operator’s manual d5/d7
TRANSCRIPT
Operator’s manualD5/D7
WARNING! Operating, servicing and maintaining a marine vessel can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead which are known to the State of California to cause cancer and birth defects or other reproductive harm.
Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust when operating, servicing and maintaining the engine.
• Always start and operate the engine in a well-ventilated area.• If in an enclosed area, vent the exhaust to the outside.• Wear gloves or wash your hands frequently when servicing the vessel.• Do not modify or tamper with the exhaust system.• Do not idle the engine except as necessary.
For more informationwww.P65warnings.ca.gov/marinewww.p65warnings.ca.gov/products/diesel
© 2021 AB VOLVO PENTA Volvo reserves the right to make changes Printed on environmentally friendly paper
Table of Content
Foreword ...................................................................................................... 3Safety Information ...................................................................................... 4
Maneuvering .......................................................................................... 12Introduction ............................................................................................... 13
About this Manual ................................................................................... 13Warranty .................................................................................................. 14Your New Boat ........................................................................................ 14Running in the engine ............................................................................. 15Fuel, oils and coolant .............................................................................. 15Maintenance and replacement parts ....................................................... 15Excessive strain on a product and components ...................................... 16Volvo Penta EVC system, integrity and modification .............................. 16Installation and use of Volvo Penta External Helm ................................. 16Environmental care ................................................................................. 17Recording engine data ............................................................................ 17Certified Engines ..................................................................................... 18Volvo Penta Dealer Network ................................................................... 19Volvo Penta Action Service ..................................................................... 19
Instruments and Controls ........................................................................ 20Instrument Panel ..................................................................................... 20Warning display ....................................................................................... 21Ignition switch .......................................................................................... 21Controls ................................................................................................. 22
Dual lever control ................................................................................. 23Optional ..................................................................................................... 25
Trolling ................................................................................................... 25Slip Valve ............................................................................................. 25
Propeller Shaft Brake ............................................................................ 25Starting ...................................................................................................... 26
Before Starting ...................................................................................... 26Starting the Engine ............................................................................... 27
Operation ................................................................................................... 29Reading the Instruments ...................................................................... 29Alarms .................................................................................................... 30Maneuvering .......................................................................................... 31
Cruising Speed .................................................................................... 32Engine Shutdown ...................................................................................... 33
Stop the Engine ..................................................................................... 33Auxiliary stop ........................................................................................ 33
After Engine Shutdown ........................................................................ 34Operation Break ................................................................................... 34Cold Weather Precautions ................................................................... 35
Fault handling ........................................................................................... 36Fault Tracing .......................................................................................... 36
In Case of Emergency .............................................................................. 37Starting Using Auxiliary Batteries ....................................................... 37
Maintenance Schedule ............................................................................. 38Maintenance .............................................................................................. 39
Orientation ............................................................................................... 39Engine, General ..................................................................................... 40
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Air Filter, Change ................................................................................. 40Drive belt, check and change ............................................................... 41
Lubrication System ............................................................................... 43Oil level, checking and topping up ....................................................... 43Engine Oil, Change .............................................................................. 44Oil filter, Change .................................................................................. 45
Fuel System ........................................................................................... 46Fuel filter, Change ................................................................................ 46Fuel system, bleeding .......................................................................... 47Fuel pre-filter ........................................................................................ 48
Freshwater System ............................................................................... 49Coolant, Draining ................................................................................. 51Freshwater system, Flushing ............................................................... 52
Seawater System ................................................................................... 53Seawater System, Draining ................................................................. 54Anodes, Check and Change ................................................................ 55Impeller, Check and Change ............................................................... 55Seawater Filter, Check and Cleaning .................................................. 56Intake Manifold, Checking the Drain Hole ............................................ 56
Electrical System .................................................................................. 57Fuses ................................................................................................... 57Electrical Connections ......................................................................... 57Battery .................................................................................................. 58Electrical Installations .......................................................................... 59Electrical Welding ................................................................................ 61
Reversing gear ...................................................................................... 62Oil level, checking and topping up ....................................................... 62Transmission Oil, Change .................................................................... 63Oil Strainer, Cleaning ........................................................................... 64
Storage ....................................................................................................... 65Bringing Out of Storage ....................................................................... 66
Technical Data ........................................................................................... 67Viscosity .................................................................................................. 68Coolant, Mixing ....................................................................................... 72Identification Numbers ......................................................................... 74
Index ........................................................................................................... 75
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ForewordWelcome!Congratulations on your new boat equipped with a Volvo Penta marine engine.Volvo Penta engines are designed to fulfill Volvo’s core values; quality, safety andenvironmental care. After more than 100 years as an engine manufacturer, theVolvo Penta brand has also become a symbol of reliability, technical innovation, top-of-the-range performance and long service life. Volvo Penta marine engines are used allover the world, in all possible operating conditions for professional as well as leisurepurposes.
Make sure to thoroughly read through this Operator’s Manual and take necessary actionsregarding running and maintenance before your maiden voyage. It contains theinformation you need to be able to operate and maintain the engine safely and correctly.Pay careful attention to the safety instructions included in the manual.
As the owner of a Volvo Penta marine engine, you become part of a worldwide networkof dealers and service workshops that assist you with technical advice, servicerequirements and replacement parts. Contact your nearest authorized Volvo Penta dealerfor assistance.
It is possible to buy additional literature about your Volvo Penta engine, e.g. the Service& Maintenance manual. More information on how to do this can be found atwww.volvopenta.com.
Information about your closest Volvo Penta dealer and other useful news andinformation can be found at www.volvopenta.com and by following Volvo Penta onFacebook.
www.volvopenta.com
www.facebook.com/volvopenta
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Safety InformationThis chapter describes how safety precautions arepresented in the manual and on the product. Read thechapter through very carefully before you start theengine or do any maintenance or service. It has to dowith your safety; an incorrect operation can lead topersonal injury and damage to products or property.It also gives you an introduction to the basic safetyrules for using and looking after the engine.
If anything remains unclear or if you are unsure ofsomething, contact your Volvo Penta dealer forassistance.
IMPORTANT:Always follow local safety instructions andregulations.
Safety texts have the following order of priority:
DANGER!Indicates a hazardous situation, which, if not avoided, result in death or serious injury.
WARNING!Indicates a hazardous situation, which, if not avoided, could result in death or seriouspersonal injury.
CAUTION!Indicates a hazardous situation, which, if not avoided, could result in minor or moderatepersonal injury.
IMPORTANT:Indicates a situation, which, if not avoided, could result in property damage.
NOTICE! Used to draw attention to important information that facilitates work oroperations.
!This symbol is may be used on the product to call your attention to the fact that this issafety information. Always read such information very carefully.
Make sure that warning and information symbols on the engine are clearly visible andlegible. Replace symbols that have been damaged or have been painted over.
In some cases, this symbol is used on our products and refers to important informationin the Operator’s Manual.
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Most chemicals such as engine and transmission oils,glycol, petrol and diesel oil and chemicals used inworkshops such as degreasing agents, paint andsolvents are harmful to health.
Carefully read the instructions on the productpackaging! Always follow the safety regulations, suchas the use of protective masks, goggles, gloves, etc.Make sure that other personnel are not exposed tosubstances that are hazardous to health. Ensure goodventilation.
Manage used and leftover chemicals in the prescribedmanner.
Daily Checks WARNING!
Do not start the engine if there is reason to suspect fuelleaks or if there is explosive material nearby.
Make it a habit to give the engine and enginecompartment a visual check before the engine isstarted and after operations, once the engine hasstopped. This helps you to quickly discover fuel,coolant or oil leakages or any other abnormality thathas occurred, or is about to occur.
Personal safety equipment CAUTION!
Always use appropriate safety equipment. Personalprotective equipment does not eliminate the risk ofinjury but it will reduce the degree of injury if anaccident does happen.
Some examples are ear protection, eye and faceprotection, protective footwear, personal protectiveequipment, head protection, protective clothing,gloves and respirators.
WARNING!Ensure that all machine guards and safety devices arein place and are functional.
CAUTION!Never use tools or products that show signs ofdamage.
Protect your eyes CAUTION!
Wear safety glasses.
Always wear safety glasses if there is a risk ofsplintering, sparks and spray from the electrolyte (so-called battery acid), or other chemicals. Your eyes arevery delicate and damage can result in loss of sight!
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Protect your skin CAUTION!
Risk of skin damage.
Avoid getting oil on your skin! Prolonged or repeatedexposure to oil can dry out the skin. Thereafter,irritation, dryness and eczema and other skin problemsmay occur.
Use protective gloves and avoid oil-soaked clothesand rags. Wash regularly, especially before eating.Wear suitable protective creams to prevent skin fromdrying out and to facilitate cleaning.
Fire safety WARNING!
Fire and Explosion Risk!Accidental spark could ignite fuel vapors.
All fuels – as well as many lubricants and chemicals –are flammable. Do not allow open flames or sparksnear them. Smoking forbidden! Hydrogen from thebatteries is also very flammable and explosive incertain mixture with air.
Ensure that the workplace is well ventilated and takethe necessary precautions before welding or grindingbegins. Always ensure that there is a fire extinguisherclose at hand in the work area.
Spare parts — safety WARNING!
Always use spare parts with the same quality asgenuine Volvo Penta parts to minimize the risk of anexplosion or fire.
Components in fuel systems and electrical systems onVolvo Penta engines are designed and manufacturedto minimize the risk of explosions and fire, inaccordance with applicable legal requirements.
Used oils, filters and chemicals etc. WARNING!
Risk of fire.Store fuel soaked rags and other flammable materialso that there is no danger of them catching fire.
Oil-soaked rags can spontaneously ignite undercertain circumstances.
IMPORTANT:Used fuel and oil filters are environmentally hazardouswaste and must be taken to an approved wastemanagement facility for correct handling, as must anyused lubricating oil, contaminated fuel, paint residue,solvents, degreasers and wash residue.
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Prevent start of the engine WARNING!
Immobilize the engine by turning off the power supplywith the main switch(es) and lock it (them) in the offposition before starting work. Place a warning noticeat the main switch.If the engine is equipped with BMS (BatteryManagement System), always disconnect both batterycables from the battery terminals.
Ventilation when running the engine WARNING!
Only start the engine in a well-ventilated area. Ifoperating the engine in a closed area ensure that thereis exhaust ventilation leading out of the work area toremove exhaust gases and crankcase ventilationemissions.
The engine must not be operated in areas where thereare explosive materials or stored gas.
Rotating parts and hot surfaces DANGER!
Working with or approaching a running engine is asafety risk. Watch out for rotating components and hotsurfaces.If the engine is in operation and operates anotherdevice, you must not, under any circumstances,staying close to the engine.
Work on running engines is strictly prohibited. Thereare however adjustments that require the engine to berun. Approaching a running engine is a safety risk.Loose clothing and long hair can get caught in therotating parts; careless movements or a dropped toolcan lead to serious personal injury.
Be careful to avoid hot surfaces (exhaust pipes,turbochargers, charge air manifolds, start elementsetc.) and hot fluids in pipes and hoses on engines thatare running or have just stopped. Re-install allprotective covers that were removed duringmaintenance work before starting the engine.
Information on the engineIMPORTANT:
Make sure that all warning and information decals onthe product are always visible. Replace decals whichhave been damaged or painted over.
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Prohibition on use of start spray WARNING!
Never use start spray or similar agents to start anengine. This may cause an explosion in the inletmanifold. Risk of personal injury.
Before start of engine WARNING!
Never start the engine if there is reason to suspect fueland/or gas leaks, or if there is explosive materialnearby.
IMPORTANT:Only start the engine with the air filter and protectivecaps fitted. Foreign objects in the inlet line could causemachine damage. Also make sure that no tools or otherparts have been left next to the engine.
WARNING!Never start the engine with the valve cover removed.There is a risk of personal injury.For engines with turbochargers, the rotatingcompressor turbine can in addition cause seriouspersonal injuries.
Before any work on the electrical system WARNING!
Always stop the engine first. Then disconnect thecurrent at the main switches and any external powersupply before working on the electrical system – tominimize the risk of electrical hazards.
IMPORTANT:Never disconnect the current using the main switcheswhen the engine is running or by disconnecting thebattery cables.The alternator and electronics could be damaged.
Avoid damage to the engine controlmodule and other electronicsIMPORTANT:
Switch off the main switch before connecting ordisconnecting a connector.
Before welding workIMPORTANT:
Before any work with electric weld can begin, theconnection to all control units must be disconnected.After finished welding, re-connect the connection to allcontrol units before connecting any battery cable.
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Before any work on the cooling system WARNING!
Stop the engine and let it cool before starting work onthe cooling system. Hot fluids and hot surfaces cancause burns.
Risk of water penetration/sinking WARNING!
If a launched boat is equipped with sea water tap andsafety valve, ensure that these are closed before anywork is allowed to begin on the cooling system.Remember to open the tap and valve before startingthe engine!
Hot coolant under pressure CAUTION!
Hot coolant can cause burns. Avoid opening the fillercap for the coolant when the engine is still hot. Steamor hot coolant can spray out and system pressure islost.
Open the filler cap slowly and release the pressure inthe cooling system if the filler cap or valve must beopened – or if a plug or a coolant hose must beremoved from a hot engine.
Hot oil under pressure CAUTION!
Hot oil can cause burns. Avoid getting hot oil on theskin. Ensure that the lubrication system is notpressurized before starting any work. Never start oroperate the engine without the oil filler cap is on. Thereis a risk that hot oil can spray out.
Refueling WARNING!
There is always a risk of fire and explosion duringrefueling. Smoking is forbidden and the engine mustbe stopped.
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Proper fuel qualityIMPORTANT:
Always use the fuel recommended by Volvo Penta.See Technical Data in Operator’s Manual. Other fuelcan damage the engine.Wrong fuel quality can also lead to higher servicecosts.
WARNING!Risk of personal injury.Wrong fuel quality in a diesel engine can cause the fuelcontrol mechanism to bind which can cause the engineto overspeed!
Legal requirements to use proper fuelIMPORTANT:
To meet regulatory requirements for certified emissionlevels must always recommended fuel according toTechnical Data in the Operator’s Manual be used.
At any leak detection on the fuel system WARNING!
Wear safety goggles!Be extremely careful when searching for leaks in thefuel system high-pressure circuits. There is very highpressure in the jet from pipes and injectors. The fuelmay penetrate the tissue and cause serious risk ofblood infection (septicemia).
Handling of fuel pipesIMPORTANT:
High pressure pipes for fuel must not be bent orstraightened under any circumstances. Cracks mayoccur. Damaged pipes must be replaced.
Safe handling of batteries WARNING!
Risk of fire and explosion. Never allow an open flameor electric sparks near the batteries.
A spark caused by an incorrectly connected batterycan be enough for the battery to explode with seriousinjuries.
Do not touch the connections during start attempts.Sparking hazard! Do not lean over batteries.
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Correct polarity of the batteriesIMPORTANT:
Make sure that the positive (+) and negative (–) batterycables are correctly connected to the correspondingbattery terminals. Wrong connection may causesevere damage to electrical equipment.
Risks of electrolyte in batteries WARNING!
Always wear protective goggles when charging orhandling batteries.Battery electrolyte is highly corrosive.
Rinse immediately with copious amounts of water if theelectrolyte gets in your eyes. Search directly after therinsing help by medical staff.
If it comes electrolyte to unprotected skin, washimmediately with soap and water.
Layout of the battery compartmentIMPORTANT:
Make sure the battery compartment is designedaccording to current safety standards.
Cleaning the engine and componentsIMPORTANT:
Never use a high pressure washer for cleaning ofengine or engine components.
Cleanliness for sensitive componentsIMPORTANT:
Observe meticulous cleanliness when handlingsystem components.Even minimal amounts of dirt could cause abreakdown.
Adjustment of the clutch CAUTION!
Clutch adjustments must be carried out with the enginestopped.
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Maneuvering WARNING!
A rotating propeller can cause serious injury. Checkthat nobody is in the water before engaging ahead orastern. Never drive near bathers or in areas wherepeople could be in the water.
To avoid passengers falling overboard, refrain fromextreme and sudden rudder movements and ahead/astern movements.
Lanyard switchWe recommend installing and using a lanyard switch(optional), especially if the boat is capable of highspeeds. The lanyard switch stops the engine if thedriver looses control of the boat.
Accidents at seaMaritime rescue statistics show that a large number ofboat accidents are caused by inadequate engine andboat maintenance and the lack of safety equipment.Make sure that the boat engine is properly maintainedby making sure that the recommended service isperformed, and that necessary safety equipment isavailable and functional.
Stern turbulence WARNING!
Carbon Monoxide Poisoning. When the boat movesforward, an area of lower pressure air is formed behindthe boat — so-called turbulence. In certain conditions,this turbulence can be powerful enough to draw theexhaust fumes into the cockpit or cabin, creating a riskof carbon monoxide poisoning to people on board.
The turbulence problem is most pronounced on tall,broad-beamed boats with a transom stern. But evenfor other boat types, low-pressure suction can be aproblem in certain conditions, such as driving withcockpit awnings rigged. Other factors that can increasethe effect of turbulence are wind conditions, loaddistribution, swell, trim, open hatches and ventilatorsetc.
Most modern boats are, however, designed so that theproblem of low-pressure suction is very rare. Shouldturbulence nevertheless occur, hatches or ventilatorsmust not be opened since this might exacerbate theproblem. Instead, try to change the speed, trim or loaddistribution. If possible, take down or open the cockpitawning. Contact your boat dealer for the best solutionfor your boat.
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IntroductionCheck that you heave received the correctoperator’s manual before continuing reading. Ifnot, please contact your Volvo Penta dealer. Readthe Operator’s Manual carefully and learn to handle theengine, controls and other equipment in a safe mannerbefore you start the engine.
For engine designations, refer to TechnicalData, page 67. The designation is stated on theengine plate, refer to Technical Data, page 74.
The illustrations in this book may cover several producttypes, which means that there may be slightdifferences between the illustrations and thepurchased product. This does, however, not affect thevalidity of the information and/or instructions in themanual. Volvo Penta reserves the right to makealterations to specifications, design features, andillustrations without prior notice.
At service, software can be updated that affects thefunctionality described in this manual.
About this ManualThis Operator's Manual has been prepared to give youthe greatest possible benefit from your Volvo Pentamarine engine. It contains necessary informationregarding safe and correct engine operation andmaintenance.
Always have the Operator's Manual available. Store itsafely and do not forget to hand it over to the nextowner if you sell your boat.
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WarrantyYour new Volvo Penta marine engine is covered by alimited warranty, subject to the conditions compiled inthe Warranty Information. Note that AB Volvo Penta’sliability is limited to the specification in the WarrantyInformation and Emission Control System WarrantyStatement.
Volvo Penta warranty terms and conditions can befound via http://manual.volvopenta.com/coupon/. Usethe publication number (at the bottom of each page) ofthis the manual as reference number.
Read the information carefully, as soon as possibleafter delivery. It includes important information aboutservice and maintenance; the owner is responsible forbeing familiar with, checking and implementing these.Otherwise AB Volvo Penta may deny its warrantyobligations in part or in full.
NOTICE! Make sure that a Commissioning has beencarried out on your Volvo Penta engine. This should bedone together with your Volvo Penta dealer whenfinalizing the purchase. Without a properCommissioning registration the warranty will not bevalid.
Contact your Volvo Penta dealer if you have notreceived the Warranty Information or ServiceBook.
Your New BoatCarefully read through the instructions and otherinformation that is delivered with the new boat. Learnto handle the engine, controls and other equipment ina safe and proper manner. If this is your first boat or ifthe boat type is unfamiliar to you, we recommend thatyou practice maneuvering the boat before casting offon the maiden voyage. Make yourself familiar with theboat’s seakeeping and maneuvering qualities atdifferent speeds, sea states and load conditions.
Bear in mind that a person in charge of a boat underway bears the legal responsibility of knowing andfollowing the regulations for passage and safety afloat.Learn which regulations apply to you and your watersby contacting the relevant authorities or maritimesafety organization. We recommend that you completea boat driver’s course.
Introduction
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Running in the engineThe engine must be run in during the first 10 hours ofoperation. Do this by using the engine in normaloperation, where full load is only applied for shortperiods of time. Never run the engine at constantspeed for any longer periods of time.
Since oil consumption is higher during the running inperiod, be sure to control the oil level more frequentlythan normally recommended. See Maintenance formore information.
Fuel, oils and coolantOnly use the fuels and oils recommended in theOperator’s Manual, other viscosity and quality maycause malfunctions, increased fuel consumption andpossibly shorten the life of the engine.
Always change the oil, oil filters and fuel filters at thespecified maintenance intervals.
Make sure to always use suitable and correctly mixedcoolant.
If an unsuitable coolant has been used, or if theinstructions for coolant mixture have not beenfollowed, future warranty claims related to engine andaccessories may be denied.
Maintenance and replacement partsVolvo Penta engines are designed for maximumreliability and long life and built to withstand ademanding environment. The engines are alsodesigned to have a minimal environmental impact.These qualities will be maintained through regularservicing and the use of spare parts with the samequality as genuine Volvo Penta parts. If reliable andpurpose-built parts are not used, your safety, health,and the machine’s function may be compromised.Volvo Penta has a world-wide network of authorizeddealers.
The authorized dealers are Volvo Penta productspecialists, and have the accessories, genuine parts,test equipment and special tools needed for highquality service and repair work. Always observe themaintenance intervals in the manual, the completeService Protocol can be found at volvopenta.com.Remember to note the engine / transmissionidentification number when you order service andspare parts.
Introduction
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Excessive strain on a product andcomponentsVolvo Penta products and components are notdimensioned for external loads. Never stand or steponto an engine, transmission or its components. Loadscan bring about damage and the malfunction of aproduct or property.
Volvo Penta EVC system, integrityand modificationThe Electronic Vessel Control (EVC) system is acomplete vessel control system for engine, gear andvessel steering control. Modifying the EVC system orconnecting spare parts or systems that do not complywith the quality of genuine Volvo Penta parts mayadversely affect the system performance, safety andwarranty coverage.
Volvo Penta recommends only the use of electronicsystems and spare parts with the same quality asgenuine Volvo Penta parts. Contact your local VolvoPenta dealer for detailed information and advice.
Installation and use of Volvo PentaExternal HelmInstallation and use of Volvo Penta External Helm.Volvo Penta External Helm enables use of controlsystems provided by third parties, including remotesystems, by connection to Volvo Penta EVC Systemthrough Volvo Penta External Helm. Such controlsystems are in this section referred to as third partysystems. The third party system features necessary toenable connection with the Volvo Penta External Helmare specified in the External Helm InterfaceSpecification.
Volvo Penta EVC system safety is based on mannedoperations of the vessel according to applicable laws.The safety features of Volvo Penta EVC system aredescribed throughout the Operators Manual. Any useof third party systems through Volvo Penta ExternalHelm is on the full responsibility of the operator. It isthe operator’s responsibility to stay alert, operate thevessel safely, adopt adequate additional safetyfeatures relevant due to the use of the third partysystem, and be in control of the vessel at all timesaccording to applicable laws. Volvo Penta will notassume any liability for the functionality of third partysystems and shall not in any event be liable for anydamage, direct or indirect, to property, person orotherwise, arising as a result of any usage of third partysystems enabled by Volvo Penta External Helm.
Introduction
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Environmental careEnvironmental care is a core value at Volvo Penta.Energy efficiency and low emissions are among themost important product related aspects and priorityfocus areas for Volvo Penta business. Several of theglobal challenges the world faces are directly orindirectly related to power industries and transports.We recognize that Volvo Penta is part of theenvironmental problems, but we are also convincedthat we are a part of the solution.
Volvo Penta currently has a broad engine program inwhich great advances have been made in reducingexhaust emissions in the same time as the fuelconsumption has been improved. Through regularmaintenance, the Volvo Penta engines retain its lowfuel consumption and low emissions. We hope that youwill be keen to preserve these qualities.
Always follow the directions in the Operator’s Manualregarding fuel grades, operation and maintenance toavoid unnecessary environmental impact. Contactyour Volvo Penta dealer if you notice any changessuch as increased fuel consumption or exhaust smoke.
Remember always to hand in environmentalhazardous waste such as drained oil, coolant, oldbatteries, etc. for treatment at a recycling facility. Ourunited efforts can make a valuable contribution to theenvironment.
Recording engine dataOne or more computers in your Volvo Penta enginecan record detailed information. Data — such as usageand information of other systems and modules on theengine — can be included. This data can include infor-mation such as boat position and usage. Only a lim-ited amount of data can be stored.
AB Volvo Penta and authorized workshops will notdistribute this stored information without permission.AB Volvo Penta may, however, be forced to providethis information if required by national legislation. Ingeneral, AB Volvo Penta and authorised workshopsmay read and use the information.
Introduction
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Certified EnginesIf you own an emission-certified engine used in anarea where exhaust emissions are regulated bylaw, this places special demands on the care andmaintenance you provide your engine.
NOTICE! Neglects or failure to follow the points listedhere may invalidate the engine emission certificate.This means AB Volvo Penta can no longer guaranteeengine conformity with the certified model. Volvo Pentais not responsible for damages or costs arising as aresult of this.
• Certification means that an engine type has beenchecked and approved by the relevant authority.The engine manufacturer guarantees that allengines of the same type are equivalent to thecertified engine.
• It is the responsibility of the operator/user to ensurethat no intentional misuse of the engine takes place.
• Volvo Penta maintenance and service intervalsmust be complied with.
• Any case of malfunction must be rectified withoutdelay.
• Only use genuine Volvo Penta parts or spare partswith the same quality as genuine Volvo Penta parts.
• Volvo Penta recommends that service to injectionpumps, pump settings and injectors always arecarried out by a qualified workshop.
• The engine must not be converted or modified in anyway, except with accessories and service kits thatVolvo Penta has approved for the engine.
• No installation changes to the exhaust pipe andengine air inlet ducts may be made.
• No warranty seals (where present on the product)may be broken by unauthorized persons.
• The general instructions in the Operator's Manualconcerning operation, service and maintenanceapply.
Introduction
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Volvo Penta Dealer NetworkThe Volvo Penta global network of authorized dealersis at your service. We strongly recommend that youtake your product to an authorized Volvo Penta dealerfor service and repair. They are specialists in VolvoPenta products and have the accessories, genuineVolvo Penta parts, the special tools and the latestservice information for high quality service and repairwork.
Dealer Locator ServicesLocate the nearest Volvo Penta dealer through ourdealer locator on www.volvopenta.com or downloadthe dealer locator app to your smartphone.
Volvo Penta Action ServiceOur global dealer network, your first line of contact, isbacked up by Volvo Penta Action Service, a phonebased breakdown and support service providingassistance 24 hours a day, every day of the year.
How it worksA dedicated operator will support you all the waythrough your case and keep you updated on status andprogress.Whenever on-site assistance or technical support isneeded, the operator will put you in contact with theclosest Volvo Penta dealer that can support yourproduct.
Phone numbersFind your Volvo Penta Action Service phone numberand more information on www.volvopenta.com.
Introduction
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Instruments and ControlsThis chapter describes the instruments, panels and controls Volvo Penta sells for your engine.If you would like to complement your instrumentation, or if your boat is equipped with instruments not describedhere, we ask that you contact your Volvo Penta dealer.
Instrument PanelInstrumentation for the main control position andauxiliary control position.
1 Engine coolant temperature gauge. Indicates theengine coolant temperature.
2 Oil pressure gauge. Indicates the pressure of theengine lubricant.
3 Voltmeter. Indicates the charge voltage from thegenerator when the engine is running and thebattery voltage when the engine is stopped.
4 Tachometer. Indicates the speed of the engine inrpm.
5 Hour Meter. Shows the total number of enginerunning hours as a decimal number.
6 Press button for testing and acknowledging alarms,refer to section Warning display.
7 Audible Alarm. Siren for acoustic alarm that soundsif one of the warning lamps comes on.
8 Warning display. Refer to section Warning display.
9 Ignition switch. Refer to section Ignition switch.
10 Press button for instrument illumination.
11 Oil pressure gauge. Indicates the oil pressure in thereverse gear.
12 Charge air pressure gauge. Indicates theturbocharger boost pressure.
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Warning displayIf the acoustic alarm sounds, one of the warningdisplay lamps will immediately start to flash to indicatethe cause of the alarm.
1 High coolant temperature or low water level.
2 Oil pressure too low.
3 No charge voltage. Alternator not charging.
4 Not in use.
After an alarmPress the “Alarm test” button to acknowledge andterminate the acoustic alarm. The relevant warninglamp will continue to flash until the fault has beenrectified.
Alarm testAfter pressing the “Alarm test” button, the warninglamps will come on and the acoustic alarm will start tosound. Make a habit of always performing an alarm testbefore starting.
Ignition switchTogether with the starter keys a plate containing thekey code is delivered. This code is required whenordering additional starter keys. Keep the code in asafe place.
S = Stop position.0 = The key can be inserted or removed.I = Power on (Running engine).II = Not used.III = Start position.
1 2 3 4
P000
3031
ALARM TESTP0003070
Instruments and Controls
47713336 03-2021 © AB VOLVO PENTA 21
ControlsThis section describes the controls Volvo Penta sellsfor your engine. Contact your dealer if your boat isequipped with controls other than those describedhere, and you feel uncertain about their function.
ManeuveringA single-lever control operates both gearshift andthrottle functions from the same lever.The engine can only be started with the control leverin the neutral position.
N = Neutral position. Reverse gear/drivedisengaged and engine at idle.
F = Reverse gear/drive engaged for movementahead.
R = Reverse gear/drive engaged for movementastern.
T = Engine rpm control (throttle).NF R
T T
1P0002427
Disconnecting the gearshift functionThe gearshift function can be disconnected so that thecontrol lever only operates the throttle.
1 Put the control lever in neutral (N).
2 Depress the neutral button (1), and keep itdepressed at the same time as the lever ismoved forward.
3 Release the neutral button, the shift function isdisengaged and the lever only influences enginerevolutions.
The gear shift function is reconnected automaticallywhen the lever is returned to the neutral position.
CAUTION!Take care not to engage the gear by mistake.
Instruments and Controls
22 47713336 03-2021 © AB VOLVO PENTA
Adjusting the friction brakeThe lever is fitted with a friction brake to allowadjustment for easier or stiffer movement as required.The friction brake only affects movement of the throttlecontrol lever.
1 Lift away the cover from the control. On side-mounted controls the lever must be removed first.
2 Move the lever to the half throttle/astern position.
3 Adjust the friction brake by turning the screwclockwise (+) for stiffer lever movement, andcounterclockwise (-) for easier movement.
4 Replace the cover and the lever.
Dual lever control
ManeuveringA twin-lever control has separate levers for thegearshift function (1) and rpm control (throttle) (2).The engine can only be started with the control leverin the neutral position.
Black lever (1)N = Neutral position. Reverse gear/drive disengaged
and engine at idle.F = Reverse gear/drive engaged for forward motion.R = Reverse gear/drive engaged for rearward
motion.
Red lever (2)Engine rpm control (throttle).
Control A
Control B
Instruments and Controls
47713336 03-2021 © AB VOLVO PENTA 23
Adjusting the friction brakeThe control lever is fitted with a friction brake that canbe adjusted to apply more or less resistance to levermovement. Adjust the friction brake by turning thescrew (control A), or by twisting the lever (control B).Turn clockwise (+) for stiffer lever movement, andcounterclockwise (–) for easier movement.
Control A
Instruments and Controls
24 47713336 03-2021 © AB VOLVO PENTA
Optional
Trolling
Slip ValveAll reverse gears that are available for the D5/D7engines can be fitted with a trolling valve so that thelowest speed of the boat can be variably reduced by1–80% at engine speeds up to 1100 rpm.
IMPORTANT!Risk of overheating the reverse gear if the trolling valveis used at higher engine speeds than 1100 rpm.
ManeuveringDisengage the reverse gear and set the trolling valvefor maximum slip. Engage “Forward” or “Reverse” andset the desired slip position within the permitted enginespeed range. In order to attain full propeller output, thetrolling valve lever must always be in “disengaged”position when not being used.
Propeller Shaft BrakeIn certain operational circumstances, the propellermay cause the propeller shaft to rotate when theengine is stopped. This passive rotation isuncomfortable and can be harmful to the reversinggear as its oil pump, which is driven by the input shaft,will not operate when the engine is stopped.The propeller shaft may be allowed to rotate with astopped engine for up to 6–8 hours. After this, theengine must be started and run for at least five minutesfor lubrication and cooling of the reversing gear.In cases where the propeller shaft may rotate fasterthan in normal operations, e.g. boat under sail, atemperature gauge should be installed for monitoringthe oil temperature.Max. permissible temperature for ZF reversing gearsis 95°C (203°F).When the above-mentioned regulations cannot bemet, or when the shaft needs to be stopped for reasonsof comfort, a shaft brake must be fitted. On isolatedoccasions, the propeller shaft flange may be locked ina suitable manner instead.
47713336 03-2021 © AB VOLVO PENTA 25
StartingMake a habit of visually checking the engine, engine bay and transmission before start. This will help you todiscover quickly if anything abnormal has occurred, or is about to occur. Also check that instruments and warningdisplays show normal values when you have started the engine.To minimize cold start smoke we recommend you install an engine heater or engine bay heater if temperaturesbelow +5°C (41°F) are encountered.
WARNING!Never use start spray or similar agents to start an engine. This may cause an explosion in the inlet manifold. Riskof personal injury.
The engine can be equipped with a temperature switchfor start smoke limitation above +5°C, that is availablein the Volvo Penta accessory program.
Before Starting
• Open the fuel cock.
• Open the sea cock where fitted.
• Check the engine and transmission oil level.
• Check the coolant level.
• Turn the main switches on.
IMPORTANT!Never disconnect the current with the mainswitches when the engine is running. Thealternator and electronics could be damaged.
• Start the engine bay fan, where fitted, and allow it torun for at least four minutes.
• Check that there is sufficient fuel for the planned trip.
26 47713336 03-2021 © AB VOLVO PENTA
Starting the Engine
Put the gear in neutralPut the gear in neutral by moving the control lever toneutral at all stations.
WARNING!Check all control positions to make sure that a gear isnot engaged. This is essential for boat’s equipped withcontrols that allow starting the engine in gear.
Single lever controlMake sure the lever is in neutral position “N.” Thismeans the accelerator is in idle position and thereverse gear is disengaged.
Dual lever controlPut the forward/reverse lever in neutral position toenable starting. Move the accelerator all the way backto idle position.
Turn on the powerTurn on the power by putting the starter key in position“I”.
Check warning lamps and alarmsPress the “Alarm test” button on the instrument panelto make sure the warning lamps come on and theacoustic alarm sounds.
Starting
47713336 03-2021 © AB VOLVO PENTA 27
Start the engineStart using the ignition switchTurn the key to position III. Release the key and let itspring back to position I as soon as the engine hasstarted.If repeated start attempts are needed, the key must beturned back to position 0 first.
Overheating protectionIf the starter motor is engaged for its maximumactivation time (30 seconds), the starter motor circuitis cut automatically to protect the starter motor fromoverheating. If possible, leave the starter motor to coolfor at least five minutes before making a new startattempt.
Read the instruments and warm theengine upAllow the engine to idle for the first ten seconds. Readthe instruments and make sure they show normalvalues. Test that warning lamps and alarm functionproperly.Warm the engine up at low speed and low load, sonormal operating temperature is reached before fullpower is used.
IMPORTANT!Never race the engine when it is cold.
Check the oil level in the reverse gearCheck the oil level when the reverse gear has reachedoperating temperature, please refer to Oil level,checking and topping up, page 62.
Starting
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OperationLearn to handle the engine, controls and other equipment in a safe and proper manner before casting off on yourmaiden voyage. Remember to avoid sudden and extreme rudder maneuvers and gear shifts. There is a risk forpassengers and crew falling over or falling overboard.
WARNING!A rotating propeller can cause serious injury. Check that nobody is in the water before engaging ahead or astern.Never drive near bathers or in areas where people could be in the water.
NOTICE! The handle on the oil drain pump must notbe mounted during operation.
Reading the InstrumentsRead off the instruments and alarm displayimmediately after start, and then regularly duringoperation.
Oil PressureWhen the engine is warm and idles slowly the oilpressure gauge should show a reading of minimum 80kPa (11.6 psi).The acoustic alarm will sound automatically in case oflow oil pressure.
Coolant TemperatureDuring operation, the temperature gauge should showa reading of maximum 100°C (212°F).The acoustic alarm will sound automatically in case thecoolant temperature is too high.
Battery ChargingDuring operation, the charge voltage gauge shouldshow a reading of 28 V or 14 V for a 24 respectively 12V system.The acoustic alarm will sound automatically in case thecharge voltage is missing..
0
x10 kPa0
psi
2 4 6 8 10
30 60 90120150
P0003024
100
4080100 8 10
150 200
250
F
P0003023
1822 26
2824
3032
10
20
VOLT
P0003025
47713336 03-2021 © AB VOLVO PENTA 29
AlarmsIf the acoustic alarm sounds, one of the warningdisplay lamps will immediately start to flash to indicatethe cause of the alarm:
1 High coolant temperature or low water level.Slow the engine speed to idle/disengaged. Iftemperature does not drop, the engine must bestopped. Investigate the cause, see Faulthandling, page 36, and rectify it.
2 Low oil pressureIMPORTANT!Stop the engine immediately after an alarm for lowoil pressure. Investigate the cause, see Faulthandling, page 36, and rectify it.
3 No charge voltage.Investigate the cause, see Faulthandling, page 36, and rectify it.
P0013822
+-
1 2 3
Operation
30 47713336 03-2021 © AB VOLVO PENTA
ManeuveringThe chapter contains functional descriptions of thecontrols available from Volvo Penta.When changing gear the engine must be at low idlingspeed. There must be a brief pause after engagingreverse gear, before increasing the engine speed. Thepause must be approximately two seconds long toensure the reverse gear clutch plates are properlyengaged.
IMPORTANT!It is important all engines are running during reversingmaneuvers to avoid the risk of water entry via theexhaust pipe into the stationary engine.
Pulling away
1 Move the lever from neutral to the engagementposition for the desired direction of travel. Wait forapproximately two seconds.
2 Increase gradually to the desired engine speed.
Forward–Reverse
1 Slow the engine speed to idling and allow the boatto loose most of its speed.
2 Move the lever to neutral. Wait for approximatelytwo seconds.
3 Move the lever to reverse. Wait for approximatelytwo seconds and then increase the engine speedgradually.
IMPORTANT!A direct forward–reverse maneuver can damage thetransmission and engine. It is therefore alwaysnecessary to stop with the lever in neutral for a fewseconds. Allow the boat to loose most of its speed aswell before engaging. If the speed of the boat is toohigh, there is a risk of the propeller torque being so highthat the engine will stop and start reversing, causingthe engine to break down.
Operation
47713336 03-2021 © AB VOLVO PENTA 31
Cruising SpeedFor best fuel economy operations at full speed must beavoided. We recommend a cruising speed that is atleast 10% below the maximum engine revolutions attop speed (full throttle).Depending on hull type, the choice of propeller, theload and sea state etc., the maximum revolutions attop speed may vary, but they should be within the fullthrottle range; refer to Technical Data, page 67.
If the engine is unable to reach its maximum throttlerange, this may be due to a number of factorsmentioned in Fault handling, page 36.Select a propeller with greater pitch if actual enginerevolutions exceed the full throttle range. Contact yourVolvo Penta dealer for advice.
Operation
32 47713336 03-2021 © AB VOLVO PENTA
Engine ShutdownAllow the engine to run at low idle, in neutral, for a few minutes after operations are completed. In this way after-boiling is avoided at the same time as temperature equalization takes place. This is especially important whenthe engine has been run at high rpm or under heavy load.
Stop the EngineIMPORTANT!Never disconnect the current with the main switcheswhen the engine is running. The alternator andelectronics could be damaged.
1 Disengage the reverse gear by moving the lever toneutral position.
2 Turn the key to stop position ”S”.
3 Hold the key in position until the engine hasstopped, the key will return to “0” automaticallywhen released and can then be removed.
Auxiliary stopIf a fault occurs that prevents the engine being stoppedby the normal method, it can be stopped manually.
WARNING!Working with or approaching a running engine is asafety risk. Watch out for rotating components and hotsurfaces.
1 Move the speed adjustment lever (1) to low idle.
2 Move the shut-off lever (2) in the direction of thearrow until the engine comes to a stop. The warningdisplay lamps for “No charge voltage” and “Low oilpressure” will turn on when the engine stops.
3 Turn the key to position ”0”. The warning displaylamps will turn off.Don’t turn off the engine when under full load.Subsequently allow the engine to idle for approx. 2min.
47713336 03-2021 © AB VOLVO PENTA 33
After Engine ShutdownD7A T, D7A TA, D7A-B TA, D7C TA, D7C-B TA
• Check the engine and engine bay for leakages.
• Close the fuel tap.
• Close the sea cock where fitted.
• Take an hour meter reading and carry outpreventive maintenance according to themaintenance schedule.
• Turn off the main switch before any long stoppage.
Operation BreakOperation break with the boat in waterIf the boat is not used, but left in the water, werecommend you to warm up the engine at least onceevery fortnight. This will prevent corrosion damage inthe engine.If you expect the boat to be unused for two months ormore, we recommend you to preserve the engine,please refer to Storage, page 65.
Engine Shutdown
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Cold Weather PrecautionsIf the engine bay cannot be kept frost free, the seawater system must be drained and the freshwatersystem coolant must have sufficient freeze protectionto prevent freeze bursting; refer toMaintenance, page 49 and Seawater System,Draining, page 54 respectively for more detailedinformation.Check the charge status of the battery. A poorly-charged battery can freeze and burst.
Engine Shutdown
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Fault handling
Fault TracingSymptoms and possible causes
Engine can’t be stopped. 1, 2, 3, 5,Starter motor does not rotate or rotates slowly 1, 2, 3, 4, 5Engine does not start. 6, 7, 8, 9, 28Engine starts then stops 7, 8, 9, 13Engine is difficult to start 7, 8, 9, 13Engine does not reach correct speed at wide openthrottle (WOT)
7, 8, 9, 10, 11, 12, 13, 18
Engine knocks 14Engine Runs Rough 7, 8, 9, 13, 14Engine vibrates 18, 19High fuel consumption 10, 11, 13, 15Engine exhaust smoke is black 13, 15, 18Engine exhaust smoke is blue or white 14, 15, 26Oil pressure is too low 16, 17Coolant temperature too high 20, 21, 22, 23, 24, 25, 26No or poor charging 2, 27
1 Flat / poor batteries2 Poor contact/open circuit in electrical wiring3 Main switch turned off4 Engine control not in neutral5 Check fuses at engine.6 Check fuel level7 Blocked fuel filter/supply pump8 Air in the fuel system.9 Water in fuel indicator10 Boat abnormally loaded11 Fouled hull/propeller12 Engine speed control wrongly adjusted13 Insufficient air supply14 Coolant temperature too high
15 Low coolant temperature16 Oil level too low.17 Blocked oil filter18 Defective/wrong propeller19 Faulty engine mounting20 Coolant water level is too low21 Air in fresh water system22 Blocked seawater filter or sea water intake23 Slipping or broken drive belt for circulation pump.24 Worn or broken impeller in seawater pump25 Defective thermostat26 Oil level too high27 Water in the fuel pre-filter
36 47713336 03-2021 © AB VOLVO PENTA
In Case of Emergency
Starting Using AuxiliaryBatteries
WARNING!Explosion hazard. Batteries contain and give off anexplosive gas which is highly flammable and explosive.A short circuit, open flame or spark could cause aviolent explosion. Ventilate well.
WARNING!Never confuse the positive and negative poles on thebatteries. Risk of arcing and explosion.
1 Check that the auxiliary battery has the samevoltage as the engine system voltage.
2 Connect the red positive cable to the plus (+)terminal on the discharged battery and then to theplus terminal on the auxiliary battery.
3 Connect the black start cable to the minus (–)terminal on the auxiliary battery and to a place alittle distance away from the discharged battery,e.g. the start motor's negative terminal.
WARNING!The black jumper cable (–) must never come in contactwith the positive connection on the starter motor.
4 Start the engine and let it run at fast idle forapproximately 10 minutes to charge the batteries.Make sure there is no extra equipment connectedto the electrical system.
WARNING!Working with or approaching a running engine is asafety risk. Watch out for rotating components and hotsurfaces.
WARNING!Do not touch the connections during the start attempt:Risk of arcing.Do not bend over any of the batteries either.
5 Turn off the engine. Remove the start cables in theexact opposite order to their connection.
47713336 03-2021 © AB VOLVO PENTA 37
Maintenance ScheduleYour Volvo Penta engine and its equipment are designed for high reliability and long life. The engines are built tohave the smallest possible environmental impact. If given preventive maintenance, according to the maintenanceschedule, these qualities will be retained and unnecessary malfunctions will be avoided. In order for the warrantyto be valid, the owner must make sure that the services in the service intervals are performed.
NOTICE! For emission related warranty rights see Emission Control System Warranty Statement.
Service IntervalsService intervals are shown below. The service content can be found in the Service Protocol available fordownload at www.volvopenta.com.
NOTICE! More information on how to perform service and maintenance can be found in the Service andMaintenance handbook. Information on how to purchase the Service and Maintenance handbook can be foundat www.volvopenta.com.
Extended service intervalsThe interval between engine oil changes may be extended in certain circumstances. To determine whether theservice interval may be extended, Volvo Penta's conditions for extended service intervals must be met and an oilanalysis performed. Contact your Volvo Penta dealer for further information.
38 47713336 03-2021 © AB VOLVO PENTA
MaintenanceThis chapter contains general technical information and instructions on how the common maintenance items thatmust be carried out. Read through the instructions carefully before starting work.Read through the safety precautions for maintenance and service in the Safety precautions for maintenance andservice operations chapter before work on the engine is begun.Volvo Penta recommend that all servicing with the engine running should be undertaken by an authorized VolvoPenta workshop. The intervals when maintenance items must be carried are indicated in the MaintenanceSchedule.
WARNING!Care and maintenance work should be done with the engine stopped unless otherwise specified. Stop the enginebefore opening or removing the engine hatch/hood. Make it impossible to start the engine by removing the startkey and cutting the system voltage with the main switches.
NOTICE! More information on how to perform service and maintenance can be found in the Service andMaintenance handbook. The manual is available for download at www.volvopenta.com.
Orientation
D7A TA 1 Turbo
2 Starter motor
3 Oil Sump
4 Oil drain pump
5 Alternator
6 Seawater out
7 Charge air cooler
8 Coolant filler cap
9 Expansion tank
10 Heat exchanger
11 Coolant Pump
12 Fuel pump
13 Fuel inlet
14 Fuel Filter
15 Oil filter
16 Oil dipstick
17 Connection for hydraulic pump or compressor
18 Seawater Pump
19 Connection for hydraulic pump
20 Seawater intake
21 Oil filler cap, engine
22 Oil cooler
23 Injection Pump
7
6
5
4
3 2
1
8
9
10
11
1213141516
17
1918
20
232221
P 1974000
47713336 03-2021 © AB VOLVO PENTA 39
Engine, General
General inspectionMake a habit of visually checking the engine andengine bay before starting, and after operations whenyou have stopped the engine. This will help you toquickly discover abnormalities, or if something is aboutto happen.Look especially carefully for oil, fuel and coolantleakages, loose bolts, worn or poorly-tensioned drivebelts, loose cable connections, damaged electricalcables and hoses. This inspection only takes a fewminutes and can prevent serious malfunctions andexpensive repairs.
WARNING!Risk of fire.Remove all accumulations of fuel, oil and grease whendetected on the engine or in the engine room.
WARNING!If an oil, fuel or coolant leak is detected, the cause mustbe investigated and the fault rectified before the engineis started.
Never direct the jet from a high-pressure washer atseals, rubber hoses or electrical components. Neveruse the high pressure setting for engine cleaning.
Air Filter, Change1 If indicator is all red after the engine is stopped,
change the filter insert.
2 Undo the hose clamp below the air filter cartridgeand pull off the cartridge.
3 Replace the air filter cartridge and tighten the hoseclamp.
4 Press the button on the service indicator to resetthe signal after service. The indicator is now readyto operate again.
IMPORTANT!Scrap the old filter. It must not be cleaned.
P0013783
Maintenance
40 47713336 03-2021 © AB VOLVO PENTA
Drive belt, check and change
WARNING!Stop the engine before doing any maintenance work.
CheckCheck belt tension and condition regularly. If the beltis too tight it can damage bearings and if it is too looseit may slip. Check and adjust after operation when thebelt is warm.
IMPORTANT!Always change a belt, which looks worn or cracked.Belts which operate in pairs must be changedtogether.
Adjust and replaceAdjust and change as necessary. It can generally besaid that the belts are correctly tensioned if they canbe pressed down 10 mm (3/8") by thumb pressure.Clean the belt grooves before fitting a new belt.
Alternator belt
Adjust
1 Loosen the screw (5).
2 Push the alternator belt pulley (4) to the rightuntil the belt is correctly tensioned.
3 Tighten the screw.
Replace
1 Remove the belt for the fuel pump as describedin “Coolant pump / Fuel pump, Adjust”
2 Loosen the screw (5).
3 Push the alternator belt pulley (4) to the rightuntil the correct belt tension is achieved.
4 Tighten the screw (5).
5 Replace the belt for the fuel pump and tensionthe belt as described in Coolant pump / Fuelpump, Adjust”.
Maintenance
47713336 03-2021 © AB VOLVO PENTA 41
Coolant pump / Fuel pump
12
3
P0003681
Adjust
1 Loosen screws (1) and (2).
2 Push the fuel pump (3) to the left until the belt iscorrectly tensioned.
3 Tighten the screws.
Replace
1 Loosen screws (1) and (2).
2 Push the fuel pump (3) to the right.
3 Remove the belt and replace it with a new one.
4 Push the fuel pump (3) to the left until the belt iscorrectly tensioned.
5 Tighten the screws.
Maintenance
42 47713336 03-2021 © AB VOLVO PENTA
Lubrication System
Oil change intervals can vary depending on oil quality,refer to Technical Data, page 68.
Oil change intervals must never exceed a period of 12months.
If you want longer oil change intervals than stated inthe table Technical Data, page 68, the oil changeinterval can under certain conditions be increased. Tosee if the engine complies, Volvo Penta oil analysisneed to be performed. Contact your Volvo Pentadealer for further information.
Oil level, checking and topping upThe oil level must be inside the marked area on thedipstick and should be checked daily before the firststart.
When checking the oil level; take the oil dipstick outand wipe it. Put it back and remove it again to read theoil level.
IMPORTANT!Do not fill up above the maximum oil level. Only use arecommended grade of oil, please refer to TechnicalData, page 68.
1 Top up the oil through the filler opening in theventilation cover.
2 Wait 15 minutes after topping up to allow the oil timeto reach the sump before checking the level again.
3 Check the level again.
Maintenance
47713336 03-2021 © AB VOLVO PENTA 43
Engine Oil, ChangeAlways follow the recommended oil change interval.Use an oil drain pump (optional) to pump the oil out ofthe oil pan.
1 Run the engine until warm so that the oil is easierto pump. Then stop the engine.Wait 15 minutes to allow the oil time to reach thesump.
WARNING!Hot oil and hot surfaces can cause burns.
2 Connect a suitable hose to the drain pumpdischarge (1) and lead it to a collection vessel.
3 Open the tap (2) under the drain pump to theposition for draining engine oil (E).
4 Replace the oil filter and by-pass filter at every oilchange. Refer to Oil filter, Change, page 45.
5 Close the tap (S). Refill with new oil to the correctlevel. For engine oil quantity, refer to Oil level,checking and topping up, page 43.IMPORTANT! Only use a recommended grade ofoil.
6 Start the engine and let it idle. Check the oilpressure. Check that no leaks are present at thefilters.
WARNING!Working with or approaching a running engine is asafety risk. Watch out for rotating components andhot surfaces.
7 Stop the engine. Wait 15 minutes before checkingthe oil level. Top up as needed.
Hand in the old oil and filters to a recycling station.
Maintenance
44 47713336 03-2021 © AB VOLVO PENTA
Oil filter, ChangeChange the oil filter every second oil change.
1 Drain the oil, see Engine Oil, Change, page 44 .
2 Put a vessel underneath the filter to avoid oil spill.
3 Unscrew the oil filters with a suitable filter wrench.
4 Lightly oil the rubber seal of the new filters andmake sure its mating surfaces on the filter bracketsare clean.
5 Screw on the filter by hand until the rubber gasketjust touches the filter holder sealing surface. Thentighten the filter a further 3/4 to 1 turn.
6 Fill up with oil , refer to Oil level, checking andtopping up, page 43.
7 Start the engine (idle) and make sure that noleakages occur. Check the oil level once the enginehas stopped.
Maintenance
47713336 03-2021 © AB VOLVO PENTA 45
Fuel SystemOnly use the grades of fuel recommended in the fuelspecification, refer to Technical Data, page 69.Always observe the greatest cleanliness duringrefueling and work on the fuel system.
All work on the injectors of the engine must be carriedout by an authorized Volvo Penta workshop.
WARNING!Fire hazard. When carrying out work on the fuel systemmake sure the engine is cold. A fuel spill onto a hotsurface or an electrical component can cause a fire.Store fuel soaked rags so that they cannot cause fire.
WARNING!Store fuel soaked rags and other flammable materialso that there is no danger of them catching fire. Fuelsoaked rags can ignite spontaneously under certainconditions.
NOTICE!
The level in the fuel tank must when the tank is full bemax. 2 m above the fuel feed pump and when the tankis empty max. 1.5 m below the pump.
Fuel filter, Change
Single fuel filter1 Close the fuel shut-off valve.
2 Clean the filter bracket and place a receptacleunder the filter.
3 Unscrew the filter.
4 Make sure the new filter are absolutely clean andthat the gasket undamaged. Lightly moisten thegasket with oil.
5 Screw on the filters by hand until they make contactwith the sealing surface. Then screw a further halfturn, not any more.
6 Open the shut-off valve.
7 Bleed the fuel system, refer to Fuel system,bleeding, page 47.
8 Start the engine and make sure there are no leaks.
9 Leave the old filters to a destruction plant.
Maintenance
46 47713336 03-2021 © AB VOLVO PENTA
Switchable fuel filtersSwitchable fuel filters can be changed while the engineis running since the flow of fuel can be cut off to onefilter at a time.
WARNING!Working with or approaching a running engine is asafety risk. Watch out for rotating components and hotsurfaces.
1 Turn the lever (2) to its right-hand end position.
2 Unscrew the left-hand fuel filter. Use a filter wrenchif necessary.
3 Screw the filters on by hand until they make contactwith the sealing surface. Then screw a further halfturn, not any more.
4 Vent the system by opening the left-hand bleedscrew (1) on the filter bracket. Put the lever inoperating position (straight up). Close the bleedscrew when air free fuel flows out.
5 Put the lever in its left-hand end position andchange the right-hand fuel filter in the same way.
Fuel system, bleeding
The fuel system must be bled e.g. after changing fuelfilter, if the fuel tank has been run dry and after longstops. Refer to the next page for bleeding whenreplacing a switchable fuel filter during operation.
IMPORTANT!Do not loosen the injectors delivery pipes. If thedelivery pipes are loose they must be changed.
1 Position fuel collection container under the filtercartridge and pressure maintenance valve (2)
2 Open pressure maintenance valve (B) and bleederscrew (1).
3 Turn the engine over with the starter (max. 20 sec.)until bubble-free fuel escapes first from the bleederscrew (1) and then from the pressure maintenancevalve (2).
4 Firmly tighten bleeder screw (1) and pressuremaintenance valve (2).
5 Start the engine and make sure there are no leaks.
1
2
P0003058
Maintenance
47713336 03-2021 © AB VOLVO PENTA 47
Fuel pre-filterA fuel pre-filter with water separation must be installed.The water level needs to be checked regularly. Theelectrical connector pins (1) in the bowl can beconnected to an alarm that will warn when there iswater in the pre-filter.
2
1
3
P0003690
Fuel pre-filter, draining water /contamination
1 Position a container under the filter.
2 Drain off water and contaminants through thedraining valve (3).
Fuel pre-filter, cleaning1 Stop the engine.
2 Place a container under the filter.
3 Undo the bleed screw (2). Contaminants andwater drops will release from the bottom of thefilter element and drop down to the bottom of thebowl.
4 Open the draining valve (3) by pushing it in andturning simultaneously. The clean fuel abovethe filter will flush through the filter elementtaking smaller dirt and water particles with it.
5 Let the fuel flush until clean fuel flows out.
6 Close the draining valve.
7 Tighten the bleed screw, but not to tight.
8 Start the engine.
Fuel Pre-filter, ChangeChange the filter element according to therecommendations in the Service Protocol, or earlier ifthe pressure at the fuel inlet of the feed pump, atmaximum rpm, shows a low pressure above 50 kPa(7.2 psi).
1 Stop the engine.
2 Loosen the screws on the lid and remove it.
3 Take out the spring frame.
4 Take out the filter element and replace it with a new
5 Place the spring frame on top of the filter element.
6 Check the lid gasket, replace it if necessary.
7 Place the gasket and lid in its right position.
8 Tighten the screws firmly.
Maintenance
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Freshwater SystemThe cooling system ensures that the engine operatesat the correct temperature. It is a closed system thatshould always be filled with a coolant mixture.
IMPORTANT:Coolant of a suitable chemical composition must beused all year round to protect the engine againstinternal corrosion, cavitation and freeze bursting.This even applies when there is no risk for freezedamage, to make sure the engine always has acomplete corrosion protection.
Therefore, the use of anti-corrosion agents alone, orwater alone as a coolant, is not permitted in VolvoPenta engines.
The coolant must be based on Organic AcidTechnology (OAT). Using an improper coolant ormixing with another coolant will rapidly reduce theperformance and lifetime of the engine. Materialincompatibility can lead to leakages, which - in theworst case - can cause engine breakdown.
Volvo Penta strongly recommend the use of our owncoolants, ”Volvo Penta Coolant VCS Ready Mixed” orthe concentrate ”Volvo Penta Coolant VCS”, whichensure the protection of the cooling systemcomponents from corrosion, ageing, swelling andcracking, thereby ensuring optimal engine lifetime.
Over time the corrosion protection additives becomeless effective, and consequently the coolant must bechanged at regular intervals to maintain sufficientprotection of the engine. The latest Service Protocolthat specifies service intervals can be found atvolvopenta.com.
Coolant, MixingIt is extremely important that the system is filled withthe correct coolant concentration; refer to TechnicalData, page 72.The coolant should be mixed with distilled, deionizedwater. For Volvo Penta specified water requirements;refer to Technical Data, page 72.
NOTICE! If water quality can not be guaranteed, useready mixed coolant.
Maintenance
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Checking the coolant level WARNING!
Do not open the coolant filler cap when the engine ishot. Steam or hot fluid could spray out, causing severeburns.
The engine is equipped with a level switch for coolantas standard.When engine is cold the coolant level must be visibleat the lower edge of the filler neck on the expansiontank (1).
If a separate expansion tank is installed, the coolantlevel must be between the MAX and MIN markings. Fillaccording to section Filling with coolant.
Filling with coolant WARNING!
Burn hazard. Steam and hot fluid may spray out. Stopthe engine and allow it to cool before opening the fillercap.
IMPORTANT!Top up with the same type of coolant as already usedin the system. Different types of coolant must not bemixed.
Topping up
1 Fill coolant up to the lower edge of the filler neck.
2 Fill slowly so that the evacuated air is able to passthrough the filler opening.
Filling a empty cooling system
1 Open the vent tap by the charged air cooler.
2 Make sure any other systems such as heater, waterheater, etc., connected to the cooling system arealso ventilated.
3 Fill with coolant via the filler opening on theexpansion tank. Fill slowly so that the evacuated airis able to pass through the ventilation cock/cocksand the filler opening.
4 Close the ventilation cocks/cocks as coolant that isfree from air runs out of them.
5 Cease filling when the correct level is attained.
6 Start the engine and run it until it reaches operatingtemperature.IMPORTANT!The engine must not be started before the systemhas been bled and filled.
7 Stop the engine and allow it to cool down. Checkthe coolant level
8 Top up if needed.
Maintenance
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Bleeding the coolant system1 The cooling system is automatically bled via the
pressure relief spring on the pressure cap.
2 Check that the closure plug (1) and seal ring forleaks when the engine is in operation. Tighten thepug if necessary.
Coolant, Draining
WARNING!Stop the engine and let it cool before starting work onthe cooling system. Hot fluids and hot surfaces cancause burns.
WARNING!All coolant is hazardous and harmful to theenvironment. Do not consume. Coolant is flammable.
Drain the coolant via taps (F).
1 Remove the filling cap (1) from the expansiontank.
2 Open the taps and allow all the coolant to drainoff into a suitable vessel.Check that all coolant really does drain out.Deposits may need to be cleared away, insidethe drain plug(s)/tap(s).
3 Also drain the heating system, tap water heateretc., if connected to the engine’s freshwatersystem.
4 Close all drain taps.
5 Collect the old coolant and hand it to a re-cyclingstation for destruction.
Maintenance
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Freshwater system, Flushing
The cooling system should be flushed when thecoolant is changed, to avoid loss of coolingperformance due to deposits in the cooling system.
1 Drain the coolant, please refer to Coolant,Draining, page 51.
2 Put a hose into the filling hole in the heat exchangerand flush with fresh water.
3 Flush until the water which runs out of the drainpoints is clean.
4 Close all drain points when all coolant has run out.
5 Fill up with coolant, please refer toMaintenance, page 50.
Maintenance
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Seawater SystemThe seawater system is the engine’s external coolingsystem. The seawater system sucks in water throughthe seawater inlet and pumps it through the heatexchanger and the reverse gear oil cooler. The systemis protected from galvanic corrosion by means of zincanodes located in the heat exchanger and the reversegear oil cooler.
WARNING!Risk of water entry. Water will flow into the boat if anyhose, plug etc. located below the waterline is removedwhen the boat is in the water. Always close the seacocks. If the boat does not have sea cocks the waterflow must be blocked in a safe manner. If this is notpossible, the boat must be drawn up on land beforework starts.
Maintenance
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Seawater System, Draining
WARNING!Risk of water entry. Close the seawater cocks beforedoing any work on the seawater system.
A
A
B
P0003678
The seawater system must be drained during coldweather when there is a risk of freezing to prevent thesystem from bursting. An alternative to draining is tokeep the engine room free from frost using anapproved heater fan.
1 Close the seawater cock.
2 Remove the drain plugs A, B (only -TA ), one ata time, and allow the water to run out until alldrain points on the engine have beendismantled.IMPORTANT!Make sure the coolant really runs out. It may benecessary to clean away deposits inside thedrain cocks.
3 Drain the water from the reverse gear oil coolerby opening tap kranen (1).
4 Drain any extra equipment such as the seawaterfilter.
5 Connect all hoses, close all drain taps and plugsbefore you leave the boat.
Maintenance
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Anodes, Check and Change WARNING!
Risk of water entry. Close the seawater cocks beforedoing any work on the seawater system.
1 Close the sea cock.
2 Open the drain tap (1) on the reverse gear oil coolerand drain off the seawater.
3 Remove the zinc anode (2) in the reverse gear oilcooler.
4 Check the zinc anode and replace if more than 1/3of the original size has been used up. If not, cleanthe zinc anode with emery cloth to remove the oxidelayer before re-installing.
IMPORTANT!Use emery paper. Do not use a wire brush orother steel tools when cleaning, as these maydamage the galvanic protection.
5 Install the zinc anode. Make sure that good metalliccontact is obtained between the anode and thecasting.
6 Close the drain tap (1).
7 Open the sea cock before starting the engine.
8 Check that no leakage occurs.
Impeller, Check and Change
WARNING!Risk of water entry. Close the seawater cocks beforedoing any work on the seawater system.
1 Close the seawater cock.
2 Remove the cover (1) and seal (2). Remove theimpeller (3) carefully.Are there visible cracks or other defects the impellershould be replaced.
3 Clean the inside of the housing. Lubricate the pumphousing and the inside of the cover with a water-resistant grease that is not aggressive on rubber.
4 Install the impeller.
5 Fit the cover with a new seal.
6 Open the seawater cock.
Always carry a spare impeller and seal.
1
2
3
P0003701
Maintenance
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Seawater Filter, Check and CleaningThe seawater filter is auxiliary equipment.
If the water where the boat is used has a lot ofcontaminants, seaweed, etc. the filter should bechecked more frequently than stated in themaintenance schedule, Otherwise there is a risk thatthe filter may be blocked resulting engine overheating.
WARNING!Risk of water entry. Close the seawater cocks beforedoing any work on the seawater system.
1 Close the sea cock.
2 Remove the cover (1) and lift out the insert.
3 Clean the insert and the housing (2).
4 Install the parts as illustrated. Inspect the gaskets.Replace as necessary.
5 Open the sea cock and check for leaks.
Intake Manifold, Checking the DrainHoleSteam may be generated during operations; it drainsvia a hole at the bottom of the charge air cooler. Checkthat the hole is not blocked.
CAUTION!Burn hazard! Steam may evaporate through the drainhole.
IMPORTANT!If a large amount of coolant flows out of the drain hole,the charge air cooler must be removed and pressuretested.
This work must be carried out by an authorizedworkshop.
1 Position a collecting container under the air coolerbefore unscrewing the plug (1).
2 Allow lubrication / condensation water to drain.
3 Tighten the plug (1) with a new seal.
4 After starting the engine, check for leaks andtighten the screw if necessary.
Maintenance
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Electrical SystemThe engine is equipped with a 2-pole electrical systemand an alternator.
WARNING!Always stop the engine and break the current using themain switches before working on the engine.
IMPORTANT:Contact a Volvo Penta dealer for information if any arcwelding will be performed on the application.Arc welding can cause damage to the engine and theelectronics.
FusesThe engine is equipped with a semi-automatic fuse(8A) which cut the current if overloaded. The fuse islocated in the junction box on the engines service side.
The semi-automatic fuse are re-set by pressing the redbutton, once any faults have been attended to.
IMPORTANT!Always investigate the cause of the overload. If thefuse trips frequently, contact an authorized VolvoPenta workshop.
Electrical Connections
Check that electrical connections are dry, free fromoxide, and that they are securely tightened.
Maintenance
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Battery WARNING!
Risk of fire and explosion. Never allow an open flameor electric sparks near the batteries.
WARNING!Battery electrolyte is a corrosive acid and should behandled with care. If you spill or splash electrolyte onany part of the body, immediately flush the exposedarea with liberal amounts of water and seek medicalattention as soon as possible.
WARNING!Ventilate the engine compartment before working onbatteries or battery connections.
IMPORTANT:Batteries can be damaged if they are left discharged,and can also freeze and burst easier in cold weather.If the engine is not going to be used for a longer periodof time, the batteries should be fully charged, tricklecharged if possible.
MaintenanceIt is important to always follow the batterymanufacture’s recommendation and instruction whenreplacing and charging batteries. Depending onbattery type, the instructions for maintenance andcharging may vary.Modern batteries are normally maintenance free, butthere are some actions that are recommended toincrease the battery service life and avoid accidents:
• Keep the batteries clean and dry. Contaminationand oxide on the batteries and battery poles canresult in stray currents, voltage drop and discharge,especially in wet weather.
• Remove oxidation from the battery poles andterminals, using a brass brush.
• Tighten the terminals securely and grease them withterminal grease or petroleum jelly. Loose batteryconnections may cause damage to the engine’selectrical system.
• Charge the battery regularly. A battery that is keptfully loaded has a maximum service life. The easiestway to check if a battery needs charging is to use avoltmeter.
NOTICE! If low starter battery alarm occur, the batterymay get drained which might result in loss of functionsand engine stopping.
Maintenance
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Replacing BatteryIMPORTANT:
Make sure that the new battery fulfills the specificationsin Technical Data. Read the information supplied withthe battery before you begin the installation.
IMPORTANT:Do not disconnect the batteries with the enginerunning.Sensitive electrical components can be immediatelydamaged.
WARNING!Never confuse the positive and negative poles on thebatteries. Risk of arcing and explosion.
Disconnecting (A)
1 Untighten the nut and remove the – cable (black).
2 Untighten the nut and remove the + cable (red).
Remove the battery.
Connecting (B)
Place the new battery.
1 Connect the + cable (red) to the + pole on thebattery and tighten the nut.
2 Connect the – cable (black) to the – pole on thebattery and tighten the nut.
NOTICE! Hand in the old battery to a re-cycling station.
Electrical InstallationsAn incorrectly designed electrical installation maygenerate leakage current from the electrical system.Leakage current can in turn render galvanic protectioninadequate in respect of propellers, propeller shafts,rudder posts, the keel etc., and may cause damagethrough electrochemical corrosion.
Maintenance
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WARNING!Work on the low voltage circuits in the boats should bedone by a person with electrical training or knowledge.Installation or work on land current equipment mustonly be done by a competent electrician, in accordancewith local regulations for mains electricity.
The following must always be heeded:
1 If shore power is connected it must always beground protected ashore, never in the boat.Furthermore, the shore power installation should beequipped with a ground fault circuit interrupter.The shore power installation (transformer, inverter,battery charger etc.) must be designed for marineuse where the high-tension side is galvanicallyseparated from the low-tension side.
2 Electrical cables must be run and clamped suchthat there is no risk of exposure to chafing, damp orbilge water.
3 Ground protection for radios, navigationinstruments, rudder, boarding ladders or otherequipment where separate cables for groundprotection are present, must be clustered to acommon ground connection that is not connectedto the engine or reverser gear.
IMPORTANT:The engine and reversing gear must never beused as earth planes.
4 The start battery must have a main switch (1)connected to the battery's positive (+) side. Themain switch must break the circuit to all equipmentand be switched off when the boat is not in use.
5 If an auxiliary battery is used, a main switch mustbe placed between the auxiliary battery's positive(+) terminal and the circuit breaker panel for theboat's electrical equipment. The main switch mustbreak the circuit to all equipment connected to theauxiliary battery and must be switched off whenpower is no longer required. All equipmentconnected to the auxiliary battery must haveseparate main switches.
For simultaneous charging of two independent batterycircuits a separate charging distributor (accessory)should be installed on the standard alternator.
Maintenance
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Electrical WeldingRemove the positive and negative cables from thebatteries, then disconnect all cables connected to thealternator.
Always connect the welder ground clamp to thecomponent to be welded, and as close as possible tothe weld site. The clamp must never be connected tothe engine or in such a way that current can passthrough a bearing.
IMPORTANT!After finished welding, re-connect the alternatorterminals before connecting the battery cables.
Maintenance
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Reversing gear
Oil level, checking and topping up
CheckingCheck the oil level when the reverse gear has reachedworking temperature, with the engine at idle andcontrol lever at neutral.
1 Pull up and dry off the dipstick (1) and insert inthe reverse gear again.
WARNING!Working with or approaching a running engine is asafety risk. Watch out for rotating components andhot surfaces.
2 Pull out the dipstick again and check the oil level.The correct level is between MAX and MINmarks.
FillingTop up with oil as required through the filler opening(2) on the top of the reverse gear, refer to TechnicalData, page 73 for oil grade and volume.
IMPORTANT!Never over-fill the reversing gear. The oil level mustalways be within the recommended range.
Maintenance
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Transmission Oil, ChangeThe oil can be drained by removing the drain plug onthe reverse gear or by the using the manual oil drainpump.
1 Remove the dipstick. Connect a hose from the oilscavenging pump to the dipstick tube.
2 Set the knob under the pump housing in position forpumping the reverse gear.
3 Suck the oil up and put the dipstick back.
4 Fill with oil through the filler opening on top of thereverse gear. Please refer to TechnicalData, page 73 for oil grade and capacity.
IMPORTANT!Never over-fill the reverse gear.
5 Start the engine and run until the reverse gear hasreached operating temperature.
6 Check the oil level with the engine at low idlingspeed and the controls in neutral position. The oillevel must reach to the upper mark on the dipstick.Top up oil if needed.
Maintenance
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Oil Strainer, Cleaning
WARNING!Working with or approaching a running engine is asafety risk. Watch out for rotating components and hotsurfaces.
1 Remove the lid/plug and carefully remove thestrainer from the housing (4).
IMPORTANT!Cleanliness! Dirt must not be allowed to get intothe reverse gear.
2 Clean the strainer and other components in paraffin(kerosene).
3 Carefully put the components back again.
4 Tighten the plug/screw.
5 Start the engine and check carefully that no leakageoccurs.1
1
ZF45
ZF220, ZF280P0003683
Maintenance
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StorageThe boat must be inhibited to prevent damage to the engine and other equipment if the boat is not used for twomonths or more. It is important that this is done in the correct manner, and nothing is forgotten. For this reason,we have compiled a check list of the most important points.Before the boat is taken out of service for a long period of time, an authorised Volvo Penta workshop should lookover the engine and other equipment. Have any faults and deficiencies attended to, so that the equipment is inorder, ready for the next start.
CAUTION!Read the chapter on Maintenance in the Operator`s Manual before starting work. It contains instructions on howto carry out maintenance and service operations in a safe and technical correct manner.
Some conservation oils are flammable. Some are also dangerous to breathe. Ensure good ventilation. Use a facemask when spraying.
IMPORTANT:When cleaning with a high pressure washer, make sure to never aim the water jet at seals, rubber hoses orelectrical components.
Inhibiting• Warm the engine up to normal operating
temperature and check that the oil level in thereversing gear reaches the MAX mark on thedipstick. Stop the engine.
• Max 8 month’s stoppage:Change the oil and oil filter on the engine, thenwarm it up afterwards.More than 8 month’s stoppage:Conserve the lubrication and fuel systems withconservation oil. Please refer to “Conservation ofthe lubrication and fuel systems for more than 8months’ stoppage”.
• Check that the coolant offers sufficient freezeprotection. Top up as necessary.Alternatively, you can drain the coolant (also drainthe coolant filter).
• Close the sea cock and drain the water from theseawater system.
• Remove the impeller from the seawater pump.Store the impeller in a sealed plastic bag, in a coolplace.
• Drain any water and contamination from the fuelfilters and fuel tank. Fill the fuel tank completely, toavoid condensation.
• Disconnect the battery cables, clean and chargethe batteries. Trickle charge the batteries while theboat is laid up. A poorly charged battery canfreeze and burst.
• Clean the outside of the engine. Do not use a highpressure washer for engine cleaning. Touch uppaint damage with Volvo Penta original paint.
• Check and rust-proof any control cables.
• Put a note on the engine with the date, type ofconservation and the conservation oil used.
• Cover over the engine air inlet, exhaust openingand engine if necessary.
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Conservation of the lubrication and fuel systems for more than 8 months’ stoppage:
• Drain the oil from the sump and engine and fill theengine up with conservation oil* to just above theMIN marking on the dipstick.
• Connect the fuel supply (1) and return fuel pipes (2)to a jerrican filled with 1/3 conservation oil*and 2/3diesel fuel.
• Vent the fuel system.
• Start the engine and run at a fast idle until about 2litres (0.5 US gals.) have been used.Stop the engine and connect the ordinary fuel pipes.
• Empty the conservation oil out of the engine.
• Follow the other instructions on the previous page.
* Conservation oils are sold by oil companies.
Bringing Out of Storage• Remove any covers from the engine, air inlet and
exhaust pipe.
• Top the engine up with the correct quality of oil ifnecessary, see Technical Data, page 68. Install anew oil filter if the filter was not changed duringconservation.
• Check that there is oil in the reversing gear.
• Install new fuel filters and vent the fuel system.
• Check the drive belt(s).
• Check the condition of all rubber hoses, and re-tighten the hose clamps.
• Close the drain taps and install the drain plugs.
• Insert the impeller in the seawater pump, using arotating movement (anti-clockwise).
• Check the coolant level and anti-freeze. Top up ifnecessary.
• Connect the fully charged batteries.
• Open the sea cocks.
• Start the engine (if the boat is in the water) and warmup at a fast idle before loading the engine.
• Check that no oil, fuel or coolant leakage occurs.
• Check the oil level in the reversing gear. Top up ifnecessary.
1
2
P 1969000
Storage
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Technical DataProduct sales designation D5A TA D7A TA D7C TAProduct designation D5A-B TA D7A-B TA D7C-B TAMax torque Refer to the sales literatureNo. of cylinders 4 6 6Bore 108 mm
4.25”108 mm4.25”
108 mm4.25”
Stroke 130 mm5.11”
130 mm5.11”
130 mm5.11”
Displacement 4.76 dm3 7.15 dm3 7.15 dm3
Engine, dry weight 525 kg1157 lbs
690 kg1521 lbs
690 kg1521 lbs
Compression ratio 17.6:1 17.6:1 17.6:1Low idle, r/min.(1)
775 (±25) 750 (±25) 750 (±25)
1) If needed, the speed can be adjusted within the range 550–800 rpm.
Crankshaft power
1900 ± 25 rpm 2300 ± 25rpm
D5A-B TA R1 89 kWR2 103 kW
R1 102 kWR2 118 kW
D7A-B TA R1 130 kWR2 153 kW
R1 148 kWR2 174 kW
D7C-B TA R1 146 kWR2 169 kW
R1 166 kWR2 195 kW
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Lubrication System
Engine D5 D7
Oil capacity including oil filters, approx.:No engine inclination 14 liters 23 liters
Oil pressure, hot engine:Oil pressure during neutral 80 kPa 80 kPaat operating speed 1100 r/min 450 kPa 450 kPa
Oil quality (1)
Sulfur content in fuel, by weight<0,5 % 0,5 – 1,0 % > 1,0 % (2)
Oil change interval, reached first in operation:VDS-3VDS-2 (4)
ACEA: E7, E5, E3 (3)
API: CI-4, CH-4
500 hours or 12 months 250 hours or 12 months 125 hours or 12 months
1) Lowest recommended oil grade. Engine oil with higher oil grade is always possible to use.2) If sulphur content is > 1.0% by weight, use oil with TBN > 15.3) API: CG-4 or CH-4 are acceptable in markets outside Europe, instead of ACEA E3.(4) The oil must also comply with at least one of the following specifications: ACEA:E7, ACEA:E5, Global DHD-1,API:CI-4, API:CH-4.
VDS = Volvo Drain SpecificationACEA = Association des Constructeurs Européenne d'AutomobilesAPI = American Petroleum InstituteGlobal DHD = Global Diesel Heavy DutyTBN = Total Base Number
Viscosity
Select the viscosity according to the table.
The temperature values refer to stable ambienttemperatures.
Technical Data
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Fuel quality requirements for diesel engines
General requirementsVolvo Penta diesel engines are certified for compliance with emission legislations with the diesel test fuelsspecified by law. These fuels correspond with diesel fuel standards EN 590, ASTM D975 and JIS K2204 andparaffinic diesel fuel standard EN 15940. Volvo Penta guarantees compliance with emission legislation andfulfillment of expected lifetime as long as the specified restrictions are followed.
It is the responsibility of the fuel suppliers to always ensure that their fuels meet relevant requirements and arefit for their intended purpose. Their responsibility includes any use of additives for proper engine performance andfunction.Special requirements are placed on cold-flow properties, that is, temperature limit values of fuel filterability duringoperation in winter conditions.
For IWW stage V, only diesel fuels according to EN 590 and EN 15940 is approved for use according to emissionregulations. The engine must be used as intended and serviced according to operators manual to fulfill the exhaustemissions.
Restrictions for specified diesel fuels
• Max density for ASTM D975 No 2–D: 860 kg/m3
Insufficient density reduces the power and increases the fuel consumption. Excessive density endangersthe durability and function of the fuel injection equipment.
• Max lubricity (wsd 1.4) for JIS K 2204: 460 μmSufficient fuel lubricity is essential to protect the fuel injection system against excessive wear.
Restrictions for other diesel fuelsVolvo Penta also approves the use of other diesel fuels as long as the here specified restrictions are followed.However Volvo Penta does not guarantee compliance with emission legislation or fulfillment of expected lifetimewith these other diesel fuels.
NOTICE! Operators must check permission for usage of these fuels according to regional, national or localregulations.
Technical Data
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• Min cetane number: 40An insufficient cetane number (“ignitability”) leads to poor startability and increased exhaust emissions.
• Max density at 15°C: 860 kg/m3
Insufficient density reduces the power and increases the fuel consumption. Excessive density endangersthe durability and function of the fuel injection equipment.
• Viscosity between 1.9 to 4.6 mm/s2 at 40°C:Insufficient viscosity reduces the power and increases the fuel consumption. Excessive viscosity endangersthe durability and function of the fuel injection equipment.
• Max lubricity (wsd 1.4): 520 μmSufficient fuel lubricity is essential to protect the fuel injection system against excessive wear.
• Max FAME (biodiesel) content: 10% (V/V)FAME is blended into diesel fuel. For engines with exhaust after-treatment system max 10% FAME (B10).
• Max sulfur content: 1000 mg/kg for engines with exhaust after-treatment systems.
• Max sulfur content: 5000 mg/kg for engines without exhaust after-treatment systems.
Paraffinic fuels - HVO and GTLParaffinic diesel fuels (“Synthetic Diesel”) have higher cetane numbers and lower densities than diesel fuels. HVO(Hydrotreated Vegetable Oils) is renewable paraffinic fuels. GTL (Gas-To-Liquid) is fossil paraffinic fuels. VolvoPenta approves the use of paraffinic diesel fuels that complies with standard EN 15940. The fuel guaranteescompliance with emission legislation and fulfills the expected lifetime as long as the service requirements arefollowed. Volvo Penta also approves the use of fuel blends between these paraffinic fuels and diesel fuels thatcomply with the quality requirements.
Biodiesel fuelsAlternative fuels including biodiesel that are not substantially similar to the required test fuels may adversely affectengine emissions compliance. As a result, Volvo Penta does not warrant the engine will conform to applicableemissions limits when operated on, or having been operated on, biodiesel or other alternative fuels that are notsubstantially similar to specified test fuels used for certification. The use of biodiesel up to maximum 10% (B10)in and of itself, will not affect the manufacturers mechanical warranty, provided the biodiesel used in blendconforms to EN590, EN16734, ASTM D975 and ASTM D7467. Other relevant local fuel standards that fulfill theabove mentioned standards may also be used. A minor drop in engine power will occur when using biodiesel.
NOTICE! FAME (Fatty Acid Methyl Esther) blended fuel has the disadvantage that fungi/bacteria/oxidation willoccur after some time depending on ambient temperature, sun light, water in the fuel tank, how aged the fuel waswhen filling etc. These problems increase with higher amount of FAME. The FAME fuel is also hygroscopic whichcan increase the fungi problem. Therefore the recommendation is not to use more than 10% FAME in the fuel,unless frequently refilling of the fuel tanks. During longer periods than 4 weeks, without refilling, therecommendation is to not to use diesel fuel with any FAME at all. The engine problem that will occur is cloggedfuel filters and an unplanned engine stop.
Higher levels of biodiesel up to B30 may be used with restrictions. Fuel according to EN 16709 or ASTM D7467,or relevant local fuel standards that fulfill mentioned biodiesel fuel standards must be used. Volvo Penta does notwarrant the engine will conform to applicable emissions limits when operated on biodiesel or another alternativefuels, that are not substantially similar to specified test fuels used for certification.
Technical Data
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Service restrictions for diesel fuel with FAME content between 11% and 30% (B11 to B30)
• Lube oil quality VDS-4,5 shall be used
• Oil dilution may occur. Make sure that oil level is not exceeding maximum level, in that case change the oil
• Lube oil and filter change intervals shall be halved, or utilize oil sampling analysis
• The engines should be fitted with fuel filters with water separators
• A fuel heater is required, when high FAME diesel fuels are used below freezing point
• Biodiesel is aggressive to some materials used in fuel system components. Inspect seals, hoses, rubberand plastic components daily. Replace any component that is damaged, softened or leaking. Clean biodieselfrom painted surfaces immediately to prevent paint damage.
• Do not use these fuels for engines with long downtime periods
• If the engine has not been used for a period of 4 weeks or more, the tank and the fuel system shall be flushedclean by running the engine on at least one full tank of diesel fuel
• When shifting from diesel fuel to high FAME diesel fuel- The fuel hoses and sealings shall be replaced- The fuel tank shall be cleaned and the fuel filter shall be replaced after 50h
Technical Data
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Cooling System
D5 D7Coolant volume
with seawater cooling 21 liters(5.6 US gal)
26 liters(6.9 US gal)
with keel cooling 11 liters(2.9 US gal)
14 liters(3.7 US gal)
The thermostat begins opening / is fully opened 83°C/95°C(181°F/203°F)
83°C/95°C(181°F/203°F)
Coolant, Mixing
WARNING!All coolant is hazardous and harmful to theenvironment. Do not consume. Coolant is flammable.
IMPORTANT:Always use the same type of coolant that is already inthe engine.Different types of coolant must not be mixed with eachother.Risk of reduced cooling function and performance byclogging and isolation.
Coolant shall be based on Organic AcidTechnology (OAT).
Follow the mixing recommendation on theproduct.The coolant should be mixed with distilled, deionizedwater. For Volvo Penta specified water requirements;refer to Water Quality.
NOTICE! Always use “Ready Mixed” coolant if waterquality cannot be determined or if it does not fulfillASTM D4985.
NOTICE! Never mix more than 60% concentratedcoolant with water. A greater concentration providesreduced cooling effect with the risk for overheating andreduced freeze protection.
Technical Data
72 47713336 03-2021 © AB VOLVO PENTA
Water QualityASTM D4985:Total solid particles <340 ppmTotal hardness <9,5° dHChloride <40 ppmSulfate <100 ppmpH value 5.5–9Silica (acc. ASTM D859) <20 mg SiO2/l
Iron (acc. ASTM D1068) <0.10 ppmManganese (acc. ASTM D858) <0.05 ppmConductivity (acc. ASTM D1125) <500 µS/cmOrganic content, CODMn (acc. ISO8467) <15 mg KMnO4/l
Electrical System
System voltage 12V 24V
Battery capacity 170 Ah 115 AhBattery electrolyte density at +25°C:
Fully charged battery 1,28 g/cm3
(1,24 g/cm3)(1)1,28 g/cm3
(1,24 g/cm3)(1)
Battery recharged at 1,24 g/cm3
(1,20 g/cm3)(1)1,24 g/cm3
(1,20 g/cm3)(1)
1) Applies to batteries with tropical acid.
Reversing gear
Type designation ZF 45 ZF 220 ZF 280Oil capacity (exl. oilcooler), approx.
3,0 liters 5,3 liters 4,8 liters
Oil quality See ZF Operator's Manual See ZF Operator's Manual See ZF Operator's ManualViscosity See ZF Operator's Manual See ZF Operator's Manual See ZF Operator's ManualOil pressure duringoperation
2,1 MPa 2,5 MPa 2,5 MPa
Weight 73 kg 70 kg 82 kg
Technical Data
47713336 03-2021 © AB VOLVO PENTA 73
Identification NumbersThere are type plates on the engine and transmission, marked with identification numbers. This information mustalways be used as reference when service and spare parts are ordered. You will probably find similar plates onyour boat and its equipment. Note this information below, make a copy of the page and store it in a safe place,so that you can have the information available if the boat is stolen.The appearance and location of the type plates is shown below. The figures in brackets refer to the location ofthe identification number on the type plate.
A
B
p0020112
A Engine plate
1 Product designation
2 Engine Power
3 Engine Power
4 Serial number
5 Specification number
6 Engine Speed
MODELKW
RPM KwredHP
TIM BTDCFUEL RATE
DISPL
CODESPECAdd
mm /3STR
L
SER NOC.SPEC
VALVE LASH MM IN
MADE IN GERMANY
EXH
01223270
EP
1 2 3 4 5
6P 1947700
B Certification label B
p0020113
Technical Data
74 47713336 03-2021 © AB VOLVO PENTA
AAbout this Manual......................................................13Air Filter, Change...................................................... 40Alarms....................................................................... 30Anodes, Check and Change..................................... 55Auxiliary stop............................................................. 33BBattery....................................................................... 58Bringing Out of Storage.............................................66CCertified Engines....................................................... 18Cold Weather Precautions........................................ 35Controls..................................................................... 22Coolant, Draining.......................................................51Cruising Speed..........................................................32DDrive belt, check and change.................................... 41Dual lever control...................................................... 23EElectrical Connections...............................................57Electrical Installations................................................59Electrical System.......................................................57Electrical Welding......................................................61Engine Oil, Change................................................... 44Engine, General........................................................ 40Environmental care................................................... 17Excessive strain on a product and components........16FFault Tracing............................................................. 36Freshwater System................................................... 49Freshwater system, Flushing.................................... 52Fuel filter, Change..................................................... 46Fuel pre-filter............................................................. 48Fuel System.............................................................. 46Fuel system, bleeding............................................... 47Fuel, oils and coolant................................................ 15Fuses.........................................................................57IIdentification Numbers...............................................74Ignition switch............................................................21Impeller, Check and Change.....................................55Installation and use of Volvo Penta External Helm... 16Instrument Panel....................................................... 20Intake Manifold, Checking the Drain Hole................. 56LLubrication System....................................................43MMaintenance and replacement parts......................... 15Maneuvering........................................................12, 31OOil filter, Change........................................................45Oil level, checking and topping up.......................43, 62Oil Strainer, Cleaning................................................ 64Operation Break........................................................ 34Orientation.................................................................39
RReading the Instruments........................................... 29Recording engine data.............................................. 17Reversing gear.......................................................... 62Running in the engine............................................... 15SSeawater Filter, Check and Cleaning........................56Seawater System...................................................... 53Seawater System, Draining.......................................54Slip Valve.................................................................. 25Starting Using Auxiliary Batteries.............................. 37Stop the Engine.........................................................33TTransmission Oil, Change......................................... 63Trolling.......................................................................25VViscosity.................................................................... 68Volvo Penta Action Service....................................... 19Volvo Penta Dealer Network..................................... 19Volvo Penta EVC system, integrity and modification 16WWarning display.........................................................21Warranty....................................................................14YYour New Boat.......................................................... 14
Index
47713336 03-2021 © AB VOLVO PENTA 75
This Operator’s Manual may be ordered in a different language free of charge up to 12 months after delivery, via internet.http://manual.volvopenta.com/coupon/If internet access isn‘t possible, please contact your Volvo Penta dealer.
Diese Betriebsanleitung kann bis zu 12 Monate nach-der Lieferung über Internet kostenlos in einer anderenSprache bestellt werden. http://manual.volvopenta.com/coupon/Wenn Sie keinen Internet-Zugriff haben, kontaktierenSie bitte Ihren Volvo Penta-Händler.
Ce manuel d‘utilisation peut être commandé gratu-itement sur Internet en différentes langues, jusqu‘à 12 mois après la date de livraison.http://manual.volvopenta.com/coupon/Veuillez contacter votre Distributeur Volvo Penta si vous avez un problème d‘accès à l‘Internet.
El presente libro de instrucciones puede solicitarse en otro idioma diferente, libre de cargo, hasta 12 meses des-pués de la entrega, mediante internet.http://manual.volvopenta.com/coupon/Si no se tiene acceso a internet, contacten al su concesionario Volvo Penta.
Denna instruktionsbok kan beställas via internet på ett annat språk gratis i upp till 12 månader efter leverans.http://manual.volvopenta.com/coupon/Kontakta din Volvo Penta-återförsäljare om du inte har tillgång till internet.
Dit instructieboek kan gratis via internet in een a dere taal worden besteld tot 12 maanden na aflevering.http://manual.volvopenta.com/coupon/Als toegang tot het internet niet mogelijk is, neem dan contact op met uw Volvo Penta dealer.
Denne instruktionsbog kan bestilles gratis på et andet sprog via Internettet i op til 12 måneder efter leveringen.http://manual.volvopenta.com/coupon/Hvis det ikke er muligt at bestille via Internettet, bedes du kon-takte din Volvo Penta forhandler.
Tämä käyttöohjekirja on tilattavissa Internetin kautta veloituksetta eri kielillä 12 kuukauden ajan toimituksen jälkeen.http://manual.volvopenta.com/coupon/Jos sinulla ei ole Internet-yhteyttä, ota yhteys lähimpään Volvo Penta jälleenmyyjään.
Este Manual do Operador pode ser encomendad em idiomas diferentes isento de custos até 12 meses após entre-ga, via internet.http://manual.volvopenta.com/coupon/Se não for possível aceder à internet, contacte o seu conces-sionário Volvo Penta.
To παρόν Βιβλίο Χρήσης μπορεί να παραγγελθεί δωρεάν σε άλλη γλώσσα μέχρι 12 μήνες μετά την παράδοση,μέσω διαδικτύου.http://manual.volvopenta.com/coupon/Εάν δεν είναι δυνατή η πρόσβαση στο ιαδίκτυο,παρακαλούμε επικοινωνήστε με το δικό σας αντιπρόσωπο της Volvo Penta.
Данное руководство по эксплуатации можно бес-платно заказать на другом языке по Интернету в течение 12 месяцев после доставки.http://manual.volvopenta.com/coupon/Если доступ к Интернету отсутствует, обратитесь к своему дилеру компании Volvo Penta.
Bu Kullanım Kılavuzu, teslimden 12 ay sonrasına kadar İnternet yoluyla ücretsiz olarak farklı bir dilde sipariş edilebilir.http://manual.volvopenta.com/coupon/İnternet mümkün değilse, lütfen Volvo Penta yetkili satıcınızla temasa geçin.
Il manuale per l‘operatore può essere ordinato tra-miteInternet, in varie lingue e per consegna gratuita, entro 12 mesi dalla consegna del prodottohttp://manual.volvopenta.com/coupon/Se l‘accesso a Internet risulta impossibile, contattare la con-cessionaria Volvo Penta.
本操作手册可通过互联网以不同的言进行订购，交付后可免费使用达12 个月。http://manual.volvopenta.com/coupon/如果无法访问互联网，请与沃尔沃遍达经销商联系。
Este Manual de operador pode ser encomendado em um idioma diferente, gratuitamente, até 12 meses após a entrega, via internet.http://manual.volvopenta.com/coupon/Caso o acesso à internet não for possível, contatar seu distri-buidor Volvo Penta.
このオペレーターズ マニュアルの他言語版が、発行
後最高12か月間、インターネットより無料で発注可能です。http://manual.volvopenta.com/coupon/インターネットにアクセスできない場合は、担当のボルボペンタディーラーまでご連絡ください。
© 2021 AB VOLVO PENTA Volvo reserves the right to make changes Printed on environmentally friendly paper
AB Volvo PentaSE-405 08 Göteborg, Sweden
www.volvopenta.com 4771
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