
the packaging. The batteries contain an extremely corrosive elec-
Some chemicals such as inhibiting oil are inflam- trolyte. Protect your skin and clothes when charging
mable and dangerous if breathed in as well. Ensure or handling batteries. Always use protective goggles
good ventilation and use a protective mask when and gloves.
spraying. Read and follow the instructions on the If battery electrolyte comes into contact with un-
packaging. protected skin wash off immediately using plenty of
Store chemicals and other hazardous materials out water and soap. If battery acid comes into contact
of the reach of children. To protect the environment with the eyes, flush immediately with plenty of water
please dispose of used or leftover chemicals at a and obtain medical assistance without delay.
properly designated disposal site for destruction.

Cooling system
There is a risk of water penetration when working on
the seawater system. Turn off the engine and close
the sea cock before starting work on the system.
Avoid opening the coolant filler cap when the engine
is hot. Steam or hot coolant can spray out and cause
burns.
If work must be carried out with the engine at operat-
ing temperature and the coolant filler cap or a cock
open or a coolant hose disconnected, open the cool-
ant filler cap carefully and slowly to release pressure
before removing the cap completely. Note that the
coolant may still be hot and can cause burns.

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


Introduction
This Operator's Manual has been compiled to help you get the most from your Volvo Penta engine. It contains
all the information you need in order to operate and maintain your engine safely and correctly. Please read the
Operator's Manual carefully and learn how to operate the engine, controls and other equipment safely.
Always have the Operator's Manual available. Keep it in a safe place and do not forget to give it to the new
owner if you sell your boat.

Care of the environment

We would all like to live in a clean and healthy envi- The engine can be expected to use more engine oil
ronment. Somewhere where we can breathe clean during the running-in period than would otherwise be
air, see healthy trees, have clean water in our lakes normal. Check the oil level more often than is nor-
and oceans, and are able to enjoy the sunshine wit- mally recommended.
hout being worried about our health. Unfortunately,
this cannot be taken for granted nowadays but is so- The prescribed warranty inspection “First Service
mething we must work together to achieve. Inspection“ must be carried out during this first period
of operation. For more information: See the Warranty
As a manufacturer of marine engines, Volvo Penta and Service Book.
has a special responsibility, why care of the environ-
ment is a core value in our product development. To-
day, Volvo Penta has a broad range of engines where
progress has been made in reducing exhaust emis- Fuel and oils
sions, fuel consumption, engine noise, etc. Only use the fuel and oils recommended in the chap-
ter Technical Data. Other grades of fuel and oil can
We hope you will take care in preserving these quali-
cause operating problems, increased fuel consump-
ties. Always follow any advice given in the Operator's
tion and, in the long-term, a shorter engine service
Manual concerning fuel grades, operation and main-
life.
tenance and you will avoid causing unecessary in-
terference to the environment. Get in touch with your Always change oil, oil filters and fuel filters at the
Volvo Penta dealer if you notice any changes such as recommended intervals.
increased fuel consumption exhaust smoke.
Adapt speed and distance to avoid wash and noise
disturbing or injuring animal life, moored boats, jet-
ties, etc. Leave islands and harbours in the same Service and replacement parts
condition as you want to find them. Remember to Volvo Penta marine engines are designed for high
always leave hazardous waste such as waste oil, operational reliability and long service life. They are
coolant, paint and wash residue, flat batteries, etc., constructed to withstand the marine environment
for disposal at a destruction plant. while also affecting it as little as possible. Through
regular service and the use of Volvo Penta original
Our joint efforts will make a valuable contribution to spare parts, these qualities will be retained.
our environment.
The Volvo Penta worldwide network of authorized
dealers are at your service. They are specialists in
Volvo Penta products and have accessories and
Running-in the original replacement parts, test equipment and
The engine must be run in for its first 10 operating special tools necessary for high quality service and
hours as follows: repair work.
Operate the engine normally. Do not operate it at full Always follow the maintenance intervals contained in
load except for short periods. Never run the engine at the Operator's Manual. Remember to state the en-
a constant engine speed for long periods during the gine/transmission identification number when order-
running-in period. ing service and replacement parts.


 Introduction

Certified engines
It is important to be aware of the following information ● The engine must not be modified in any way
if you own or run an engine that is exhaust emission except with accessories and service kits approved
certified: by Volvo Penta.
Certification means that an engine type is inspected ● No modifications to the exhaust pipes and air sup-
and approved by the authorities. The engine manu- ply ducts for the engine may be undertaken.
facturer guarantees that all engines manufactured of
that type correspond to the certified engine. ● Seals may only be broken by authorized person-
nel.
This places special requirements for mainte-
nance and service as follows: Otherwise the general instructions contained in the
Operator's Manual concerning operation, service and
● The maintenance and service intervals recom-
maintenance must be followed.
mended by Volvo Penta must be observed.
● Only genuine Volvo Penta replacement parts may IMPORTANT! Late or inadequate maintenance/
be used. service or the use of spare parts not approved
● The service of injection pumps and injectors or by Volvo Penta will invalidate AB Volvo Penta’s
pump settings must always be carried out by an responsibility for the engine specification being
authorized Volvo Penta workshop. in accordance with the certificated variant.
Volvo Penta accepts no responsibility or liabil-
ity for any damage or costs arising due to the
above.

Warranty
Your new Volvo Penta marine engine is covered by a limited warranty according to the conditions and
instructions contained in the Warranty and Service book.
Note that AB Volvo Penta’s liability is limited to that contained in the Warranty and Service Book. Read this
book as soon as you take delivery of the engine. It contains important information about warranty cards,
service and maintenance which you, the owner, must be aware of, check and carry out. Liability covered
in the warranty may otherwise be refused by AB Volvo Penta.
Contact your Volvo Penta dealer if you have not received a Warranty and Service Book and a cus-
tomer copy of the warranty card.


 Declaration of Conformity for Recreational Craft Propulsion Engines with the exhaust
emission requirements of Directive 94/25/EC as amended by 2003/44/EC

D2
Engine manufacturer: Body for exhaust emission assessment:
AB Volvo Penta NKIP
Gropegårdsgatan Nipkowweg 9
405 08 Göteborg Postbus 65
Sweden 8500AB Joure
Netherlands
ID Number: 0613

Module used for exhaust emission assessment .......... B + F

Other Community Directives applied ............................ EMC 89/336/EEC

Description of engine(s) and essential requirements

Engine Type .................................................................... 4 stroke diesel engine

Engine model(s) covered by this declaration EC Type certificate number

D2-55.................................................................................. CE-RCD-542
D2-75.................................................................................. CE-RCD-543

Standards Used Other normative

Essential requirements
document used

Annex I.B – Exhaust Emissions

Engine identification Volvo Penta std Annex 1.B.1

Exhaust emission requirements EN ISO 8178-2:1998 Annex 1.B.2

EN ISO 8178-4:1996
Durability Annex 1.B.3
Volvo Penta std

Operator’s manual Annex 1.B.4

ISO 10240:2004

EMC Directive EN 61000-3-2,

EN 61000-3-3,
CISPR 25

This declaration of conformity is issued under the sole responsibility of the manufacturer. I declare on behalf of the engine manufacturer that
the engine(s) will meet the requirements of above mentioned directives when installed in a recreational craft, in accordance with the engine
manufacturer’s supplied instructions and that this (these) engine(s) must not be put into service until the recreational craft into which it is
(they are) to be installed has been declared in conformity with the relevant provisions of the above mentioned Directives.

Name and function: Sam Behrmann, Product Liability Signature and title:
(identification of the person empowered to sign on behalf (or an equivalent marking)
of the engine manufacturer or his authorised representative)

Date and place of issue: (yr/month/day) 2006/04/27 Göteborg PL-81/05 issue 03

10
Identification number
Your engine and transmission has identification plates with identification numbers. This information should al-
ways be quoted when ordering service and replacement parts. Make a note of the details below, make a copy of
the page and keep it so that you have a copy should the boat be stolen.
The appearance and location of identification plates is shown below. The figures in brackets refer to the location
of the identification numbers on the identification plate.

1
3

Engine plate (1)

Product designation (1)...............................................
Serial number (2).........................................................
Product number (3)......................................................
Certification number (4)...............................................

Engine and transmission decal (2)

Product designation (1)...............................................
Serial number (2).........................................................
Product number (3)......................................................
Produktbeteckning (5).................................................
Utväxling (6)................................................................
Serienummer (7)..........................................................
Produktnummer (8)......................................................

S-driv e /reverse gear plate (3)

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

XXXXXX (7)
Gear ratio (6)...............................................................
XXX (5) XX (8)
XXXXXXXXXX (6)
Serial number (7)........................................................
Product number (8)......................................................
Propeller designation . ................................................

11
Presentation

1 2 3 11 12

10

8 6 13 17

7 14 15 16

D2-55 with reverse gear MS25L D2-55 with reverse gear MS25L

1 2 3 4 5 11 12

10

8 7 9 13 14 15 16 17

D2-75 with reverse gear HS25A D2-75 with reverse gear HS25A

12
 Presentation

1 2 3 4 5 11 12

10

8 19
13 14 15 16 17
7
18

20
21 22
D2-75 with sailing boat drive 150S D2-75 with sailing boat drive 150S

1. Coolant filler cap 8. Generator 15. Fuel filter

2. Relay box 9. Dipstick, reverse gear/S-drive 16. Injection pump
3. Heat exchanger 10. Air cleaner (ACL)/Air intake 17. Seawater pump
4. Charge air cooler 11. Dipstick, engine 18. Cooling water intake, S-drive
5. Turbo 12. Oil filler cap, engine 19. Sea cock, S-drive
6. Oil cooler, reverse gear 13. Fuel pump 20. Folding propeller
7. Starter motor 14. Oil filter 21. Sacrificial anodes
22. Oil drain plug, S-drive

13
Instrumentation
This section describes the instrument panels available as standard alternatives for your engine from Volvo
Penta, for Volvo Penta optional extra instruments see next section. Note that in certain boats instruments, alarm
panels, key switches etc. may be installed separately without the instrument panels shown here.
If you want to install additional instrumentation, or your boat is equipped with instruments not described here,
please contact your Volvo Penta dealer.

The system does not have an ignition switch. To stop

unauthorized persons starting the engine the wheel-
house should have a lock or a lockable main switch
should be used.

Control panel

On/Off button (1). Press this button to engage or turn

off the system.
NOTE! The control panel can not be turned off while
the engine is running.
Start button (4), when this button is pressed the glow
function is activated and the starter motor is engaged.
Multifunction button (2).
- Alarm acknowledgment. If there is an alarm the
LCD screen on the tachometer will show a flashing
alarm warning and the alarm buzzer sound.
1 2 3 4 The alarm is acknowledged by pressing the mul-
tifunction button. The alarm buzzer stops and the
alarm warning continues to show in a steady light
until the malfunction is corrected.
- Background lighting. Used to light up and exting-
uish background lighting of the tachometer LCD
screen. Press the button 1-5 seconds to light or
extinguish background lighting.
Background lighting can be adjusted in five stages
by pressing the multi function button less than 1
second.
- Contrast adjustment of the tachometer LCD
screen, press the button for more than 5 seconds
to adjust contrast.

Stop button (3). The engine stop running when this

button is pressed.

IMPORTANT! Read the starting instructions in

the “Starting the engine ” chapter.

14
 Instrumentation

Tachometer/LCD Gauge
The tachometer provides you with the engine RPM
on the dial gauge. Multiply this value by 1000 for re-
volutions per minute.
The LCD screen on the tachometer shows engine
operating time in hours and tenths of an hour and
also symbols for operating information.
If a fault occurs the associated symbol will light up on
the LCD screen to provide you with a visual warning
LCD screen and the alarm buzzer sound.

Tachometer

Symbols for operating information

The "Preheat" symbol will show when the glow func-

Preheat tion is activated.

The "Crank" symbol will show when the starter motor

Crank is engaged.

Stop The "Stop" symbol will show when the stop button is
pressed.

Fuel level The "Fuel level" symbol will show when 20% or less
of usable fuel remains in the tank.
NOTE! The engine has to run at least one minute be-
fore this function is activated.

System failure The "System failure" symbol will show at short circuit
or a broken wire.

Extra alarm for optional switch function.

15
Instrumentation

Coolant temperature
The coolant temperature symbol shows when the
coolant temperature is too high.
Coolant temperature
Stop the engine if this lamp lights up during opera-
tion.

WARNING! Continued operation when the coo-

lant temperature is too high can cause serious
engine damage.

Check the coolant level. Please refer to “Mainte-

nance: Freshwater system”.

WARNING! Do not open the coolant filler cap

when the engine is warm this could cause se-
rious engine and personal damage. Steam or
hot fluid could spray out.

Check that the sea water filter, if installed, is not

blocked. Please refer to “Maintenance: Sea water
system”
Check the impeller in the sea water pump. Please
refer to “Maintenance: Sea water system”.

Oil pressure
If the oil pressure shows during operation, the oil
pressure in the engine is too low.
Oil pressure Stop the engine at once.

WARNING! Continued operation when the oil

pressure is too low can cause serious engine
damage.

Check the oil level in the engine. Please refer to

“Maintenance: Lubrication system” to check and
top the oil up.
Also check that the oil filter is not blocked. Please
refer to “Maintenance: Lubrication system”

Voltage
The battery lamp shows if the alternator is not char-
Voltage ging or voltage is too high, this can be due to a fault
in the electrical system or because the alternator
drive belt is slack.
Stop the engine
Check the alternator drive belt.

WARNING! Do not continue operation if there

is any problem with the alternator drive belts.
This could cause serious engine damage.

Check that there is no poor contact/broken wires.

16
 Instrumentation

This section describes the instrument and control panels sold by Volvo Penta as optional extras for your engine.

Voltmeter Coolant temperature Fuel level Alarm display

Voltmeter
The operating charge volatage is approx. 14 V. When
the engine is stopped battery voltage is approx. 12 V.

Coolant temperature
Normal operating temperature is between 75–95°C.
The acoustic alarm will automatically go off if the
engine coolant temperature is too high.

IMPORTANT! If the alarm sounds: Reduce

engine speed to idle (neutral). Stop the engine if
the temperature does not drop. Investigate and
correct the malfunction.

Alarm display
The alarm display provides you with a visual warning,
if and when an alarm occurs, to notify you of an exis-
ting malfunction.
The warning lamps light up, in sequence, when the
engine is started. Check that all lamps function and
that they go out once the engine is started.
If a fault occurs the associated lamp on the alarm
display will light up, the Tachometer LCD screen will
show an alarm warning and the alarm buzzer sound.
NOTE! Warning lamps should never light up during
operation.

17
Instrumentation

System Failure (red indication)

The "System Failure lamp" will light up at short circu-
it, broken wire and AUX failure.
Red: for faults requiring immediate action or attention
by the operator. The buzzer will sound constantly.

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.

WARNING! Continued operation when the oil

pressure is too low can cause serious engine
damage.

Check the oil level in the engine. Please refer to

“Maintenance: Lubrication system” to check and
top the oil up.
Also check that the oil filter is not blocked. Please
refer to “Maintenance: Lubrication system”

Fuel level (orange indication)

The "Fuel level" symbol will show when 20% or less
of usable fuel remains in the tank.
NOTE! The engine has to run at least one minute be-
fore this function is activated

18
 Instrumentation

Battery (orange indication)

The battery lamp lights up if the voltage is too high
(>15 V) or the alternator is not charging, this can be
due to a fault in the electrical system, or because the
alternator drive belt is slack.
Stop the engine
Check the alternator drive belt.

WARNING! Do not continue operation if there

is any problem with the alternator drive belts.
This could cause serious engine damage.

Check that there is no poor contact/broken wires.

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 opera-
tion.

WARNING! Continued operation when the coo-

lant temperature is too high can cause serious
engine damage.

Check the coolant level. Please refer to “Mainte-

nance: Freshwater system”.

WARNING! Do not open the coolant filler cap

when the engine is warmcould cause serious
engine and personal damage. Steam or hot fluid
could spray out.

Check that the sea water filter, if installed, is not

blocked. Please refer to “Maintenance: Sea water
system”
Check the impeller in the sea water pump. Please
refer to “Maintenance: Sea water system”.

Coolant level
This indicator is not activated for the engine.

Oil level
This indicator is not activated for the engine.

19
Instrumentation

Display EVC System

Introduction
The Volvo Penta EVC System Display is an instru-
ment that displays the engine’s operating information
and allows communication with the engine electrical
system.
NOTE! The display is preset for engines larger than
D2 and therefore, before the display can be used with
D1/D2 engines, engine series D1/D2 must be selec-
ted in the configuration menu SETTINGS/ENGINE
SERIES (refer to the configuration menu section).
Operating information is shown on an LCD display.
The driver can select the display mode with the five
1 2 3 4 5 buttons at the front of the instrument.
Three of the four buttons to the left show operating
information in different ways. The button at the far
right (5) is used to adjust the display contrast and
to access the configuration menu. It can be used to
make display settings, amongst other things. The
configuration menu can also show display mode
SYSTEM INFORMATION (which is also available
via button 2, see diagram below). The display mode
functions in the same way as the EVC System Tacho-
meter.
Before using the display, certain display settings must
be made. To see which settings can be made, refer to
the configuration menu section.

Structure for the main menus in the display

Button 1 Button 2 Button 3 Button 4 Button 5

Engine Multi No display Graph Contrast/

(standard (displays mode Configuration
display of several
operating windows)
info)
Button 2 Button 4 Button 5 Button 5
depressed depressed depressed depressed >

Numerical
Graph Contrast Configuration menu
display
display 1 - System information
- Settings
- System

Instrument
display Graph
display 2

More displays available

System information

20
 Instrumentation

Start image
This is the starting image that is shown on the display
for a brief period after starting.
If the display emits a high pitched sound continuously
after starting, the self-test has failed. The display may
still function but may act erratically.

Symbols for operating information

Oil pressure System failure

Coolant temperature Fuel level

Voltage Extra alarm for optional function

Display after starting screen

The ENGINE display mode (button 1) is always shown
after the starting screen when the display is first star-
ted up (more information about this display mode can
be found in the instructions below). Once the display
has been used, it will always show the display mode
that was selected when the display was last switched
off, next time it starts up.

Transfer fault
If the display does not register the transfer of opera-
ting information from the electrical system, the pop-up
window CONNECTION LOST flashes. When opera-
ting information has been registered/reset, the pop-up
window disappears.

21
Instrumentation

Set display contrast

Press button 5 (far right) to set display contrast. Then
press the appropriate buttons to adjust the levels and
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:
- reach display mode SYSTEM INFORMATION
- make certain settings for the display
- calibrate depth offset and speed
- reach information and functions for
display service
Please refer to the configuration menu structure be-
low and read the following section, which explains
each section in the menu.
Important! Before the display can be used
with D1/D2 engines, engine series D1/D2 must
be selected in the configuration menu SET-
TINGS/ENGINE SERIES (see diagram below).
NOTE! The engine must have the system switched
on when you change the display settings or calibrate
functions.

Configuration menu structure

System Read more about this display mode

information in the section after the diagram.

Settings Language (8 available)

Click sound ON, OFF
Engine PORT, STARBOARD
TWIN, SINGLE Engine [2500 rpm: 9000 rpm] in stages of 500 rpm
Engine series D1/D2, >D2 Speed On, off
Settings GLOBAL, LOCAL Speed [10 KNOT: 100 KNOT] in stages of 10 (in appropriate units)
Display Graph interval 2MIN, 10MIN, 30MIN, 60MIN, 2 H, 4 H, 8 H

Units Menu UNITS is only

Speed Knots, mph, km/hr
available if LOCAL
Distance NM, Miles, km
is selected in menu
Oil pressure kPa, psi
SETTINGS
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
Calibration Depth offset
Speed
System Demo Menu SYSTEM is for
Com Viewer service technicians
Prog. tx
About

22
 Instrumentation

Display mode System Information

SYSTEM INFORMATION is a display mode that
functions in the same way as the EVC System Tacho-
meter.
Control panel Instructions about how the display in the tachometer
functions can be found in the section concerning the
tachometer in this instruction book.

“System information” display mode

Alarm
The display automatically switches to display mode
SYSTEM INFORMATION when an alarm is to be dis-
played. Instructions about how the alarm should be
handled can be found in the chapter ”Operation”. To
exit the system, press button 5.

Alarm example

Settings
The menu SETTINGS is used for making various set-
tings on the display.
- Language: This is where you select the display
language (8 different languages are available).
- Bleep: This is where you select whether a bleep
should be heard when a button is pressed. (ON/
OFF)
- Engine: This is where you select the engine for
which operating data will be displayed. (SINGLE,
PORT, STARBOARD or TWIN.) Choose SINGLE.
- Engine series: This is where you select the eng-
ine for which the display has been installed. (D1/
D2, >D2) For D1/D2, this setting must be made
before the display can be used.
- Settings: (LOC, GLOB) Choose LOC.
- Display: This is where you set the measurement
intervals of the speedometers and tachometers.
Rpm engine: [2500 rpm: 9000 rpm] in steps of
500 rpm. Set to 4000 rpm
- Speed: Change speed display (on/off)
- Speed: [10 KNOT: 100 KNOT] in steps of 10
(in current measurement unit for speed)
- Graph interval: 2 MIN,10 MIN, 30 MIN, 60 MIN,
2 H, 4 H, 8 H

23
Instrumentation

- Calibration: This is where depth offset and speed

calibration are made. See calibration procedure
below.
- Units: (This menu is displayed only if LOCAL is
selected in menu SETTINGS.) This is where
you select the measurement units to be used
to display operating information. Fo D1/D2,
LOCAL shall always be selected and the mea-
surement units set as desired.
- 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)

Depth offset calibration

Note! The engine must have the system switched on
when functions are calibrated.
The depth sounder can be placed somewhere on
the hull that it 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.
OFFSET can be adjusted upwards (+) or downwards
(-) in steps of 0.1 units.
The adjusted value is stored when you press button
BACK.

Speed calibration
Note! The engine must have the system switched on
when functions are calibrated.
Perform speed calibration when the boat is moving.
Compare the sensors speed value SPEED DATA
with the GPS speed value (or another boat with the
same speed) and adjust the calibration value CALI-
BRATION so that the correct speed value is shown
on the DISPLAY.
Calibration value CALIBRATION for the boat’s speed
sensor can be adjusted upwards (+) or downwards
(-) in steps of 0.01 unit (+ or - 1%).
The adjusted value is stored when you press button
BACK.

24
 Instrumentation

System
The SYSTEM menu is to give necessary functions
and information to service technicians.
- Demo: Switch between demo mode ON/OFF. The
display is in normal operating mode when demo
is OFF.
- Com Viewer: Shows the latest messages recei-
ved on the communication inputs
- Prog tx: Transfers the content of the application
program on 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

Display mode Engine (Button 1)

This display mode shows the engine speed and boat
speed in the form of standard instruments. Opera-
tion time is shown in the lower window. The fuel level
gauge is only displayed if there is a tank sender.
The scale values for maximum engine speed and
maximum speed can be set in the configuration
menu.
Only metric values are displayed, but other units can
be displayed if they have been chosen in the configu-
ration menu.
If information about boat speed is not available, the
display shows coolant temperature instead.

25
Instrumentation

Display mode Multi (button 2)

This display mode shows operating information in
four different windows (see below). The user can
choose which operating information is to be shown in
which window.
The information can be displayed as figures or as a
standard instrument. The display switches between
different modes when button 2 is pressed repeatedly.
Example of display in several windows If an item of operating information is not available, the
unit displays ”—” and the analog gauge needle is not
shown.
From display mode MULTI one can also reach SYS-
TEM INFORMATION, the display mode that functions
in the same way as the small display in the tachome-
ter. Read more about display mode SYSTEM INFOR-
MATION in the configuration menu section.

Set the appearance of display mode Multi

Display mode MULTI has a mode for setting which
operating information should be displayed in which
window.
The setting mode is reached by pressing button 5
(far right), when you are in the display mode MULTI.
Press button 5 to choose setting mode Please refer to the illustrations below.
Note! The type of operating information available
depends on the electrical system in the boat and the
sensors that the boat is equipped with. Optional sen-
sors include depth sounder, water temperature and
speed.
Note! The following applies for standard instrument
display:
The maximum engine speed range can be set on the
configuration menu.
The voltage range can be [8V: 16V] and is changed
Buttons 1 to 4 are used to adjust the
corresponding window (refer to the black automatically, depending on the latest data value.
markings)

Display mode Graph (button 4)

This display mode shows operating information 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 cannot 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.
The maximum time interval can be set to one of the
following values in the configuration menu: 2 min, 10
(shows engine speed) min, 30 min, 1 h, 2 h, 4 h, 8 h.
The interval on the Y-axis is set automatically for the
best view.

26
Controls
The shift function and engine speed control are combined in one lever. If necessary the shift function can be eas-
ily disengaged so that only the engine speed (rpm) is affected by the lever. The control lever has an adjustable
friction brake.
NOTE! A neutral position switch is available as an accessory, this will only permit the engine to be started with
the drive/reverse gear disengaged.

Maneuvering
Shifting and engine speed are controlled with the
same lever (1).
T
N = Neutral position. Drive/reverse gear disengaged.
T
F = Drive/reverse gear engaged for movement ahead.
1 R = Drive/reverse gear engaged for movement
astern.
T = Engine speed control
2

For top-mounted controls

Disengaging the shift function

T
● Move lever (1) to the neutral position (N).
T
● Press in button (2), move the lever slightly forward
1 and release the button.
The shift function is now disengaged and the
lever affects only engine speed. When the lever is
moved back to the neutral position it will automati-
cally re-engage.
2
IMPORTANT! Take care not to engage the
drive/reverse gear by mistake.

For side-mounted controls

Adjusting the friction brake

The friction brake only affects the engine speed con-
trol movements.
● Lift the cover over the control. For side-mounted
controls the lever must first be removed.
● Set the lever to the half-open throttle/reverse posi-
tion.
● Adjust the friction brake. Turning the screw clock-
wise (+) makes the lever movement stiffer, while
turning counterclockwise (–) makes it easier to
move the lever.
● Reinstall the cover and lever.

27
Starting the engine
Make a habit of checking the engine and engine compartment visually before operating the boat. This will help
you to quickly detect anything unusual that has or is about to happen. Also check that instruments and the warn-
ing display are indicating normal values when you have started the engine.

Before starting
● Open the cooling water intake sea cock.

● Open fuel valve.

● Carry out the actions in the “Daily before the first

start-up” section in the maintenance schedule

● Switch on the main switch.

IMPORTANT! Never break the circuit with the
main switch while the engine is running. This
could damage the generator.
● Start the engine compartment fan if one is fitted
and let it run for at least four minutes.

● Check that there is sufficient fuel.

Starting method
Press the on/off button (1) to activate the control pa-
nel. The Volvo Penta logo will show in the LCD screen
and two beeps indicate the system is ready.

28
 Starting the engine

Check the warning lamps and LEDs

Each time the system is activated all bulbs and LEDs
are illumintaed on the alarm display (optional extra).
Check that all bulbs and LEDs function!

Start the engine

To start the engine press the start button (1) untill the
engine starts. The pre-heat symbol shortly shows on
the LCD screen. The pre-heat process runs for 20 se-
conds after the button is pressed.
NOTE! If the preheat button is pressed breifly and
not untill the engine starts the preheat process will be
runing for 20 seconds. The preheat symbol will show
on the LCD screen.
The pre-heat process will only run if the engine tem-
perature is less than 50°C.

Read the instruments and warm the

engine up
1 Allow the engine to idle for the first ten seconds, and
check that instruments and warning displays show
normal values. Check that no warning lamps flash on
the alarm display.
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.

29
Operation
Avoid violent and unexpected changes in course and gear engagement. There is a risk that someone aboard will
fall over or overboard.

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

Checking instruments
Check the instruments and warning display directly
after starting the engine and then at regular intervals
while driving the boat. Stop the engine if there is an
abnormal reading or any warning lamp comes on and
the alarm sounds. For engines with measuring instru-
ments the following standard values apply:

Cruising speed
Operating the engine at wide open throttle (WOT)
should be avoided since it is both uneconomical and
uncomfortable. Volvo Penta recommends a cruising
speed in the range 500–1000 rpm lower than maxi-
mum rpm at WOT. Depending on hull type, choice
of propeller, load and conditions etc. the maximum
engine speed at top speed can vary, but it should be
within the WOT range.

Wide Open Throttle range:.............. 2,700–3,000 rpm

30
 Operation

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

1. Reduce engine speed to idling and, if possible, let

the boat lose most of its speed.

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

3. Move the gear control lever quickly and firmly into

3.
astern, then increase the speed.

Trolling operation valve

HS25 reverse gear can be equipped with a trolling
operation valve which makes it possible to steplessly
reduce the boats lowest speed by 20-80% at engine
speeds up to 1200 rpm.

IMPORTANT! At engine speeds above 1200

rpm, the reversing gear can overheat.

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

31
 Alarm
If there is an alarm the tachometer LCD screen will
show a flashing warning icon and the alarm buzzer
sound.
If the boat is equipped with an alarm display (optional
extra) the relevant lamp will start to flash.
Please refer to chapter "Instruments" for more infor-
mation about the warning icons and the alarm display
LCD screen indicator lights.

Tachometer
1. Reduce engine speed to idling.
2. Acknowledged the alarm by pressing the multi-
function button (1). The alarm buzzer stops and
the warning icon continues to show in a steady
light until the malfunction is corrected.

Please refer to the “Instrumentation” chapter where

you will find information about the alarm symbols.

Alarm example

Alarm dispaly (optional extra)

32
Stopping the engine
The engine should be run for a few minutes at idle (in neutral) before turning it off. This will avoid boiling and
even out the temperature. This is especially important if the engine has been operated at high engine speeds
and loads.

Stopping
Press the Stop button (1) untill the engine stops run-
ning.

1
After stopping the engine
● Inspect the engine and engine compartment for
any leaks.
● Close the fuel cock and sea cock for the cooling
water intake.
IMPORTANT! Do not forget to open the cocks
before the engine is started again.
● Read off the hours counter and do preventive
maintenance as in the maintenance schedule.
● Switch off the main switch if the boat is not to be
used for some time.
IMPORTANT! Never break the circuit with the
main switches while the engine is running. This
could damage the generator.

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

Cold weather precautions

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

IMPORTANT! A poorly charged battery may

burst as a result of freezing.

33
Maintenance schedule
Your Volvo Penta engine and associated equipment is designed to provide high operational reliability and long
service life. They are constructed to withstand the marine environment while also affecting it as little as possible.
Preventive maintenance in accordance with the maintenance schedule will ensure that it retains these qualities
and avoid unnecessary operational disturbances.

Warranty inspection
The prescribed warranty inspection “First Service Inspection” must be carried out at an authorised Volvo Penta
workshop during this first period of operation. Directions for when and how this is to be carried out can be found
in the Warranty and Service Book.

Extended Protection
Volvo Penta offers an Extended Protection for your marine diesel engine, including transmission, if used for plea-
sure use only. To be valid a Extended Protection service has to be performed at the owners cost and expense by
an authorized Volvo Penta distributor, dealer or workshop before the expiry of the 12 months Warranty Period.
Further directions can be found in the Warranty and Service Book.

Maintenance schedule
WARNING! Read the chapter “Maintenance” thoroughly before starting any mainte-
nance work. It contains directions for performing maintenance in a safe and correct
manner.

IMPORTANT! When both operating time and calendar time is given, the one occur-
ring first is to apply. Maintenance points marked with are to be carried out at an
authorised Volvo Penta workshop.

Daily before starting for first time

● Engine and engine room. General inspection................................................ page 36
● Engine oil. Checking level............................................................................... page 39
● Coolant. Checking level.................................................................................. page 42

Every 14 days
● Fuel pre-filter. Drain water.............................................................................. page 48
● Drive belt. Check............................................................................................ page 37
● Seawater filter. Cleaning................................................................................. page 44
● Battery. Check electrolyte level....................................................................... page 50
● Reverse gear. Check oil level......................................................................... page 54
● S-drive. Check oil level................................................................................... page 54

Least once a year, included in Extended Protection

● Folding propeller. Cleaning............................................................................. page 56
● S-drive. Check rubber seal (hull/drive)........................................................... page 58

34
 Maintenance: Seawater system

Every 200 operating hours or at least once a year, included in Extended Protection
● Reverse gear. Oil change............................................................................... page 55
● Reverse gear (HS25) Cleaning the oil filter.................................................... page 55
● Reverse gear. Lubricate propeller shaft seal.................................................. page 58
● S-drive. Oil change......................................................................................... page 54
● S-drive/Reverse gear. Checking corrosion protection..................................... page 56

Every 500 operating hours or at least once a year, included in Extended Protection
● Engine oil. Replace......................................................................................... page 39
● Oil filter. Replace............................................................................................ page 39
● Fuel filter. Replace.......................................................................................... page 48
● Fuel pre-filter. Replace................................................................................... page 48
● Idling speed. Check........................................................................................ page 38
● Seawater pump. Check impeller..................................................................... page 43
● Vacuum valve. Cleaning................................................................................. page 44

Every 500 operating hours or at least once every two years

● Air Cleaner (ACL). Cleaning........................................................................... page 38
● Coolant . Replace............................................................................................ page 42
● Heat exchanger. Cleaning.............................................................................. page 42
Injectors. Test pressure................................................................................not shown
Valve clearance. Adjustment.......................................................................not shown

Every 500 operating hours or at least every fifth year

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

Every seventh year

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

35
Maintenance
This chapter contains instructions regarding how the above maintenance points should be carried out together
with general technical information. Read the instructions carefully before starting work. Maintenance intervals
are contained in the chapter above. Maintenance schedule

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

WARNING! Unless otherwise specified all maintenance and service must be carried out with the engine
stopped. Stop the engine before opening or removing engine hatches. Immobilize the engine by removing
the ignition key, turning off the power supply with the main switch.

Engine, general

General inspection
Make a habit of “visually” inspecting the engine and
engine room before starting the engine and after
stopping when the engine has been turned off. This
will help you to quickly detect abnormalities that have
occurred or are about to occur.
Look especially carefully for oil, fuel and coolant
leaks, loose bolts, worn or slack drive belts, loose
connections, damaged hoses and electric cables.
This inspection takes only a few minutes but can
prevent serious operating diesturbances and costly
repairs.

WARNING! Accumulations of fuel, oil and

grease on the engine or in the engine room is a
fire hazard and must be removed immediately
they are detected.

IMPORTANT! If an oil, fuel or coolant leak is de-

tected, the cause must be investigated and the
fault rectified before the engine is started.

IMPORTANT! Never point high-pressure water

jets directly at seals, rubber hoses or electrical
components. Never use the high-pressure func-
tion when washing the engine.

36
 Maintenance: Engine, general

Drive belt. Check

The belt drives both the circulation pump and the
generator. A belt that is too loose can result in slip-
page, poor cooling and poor charging. A belt that is
too tight can damage the bearings in the circulation
pump and damage the generator.
Check the tension of the belt regularly. Adjust as
required. Check that the belt is not cracked or dam-
aged. Replace a worn belt. Keep a spare belt on-
board.

Drive belt. Adjusting and replacing

10 mm WARNING! Always turn the engine off before
starting maintenance work.
4
IMPORTANT! Tighten screw (1) to 50 Nm.

Check and adjust as necessary after operating the

engine when the belts are warm. It should be possi-
ble to depress a belt at the correct tension approx. 10
1 mm between the pulleys using normal thumb pres-
sure.
Loosen the alternator fixing screws (1-3). Tension the
belt with the adjustment screw (4), to the correct ten-
sion. Tighten the screws (1-3). Check the tension.
To replace the belt slacken off screws (1 and 2).
Press the generator in towards the cylinder block so
that the belt can be removed. Clean off the pulley
grooves. Install the new belt. Adjust as above. Check
belt tension again after a few hours’ operation.

37
Maintenance: Engine, general

Air Cleaner (ACL). Cleaning

Remove the hose clamp (1) and remove the filter.
Remove the spring inside the filter. Clean the filter as
necessary by washing it in soapy water. Then rinse it
in clean water. Squeeze the filter out and leave it to
dry.
IMPORTANT! Take care that no contaminants
enter the engine.

Idling. Adjustment
For engine idling speed: Please refer to the Technical
A Data chapter. A lower engine speed can cause the
engine to stall and a higher engine speeds can cause
B extra stresses to the drive/reverse when shifting.

C Adjust with the engine at operating temperature as

follows:
1* Set the control lever in the neutral position. Check
that gap (A) is approx. 3 mm. Adjustment: Slacken
off the locknut (B) and adjust until the correct gap
is obtained with screw (C). Tighten the locknut.
*This point does not apply to boats with double control posi-
tions.

2 Start engine and allow to idle with gear selector in

neutral.

E WARNING! Approaching or working on a run-

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

3 Slacken off locknut (D). Adjust engine speed with

adjustment screw (E). Tighten the locknut. Repeat
step 1.

Wastegate (D2-75)
If the engine is not used for a longer period of time
there is a risk that the turbochargeer boost pressure
valve may stick. Check that the shaft turns.

38
 Maintenance: Lubrication system

Lubrication system

IMPORTANT! With a new or reconditioned engine, the oil and oil filters must be changed after 20-50 hours
of operation. After that they should be changed every 500 operating hours or at least once a year. Use only
the recommended grades of oil: See the chapter ”Technical Data”.

Oil level. Checking and topping up

The oil level should be within the marked area on the
dipstick (1). It should be checked every day before
1 the engine is started. Topping up is done through the
valve cover (2). Top up oil slowly. Wait a few minutes
before checking the oil level again to give the oil
time to run down to the oil pan. Then check the level
again. Use only the recommended grades of oil: See
the chapter ”Technical Data”.

IMPORTANT! Do not fill the oil above the MAX

level.

Oil and oil filters. Changing

1. Run the engine to operating temperature so that
the oil is easier to suck out. Stop the engine.
2. Suck out the oil using an oil drain pump through
oil drain pipe.
WARNING! Hot oil and hot surfaces can
cause burns.
3. Unscrew the old filter. (To avoid oil spills put a
plastic bag over the filter before it is unscrewed).
4. Check that the engine mating surface is clean.
5. Moisten the filter rubber gasket with a little oil.
Screw on the new filter by hand until it is in con-
tact with the mating surface. And then a further
half turn but no more!
6. Top up oil to correct level. Start the engine and
let it idle. Check that the warning lamp for low oil
pressure goes out.
7. Stop the engine. Wait for approx. 10 minutes
before checking the oil level. Top up if required.
Check that there are no leaks round the oil filter.
NOTE! Collect up the old oil and filter for deposit
at a proper disposal site.

39
Maintenance: Freshwater system

Freshwater 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 % con-
centrated coolant and 60 % water to protect against internal corrosion, cavitation and damage caused by freez-
ing.
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 ade-
quate 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 re-
placed, 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, cavi-
tation and frost damage.

“Volvo Penta Coolant, Ready Mixed” is a ready-

mixed coolant, 40% “Volvo Penta Coolant” and 60%
water. This concentration protects the engine against
corrosion, cavitation damage and freezing conditions
down to -28 °C (18°F).

40
 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 cor-
rosion, 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 % concen-
trate (Volvo Penta Coolant) in the cooling liquid, this
will give reduced cooling effect and increase the risk
of overheating, and will give reduced freezing protec-
tion.

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

41
Maintenance: Freshwater system

Coolant level. Checking and topping up

WARNING! Do not open the engine coolant
MAX system filler cap when the engine is still hot ex-
MIN cept in an emergency. Steam or hot coolant may
spray out.

1 Turn the filler cap to the first stop and let any pres-
sure escape from the system before removing the
cap. Top up coolant if necessary. The level should lie
between the filler neck lower edge and the level spur
(1). Reinstall the filler cap.
If a separate expansion tank is installed (optional
extra), the coolant level should be between the MAX
and MIN levels on the extra expansion tank.
IMPORTANT! When filling a completely drained
system the coolant level must be checked after
an hours use because the system is self bleed-
ing. Top up if required.

Coolant. Draining
Put a suitable collection vessel underneath the eng-
ine drain plug (1) and underneath the heat exchan-
ger drain tap (2). Remove the filler cap on the heat
exchanger to let the coolant run out faster. Open the
drain plug (1) and the drain tap (2) and drain off all
coolant. Before new coolant is put in, clean the heat
exchanger as in the following paragraphs.
1 NOTE! Deposit old coolant at a properly designated
disposal site.

Heat exchanger. Cleaning

Cooling performance is reduced by scaling in the
heat exchanger. It should therefore be flushed when
the coolant is changed.
1. Drain the coolant as above.
2. Insert a hose into the filling pipe on the heat ex-
changer. Rinse with fresh water until the water
which runs out of the drain tap and the engine
block is clean. Let all the water run out.
3. Close the drain tap and the drain plug. Fill up with
coolant to the correct level. Put the filler cap back.
2

42
 Maintenance: Seawater system
Seawater system
The sea water system is the external cooling system of the engine. On engines with a stern drive, the sea water
pump sucks in water via the drive, after which the water passes the sea water filter (optional extra) before it is
pumped through the heat exchanger. Finally, the water is pumped out into the exhaust elbow pipe, where it is
mixed with the exhaust gases.
On engines with a reverse gear, the sea water pump suck in water via the sea water inlet, after which the water
passes the sea water filter (optional extra) and the reverse gear oil cooler before it is pumped through the heat
exchanger. Finally, the water is pumped out into the exhaust bend, where it is mixed with the exhaust gases.

WARNING! There is a risk that water will enter while working on the seawater system (if the boat is in the
water). Water may flow into the boat if a hose, plug or similar object located below the waterline is removed.
So always close the seawater cock. If the boat does not have a seawater cock, the flow of water must be
stopped in a safe manner. The boat must be brought up on land if this is not possible.

Impeller. Checking/Replacing
WARNING! Risk for water penetration. Close
the sea cock.

Close the sea cock. Remove cover (1) on the seawa-

ter pump. Remove impeller (2). If there are cracks or
other defects the impeller must be replaced. Lubri-
cate the pump housing and the inside of the cover
with a little glycerin. Reinstall the impeller using a
clockwise rotating movement. Install the cover togeth-
er with a new gasket. Open the sea cock.
IMPORTANT! The impeller will be damaged if
other types of lubricant than glycerin are used.
2
IMPORTANT! Always carry a spare impeller on
1 board.

43
Maintenance: Seawater system

Vacuum valve. Cleaning

Some engines have a vacuum valve installed in the
seawater piping.

WARNING! Risk for water penetration. Close the

sea cock.

Close the sea cock. Disassemble the valve. Unscrew

the hexagonal cover. In the cover there is a mem-
brane and a gasket. Clean all the parts. Turn the
cover upside down. Install the membrane first and
then the gasket. Turn the valve housing upside down
as well. Screw the cover into position, but not too
hard (0.2 kpm), or the valve may stop working.

Seawater filter. Cleaning

The seawater filter is an accessory. Screw off cover
(1) and remove seal plate (2). Lift out and clean the
insert (3).
1
IMPORTANT! If the boat is used in water that
has a lot of contaminants, seaweed etc. the filter
must be checked more frequently than indicated
in the maintenance schedule. Otherwise there
2 is a risk the filter will clog and the engine will
overheat.
3

44
 Maintenance: Seawater system

Seawater system. Flush cleaning and

corrosion inhibition
When laying up during winter (or out of season), the
2 seawater system must be flushed clean of all depos-
its and salt crystals. It must also be treated to protect
against internal corrosion.

WARNING! Risk of water penetration. This work

must be carried out with the boat on dry land.
Approaching or working on a running engine is
dangerous. Watch out for rotating components
and hot surfaces.
Glycol is harmful to health (dangerous if ing-
ested). Collect used and drained glycol and take
1 it to a proper disposal site.

1. Open the seawater cock (1).

2. Disconnect the hose at the seawater cock (1) or
on the outlet side of the sea water filter (2) (if the
engine is equipped with such a filter).
3. Place the free end of the hose in a bucket of fresh
water. Fill the system.
IMPORTANT! The impeller will be damaged if
it runs dry.
4. Check that there is nobody close to the propeller
and there is nothing that will get splashed behind
the exhaust outlet.
5. Set the control lever to neutral. Start the engine.
Let the engine run at fast idle for a few minutes.
Stop the engine.
6. Fill the bucket with an anti-freeze mixture (40%
Volvo Penta glycol and 60% fresh water). Collect
the mixture from the system in a suitable contai-
ner.
7. Start the engine and let it idle. Stop the engine
just before the mixture is finished.
Repeat as necessary until the entire system has
been flushed with the mixture.
8. Reconnect the hose.
This mixture prevents corrosion and protects against
freezing. It must be left in the seawater system
throughout the laying-up period. Drain the mixture
just before the boat is launched.

45
Maintenance: Seawater system

Seawater system. Draining

8 If it is not possible to keep the engine compartment
free of frost, the seawater system must be drained to
prevent freezing damage.
2
Note that all the seawater must be drained. The type
4 9
of drainage must be adapted to the way in which the
5
engine is installed and any additional equipment that
7 is connected, for example sea water filter (2), vacuum
3
valve (8), silencer (7) etc.

WARNING! Risk of water penetration. Close the

5 sea cock before starting work.

IMPORTANT! If the boat is laid-up for winter or

1 the off season, the seawater system must be
instead flushed clean and protect against corro-
sion according to the instructions in the previous
130S / 150S section.

Draining:
8 1. Close the seawater cock (1).
2. Remove the cover and sealing plate on the sea
water filter (2).
2
4 9
3. Remove the cover (3) from the seawater pump.
Let the water run out.
7
3 4. Open the drain cock (4) on the rear end of the
heat exchanger and drain the water off.
D2-75:
Open the drain cock on the charge air cooler (9)
draining the water.

6 5. Disconnect the hoses where indicated by the ar-

5 1 rows (5). Drain the hoses.
6. Open the drain plug (6) on the reverse gear oil
MS25 / HS25 cooler and drain the water off. Close the drain
plug.
7. Drain the silencer (7), the exhaust system and any
other additional equipment connected to the sea-
water and exhaust systems.
6 8. Reinstall all hoses, the cover on the seawater
pump and the cover and sealing plate on the
seawater filter. Close the drain cock on the heat
exchanger.
D2-75:
Close the draincock on the charge air cooler.
6 9. Opened the seawater cock the next time the boat
is used.
HS25 MS25
WARNING! Check that there is no leakage in
the seawater system.

46
 Maintenance: Fuel system

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

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

Venting the fuel system

The fuel system must be vented after fuel filters have
been replaced or after refilling the fuel tank after it
has been run dry.
1. Open vent screw (1) on the filter mounting approx.
1 2 three turns. Avoid fuel spillage. Use rags around
the venting point.
3
2. Pump the fuel using hand pump (2) until there are
4
no more air bubbles visible in the fuel. Continue
pumping and at the same time tighten the venting
screw.
There is a strainer (3) in the intake manifold for
the pump. The strainer does not normally need to
be cleaned since the engine should be installed
with a fuel pre-filter. Low output may be due to a
blocked strainer.
If any of the two o-rings (4) are damaged
they need to be replaced.
3. Start the engine and check for leaks.

WARNING! Approaching or working on a run-

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

47
Maintenance: Fuel system

Fuel filter. Changing

Clean the filter mounting. To avoid fuel spills put a
plastic bag over the filter before it is unscrewed. Un-
screw the filter. Moisten the filter rubber gasket with
a little oil. Screw on the new filter by hand until it is in
contact with the mating surface. And then a further
half turn but no more! Vent fuel system. Deposit the
old filter at a properly designated disposal site.
Start the engine and check for leaks.

WARNING! Approaching or working on a run-

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

Fuel pre-filter. Draining and replacing

filter insert
Draining
1 The fuel pre-filter is an optional extra.
Position a container under the fuel filter. Drain off
water and contaminants using the cock/plug at the
bottom of the filter bowl.

IMPORTANT! Wait a few hours after the engine

has been turned off before draining the filter.

Replacing filter insert

Close fuel cock at the fuel tank. Position a container
under the fuel filter.
Remove the filter bowl by undoing screw (1). Empty
and clean the filter bowl. Replace insert and reinstall
the bowl. Open fuel cock. Vent fuel system. Deposit
the old filter insert at a properly designated dis-
posal site.
Start the engine and check for leaks.

WARNING! Approaching or working on a run-

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

48
 Maintenance: Electrical system

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

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

IMPORTANT! Never break the circuit with the

main switches while the engine is running.

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

49
Maintenance: Electrical system

Battery. Maintenance
WARNING! Risk of fire and explosion. Never
allow an open flame or electric sparks near the
battery or batteries.

WARNING! Never mix up battery positive and

negative terminals. This may cause sparks and
an explosion.

WARNING! The battery electrolyte contains ex-

tremely corrosive sulfuric acid. Protect your skin
and clothes when charging or handling batter-
ies. Always use protective goggles and gloves.
If battery electrolyte comes into contact with
unprotected skin wash off immediately using
plenty of water and soap. If battery acid comes
into contact with the eyes, flush immediately
with plenty of water and obtain medical assist-
ance without delay.

Connecting and disconnecting

First connect the red battery lead + to the battery +
terminal. Then connect the black battery lead - to the
battery - terminal.
When disconnecting the battery, disconnect the -lead
(black) first and then the + lead (red).

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

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

50
 Maintenance: Electrical system

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

WARNING! The battery electrolyte contains ex-

tremely corrosive sulfuric acid. Protect your skin
and clothes when charging or handling batter-
ies. Always use protective goggles and gloves.
If battery electrolyte comes into contact with
unprotected skin wash off immediately using
plenty of water and soap. If battery acid comes
into contact with the eyes, flush immediately
with plenty of water and obtain medical assist-
ance without delay.

If the battery has discharged it must be charged. f

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

IMPORTANT! Follow the instructions supplied

with the battery charger carefully. To avoid elec-
trolytic corrosion when an external charger is
connected, always disconnect the battery leads
before connecting the charger.

When charging, unscrew filler plugs but leave them in

their holes. Ventilation should be good, particularly if
the batteries are being charged in an enclosed area.

WARNING! Always switch off the charging

circuit before removing the battery charger
connectors. Never mix up battery positive and
negative terminals. This may cause sparks and
an explosion.

Special instructions apply when boost charging the

batteries. Avoid boost charging the batteries as it will
shorten their service life.

51
Maintenance: Electrical system

Electrical installations
Leakage current from the electrical system can be
caused by incorrect installation of electrical equip-
ment. Leakage current can knock out the galvanic
protection of components such as the drive, propel-
ler, propeller shaft, rudder stock and keel and cause
damage by electrolytic corrosion.

IMPORTANT! Work on the boat’s low tension

circuit should only be carried out by qualified or
experienced persons. Installation or work on the
shore power equipment must only be carried
out by electricians authorized to work with high-
voltage installations.

The following should always be observed:

1. If shore power is connected, the protector ground
should be ashore, never in the boat. Shore power
should always have a ground fault circuit breaker.
Shore power units (transformer, rectifier, battery
chargers etc.) must be intended for marine usage
and the high tension circuit must be galvani-
cally separated from the low tension circuit.
2. Route and clamp electric cables so that they will
not be exposed to rubbing, damp or bilge water in
the keelson.
3. The S-drive is electrically isolated (A) from the
engine and must never be used as a ground.
IMPORTANT! The S-drive must never be
C used as a ground or be electrically con-
A nected to other equipment such as the radio,
navigational equipment, the rudder, bathing
steps etc.
Protective grounds for the radio, navigational
equipment, rudder, bathing steps or other equip-
B ment with separate ground leads must be con-
nected to a common ground terminal (B).
4. There must be a main switch (C) connected to
the starter battery positive (+) terminal. The main
switch should cut off power to all power consum-
ing equipment and should be switched off when
the boat is not in use.

52
 Maintenance: Electrical system

5. If an auxiliary battery is in use, a main switch (D)

should be connected between its + terminal and
the fuse block. The main switch for the auxiliary
battery must cut off all power consuming equip-
ment connected to that battery and be turned off
when power is no longer needed.
All equipment connected to the auxiliary battery
should have separate switches.
To simultaneously charge two independent battery
circuits, fit a Volvo Penta charge distributor (ac-
D cessory) to the regular generator.

53
Maintenance: S drive and reverse gear

S drive and reverse gear

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

IMPORTANT! Improperly applied paint or the wrong type of paint on the keel can put the corrosion protec-
tion system out of action. For further information on painting see the chapter: Laying up/Launching

Oil level. Check

Remove the dipstick by turning counter-clockwise.
Wipe the dipstick and reinsert it in the drive / reverse
gear without screwing it in. Remove the dipstick
and check the oil level. The correct oil level is be-
tween the MAX and MIN markings.
Top up the oil as required using the dip stick tube. For
MAX
oil quality and capacity: See the chapter ”Technical
MAX
Data”.
MIN
MIN IMPORTANT! Do not overfill under any circum-
MS25 HS25 / S-drive stances. The oil level must always be within the
recommended level.

Oil change. S-drive

Remove the oil dipstick. Remove the plug on the
propeller gear housing and let the oil run out. Check
that the plug o-ring is intact. Replace if necessary.
Install the plug and o-ring. Top up oil to correct level
through the hole for the oil dipstick. For oil quality and
capacity: See the chapter ”Technical Data”.
Alternatively, it is possible to change oil without taking
the boat out of water, e.g. the oil change interval is
reached during season. Suck up oil using an oil pump
through the oil suction pipe – using this method
leaves approximately 0.5 liters (0.13 US gals) in the
S-drive. Top up oil to correct level through the hole for
the oil dipstick. For oil quality and capacity: See the
chapter ”Technical Data”.

IMPORTANT! If oil is colored gray then water

has entered the drive. Please contact an author-
ised Volvo Penta workshop.

54
 Maintenance: S drive and reverse gear

Oil change. MS25

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

IMPORTANT! Never overfill reverse gear. The

oil level should always lie at the recommended
level.

Oil change and filter cleaning. HS25

1. Clean around the lid, so that there is no risk that
dirt could fall down into the filter housing.
2. Undo screw (1) with a 6 mm Allen key. Remove
lid (2). Replace and oil in the new O-rings in the
lid.
3. Lift up the filter (3).
4. Suck up the oil with an oil drain pump, via the oil
filter housing. Connect hose to the suction pipe
(4) at the bottom of the housing.
5. Measure up the correct quantity of oil and fill the
1 reverse gear with the oil via the oil filter housing.
2 Please refer to the “Technical Data” chapter for oil
grades and volume.

IMPORTANT! Never over-fill the reverse gear.

6. Install the new filter (3) in the filter housing.
7. Install the lid. Tightening torque 5-8 Nm.
8. Put the control lever in neutral. Start and run the
engine at 1500 rpm for a few minutes to ensure
that the reverse gear oil cooler is filled with oil.
9. Stop the engine and check the oil level. Top up as neces-
sary.

55
Maintenance: S drive and reverse gear

Corrosion protection. Check

Check the sacrificial anode (1) on the drive and the
three sacrificial anodes (2) on the propeller. Replace
with a new anode if 50% of the material has perished
or at least once per season.

IMPORTANT! Use zinc sacrificial anodes for

salt water and magnesium anodes for freshwa-
ter.

Remedy any paintwork damage on the drive ac-

cording to the instruction in the chapter: Laying up /
Launching.
1 Replacing sacrificial anodes
2
1. Remove the propeller (see the next section).
2. Remove the sacrificial anodes. Thoroughly scrape
clean the mating surfaces on the drive and pro-
peller.
3. Apply thread sealant to the screws for the sacrifi-
cial anodes on the propeller.
4. Install the new sacrificial anodes. Tighten the ano-
des so that there is a good metal contact.
5. Reinstall the propeller.
The sacrificial anodes oxidise when they come into
contact with air. This reduces the galvanic protection.
There may even be oxidisation on the surface of a
completely new anode. Always clean the sacrificial
anodes before launching the boat.

IMPORTANT! Use emery paper. Do not steel

tools when cleaning, as these may damage the
galvanic protection.

Folding propeller. Cleaning

The propeller must be cleaned and lubricated once a
year. Remove the propeller and clean all components
thoroughly. Apply waterproof grease to the propeller
blade teeth and bearing surfaces so that the propel-
ler folds easily. Also apply waterproof grease to the
studs, spacing sleeve (drive), propeller shaft and hub.

WARNING! Prevent accidental starting. Remove

the ignition key and turn off the power at the
main switch before working on the propeller.

56
 Maintenance: S drive and reverse gear

Removing
1. Set the control lever in the ”Ahead” position.
A 2. Remove the propeller blade by first undoing the
locking screws (5) completely and then pressing
out the shaft studs (1).
1
3. Drive: Bend down the tabs of the tab washer (3)
and remove the locking screw (4), tab washer and
nut (6).
6 Reverse gear: Remove the nut (7), washer (8)
3
4 and then the locking screws (9).
4. Pull off the propeller hub and the spacing sleeve
(drive). Clean and lubricate as described.

5
Installing
1. Reinstall the spacing sleeve (drive) and the propel-
ler hub on the shaft.
2. Drive: Install the nut (6). Place a propeller blade
B on the hub and place a wooden block between the
propeller blade and the underwater hull. Tighten
locknut to 70 Nm.
Reverse gear: Install the washer (8) and tighten
the nut (7) to 220 Nm. Apply thread sealant to the
1
locking screws (9). After the locking screws have
been tightened apply thread sealant to the screw
5 heads as well.
3. Drive: Locate the tab washer (3) on the nut. Install
and tighten the locking screw (4) to 20 Nm and
6 bend one of the tab washer tabs to the screw
4 3 head.
IMPORTANT! The tab washer (3) must be
replaced if necessary. Use only Volvo Penta
original locking screws (4).
4. Install one propeller blade in the propeller hub
and push in the stud (1) in such a position so the
C groove in the stud is exactly centered in the hole
for the locking screw (5). Apply thread sealant to
the locking screw and tighten to 10 Nm.
1 5. Install the other blades in the same way. Check the
9
blades are at the same angle to the propeller shaft
and that they move easily.
7 8
9

5 A = 3-blade folding propeller (drive)

B = 2-blade folding propeller (drive)
C = 3-blade folding propeller (reverse)

57
Maintenance: S drive and reverse gear

Propeller shaft seal. Reverse gear

If the boat has a Volvo Penta shaft the shaft seal
must be vented and lubricated directly after launch-
ing.
Vent the bushing by pressing it together while press-
ing down on the shaft until water appears. Then
press in approx. 1 cc water repellent grease into
the seal.

IMPORTANT! The seal must be replaced every

500 running hours or every 5th year.

Rubber seal. S-drive

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

WARNING! The seal must be changed every

seven years or earlier if it is defective. This work
should be carried out by an authorized work-
shop.

58
Laying up and launching
Before taking the boat out of the water for winter/out-of-season storage have an authorized Volvo Penta work-
shop inspect the engine and other equipment.
Inhibition should be carried out to ensure that the engine and transmission are not damaged while out of com-
mission during the winter/off-season. It is important this is done properly and than nothing is forgotten. We have
therefore provided a checklist covering the most important points.

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

Inhibiting
The following are best carried out with the boat in ● Clean the outside of the engine. Do not use a high
the water: pressure spray to clean the engine. Touch up any
damaged areas of paintwork with Volvo Penta
● Change engine oil and replace oil filter.
original paint.
● Change oil in the reverse gear.
● Check all control cables and treat with rust inhibi-
tor.
● Replace fuel filter. Replace fuel pre-filter if in-
stalled.
● Repair any damaged areas of paintwork with
Volvo Penta original paint. NOTE! Read the spe-
● Run engine to normal operating temperature.
cial instructions on painting the drive under the
● Take the boat out of the water: heading: Painting the drive and underwater hull

The following should be carried out with the boat ● Disconnect battery leads. Clean and charge the
batteries. NOTE! A poorly charged battery may
out of the water: burst as a result of freezing.
● Clean the hull and drive directly after taking up the
boat (before it dries). ● Spray electrical system components with moisture
repellent spray.
IMPORTANT! Be careful when cleaning with a
high pressure water spray. Never direct the wa- ● Remove the propeller for storage. Grease the pro-
ter jet at the propeller shaft seal, grommets etc. peller shaft using water repellent grease. Disas-
semble folding propellers, clean and grease.
● Change oil in the drive.
● Check the rubber seal between the drive and hull
● Clean the vacuum valve and seawater filter (ac- carefully.
cessory).

● Clean and inhibit the seawater system.

● Remove the impeller from the seawater pump.

Store the impeller in a sealed plastic bag in a cool
place.
● Check the condition of the engine coolant anti-
freeze. Top up if required.
IMPORTANT! An anti-corrosion mixture
in the engine coolant system provides no
protection against freezing. If there is any
possibility the engine will be subjected to
freezing temperatures then the system must
be drained.

● Drain any water and contaminants from the fuel

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

59
Maintenance: Laying up and launching

Bringing out of storage

● Check oil level in the engine and drive/reverse ● Paint the drive and hull: See next page.
gear. Top up if necessary. If there is inhibiting oil
in the system drain and fill with new oil, change oil ● Check the sacrificial anode on the drive. If there
filter. For correct oil grade: See the chapter ”Tech- is less than 50% of the anode left it must be
nical Data”. replaced. Clean with emery cloth just before the
boat is launched.
● Drain the antifreeze from the seawater system.
IMPORTANT! Do not use a wire brush or other
● Install the impeller in the seawater pump (replace steel tools when cleaning, as these may dam-
if the old one looks worn). age the galvanic protection.
● Close/tighten drain cocks/plugs.
● Reinstall the propeller.
● Check drive belts.
● Launch the boat. Check for leaks.
● Check the condition of rubber hoses and tighten
hose clamps. ● Vent and lubricate the propeller shaft seal (reverse
gear).
● Check engine coolant level and antifreeze protec-
tion. Top up if necessary. ● Start the engine. Check that there are no fuel,
engine coolant or exhaust gas leaks and that all
● Connect the fully charged batteries. control functions are operating.

60
 Maintenance: Laying up and launching

Painting the drive and underwater

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

IMPORTANT! Find out what regulations apply to

the use of anti-fouling agents.

Drive
The paintwork is part of the drive’s anti-corrosion
protection and it is therefore important that any paint-
work damage is remedied.
Sand down metal surfaces lightly using a 120 grade
paper and a finer grade for painted surfaces. Wash
off using thinners or similar. Any pores in the surface
should be filled and sanded down. Paint using Volvo
Penta original primer and topcoat. Let the paint dry.
The drive should be painted with Volvo Penta anti-
fouling to prevent fouling. Apply according to the
instructions on the packaging.

IMPORTANT! The sacrificial anodes on the

drive and propeller must not be painted.

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

61
In case of emergency
Despite regular maintenance according to the maintenance schedule and perfect operation, it may occur faults
which must be attended to before the boat can travel further. This chapter contains tips for rectifying some of the
possible faults.

Starting using auxiliary batteries

WARNING! Batteries produce oxyhydrogen.
This gas is easily ignited and highly volatile. A
C B short-circuit, naked flame or spark can cause
a large explosion. Ensure that the ventilation is
good.
Never mix up battery positive and negative
terminals. This may cause sparks and an explo-
sion.
A
1. Check the auxiliary batteries have the same rated
voltage as the engine’s system voltage.
D
2. First connect the red jump lead to the discharged
battery’s + terminal (A) and then to the auxiliary
battery’s + terminal (B).

3. First connect the black jump lead to the auxiliary

battery’s - terminal (C) and then to a site (D)
where there is good contact with the cylinder
block as far away from the discharged battery as
possible.

4. Start the engine and run it at a fast idle for ap-

proximately ten minutes to charge the battery.

WARNING! Approaching or working on a run-

ning engine is dangerous. Watch out for rotating
components and hot surfaces.
Do not touch the connections while trying to
start the engine: This may cause sparks. Do not
lean over the batteries.

5. Stop the engine. Remove the jump leads in ex-

actly the opposite order to which you put them on.

62
 In case of emergency

Fault-tracing
A number of symptoms and possible reasons for engine problems are described in the table below. In case of
faults or mishaps which you cannot solve, always contact the Volvo Penta dealership.

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

Symptoms and possible causes

Starter motor not turning or slow 1, 2
Engine will not start 4, 5, 6, 7, 8, 9
Engine starts but stops again 6, 7, 8, 9
Engine difficult to start 6, 7, 8, 9
Engine does not reach correct speed at wide open throttle (WOT) 7, 8, 9, 10, 11, 12, 13, 18
Engine knocks 14
Engine runs unevenly 6, 7, 8, 9, 13, 14
Engine vibrates 18, 19
High fuel consumption 10, 11, 13, 15, 18
Black exhaust smoke 5, 13, 15, 18
Blue or white exhaust smoke 15, 25
Low oil pressure 16, 17
Engine coolant temperature too high 20, 21, 22, 23, 24
No or poor charging 2, 26

1. Discharged battery 10. Boat abnormally loaded 19. Defective engine mounting
2. Loose connection/open-circuit 11. Fouling on underwater hull/drive/propeller 20. Too little coolant
4. Stop control pulled out 12. Limited speed control lever movement 21. Blocked seawater intake/pipe/filter
5. Inadequate pre-heating 13. Insufficient air supply 22. Circulation pump drive belt slipping
6. Lack of fuel 14. Engine coolant temperature too high 23. Defective impeller
7. Fouled fuel filter 15. Engine coolant temperature is too low 24. Defective/incorrect thermostat
8. Air in the fuel injection system 16. Lubricating oil level too low 25. Lubricating oil level too high
9. Water/contaminants in the fuel 17. Blocked fuel filter 26. Generator drive belt slipping
18. Defective/incorrect propeller

63
Technical Data
Engine model
Engine model.............................................................. D2-55 D2-75
Crankshaft power, kW (hp)......................................... 41 (55) 55 (75)
Propeller shaft power, kW (hp)................................... 39 (53) 53 (72)

General
After market designation............................................. D2-55 E D2-75 C
Dispalcement, l (in3)................................................... 2.2 (134) 2.2 (134)
Number of cylinders.................................................... 4 4
Bore/stroke, mm (in)................................................... 84/100 (3.31/3.94) 84/100 (3.31/3.94)
Compression ratio...................................................... 23.3:1 23.3:1
Engine speed, rpm..................................................... 3000 2700-3000
Idling speed, rpm........................................................ 850 ±25 850 ±25
Rotation, viewed from in front..................................... Clockwise Clockwise
Max. permitted rake backwards while running............ 20° 20°
Max. list while running................................................ 30° 30°
Weight, dry engine, kg (lb).......................................... 225 (496) 233 (514)

Lubrication system
Oil volume incl. oil filter, approx.:
no engine inclination............................................... 10.5 liters (2.8 US gals) 10.5 liters (2.8 US gals)
Viscosity at –5° – +50°C............................................. SAE 15W/40, SAE 15W/40,
SAE 20W/50 SAE 20W/50
Oil drain plug tightening torque................................... 30–40 Nm (22-30 lbf.ft) 30–40 Nm (22-30 lbf.ft)

* Constant ambient air temperature

Oil grade 1) Oil change interval, reached first in operation 2):

VDS-3
or VDS-2 and ACEA E7 3)
or VDS-2 and Global DHD-1 500 hr. or 12 months.
or VDS-2 and API CH-4
or VDS-2 and API CI-4

NOTE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it comp-
lies 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.

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

64
 Technical Data

Cooling system
Thermostats, no.......................................................... 1 screws
The thermostat starts opening at............................... 83° ±2°C (178-185°F)
fully open at........................................... 95°C (203°F)
Freshwater system capacity, approx........................... 9.5 liters (2.5 US gals)

Electrical system
System voltage........................................................... 12 V
Battery capacity (starter battery)................................ 70 Ah
AC generator voltage/max. current........................... 14 V/115 A
output approx..................................... 1610 W
Starter motor, output approx....................................... 2.0 kW

Reverse gear
MS25
Type designation......................................................... MS25L MS25A
Gear ratio
Left rotating (Position B)........................................ 2.27:1 ; 2.74:1 2.23:1 ; 2.74:1
Right rotating (Position A)..................................... 2.10:1 ; 2.72:1 2.74:1
Angle (output shaft):................................................... 0° 8°
Oil volume, approx...................................................... 0.75 liters (0.79 US quarts) 0.75 liters (0.79 US quarts)
Oil grade .................................................................... ATF (Dexron II, III) ATF (Dexron II, III)
Weight........................................................................ 25 kg (55 lbs) 25 kg (55 lbs)

HS25
Type designation......................................................... HS25A-B
Gear ratio.................................................................... 2.29:1 ; 2.71:1
Angle (output shaft).................................................... 8°
Oil volume, approx...................................................... 1.8 liters (1.9 US quarts)
Oil grade .................................................................... ATF (Dexron II, III)
Weight........................................................................ 31 kg (68 lbs)

Sailing boat drive

Type designation......................................................... 130S, 130SR 150S, 150SR
Gear ratio.................................................................... 2.19:1 2.19:1
Oil volume, approx...................................................... 2.9 liters (3.1 US quarts) 3.0 liters (3.2 US quarts)
Oil grade .................................................................... ATF (Dexron II, III) ATF (Dexron II, III)
Weight........................................................................ 26.5 kg (58 lbs) 27 kg (59 lbs)
Tightening torque:
oil drain plug............................................................ 10 ±5 Nm (7.4 ±3.7 lbf.ft) 10 ±5 Nm (7.4 ±3.7 lbf.ft)

Fuel specification
Fuel must meet national and international standards at least. For example:
EN 590 (with national environmental and cold standards)
ASTM D 975 No 1-D and 2-D
JIS KK 2204
Sulphur content: According to statutory requirements.
Fuels with low density (“urban diesel” in Sweden and “city diesel” in Finland) can cause a drop in
output of 5% and an increase in fuel consumption of 2–3%.

65
 Notes
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66
 Notes
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67
 ✂
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Post or fax this coupon to: Publication number: 774 7110

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Sweden
Fax: +46 31 545 772
Orders can also be placed via
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commande à: Nom
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Nótese que el ofrecimiento vale durante 12 meses después de la fecha de entrega

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Si ricorda che l’offerta è valida per 12 mesi dalla data di consegna dell’imbarcazio-
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69
 ✂
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70
 ✂
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71
 ✂
Evet lütfen,
ücretsiz Türkçe kullanım el kitabı istiyorum
Bu kuponu şu adrese Yayın numarası: 7747121
postalayın veya fakslayın:

42200/615001/155099900192
Ýsim
Dokument & Distribution center
Ordermottagningen
Adres
ARU 2, Avd. 64620
SE-405 08 Göteborg
Ýsveç
Faks: +46 31 545 772

Sipariþler Ýnternet üzerinden de

verilebilir: Ülke
http://www.volvopenta.com/­
manual/coupon NB! Bu teklif, teknenin teslim edilmesinden itibaren 12 aylýk bir süre için geçerlidir.
Bu süre sonunda ürün daðýtýmý stoklarla sýnýrlýdýr.

72
7747110 English 01-2007