Volvo Penta d1 d2 Series

OPERATOR’S MANUAL
D1, D2
47702088 - Downloaded from www.volvopenta.com 02/06/2011 18:54:55
CALIFORNIA PROPOSITION 65 WARNING

Engine exhaust, some of its constituents, and a broad range of engine parts are known to the State of California to cause cancer, birth
defects, and other reproductive harm. Additionally, lubricants, fuels, and other fluids used in engines–including any waste created through
the wearing of engine parts–contain or produce chemicals known to the State of California to cause cancer and birth defects or other
reproductive harm.
Battery posts, terminals, and related accessories contain lead and lead compounds. Wash your hands after handling. Used engine oil
contains chemicals that have caused cancer in laboratory animals. Always protect your skin by washing thoroughly with soap and water.
Content
Foreword ...................................................................................................... 2
Safety Information ...................................................................................... 3
Introduction ................................................................................................. 8
Instruments and Controls ........................................................................ 10
Starting ...................................................................................................... 18
Operation ................................................................................................... 20
Engine Shutdown ...................................................................................... 23
Fault Handling ........................................................................................... 25
In Case of Emergency .............................................................................. 29
Maintenance Schedule ............................................................................. 31
Maintenance .............................................................................................. 33
Storage ....................................................................................................... 64
Technical Data ........................................................................................... 68
Operator's Manual Order .......................................................................... 74
Alphabetical index .................................................................................... 75
1
Foreword
Volvo Penta marine engines are used all over the world. They are used in all possible operating conditions for
professional as well as leisure purposes. This is not a coincidence. After 100 years as an engine manufacturer
the Volvo Penta name has become a symbol of reliability, technical innovation, top of the range performance and
long service life. We also believe that this is what you demand and expect of your Volvo Penta engine.
We would like you to read this operator’s manual thoroughly and consider the advice we give on running and
maintenance before your maiden voyage so that you will be ensured of fulfilling your expectations. Please pay
attention to the safety instructions contained in the manual.
As owner of a Volvo Penta marine engine, we would also like to welcome you to a worldwide network of dealers
and service workshops to assist you with technical advice, service requirements and replacement parts. Please
contact your nearest authorized Volvo Penta dealer for assistance.
You will find your closest dealer at our home page on the Internet www.volvopenta.com - amongst other
useful information about your Volvo Penta engine - we invite you to visit!
2 47702088 05-2011
Safety Information
Read this chapter very carefully. It has to do with your safety. This describes how safety information is presented
in the operator’s manual and on the product. It also gives you an introduction to the basic safety rules for using
and looking after the engine.
Check that you heave received the correct operator’s manual before you read on. If not, please contact
your Volvo Penta dealer.
!
This symbol is used in the operator’s manual and on the product, to call your attention
to the fact that this is safety information. Always read such information very carefully.
Safety texts in the operator’s manual have the following order of priority:
DANGER!
Indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING!
Indicates a hazardous situation which, if not avoided, could result in death or serious
personal injury.
CAUTION!
Indicates a hazardous situation which, if not avoided, could result in minor or moderate
personal injury.
IMPORTANT!
Indicates a situation which, if not avoided, could result in property damage.
NOTICE! Used to draw attention to important information that will facilitate work or
operations.
This symbol is used on our products in some cases and refers to important information
in the operator’s manual. Make sure that warning and information symbols on the
engine are clearly visible and legible. Replace symbols which have been damaged or
painted over.
47702088 05-2011 3
Safety Information
Your new boat Fuel filling

Read the instruction books and other information There is always a risk of fire and explosion during fuel
carefully, which came with your new boat. Learn to filling. Smoking is not permissible, and the engine
handle the engine, controls and other equipment in a should be stopped.
safe and correct manner. Never over-fill the tank. Shut the tank cap securely.
If this is your first boat, or a type of boat you are not Only use the fuel recommended in the instruction
experienced in using, we recommend that you prac- book. The wrong grade of fuel can cause serious mal-
tice operating the boat in peace and quiet. Get to know functions, power loss or stop the engine.
the way the boat reacts to sea and to the controls
under different speed, sea and loading conditions
before you cast off for your first “real” maiden voyage.
Remember that the captain of every boat is required
by law to know and to observe applicable rules for
traffic and safety at sea. Get to know the rules which
apply to you and your waters, by contacting the rele-
vant authority or sea safety organization.
It is a good idea to go on some kind of boat operation
course. We recommend that you contact a regional
boat or sea safety organization to find a suitable
course.
Daily checks Do not start the engine

Make it a habit to give the engine and engine bay a Do not start the engine if you suspect a fuel or LPG
visual check before driving (before starting the leak in the boat, close to explosive media, or if there
engine) and after operation (when you have stopped is a spillage of explosive media. An explosive envi-
the engine). This helps you to quickly discover ronment entails a risk of fire and/or explosion.
whether any leakage of fuel, coolant, oil or any other
abnormal event has happened, or is about to happen.
Manoeuvring Accidents and near misses

Avoid sudden or surprising rudder movements and
gear shifting. There is a risk that passengers could fall Life saving statistics show that inadequate care of
over, or overboard. boats and engines, and deficiencies in safety equip-
A rotating propeller can cause severe injury. Check ment are frequent causes of accidents and near
that there is nobody in the water before you engage misses at sea.
forward / astern (reverse) drive. Never drive close to Make sure that your boat and engine are maintained
bathers or in areas where you could reasonably in accordance with the advice in each instruction
expect that people could be in the water. book, and that the necessary safety equipment is on
board, and is in working condition.
4 47702088 05-2011
Safety Information
Carbon monoxide poisoning

When a boat moves forwards, an area of low pressure Most modern boats are designed so that the problem
air forms behind the boat. In adverse conditions, this of low-pressure suction is very rare, however. If low-
low pressure can be so strong that the boat’s own pressure suction does occur anyway, do not open
exhaust fumes are sucked into the cockpit or cabin, hatches or ventilators in the forward part of the boat.
which entails a risk of carbon monoxide poisoning for Strangely enough, this makes the problem worse. Try
all aboard. changing speed, trimming or load distribution instead.
The problem of low-pressure suction is worst in high, Also try taking down/opening the hood or modifying it
wide boats with a square transom. But even in other in some other manner. Ask your boat dealer for advice
types of boats, low-pressure suction can be a problem about the best solution for your particular boat.
in some conditions, such as if you drive with the hood
up. Other factors which increase the low-pressure
effect are wind conditions, load distribution, pitching,
trimming, open windows and ventilators etc.
P0003073
Remember
• Safety equipment: Life jackets for everybody aboard, communication equipment, emergency
rockets, approved fire extinguisher, first aid kit, life buoy, anchor, paddle, torches etc.
• Spare parts and tools: Impeller, fuel filters, fuses, tape, hose clamps, engine oil, propeller and
tools for the jobs you could be expected to have to do.
• Take your chart out and study your planned route. Calculate distance and fuel consumption.
Listen to weather reports.
• Tell your friends/relatives about route plans if you undertake a long journey. Remember to
notify changed plans or delays.
• Inform everybody aboard about where the safety equipment is located, and how it works. Make
sure that there is more than one person aboard who can start and operate the boat safely.
This list can be extended, since the need for safety equipment varies with the type of boat, and
where or how it is used etc. We recommend that you ask a regional boat or sea safety organization
for more detailed maritime safety information.
47702088 05-2011 5
Safety Information
Preparations Before starting the engine
Knowledge Reinstall all protective parts removed during service

The operator’s manual contains instructions on how operations before starting the engine. Check that no
to carry out general maintenance and service opera- tools or other items have been left on the engine.
tions safely and correctly. Read the instructions care-
Never start a turbocharged engine without installing
fully before starting work.
the air cleaner (ACL). The rotating compressor in the
Service literature covering more complicated opera- Turbocharger unit can cause serious personal injury.
tions is available from your Volvo Penta dealer. Foreign objects can also be sucked in and cause
mechanical damage to the unit.
Never carry out any work on the engine if you are
unsure of how it should be done, contact your Volvo Fire and explosion
Penta dealer who will be glad to offer assistance.
Fuel and lubrication oil
Stop the engine All fuel, most lubricants and many chemicals are
Stop the engine before opening or removing engine inflammable. Read and follow the instructions on the
hatches. Unless otherwise specified all maintenance packaging.
and service must be carried out with the engine stop-
ped. When carrying out work on the fuel system, make sure
the engine is cold. A fuel spill onto a hot surface or
To prevent accidental start of the boat engine, remove electrical components can cause a fire.
the ignition key, turn off the power supply to the engine
at the main switches and lock them in the OFF posi- Store fuel soaked rags and other flammable material
so that there is no danger of them catching fire. Fuel-
tion before starting work. Put up a warning sign in the

control position that work on the engine is being car- soaked rags can self-ignite under certain conditions.
ried out. Do not smoke when filling fuel, oil or in proximity of a
Approaching or working on an engine which is running filling station or in the engine room.
is a safety risk. Loose clothing, hair, fingers or a drop- Non-original components
ped tool can be caught in the rotating parts of the
engine and cause serious personal injury. Volvo Components used in the fuel and electrical systems
Penta recommend that all servicing with the engine on Volvo Penta products are designed and con-
running should be undertaken by an authorized Volvo structed to minimize the risk of fire and explosion.
Penta workshop. Using spare parts other than by Volvo Penta
Lifting the engine approved spare parts can result in fire or explosion on
board.
When lifting the engine, use the lifting eyes installed
on the engine (reverse gear where installed). Always Batteries
check that lifting equipment is in good condition and The batteries contain and emit oxyhydrogen gas,
has sufficient load capacity to lift the engine (engine especially during charging. This gas is easily ignited
weight including reverse gear and any extra equip- and highly volatile.
ment installed). For safety’s sake lift the engine using
an adjustable lifting beam. All chains and cables Do not under any circumstances smoke or use naked
should run parallel to each other and as perpendicular flame or allow sparks in the vicinity of the batteries or
as possible in relation to the top of the engine. Bear battery compartment.
in mind that extra equipment installed on the engine
may alter its center of gravity. Special lifting equip- An incorrect connection of a battery terminal cable or
ment may then be required in order to maintain the jump-start cable can cause a spark which in its turn
correct balance and make the engine safe to handle. can be sufficient to cause an explosion.
Never carry out work on an engine suspended on a
Start spray
hoist.
Never use start spray or similar agents to start an
engine equipped with air pre-heating (glow plugs/
starter element). This may cause an explosion in the
inlet manifold. Danger of personal injury.
6 47702088 05-2011
Safety Information
Hot surfaces and fluids Fuel system

There is always a risk of burns when working with a Always use protective gloves when tracing leaks. Liq-
hot engine. Beware of hot surfaces. For example: the uids ejected under pressure can penetrate body tis-
exhaust pipe, turbo unit, oil pan, charge air pipe, sue and cause serious injury. There is a danger of
starter element, hot coolant and hot oil in oil lines and blood poisoning.
hoses.
Always cover the generator if it is located under the
Carbon monoxide poisoning fuel filter. The generator can be damaged by spilled
fuel.
Only start the engine in a well-ventilated area. If oper-
ating the engine in an enclosed space, ensure that Electronic Vessel Control (EVC)
there is proper ventilation in order to remove exhaust
gases and crankcase ventilation emissions from the The boat has a advanced control system. Never cut
working area. or modify connectors, wiring or splice of the compo-
nents.
Chemicals Installing non Volvo Penta components may cause
Most chemicals such as anti-freeze, rustproofing the system to malfunction.
agent, inhibiting oil, degreasing agent etc. are haz-
Service must be done by approved workshops.
ardous to health. Read and follow the instructions on
the packaging.
Electrical system
Some chemicals such as inhibiting oil are inflammable
Cutting off power
and dangerous if breathed in as well. Ensure good
Always stop the engine and break the current using

ventilation and use a protective mask when spraying.
the main switches before working on the electrical
Read and follow the instructions on the packaging.
system. Isolate shore current to the engine block
Store chemicals and other hazardous materials out of heater, battery charger, or accessories mounted on
the reach of children. To protect the environment, the engine.
please dispose of used or leftover chemicals at a
Batteries
properly designated disposal site for destruction.
The batteries contain an extremely corrosive electro-
lyte. Protect your skin and clothes when charging or
Cooling system handling batteries. Always use protective goggles and
There is a risk of flooding when working on the sea- gloves.
water system. Turn off the engine and close the sea
If battery electrolyte comes into contact with unpro-
cock (where installed) before starting work on the sys-
tected skin, wash off immediately using plenty of
tem.
water and soap. If battery acid comes into contact with
Avoid opening the coolant filler cap when the engine the eyes, flush immediately with plenty of water and
is hot. Steam or hot coolant can spray out and cause obtain medical assistance without delay.
burns.
If work must be carried out with the engine at operat-

ing temperature and the coolant filler cap or a cock
open or a coolant hose disconnected, open the cool-
ant filler cap carefully and slowly to release pressure
before removing the cap completely. Note that the
coolant may still be hot and can cause burns.
Lubrication system
Hot oil can cause burns. Avoid skin contact with hot
oil. Ensure that the lubrication system is not under
pressure before commencing work on it. Never start
or operate the engine with the oil filler cap removed,
oil can spray out.
47702088 05-2011 7
Introduction
This Operator's Manual has been prepared to give you the greatest possible benefit from your Volvo Penta marine
engine. It contains the information you need to be able to operate and maintain the engine safely and correctly.
Please read the Operator's Manual carefully and learn to handle the engine, controls and other equipment in a
safe manner before you cast off on your maiden voyage.
Always have the Operator's Manual available. Store it safely and do not forget to hand it over to the next owner
if you sell your boat.
The Operator’s Manual describes the engine and equipment sold by Volvo Penta. The illustrations in this book
covers several varieties and might differ, the essential information is always correct though. Installations with e.g.
different controls and instrumentation might occur, in these cases we refer to this products manual.
Warranty
Your new Volvo Penta marine engine is covered by a Moderate your speed and distance so that wake and
limited warranty, under the conditions compiled in the noise do not disturb or damage animal life, moored
Warranty book. boats, jetties etc. Leave the archipelago and harbours
Please note that AB Volvo Penta’s liability is limited to in the same state you would like to find them. Remem-
the specification in the Warranty book. Read it care- ber to always hand in drained oil, coolant, paint and
fully, as soon as possible after delivery. It includes wash residue, used batteries etc. for destruction at a
important information about warranty cards, service, recycling station.
maintenance, which it is the responsibility of the If we all pull together, we can make a valuable con-
owner to know, check and carry out. If this is not done, tribution to the environment together.
AB Volvo Penta may fully or partly refuse to honour its
warranty undertakings.
Please contact your Volvo Penta dealer if you Running in
have not received a Warrant book, a Service book The engine must be “run in” during its first 10 hours,
or a customer copy of the warranty card. as follows:
Use the engine in normal operation. Full load should
Environmental care only be applied for short periods. Never run the engine
All of us want to live in a clean, healthy environment. for a long period of time at constant speed during this
Where we can breathe clean air, see healthy trees, period.
have clean water in lakes and seas, and be able to Higher oil consumption is normal during the running
enjoy the sunlight without fearing for our health. in period. For this reason, check the oil level more
Unfortunately, this is not self-evident these days, it is frequently than normally recommended.
something all of us must work hard for. After the first period of operation, the specified war-
As a manufacturer of marine engines, Volvo Penta ranty inspection “First service inspection” can be
has particular responsibility and for this reason, envi- done. For more information: Please refer to the Main-
ronmental care is a core value in our product devel- tenance Schedule.
opment. Volvo Penta has a wide engine programme
these days, where considerable progress has been Fuel, oils and coolant
made in reducing exhaust fumes, fuel consumption, Only use the fuels and oils recommended in the Oper-
engine noise etc. ator's Manual. Other grades can cause malfunctions,
We hope that you will be want to preserve these val- increased fuel consumption and eventually even
ues. Always observe the advice in the Operator's shorten the life of the engine.
Manual about fuel grades, operation and mainte- Always change the oil, oil filters and fuel filter at the
nance, to avoid unnecessary environmental impact. specified intervals.
Please contact your Volvo Penta dealer if you notice Future warranty claims related to engine and acces-
any changes such as increased fuel consumption or sories may be refused if an unsuitable coolant has
increased exhaust smoke. been used, or if the instructions for coolant mixture
have not been followed.
8 47702088 05-2011
Introduction
Service and spare parts Certified engines

Volvo Penta marine engines are designed for high If you own or operate an emission certified engine it
reliability and long life. They are built to withstand a is important to be aware of the following:
marine environment, but also to have the smallest
possible environmental impact. Through regular serv- Certification means that an engine type has been
ice and use of by Volvo Penta approved spare parts, checked and approved by the relevant authority. The
these qualities are retained. engine manufacturer guarantees that all engines
Volvo Penta’s world-wide network of authorised deal- made of the same type are equivalent to the certified
ers is at your service. They are Volvo Penta product engine.
specialists, and have the accessories, original spares, This makes special demands on the care and
test equipment and special tools needed for high qual- maintenance you give your engine, as follows:
ity service and repair work. • Maintenance and service intervals recom-
Always observe the maintenance intervals in the mended by Volvo Penta must be complied with.
Operator's manual, and remember to note the engine/
transmission identification number when you order • Only Volvo Penta original spares may be used.
service and spare parts. • Service on injection pumps, pump settings and
injectors must always be done by an authorised
Volvo Penta workshop.
• The engine must not be converted or modified,
except for the accessories and service kits
which Volvo Penta has approved for the engine.
• Installation changes to the exhaust pipe and

engine air inlet ducts must not be done.
• No seals may be broken by unauthorised per-
sonnel.
The general advice in the Operator's manual about

operation, care and maintenance apply.
Late or inadequate maintenance/service or the use of

spare parts not approved by Volvo Penta will invalid-
ate AB Volvo Penta’s responsibility for the engine
specification being in accordance with the certificated
variant.
Volvo Penta accepts no responsibility or liability for
any damage or costs arising due to the above.
47702088 05-2011 9
Instruments and Controls
This 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 described
here, we ask that you contact your Volvo Penta dealer.
Ignition Lock
The system lacks a start lock. Therefore, the helm sta-
tion should be lockable, or alternatively a lockable main
switch should be fitted, to prevent unauthorized engine
start.
Start/Stop Panel
Control Panel
On/Off button (1)

Depress the button to start or stop the system.
The panel cannot be switched off when the engine is
running.
Start button (4)

When the button is depressed the pre-heat function is
activated and the start motor engaged.
Multi-function button (2)

• Confirm the alarm. If an alarm occurs, a flashing
1 2 3 4 warning symbol will be displayed in the tachometer
window and an audible alarm will sound.
The alarm is confirmed by depressing the multi-
function button. The audible alarm is silenced and
the warning symbol is lit continuously until the fault
is remedied.
• Backlighting. To switch tachometer window back-
lighting on or off, depress the button for 1 - 5 sec-
onds.
The backlighting can be adjusted in five steps by
depressing the button for less than 1 second.
• Adjust the tachometer window contrast by holding
down the button for more than 5 seconds.
Stop button (3)

The engine stops running when the button is
depressed.
10 47702088 05-2011
Gauges
Tachometer
2 The tachometer shows engine speed; multiply the
1 RPMX1000
3 value shown on the dial by 1,000 to get the number of
engine revolutions per minute.
Operating information is displayed in the tachometer
window.
0 4
Operating information symbols

1
1 Pre-heating
The pre-heat symbol is displayed when the glow
function is active.
2 Starting
2
The start symbol is displayed when the start motor
is engaged.
3 Stopping
The stop symbol is shown when the stop button is
3 depressed.
4 Fuel level
If a fuel level sensor is installed (accessory) the fuel
level symbol is displayed when there is around 20%
4 of fuel remaining in the tank.
The engine must run for at least one minute before
the function is activated.
5 System fault
The system fault symbol lights up in the case of
5
short circuits or cable breaks.
6 Auxiliary alarm
Auxiliary alarm for accessory sensors.
6 7 Coolant temperature
The coolant temperature symbol lights up if the
AUX engine coolant temperature is too high.
8 Oil pressure
If the oil pressure lamp lights up during operations,
7 the engine oil pressure is too low.
9 Charging
The charging lamp lights up if the alternator stops
charging.
8
P0007517
47702088 05-2011 11
Optional instruments
1 These instruments are sold as engine accessories by
Volvo Penta.
1 Voltmeter, battery charging
The meter shows the alternator charge current.
During operations the charge voltage must be
around 14 V. When the engine is stopped and elec-
trical power switched on, battery voltage is around
12 V.
2 Coolant temperature gauge
The instrument shows engine coolant temperature.
During operations coolant temperature must nor-
mally be between 75-95°C (167-203°F).
3 Fuel level gauge
The fuel level gauge shows the quantity of remain-
ing fuel.
4 Alarm monitor
The alarm monitor gives a visual warning to call
attention to any alarms that occur.
P0007518
12 47702088 05-2011
EVC System Display

It is possible to present several windows with different
operational information in the EVC system display. The
various screens are selected using the instrument but-
tons.
Before the display is put to use certain settings must

be entered in the configuration menu; refer to Config-
uration menu.
It is also possible to bring up a menu identical to that

shown in the tachometer display by navigating to Sys-
tem information in the Configuration menu, or by
depressing button 2; refer to Multi, button 2.
A self-test is performed at start; the display will emit a

constant audible signal if a fault is detected. The dis-
play will continue to function, but may behave in unex-
pected ways.
Only installed functions are shown in the display.

Screens
Depress any of the buttons 1 to 4 to bring up the func-
tion menu for the buttons on the lower part of the dis-
play.
Buttons 1, 2 and 4 provide different screens.
Button 1 – Engine
Button 2 – Multi
Button 4 – Graph
G H
Use button 5 to adjust contrast and to access the con-
figuration menu for display settings; refer to Configu-
ration menu.
1 2 3 4 5
Exit the menu by waiting a few seconds or by depress-
P0001168 ing button 5 (EXIT).
Contrast
The display has five contrast settings. Depress button
5 (far right) and change the contrast by depressing +
(button 4) or – (button 3).
Store the setting by depressing EXIT (button 5).
ENGINE HOURS
HOURS 0
P0003010
47702088 05-2011 13
Engine, button 1
Engine revolutions and speed are shown in the upper
part of the window. Operating hours are displayed in
the lower part, along with a fuel level indicator if this
function is installed.
If speed information is lacking, coolant temperature will

be shown instead.
Multi, button 2
Operational information is displayed in four analog or
digital windows in the multi screen. The display can
either show several windows, or be divided so that the
lower part shows System information. To switch
between the different screens depress button 2 repeat-
edly.
P0007392
If the selected information is lacking, the symbol “—”

will be displayed: for analog instruments the dial will be
absent.
Selecting screens
Depress the right arrow (button 5) to select the infor-
mation to be displayed in each respective window.
Then repeatedly depress the button that corresponds
to the window to be set until the desired information is
shown.
The type of information accessible depends on the

type of electrical system and sensors the boat is equip-
ped with.
P0003011
14 47702088 05-2011
Graph, button 4
This screen displays operational information in the
form of graphs. Depress button 4 repeatedly to select
the information to be displayed. To set the time interval,
4000 refer to Configuration menu.
If contact with the system is lost, a straight line will pro-
ceed across the screen.
2000
P0002420
Configuration menu
Open the Configuration menu by holding down button
5 for at least 3 seconds. In this screen it is possible to
retrieve System information, enter various display set-
tings, calibrate depth compensation and speed and
retrieve other system information.
Engine ignition must be switched on when changing

display settings or calibrating functions.
Navigate through the menu using the up and down

arrows, and select using the right arrow.
System Information
This screen shows the same information as that shown
in the tachometer display; refer to Instruments and
Controls page 11 for further information.
Alarm
When the system detects a fault, the display automat-
ically switches to the System Information screen. For
further information, refer to Fault Handling page 25.
Settings
Language: setting the display language.
Bleep: setting button bleep On or Off.
Engine: setting the installation the display forms part

of, and the engine to be shown in the display (single,
port, starboard or twin).
Eng. series: setting the engine series for the display

(D1/D2, <D2). The display is factory set for engines
larger than D1/D2, therefore the display must be re-set
before it can be used on D1/D2 engines.
Display: setting speed indicator and tachometer inter-

vals.
47702088 05-2011 15
- Rpm intervals, 2500–9000 rpm in 500 rpm stages.

Set 4000 rpm.
- Speed, on/off.
- Speed intervals, 10–100 knots in 10 knot stages.
- Graph intervals: 2 min, 10 min, 30 min, 60 min, 2 h,
4 h or 8 h.
- Speed (Speed): KNOTS, MPH, KM/H
Units: Selection of operational information units to be

shown (this menu is only displayed if “Local” is selected
in the settings menu: “Local” must always be selected
for D1/D2 engines).
- Distance: NM, MILE, KM
- Oil pressure/Turbo pressure: kPa, psi
- Fuel rate: L/H, GAL/H, IGAL/H
- Temperature: °C, °F
Calibration: the engine must be switched on during

calibration.
Depth compensation
Setting the Volvo Penta echo sounder. The echo-soun-
der can be installed anywhere between the waterline
and the boat's deepest point. Set the deviation – off set
– so that the display value shows one of these points.
To adjust the value up (+), set the distance between
the echo-sounder and the waterline; to adjust the value
P0003002 down (–), set the distance between the echo-sounder
and the boat's deepest point. The value can be set in
0.1 unit stages.
Store the set value by depressing BACK (button 5).
Speed factor
The speed factor must be set while the boat is under
way. Compare the displayed boat speed value with
GPS data (or another boat) and adjust the speed factor
until the values agree.
The speed sensor calibration value can be adjusted
upwards (+) or downwards (-) in stages of 0.01 units
(+ or - 1%). Store the adjusted value by depressing
BACK (button 5).
P0003005
16 47702088 05-2011
Controls
This section describes the controls Volvo Penta sells
for your engine. Contact your dealer if your boat is
equipped with controls other than those described
here, and you feel uncertain about their function.
N Maneuvering
F R
A single-lever control operates both gearshift and
throttle functions from the same lever.
T
T
The engine can only be started with the control lever
in the neutral position.
N = Neutral position. Reverse gear/drive disengaged

and engine at idle.
1 F = Reverse gear/drive engaged for movement
ahead.
P0002427
R = Reverse gear/drive engaged for movement
astern.
T = Engine rpm control (throttle).
Disconnecting the gearshift function

The gearshift function can be disconnected so that the
control lever only operates the throttle.
1 Put the control lever in neutral (N).
2 Depress the neutral button (1), and keep it
depressed at the same time as the lever is moved
forward.
3 Release the neutral button, the shift function is dis-
engaged and the lever only influences engine rev-
olutions.
The gear shift function is reconnected automatically

when the lever is returned to the neutral position.
CAUTION!
Take care not to engage the gear by mistake.
Adjusting the friction brake

The lever is fitted with a friction brake to allow adjust-
ment for easier or stiffer movement as required. The
friction brake only affects movement of the throttle con-
trol 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 screw clock-
wise (+) for stiffer lever movement, and counter-
clockwise (-) for easier movement.
4 Replace the cover and the lever.
47702088 05-2011 17
Starting
Make a habit of visually checking the engine, engine bay and transmission before start. This will help you to
discover quickly if anything abnormal has happened, or is about to happen. Also check that instruments and
warning displays show normal values when you have started the engine.
To minimize cold start smoke we recommend the installation of an engine heater or engine bay heater if temper-
atures below +5°C (41°F) are encountered.
WARNING!
Never use start spray or similar products as starting aid. Explosion risk!
Before Starting
• Check the engine and transmission oil levels.
• Check coolant level.
• Open the sea cock.
• Open the fuel cock.
• Turn the main switch(es) on.
IMPORTANT!
Never disconnect the current with the main switches
when the engine is running. The alternator and elec-
tronics could be damaged.
• Start the engine bay fan, where fitted, and allow it to
run for at least four minutes.
• Check that there is sufficient fuel for the planned trip.
P0005851
Starting the Engine

Activate the control panel by depressing the on/off but-
ton (1). The Volvo Penta logo is displayed in the win-
dow. Two audible signals are sounded to indicate the
system is ready and that the engine may be started.
1
P0007529
18 47702088 05-2011
Starting
Check the tachometer

2 If an operational fault occurs an audible alarm will
sound and a symbol will flash in the tachometer win-
1 RPMX1000
3 dow. Refer to the Fault Handling page 25 chapter for
more detailed information and recommended actions.
- +
0 4 ! ! Check the alarm instrument (accessory).

The lamps in the alarm instrument light up each time the
ignition is turned on. Check that all lamps light up and
P0008437
then extinguish. If any lamp flashes, a fault has been
registered; refer to the Fault Handling page 25 chap-
ter for more detailed information and recommended
actions.
Start the engine

Press the start button (4). Release the start button as
soon as the engine starts.
The pre-heating symbol is displayed in the tachometer
window. Pre-heating is automatic and lasts for 20 sec-
onds.
Pre-heating only takes place if engine temperature is
below 50° (122° F).

Pre-heating may be activated before the engine is
started by depressing the start button (4) for a short
moment. Pre-heating will continue for 20 seconds. The
pre-heating symbol is displayed in the tachometer win-
P0007951 4 dow.
Read off the instruments and warm up the

engine
Allow the engine to idle for the first 10 seconds. Read
off the instruments and check that they show normal
values. Check that no warning lamps are flashing. If any
lamp flashes, a fault has been registered; refer to the
Fault Handling page 25 chapter for more detailed
information and recommended actions.
Warm up the engine at low speed and low load, so that
normal working temperature is reached before full
power is applied.
47702088 05-2011 19
Operation
Learn to handle the engine, controls and other equipment in a safe and proper manner before casting off on your
maiden voyage. Remember to avoid sudden and extreme rudder maneuvers and gear shifts. There is a risk for
passengers 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.
Reading the Instruments

Read off the instruments and alarm display immedi-
ately after start, and then regularly during operation.
Alarms
If an alarm is tripped, an audible alarm will sound and
2 a symbol will flash in the tachometer window (1).
1 RPMX1000
3 If optional equipment such as alarm instruments or an
EVC display are installed, the relevant warning lamp
will flash there also.
0 4 1 Reduce engine speed to idle.

2 Cancel the alarm by depressing the multi-function
button (2).
1 The audible alarm will be silenced. The symbol will
be lit continuously until the fault is remedied
3 Take the necessary action: refer to the Fault Han-
dling page 25 section.
SYSTEM INFORMATION
P0007519
20 47702088 05-2011
Operation
Maneuvering
Shifting between ahead and astern must be done at
idle revolutions. Shifting at higher revolutions can be
uncomfortable for those on board and cause unnec-
1
essary stress to the transmission or make the engine
stall.
Always shift between ahead and astern in

the following manner:
1 Reduce engine revolutions to idle and allow the
boat to lose most of its speed.
2 Move the control lever to the neutral position with
a quick, firm movement. Pause a moment.
2 3 Move the control lever back with a quick, firm
movement and increase revolutions.
P0005856
47702088 05-2011 21
Operation
Sailing
When sailing, set the control lever to astern if a folding
propeller is fitted.
Is a fixed propeller is fitted the control lever should be
set in neutral or reverse. When using a fixed propeller
and sailing with the control lever set to reverse the
speed is slowed down though less noise is being
made.
Cruising Speed
Avoid operations at full throttle for best fuel economy.

We recommend a cruising speed that is around
500-1000 rpm below the maximum rpm at top speed
(full throttle).
Depending on the type of hull, choice of propeller, load
and sea state etc., maximum revolutions at top speed
may vary, but should be within the full throttle range;
refer to the Engines section.
22 47702088 05-2011
Engine Shutdown
Allow 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 when
the engine has been run under heavy load at high rpm .
Stop the Engine

Press the Stop button (3) until the engine stops run-
ning.
Press the On/Off button (1) to cut the power to the sys-
tem.
If the engine is stopped and the ignition still turned on,

an alarm sounds after 10 seconds to prevent the igni-
tion is left on unintentionally and the battery will
become discharged.
Silence the alarm by turning the ignition off, or reset
the alarm with the multifunction button (2) if the ignition
is to be turned on.
1 2 3
P0014272
Auxiliary stop
If the engine cannot be stopped in a normal procedure,
it is possible to stop the engine via the auxiliary stop
mounted on the side of the engine.
After Engine Shutdown

• 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 out preven-
tive maintenance according to the maintenance
schedule.
• Turn off the main switch before any long stoppage.
1
P0005914 0
47702088 05-2011 23
Engine Shutdown
Operation break with the boat in water

If the boat is not used, but left in the water, the engine
must be warmed up at least once every fortnight. This
prevents corrosion damage in the engine.
If you expect the boat to be unused for two months or
more, it must be laid up, please refer to Stor-
age page 64
Operation break with the boat out of water

Where boats are kept laid up on land when not in use,
there is a lower level of galvanic corrosion protection
due to oxidation on the sacrificial anodes. Before
launching the boat the sacrificial anodes on the drive
and shield must be cleaned with emery paper to
remove any oxidation.
If you expect the boat to be unused for two months or
more, it must be laid up, please refer to Stor-
age page 64.
IMPORTANT!
Use emery paper. Do not use a wire brush or other
steel tools when cleaning, as these may damage the
galvanic protection.
Cold Weather Precautions

If the engine bay cannot be kept frost free, the raw
F C water system must be drained and the freshwater sys-
tem coolant must have sufficient frost protection to
70 20
60
prevent frost bursting; refer to Seawater System,
50 10 Draining page 48 and Maintenance page 43
20 respectively for more detailed information.
32 0 Check the charge status of the battery. A poorly-
20
charged battery can freeze and burst.
10
10
P0005905
24 47702088 05-2011
Fault Handling
Despite regular maintenance according to the maintenance schedule and perfect operation conditions faults may
occur which must be attended to before the boat can travel further. This chapter describes alarms and fault
handling.
If an operational fault arises an audible alarm will

sound and a symbol will flash in the tachometer win-
2 dow(1) If optional equipment such as an alarm moni-
1 RPMX1000
3 tor or an EVC display are installed, the relevant warn-
ing lamp will flash there also.
Cancel the alarm by depressing the multi-function
0 button (2). The audible alarm will be silenced. The
4 symbol will be lit continuously until the fault is rem-
edied.
This chapter describes faults and actions to be taken.
1
CAUTION!
Read the safety precautions for maintenance and
service in the Safety Information chapter before start-
ing work.
SYSTEM INFORMATION
P0007519
47702088 05-2011 25
Fault Handling
Coolant Temperature
The coolant temperature lamp is lit if the coolant tem-
perature is too high.
IMPORTANT!
Continued operations with too-high engine tempera-
ture may cause serious engine damage.
• Check coolant level. Refer toCoolant Level,
Checking and Topping Up page 45.
• Check that the raw water filter, where such is
fitted, is not clogged. Refer to Seawater Filter,
Check and Cleaning page 51.
• Check the impeller in the seawater pump. Refer
toImpeller, Check and Change page 49.
If the alarm continues despite the above actions being

carried out, run the engine at low revolutions and drive
the boat to the nearest service workshop for repair.
Oil pressure
If the oil pressure lamp lights up during operations, the

engine oil pressure is too low.
IMPORTANT!
Continued operations with too-low oil pressure will
cause serious engine damage.
• Checking Engine Oil Level, refer to Oil level,
checking and topping up page 39.
• Check that the oil filter is not blocked. Change
the oil filter as necessary; refer to Engine oil and
engine oil filter, changing page 40.
• Please contact a Volvo Penta workshop if the
fault remains.
Battery
The charging lamp lights up when the alternator stops
charging the batteries, which may result from a fault
in the electrical system or the need to tension the
alternator drive belt.
• Check belt tension. Refer to Drive Belt, Check
and Change page 37.
• Check to see if there are no short circuit, chafed
wires or wires with loose connections.
• Check the fluid level in the battery; refer to Bat-
tery, Maintenance page 53.
fault remains.
26 47702088 05-2011
Fault Handling
System failure
The "system fault" symbol is displayed when there is
a short circuit or cable break.
The symbol shows if the ignition is left on, refer to

Engine Shutdown page 23.
• Check to see if there are any chafed wires or
wires with loose connections.
fault remains.
Fuel level
The fuel level symbol is displayed when less than 20%
fuel remains in the tank if a fuel level sensor is instal-
led (optional equipment).
Auxiliary alarm
Alarm for auxiliary sensors (optional equipment).
Alarm Display (optional instrument)

1 The fuel level symbol lights up during operation
when less than 20% fuel remains in the tank if a
1
fuel level sensor is installed (optional equip-
ment).
7 2
2 The battery lamp lights up if the alternator is not
charging.
3 The coolant temperature lamp lights up when
6 3
the coolant temperature is too high.
4 This indicator is not activated for the engine.
4 5 This indicator is not activated for the engine.

5
6 The "System Failure lamp" will light up at short
P0004761
circuit, broken wire and AUX failure.
7 If the oil pressure lamp lights up during opera-
tion, the oil pressure in the engine is too low.
47702088 05-2011 27
Fault Handling
Fault Tracing
A number of symptoms and possible causes of engine malfunctions are described in the table below. Always
contact your Volvo Penta dealer if any problems occur which you cannot solve by yourself.
NOTICE! Read the safety regulations for care and maintenance in the Safety Information page 6 chapter before
work you start work.
Symptoms and possible causes

Start motor will not turn, or turns slowly 1, 2
Engine does not start 3, 4, 5, 6, 7, 8
Engine starts but stops again 5, 6, 7, 8
Engine is difficult to start 5, 6, 7, 8
Engine does not reach correct operating speed at full throttle 6, 7, 8, 9, 10, 11, 12, 17
Engine knocks 13
Engine runs roughly 5, 6, 7, 8, 12, 13
Engine vibrates 17, 18
High fuel consumption 9, 10, 12, 14, 17
Black exhaust smoke 4, 12, 14, 17

Blue or white exhaust smoke 14, 24
Lubrication oil pressure too low 15, 16
Coolant temperature too high 19, 20, 21, 22, 23
No charge, or poor charge 1, 25
1. Flat battery
2. Poor contact/open circuit in cables
3. The stop lever is pulled out
4. Insufficient preheat
5. Lack of fuel
6. Blocked air filter
7. Air in the fuel system
8. Water/contamination in fuel
9. Boat abnormally loaded
10. Fouling on hull, drive or propeller
11. Limited movement in engine control lever
12. Insufficient air supply to engine
13. Coolant temperature too high
14. Coolant temperature too low
15. Oil level too low
16. Blocked oil filter
17. Faulty / wrong propeller
18. Faulty engine mounting
19. Coolant level too low
20. Blocked raw water inlet, lines or filters
21. Circulation pump drive belt slipping
22. Faulty impeller
23. Faulty / wrong thermostat
24. Oil level too high
25. Alternator drive belt slipping
28 47702088 05-2011
In Case of Emergency
Despite regular service in accordance with the planned
maintenance schedule and perfect operating condi-
tions, faults may occur that must be remedied before
the boat can continue its trip. This chapter provides
advice on how to remedy a number of conceivable
faults.
If a fault occurs, confirm any fault alarm and take the

necessary actions. See this chapter and refer to the
Fault Handling page 25 chapter.
Starting Using Auxiliary

Batteries
WARNING!
Explosion hazard. Batteries contain and give off an
explosive gas which is highly flammable and explosive.
A short circuit, open flame or spark could cause a vio-
lent explosion. Ventilate well.
WARNING!
Never confuse the positive and negative poles on the
batteries. Risk of arcing and explosion.
P0002107 1 Check that the auxiliary battery has the same volt-
age as the engine system voltage.
2 Connect the red positive cable to the plus (+) ter-
minal on the discharged battery and then to the plus
terminal on the auxiliary battery.
3 Connect the black start cable to the minus (–) ter-
minal on the auxiliary battery and to a place a little
distance away from the discharged battery, e.g. the
start motor's negative terminal.
WARNING!
Under no circumstances may the black jumper cabel
(–) come in contact with the positive connection on the
starter motor.
4 Start the engine and let it run at fast idle for approx-
imately 10 minutes to charge the batteries. Make
sure there is no extra equipment connected to the
electrical system.
47702088 05-2011 29
In Case of Emergency
WARNING!
Working with or going close to a running engine is a
safety risk. Watch out for rotating components and hot
surfaces.
WARNING!
Do not touch the connections during the start attempt:
Risk of arcing.
Do not bend over any of the batteries either.
5 Turn off the engine. Remove the start cables in the

exact opposite order to their connection.
30 47702088 05-2011
Maintenance Schedule
Your Volvo Penta engine and its equipment are designed for high reliability and long life. The engines are built to
withstand the marine environment, but also to have the smallest possible environmental impact. If the engine and
transmission are serviced regularly according to the schedule, these qualities will be retained and unnecessary
malfunctions will be avoided.
Warranty inspection
During the initial period of use a special warranty inspection - a First service inspection - must be carried out by
an authorized Volvo Penta workshop. Instructions regarding when this must be done can be found in the Warranty
and service book.
Extended protection for leisure use

Volvo Penta offers extended protection for marine diesel engines, including power trains, applicable only to leisure
boats. For the warranty to be valid, all prescribed services must have been carried out at the owner's expense by
an authorized Volvo Penta dealer or service workshop before the 12 month warranty period has expired. Further
instructions are contained in the Warranty and service book.
C = Clean
R = Replace
A = Adjust
L = Lubricate
I = Inspect (Clean, Adjust, Lubricate or Replace if nec-

essary)
First service inspection, after 20–50 running hours 1)

Transmission, oil level I
Coolant level and antifreeze mixture I
Drive belt (tension) I
Seawater filter IC
Instrument panel function I
Start and warm up engine
Engine and transmission, oil / fuel / water leakage I
Engine and transmission, abnormal noises I
Stop Engine
Engine oil and oil filters L
Restart engine
Oil pressure / oil leakage I
1) Or within 180 days of the date of delivery, or the end of the first season, whichever comes first.
Daily, Before First Start

Engine and engine room. General inspection I
Checking Engine Oil Level I
Check coolant level. I
47702088 05-2011 31
Maintenance Schedule
Every 14 days
Drive belts, wear I
Seawater Filter, Check and Cleaning IC
Fuel pre-filter, draining water / contamination I
Batteries, electrolyte level I
Reverse gear, oil level I
S-drive, oil level I
Every 200 hours / at least once a year, included in extended protection

D1 Engine oil and oil filters1) R
Reverse gear, oil R
Reverse gear, propeller shaft seal I
S-drive, oil R
S-drive/reverse gear, corrosion protection I
1)Oil change intervals vary, depending on engine type, oil grade and sulfur content of the fuel. Se avsnitt Oil
Grade and Oil Change Interval.
Every 500 operating hours / at least once per year; included in extended warranty
D2 Engine oil and oil filters1) R
Fuel pre-filter and fuel fine filter R
Idle I
Seawater pump impeller I
Vaccum Valve, Cleaning C
1)Oil change intervals vary, depending on engine type, oil grade and sulfur content of the fuel. Se avsnitt Oil Grade
and Oil Change Interval.
Once per year; included in extended warranty

Folding Propeller C
S-drive, Rubber Sealing between Drive and Hull I
Every 500 operating hours / at least once every 2 years

Heat exchanger C
Injectors I
Valve clearance A
Every 4 years
Coolant R
Every 500 operating hours / at least once every 5 years

Reverse gear, propeller shaft seal R
Every 7 years
S-drive, Rubber Sealing between Drive and Hull R
32 47702088 05-2011
Maintenance
This chapter contains general technical information and instructions on how the prescribed maintenance items
must be carried out. Read through the instructions carefully before starting work. The times when maintenance
items must be carried are indicated in the Maintenance Schedule page 31.
Read through the safety precautions for maintenance and service in the Safety Information page 4 chapter before
work on the engine is begun.
WARNING!
Care and maintenance work should be done with the engine stopped unless otherwise specified. Stop the engine
before opening or removing the engine hatch/hood. Make it impossible to start the engine by removing the start
key and cutting the system voltage with the main switches.
D1-20 with MS10A reverse gear 1 Coolant filling

1 2 3 2 Heat exchanger
3 Relay box
6 4 Alternator
5 Starter motor
6 Oil dipstick, reverse gear
4 5
P0008052
D1-20 with MS10A reverse gear 7 Air filter/air intake

7 8 9 10 8 Fuel hand pump
9 Oil filler, engine
10 Oil dipstick, engine
11 Fuel filter
12 Oil filter
13 Injection pump
14 Raw water pump
11 12 13 14
P0008053
47702088 05-2011 33
Maintenance
D1-30 with MS15A reverse gear 1 Coolant filling

3 Relay box
4 Alternator
5 Starter motor
7
6 Oil cooler, reverse gear
7 Oil dipstick, reverse gear
4 5 6
P0008054
D1-30 with MS15A reverse gear 8 Air filter/air intake

8 9 10 11 9 Fuel hand pump

12 Fuel filter
13 Oil filter
14 Injection pump
15 Raw water pump
12 13 14 15
P0008055
34 47702088 05-2011
Maintenance
D2-40 with 130S sailboat drive 1 Coolant filling

3 Relay box
4 Alternator
5 Starter motor
6 Sea cock, S-drive
7 Cooling water inlet, S-drive
8 Folding propeller
4 5 6
8
P0008056
D2-40 with 130S sailboat drive 9 Oil dipstick, S-drive

10 11 12 13 10 Air filter/air intake
11 Fuel hand pump
14 Sacrificial anodes
15 Oil drain, S-drive
9 16 Fuel filter
17 Oil filter
18 Injection pump
19 Raw water pump
16 17 18 19
14 15
P0008057
47702088 05-2011 35
Maintenance
Engine, General
General inspection
Make a habit of visually checking the engine and
engine bay before starting, and after operations when
you have stopped the engine. This will help you to dis-
cover abnormalities quickly, or if something is about to
happen.
Look especially carefully for oil, fuel and coolant lea-
kages, loose bolts, worn or poorly-tensioned drive
belts, loose cable connections, damaged electrical
cables and hoses. This inspection only takes a few
minutes and can prevent serious malfunctions and
expensive repairs.
WARNING!
Accumulations of fuel, oil and grease on the engine or
in the engine room is a fire hazard and must be
removed immediately they are detected.
WARNING!
If an oil, fuel or coolant leak is detected, the cause must
be investigated and the fault rectified before the engine
is started.
Never direct the jet from a high-pressure washer at

seals, rubber hoses or electrical components. Never
use the high pressure setting for engine cleaning.
Air Filter, Change

1
1 Loosen the hose clamp (1) and undo the bolt (2)
and remove the filter.
Make sure that contaminants do not enter the
engine.
2 2 Install the new filter; fasten with the hose clamp and
the bolt.
P0007521
36 47702088 05-2011
Maintenance
Drive Belt, Check and Change

WARNING!
Stop the engine before doing any maintenance work.
Check belt tensions and condition regularly. A belt that

is tensioned too tightly may damage bearings, while a
belt too-loosely tensioned may slip.
Check and adjust the belt after operation, while the belt
is still warm.
2
A correctly-tensioned belt should be possible to
PRE
STA
RT
HEA
T depress approx. 10 mm (0.4”) between the pulleys.
T
BAT
IMPORTANT!
Always replace a belt that appears worn or has cracks
(belts that work in pairs must always be changed
10mm
together).
3
Adjusting the drive belt
1 Undo the alternator retaining bolts (1-2).
1
2 Using the adjuster screw (3), adjust the belt to the

correct tension.
3 Tighten the bolts (1-2) and check the tension.
Replacing the drive belt

1 Undo the alternator retaining bolts (1 and 2).
2 Press the alternator toward the engine block so
that the belt can be removed. Wipe clean the belt
grooves
3 Install the new belt. Adjust.
4 Check the belt tension again after a few hours'
operations.
P0007520
IMPORTANT!
D1-30, D2-40: Ensure that the alternator belt is placed
D1-30 and D2-40
in the groove closest to the alternator.
47702088 05-2011 37
Maintenance
Idling, adjustment
A
B For engine idle revolutions, refer to the Engines sec-
tion. Low idle revolutions may cause the engine to stall,
while higher idle revolutions cause extra stress on the
drive/reverse gear during shifting maneuvers.
Adjustment must be made while the engine is warm.

1 Put the control lever in neutral.
Check that the gap (A) is around 3 mm.
Undo locknut (B) and adjust screw (C) to give the
correct gap. Tighten the locknut.(1)
2 Start the engine and let it idle with the control lever
in the neutral position.
WARNING!
P0007955 safety risk. Watch out for rotating components and hot
surfaces.
3 Undo the locknut (D). Adjust to the correct revolu-

tions using the adjuster screw (E). Tighten the lock

nut.
4 Repeat item 1.
1. This item does not apply to boats with twin helm stations.
38 47702088 05-2011
Maintenance
Lubrication System
Oil change intervals can vary depending on oil grade
and sulphur content of the fuel, please refer toTechni-
cal Data, Lubrication System.
Oil change intervals must never exceed a period of 12

months.
If you want longer oil change intervals than given in the

table Oil Grade and Oil Change Interval, the condition
of the oil must be checked by the oil manufacturers
through regular oil testing.
P0002089
Oil level, checking and topping up

1 The oil level must be within the marked area on the oil
dipstick and must be checked daily before the first
start.
IMPORTANT!
Do not fill above the limit for max. oil level. Use only oil
of the recommended grade; refer to Technical Data,
2
Lubrication System.
MAX 1 Fill oil slowly through the oil filler on top of the
engine (1) or at the side (2).
2 Wait 5 minutes so that the oil has time to run down
MIN into the engine.
3 Check the oil level again when the engine has
cooled.
P0007522
47702088 05-2011 39
Maintenance
Engine oil and engine oil filter,

changing
Always follow the recommended oil change interval.

Use only oils of the recommended grades; refer to Oil
Grade and Oil Change Interval.
WARNING!
Hot oil and hot surfaces can cause burns.
1 Run the engine until warm so that the oil is easier

to pump. Stop the engine.
2 Connect an oil drain pump to the oil drain pipe.
Pump out the oil.
3 Unscrew the lubricating oil filter. Place a plastic bag
over the filter before it is unscrewed to avoid oil
spillage.
4 Check that the filter contact area on the engine is
clean.
5 Apply a film of oil on the new filter gasket. Screw

the filter on by hand until it touches the contact sur-
face. Then tighten an extra half turn, no more!
6 Fill with oil to the correct level through the oil filler
on top or to the side of the engine. For oil quantity,
refer to the Technical Data, Lubrication System
section.
Start the engine. Run the engine until it reaches
normal operating temperature. Check that the low
oil pressure lamp goes out and that there are no
leaks around the oil filter.
7 Turn off the engine. Wait ten minutes before check-
ing the oil level. Top up as needed.
Hand in the old oil and oil filter to a re-cycling station.
P0007523
40 47702088 05-2011
Maintenance
Fuel System
Only use the grades of fuel recommended in the fuel
specification, see Technical Data, Fuel System.
Always observe the greatest cleanliness during re-
fuelling and work on the fuel system.
All work on the unit injectors of the engine must be
carried out by an authorized workshop.
WARNING!
Fire hazard. When carrying out work on the fuel system
make sure the engine is cold. A fuel spill onto a hot
surface or an electrical component can cause a fire.
Store fuel soaked rags so that they can not cause fire.
Engine Fuel Filter Replacement

1 Clean the filter bracket.
Avoid fuel spills by placing a plastic bag around the
filter
2 Unscrew the filter
3 Apply a film of oil on the new filter gasket.
4 Screw the filter on by hand until it touches the con-
tact surface. Then tighten an extra half turn, no
more!
5 Purge the fuel system, refer to the Fuel system,
bleeding page 42 section.
6 Start the engine and check for leaks.
7 Hand in the old filter to a re-cycling station.
P0003731
47702088 05-2011 41
Maintenance
Fuel system, bleeding

1
2 The fuel system must be purged after a filter change,
if the fuel tank has been run dry and after a long-term
3
stoppage.
4
1 Open the purge screw (1) on the fuel filter approx.
three turns. Avoid fuel spills; use rags to soak up
fuel at the purging point.
2 Pump fuel up with the hand pump (2) until fuel with-
out air bubbles can be seen. Continue pumping and
tighten the purging screw at the same time.
The pump inlet pipe contains a strainer (3) which
normally does not need to be cleaned since the
engine has a fuel pre-filter. If a fuel pre-filter is not
fitted, poor feed flow can be due to a blocked
strainer.
If either of the two O-rings (4) are damaged, they
must be replaced.
P0007532
Fuel pre-filter
1
The fuel pre-filter is an optional extra.
Draining
Wait a few hours after the enginehas been turned off
before draining the filter..
Position a container under the fuel filter. Drain offwater
and contaminants using the cock/plug at the bottom of
the filter bowl.
Replacing filter insert

1 Close fuel cock at the fuel tank. Position a contain-
erunder the fuel filter.
2 Remove the filter bowl by undoing screw (1).
3 Emptyand clean the filter bowl. Replace insert and
reinstallthe bowl.
P0007533
4 Open fuel cock.
5 Vent the fuel system, please refer to sectionFuel
system, bleeding page 42.
7 Depositthe old filter insert at a properly designated
disposal site.
42 47702088 05-2011
Maintenance
Freshwater System
The freshwater system is the engine's internal cooling
system that ensures that the engine operates at the
correct temperature. It is a closed system that must
always be filled with a coolant mixture in order to pro-
tect the engine against internal corrosion, cavitation
and frost bursting.
IMPORTANT!
Coolant of a suitable chemical composition must be
used all year round. This applies even when there is
no risk for frost damage, so that the engine always has
complete corrosion protection.
The use of anti-corrosion agents alone is not permitted
in Volvo Penta engines. Never use water alone as the
coolant.
The corrosion protection additives become less effec-

tive over time, which means that the coolant must be
changed at regular intervals; refer to Maintenance
Schedule page 31. The cooling system must be
flushed whenever the coolant is changed, refer to

Freshwater system, Flushing.
Volvo Penta recommend ”Volvo Penta Coolant VCS,

Ready Mixed” or the concentrate ”Volvo Penta Coolant
VCS” mixed with pure water according to specifica-
tions, see Water Quality.
Volvo Penta Coolant VCS and VCS Ready Mixed are

based on organic acid technology (OAT). Using other
types of coolant, such as conventional or hybrid types,
can drastically reduce the heat transfer and result in
overheating of the engine.
47702088 05-2011 43
Maintenance
Coolant, Mixing
WARNING!
All coolant is hazardous and harmful to the environ-
ment. Do not consume. Coolant is flammable.
IMPORTANT!
Different types of coolant must not be mixed with each
other!
Mix: 40% “Volvo Penta Coolant” (conc.

coolant)and 60% water
This mixture protects against internal corrosion, cavi-
tation and frost bursting down to –28°C (–18°F). At60%
glycol concentration, the freezing point is lowered to –
54°C (–65°F).
Never mix more than 60% concentrate (Volvo Penta
Coolant) in the coolant. A greater concentration pro-
vides reduced cooling effect with the risk for overheat-
ing and reduced frost protection.
The coolant must be mixed with distilled, deionized

water. The water must fulfil the requirements specified

by Volvo Penta; refer toWater Quality.
It is extremely important that the system is filled with
the correct coolant concentration. Mix in a separate
clean vessel before filling the cooling system. Make
sure that the liquids mix.
44 47702088 05-2011
Maintenance
Coolant Level, Checking and

Topping Up
WARNING!
Do not open the coolant filler cap when the engine is
warm, except in emergencies, this could cause serious
X
MAX personal injury. Steam or hot fluid could spray out.
MA
MIN
MIN
1 Turn the filler cap slowly counter-clockwise and
release any pressure from the system before
removing the cap completely.
2 Top up with coolant as necessary. The coolant level
must be between the MAX and MIN marks on the
expansion tank.
3 Screw on the filler cap.
When filling a completely empty system the coolant

level must be checked after the engine has been run
for an hour or so, as the system is self purging. Top up
with coolant as necessary.
P0007524
Coolant, Draining
WARNING!
2
1 Connect a hose to the engine block drain tap (1)
and one to the heat exchanger drain tap (2).
2 Remove the filler cap on the expansion tank to
speed up coolant drainage.
3 Open the drain taps (1) and (2). Allow all the coolant
run out into a container.
4 Collect the old coolant and hand it to a to a re-
cycling station
The heat exchanger must be cleaned before new cool-

ant is added.
P0007525
47702088 05-2011 45
Maintenance
Heat Exchanger, Cleaning

3
WARNING!
Cooling performance is reduced by scaling in the hea-

2 texchanger. It should therefore be flushed when the-
coolant is changed.
1 Drain the coolant, please refer to section Coolant,
Draining page 45.
2 Loosen the hose (3) and insert a hose into the filling
pipe on the heat exchanger. Rinse with fresh water
until the water which runs out of the drain tap (1)
and the engineblock (2) is clean. Let all the water
run out.
3 Close the draining points (1 and 2) . Fill up with-
coolant to the correct level. Put the filler cap back.
P0007526
4 Fit the hose (3).
46 47702088 05-2011
Maintenance
Seawater System
The raw water system is the engine's external cooling
system. On engines with drives, the raw water pump
sucks in water via the drive, through the control sys-
tem's oil cooler to the raw water pump. The water then
passes through the raw water filter before being
pumped through the fuel cooler, intercooler, engine oil
cooler and heat exchanger. Finally the water is fed out
through the exhaust elbow, where it is mixed with the
exhaust gases.
On engines with reverse gears, the raw water pump
sucks in water via a raw water intake, after which the
water passes a raw water filter (extra equipment)
before being pumped through the intercooler, heat
exchanger, engine oil cooler and gearbox oil cooler.
Finally the water is fed out through the exhaust elbow,
where it is mixed with the exhaust gases.
WARNING!
Risk of water entry. Water will flow into the boat if any
hose, plug etc. located below the waterline is removed

when the boat is in the water. Always close the sea
cocks. If the boat does not have sea cocks the water
flow must be blocked in a safe manner. If this is not
possible, the boat must be drawn up on land before
work starts.
47702088 05-2011 47
Maintenance
Seawater System, Draining

8
2 WARNING!
5 Risk of water entry. Close the seawater cocks before
doing any work on the seawater system.
4
To prevent freeze bursting, the raw water system must
be drained during cold weather when there is a risk of
freezing. An alternative to draining is to keep the
7
engine bay warm using an approved heater fan.
3
Note that all raw water must be drained and that the
draining process must be adapted to suit the engine
installation and any auxiliary equipment connected to
it, such as a raw water filter (2), vacuum valve (8),
exhaust riser and drain tap (9) and silencer (7) etc.
130S
5 1 1 Close the sea cock (1).
2 Remove the cover and the sealing plate on the raw
8 water filter (2).
2 3 Remove the cover (3) from the raw water pump and
let the water run out.

4 9 4 Open the drain tap (4) on the heat exchanger side
panel and drain off the water.
5 Loosen the hoses at the arrows (5) and empty them
of water.
7
6 Connect a hose to the drain tap on the riser (9) and
3
lead it into a container. Open the tap and drain off
the water. Close the tap.
7 Remove the hose (6) on the reverse gear oil cooler
and drain off the water.
5 8 Drain the silencer (7), the exhaust system and other

1 auxiliary equipment connected to the raw water and
MS10 / MS15 exhaust systems.
9 Reinstall all hoses, the raw water pump cover and
the raw water filter cover and sealing plate. Close
the heat exchanger drain tap.
10 Open the raw water tap when the boat is returned
to operations.
Check that no leakage exists in the raw water sys-
tem.
MS15
P0007978
48 47702088 05-2011
Maintenance
Impeller, Check and Change
WARNING!
Risk of water entry. Close the seawater cocks before
1 Close the sea cock.

2 Remove cover on the seawa-ter pump. Remove
impeller .
If there are cracks or other defects the impeller must
be replaced.
3 Lubri-cate the pump housing and the inside of the
cover with a little glycerin.
IMPORTANT!
Impellern skadas om andra typer av smörjmedel än
glycerin används.
4 Reinstall the impeller using a clockwise rotating
movement.
5 Install the cover together with a new gasket. Open
the sea cock.
P0007527
Always carry a spare impeller on board.
47702088 05-2011 49
Maintenance
Seawater System, Cleaning and

Inhibiting
The raw water system must be flushed with fresh

water, to prevent deposits and salt crystals from build-
ing up inside it. The system must also be conserved
when the boat is laid up for winter or out-of-season
storage so that it is protected from internal corrosion.
2
WARNING!
Risk of water penetration.
Cleaning and inhibiting the seawater system should be
carried out with the boat on land.
1 WARNING!
safety risk. Watch out for rotating components and hot
surfaces.
1 Open the sea cock (1).

2 Remove the hose from the sea cock (1) or from the
outlet side of the raw water filter (2) if such is fitted
to the engine.
3 Put the free end of the hose into a bucket of fresh-
water. Proceed with refilling.
IMPORTANT!
The impeller will be damaged if it is run dry.
4 Check that there is no one in the vicinity of the pro-
peller and that nothing risks being spattered by the
exhaust outlet.
5 Set the control lever to neutral and start the engine.
Let it run at fast idle for a few minutes. Stop the
engine.
6 Fill the bucket with an antifreeze solution (40%
Volvo Penta Coolant and 60% freshwater) and
arrange for the collection of the solution throughput.
7 Start the engine and let it idle. Stop the engine just
before the mixture is depleted. Repeat until the
entire system has been flushed with the mixture.
8 Reconnect the removed hose.
9 The system is now conserved. The glycol mixture
should remain in the system during storage.
Before launching the boat, drain the mixture and
hand it to a re-cycling station.
P0007530
50 47702088 05-2011
Maintenance
Seawater Filter, Check and Cleaning

WARNING!
If the water where the boat is used contains contami-

nants, seaweed, etc. the filter should be checked more
frequently than stated in the maintenance schedule.
Otherwise there is a risk that the filter may be blocked
resulting engine overheating.
1 Close the sea cock.
2 Unscrew the cover (1) and remove the sealing plate
(2).
3 Lift out the insert (3) and clean it.
4 Replace parts as illustrated.
5 Open the sea cock and check for leaks.
Vaccum Valve, Cleaning
Certain configurations have a vacuum valve installed

in the raw water system.
WARNING!
2 1 Close the sea cock.

3 2 Remove the valve. Unscrew the hexagonal cover
1 (1).
3 The cover contains a membrane (2) and a gasket
(3). Clean all components.
4 Turn the cover upside down. First insert the mem-
brane and then the gasket.
5 Turn the valve housing upside down as well. Screw
on the hexagonal cover to around 2 Nm. If the cover
is screwed on too tightly the valve may stop work-
ing.
P0007528
47702088 05-2011 51
Maintenance
Electrical System
The engine is equipped with a 2-pole electrical system
and an alternator. System voltage is 12V.
WARNING!
Always stop the engine and break the current using the
main switches before working on the electrical system.
Isolate shore current to the engine block heater, bat-
tery charger or accessories mounted on the engine.
Main switch
IMPORTANT!
Never disconnect the current with the main switches
when the engine is running, the alternator and elec-
tronics could be damaged.
The main switches must never be switched off before

the engine has stopped. If the circuit between the alter-
nator and the battery is disconnected when the engine

is running, the alternator and electronics can be dam-
aged. For the same reason the charging circuits must
never be re-connected with the engine running.
Fuses
The engine is equipped with a strip fuse.
The fuse cut the power if the electrical system
becomes overloaded.
If it is not possible to start the engine or if the gauges
stop working during operations the fuse may have
deployed.
IMPORTANT!
Always investigate the cause of the overload. If the
fuse trips frequently, contact an authorized Volvo
Penta workshop.
p0013054
52 47702088 05-2011
Maintenance
Electrical Connections
Check that electrical connections are dry, free from
oxide, and that they are securely tightened. Spray the
connections as necessary with water-repellent spray
(Volvo Penta universal oil).
Battery, Maintenance
WARNING!
Risk of fire and explosion. Never allow an open flame
or electric sparks near the battery or batteries.
P0002107
WARNING!
WARNING!
The battery electrolyte contains extremely corrosive
sulfuric acid. Protect your skin and clothes when charg-
ing or handling batteries.
Always use protective goggles and gloves. If battery
electrolyte comes into contact with unprotected skin
whas off immediately using plenty of water and soap.
If battery acid comes in contact with the eyes, flush
immediately with plenty of water and obtain medical
assistance without delay.
Connecting and disconnecting the battery
Connecting
- 1 Connect the + cable (red) to the + pole on the bat-

tery.
+
2 Connect the – cable (black) to the – pole on the

battery.
Disconnecting
1 Remove the – cable (black).
2 Remove the + cable (red).
P0002108
47702088 05-2011 53
Maintenance
Cleaning
Keep the batteries clean and dry. Contamination and
oxide on the batteries and battery poles can cause
stray currents, voltage drop and discharge, especially
in wet weather. Remove oxidation from the battery
poles and terminals, using a brass brush. Tighten the
terminals securely and grease them with terminal
grease or petroleum jelly.
Filling
The electrolyte level should be 5–10 mm (0.2– 0.4”)
above the cell plates in the battery. Top up with distilled
water as required.
After filling, the battery should be charged for at least

30 minutes by running the engine at idle.
Some maintenance-free batteries have special

instructions, which must be followed.
P0002110
Battery, Charging
WARNING!
Risk of fire and explosion. Never allow an open flame
or electric sparks near the battery or batteries.
P0002107
WARNING!
The battery electrolyte contains extremely corrosive
sulfuric acid. Protect your skin and clothes when charg-
ing or handling batteries.
Always use protective goggles and gloves. If battery
electrolyte comes into contact with unprotected skin
whas off immediately using plenty of water and soap.
If battery acid comes in contact with the eyes, flush
immediately with plenty of water and obtain medical
assistance without delay.
WARNING!
IMPORTANT!
Observe the instruction manual for the battery charger
carefully. To avoid the risk of electrochemical corrosion
when an external charger is connected, the battery
cables should be removed from the batteries before
the charger is connected.
Always switch off the charging current before the
charging clips are removed.
54 47702088 05-2011
Maintenance
• Charge batteries if they have become discharged.

During charging, unscrew the cell plugs but leave
them in the plug holes. Ventilate well, especially if
the batteries are charged in an enclosed space.
• If the engine is not used for a longer period of time,
the batteries should be fully charged, then possibly
trickle charged (please refer to the battery manu-
facturer’s recommendations). Batteries are dam-
aged by being left discharged, and can also freeze
and burst easier in cold weather.
• Special instructions apply to boost charging. Boost
charging can shorten battery life, and should there-
fore be avoided.
P0002111
Electrical Installations
An incorrectly-carried-out electrical installation may
generate leakage current from the electrical system.
Leakage current can in turn render galvanic protection

inadequate in respect of propellers, propeller shafts,
rudder posts, the keel etc., and may cause damage
through electrochemical corrosion.
WARNING!
Work on the low voltage circuits in the boats should be
done by a person with electrical training or knowledge.
Installation or work on land current equipment must
only be done by a competent electrician, in accordance
with local regulations for mains electricity.
47702088 05-2011 55
Maintenance
The following must always be heeded:

1 If shore power is connected it must always be
ground protected ashore, never in the boat. Fur-
thermore, the shore power installation should be
equipped with a ground fault interrupter.
The shore power installation (transformer, inverter,
battery charger etc.) must be designed for marine
use where the high-tension side is galvanically sep-
arated from the low-tension side.
2 Electrical cables must be run and clamped such
that there is no risk of exposure to chafing, damp or
bilge water.
3 Ground protection for radios, navigation instru-
ments, rudder, boarding ladders or other equipment
where separate cables for ground protection are
present, must be clustered to a common ground
connection (B) that is not connected to the engine
or transmission.
IMPORTANT!
Neither the engine nor transmission may ever be
used as a ground.
The S-drive is insulated electrically (A) from the
engine and may never be used as the ground or be

connected electrically to other equipment such as
radios, navigation equipment, rudder, and boarding
ladders.
4 The start battery must have a main switch (C) con-

nected to the battery's plus (+) side. The main
switch must break the circuit to all equipment and
be switched off when the boat is not in use.
5 If an auxiliary battery is used, a main switch must
be placed between the auxiliary battery's plus (+)
terminal and the circuit breaker panel for the boat's
electrical equipment. The main switch must break
the circuit to all equipment connected to the auxili-
ary battery and must be switched off when power is
no longer required. All equipment connected to the
auxiliary battery must have separate main
switches.
For simultaneous charging of two independent battery

circuits a separate charging distributor (accessory)
should be installed on the standard alternator.
56 47702088 05-2011
Maintenance
Reverse Gear

1 Start the engine and let it run on idle a few minutes.
2 Remove the dipstick by turning counter-clockwise.
3 Wipe the dipstick and reinsert it in the reverse gear
without screwing it in. Remove the dipstick and
check the oil level. The correct oil level is between
the MAX and MIN markings.
4 Top up the oil as required using the dip stick tube.
Please refer to section Technical Data page 71
for oil quality and capacity.
IMPORTANT!
Never over-fill the reverse gear. The oil level must
always be within the recommended range.
Reverse Gear, Oil Change

1 Pull out the oil dipstick.
2 Pump out the oil with the oil drain pump through the
oil dipstick hole.
3 Measure out the correct quantity of oil and fill
through the oil dipstick hole. For oil grade and quan-
tity, refer to the Technical Data page 71 section.
4 Put the oil dipstick back in place.
P0007536 IMPORTANT!
Never over-fill the reverse gear. The oil level must
always be within the recommended range.
47702088 05-2011 57
Maintenance
Propeller Shaft Sealing, Check
If the boat is fitted with a Volvo Penta propeller shaft,

the propeller shaft seals must be lubricated before
launch and purged directly after launching.
Purge the glands by pressing them together, at the
same time as they are pressed down onto the shaft.
The press approximately 1 cm³ of water resistant
grease into the seal.
58 47702088 05-2011
Maintenance
Drive
The S-Drive is equipped with a sacrificial anode that
prevents galvanic corrosion. The galvanic protection
can be disabled by incorrect electrical installations and
suchlike. Damage caused by so-called electrolytic cor-
rosion can appear quickly and can often be extensive.
Read more about this in the Electrical Installa-
tions page 55 section.
Incorrectly performed stern drive painting or the wrong
type of hull paint may render the galvanic protection
ineffective. Read more about painting in the Stor-
age page 67 section.
Remove the oil dipstick by unscrewing it counter-clock-

wise. Wipe the oil dipstick dry and replace it into the
stern drive/reverse gear, without screwing it down. Pull
out the oil dipstick again and check the oil level. The
correct oil level is between the MAX and MIN marks.
If required, top up oil through the oil dipstick hole. For

oil grade and quantity, refer to the Technical
Data page 71 section
IMPORTANT!
Never overfill the stern drive with oil. The oil level must
always be within the marked area.
47702088 05-2011 59
Maintenance
Transmission Oil, Change

1 Pull out the oil dipstick.
2 Remove the plug from the propeller gear transmis-
sion housing and allow the oil to run out.
Check that the plug O-ring is fault free; replace as
necessary.
3 Install the plug and O-ring.
4 Fill with oil to the correct level through the oil dip-
stick hole. For oil grade and quantity, refer to the
Technical Data page 71 section.
It is also possible to replace oil without laying up the

boat, e.g. if the oil change interval is reached during
the season. Pump out the oil through a suction pipe
using an oil drain pump – this method leaves approx.
0.5 liter (0.15 US gal) remaining in the stern drive. Fill
with oil to the correct level through the oil dipstick hole.
For oil grade, refer to the Technical Data page 71
section.
The oil should have a golden brown nuance. If the oil

is gray, water has entered the stern drive. In this case
let a Volvo Penta workshop carry out checks on the
stern drive.
P0007537
60 47702088 05-2011
Maintenance
Corrosion protection, checking and

changing
Check the sacrificial anode (1) on the stern drive and

the three sacrificial anodes (2) on the propeller regu-
larly. Replace with new anodes when approximately
1/3 of an anode has corroded away.
When the boat is stored ashore, corrosion protection

deteriorates due to oxidization of sacrificial anodes in
1 contact with air. Even new anodes may have surface
2
oxidation. Before launching the sacrificial anodes must
be cleaned with emery cloth.
IMPORTANT!
Use emery paper. Do not use a wire brush or other steel
tools when cleaning, as these may damage the galvanic
P0007538 protection.
• Zinc in salt water.
• Magnesium in freshwater.
• Aluminum when the boat is used primarily in salt

water and sometimes in brackish water
Remedy any damaged stern drive paintwork according

to the instructions in the Storage page 67 section.
Replacing sacrificial anodes
1 Remove the sacrificial anodes and thoroughly

scrape clean the contact surfaces on the stern drive
and propellers.
2 Apply thread locking fluid to the bolts to the propel-
ler sacrificial anodes.
3 Install the new sacrificial anodes and fasten them
to ensure good metallic contact.
Rubber Sealing
Check the rubber seal between the drive and the hull-
regularly for cracks and wear.
IMPORTANT!
The seal must be changed everyseven years or earlier
if it is defective. This workshould be carried out by an
authorized workshop.
P0003085
47702088 05-2011 61
Maintenance
Propeller
A The propeller must be cleaned and greased once
yearly. Remove the propeller and clean all parts thor-
oughly. Brush water resistant grease on the propeller
blade cogs and bearing surfaces so that the propeller
folds easily. Also brush water resistant grease on pins,
1
spacer sleeves (stern drive), propeller shaft and in the
propeller hub.
5
3 WARNING!
2 Make sure the engine can not start during work on pro-
peller(s); remove ignition key(s) and shift drive into for-
ward or reverse.
Removal
4 1 Set the control lever to the “Ahead” position.

2 Disassemble the propeller blades by screwing out
the lock screws (4) completely and then pressing
B
out the pins (1).

3 Stern drive: Fold down the edge of the tab washer
(3) and remove the lock screw (2), tab washer and
nut (5).
1 Reverse gear: Remove the nut (6), washer (7) and
then the lock screws (8).
4 4 Pull off the propeller hub and spacer sleeve (stern
drive). Clean and grease the propeller.
Installation
1 Install the spacer sleeve (stern drive) and the pro-

5 peller hub onto the shaft.
3
2
2 Stern drive: Install the nut (5). Place a propeller
blade in the hub and secure it with a wooden wedge
between the propeller blade and hull. Tighten the
C nut to 70 Nm.
Reverse gear: Fit the washer (7) and tighten the
nut (6) to 220 Nm. Apply thread locking fluid to the
lock screws (8). Once the lock screws have been
1 8 tightened, locking fluid should also be applied to
their heads.
3 Stern drive: Place the tab washer (3) on the nut.
6 7 Install and tighten the lock screw (2) to 20 Nm and
bend one of the tab washer tabs against the bolt
head.
IMPORTANT!
The tab washer (3) must be replaced if necessary.
Only Volvo Penta original lock screws (2) may be
8 used.
5
P0007539
A 3-bladed folding propeller (stern drive)

B 2-bladed folding propeller (stern drive)
C 3-bladed folding propeller (reverse gear)
62 47702088 05-2011
Maintenance
4 Install one propeller blade to the hub and press in

the cotter pin (1) so that the groove in the pin is
aligned with the lock screw hole (2). Apply thread
locking fluid to the lock screw and tighten it to 10
Nm.
5 Install the blades the same way in consecutive
order. Check that the blades have the same angle
to the propeller shaft and that they move easily.
47702088 05-2011 63
Storage
Have an authorized Volvo Penta workshop carry out checks on the engine and other equipment before the boat
is put into winter storage. Make sure all necessary repairs and service are completed so that the boat is in top
condition before the next season.
Conservation is performed to ensure that the engine and drive train are not damaged by non-use during winter
storage. It is important that conservation is carried out in the correct manner, and that nothing is forgotten. For
this reason, we have compiled a check list of the most important points.
CAUTION!
Read the chapter on Maintenance before starting work. It contains instructions on how to carry out maintenance
and service operations in a safe and correct manner.
The engine and other equipment must be laid up to

prevent damage if they are not to be used for two
months or more. It is important that this is done in the
correct manner, and that nothing is forgotten. For this
reason, we have compiled a check list of the most
important points.
Storage
It is best to carry out the following while the boat

is still in the water:
• Change engine oil and oil filters.

• Replace oil in the reverse gear.
• Change the fuel filter. Replace the fuel pre-filter if
such is fitted.
• Run engine to normal operating temperature.
It is best to carry out the following when the boatis
out of the water:
• Clean the hull and stern drive immediately after the-

boat is taken out of the water (before they dry).
Take care when cleaning with a high pressure jet.
Never direct the water jet at the propeller shaft seal,
grommets etc.
• Change oil in the drive.
• Clean the vacuum valve and seawater filter (acces-
sory).
• Cleaning and conserving the raw water system.
• Removing the impeller from the raw water pump.
Store the impeller in a sealed plastic bag and keep
cool.
• Check the glycol content of the engine coolant. Top
up as necessary.
IMPORTANT!
The use of anti-corrosion agent alone in the engi-
necooling system does not protect against frost
damage. If there is a risk of the engine being
exposed to sub-freezing temperatures, the system
must bedrained
64 47702088 05-2011
Storage
• Empty the fuel tank of fuel, dirt and sludge. Fill the
fuel tank completely, to avoid condensation.
• Clean the outside of the engine. Do not use a high-
pressure washer to clean the engine. Touch up any
paint damage with Volvo Penta original paint.
• Check all control cables and treat with conserva-
tionagent.
• Make good an areas with paintwork damage with
Volvo Penta original paint. Read the instructions
about painting the stern drive in the section Stor-
age page 67.
• Disconnecting the batteries. Clean and charge the-
batteries. An insufficiently-charged battery can
freeze and burst.
• Spraying the components of the electrical system-
with water-repellent spray.
• Removing the propeller for winter storage. Grease
the propeller shaft with water resistant grease, VP
part # 828250.
• Check the rubber seal between the drive and hull.
47702088 05-2011 65
Storage
Bringing Out of Storage

• Check the oil level in the engine and stern drive/
reverse gear. Top up as necessary. If the system
contains conservation oil this must be drained, and
the system must then be filled with oil. For the cor-
rect oil grade, refer to Technical Data, Lubrication
System. Replace oil filter.
• Drain any antifreeze from the raw water system.
• Install the impeller in the raw water pump. Replace
the old one if it displays signs of wear; refer to the
chapter Impeller, Check and Change page 49.
• Close and tighten drain taps and plugs.
• Check drive belt tensions and conditions.
• Check rubber hoses for condition and tighten hose
clamps.
• Check the engine coolant and antifreeze. Top up as
necessary.
• Connect the fully-charged batteries.

• Painting the sterndrive and hull bottom.
• Check the sacrificial anode on the stern drive. If less
than 2/3 of the anode remain, it must be replaced.
Clean with emery cloth shortly before launch.
IMPORTANT!
Use emery paper. Do not use a wire brush or other
steel tools when cleaning, as these may damage the
galvanic protection.
• Install the propellers
• Launch the boat. Check for leaks.
• Vent and grease the propeller shaft packing box
(reverse gear).
• Start the engine. Check that there are no fuel, cool-
ant or exhaust leaks and that all controls function.
66 47702088 05-2011
Storage
Painting the Drive and

Underwater Hull
Stern drive
Paint damage must be remedied before the stern drive
is treated with anti-fouling agents.
Most countries have introduced legislation that regu-
lates the use of anti-fouling agents. Anti-fouling agents
must be approved for use in those waters where the
boat will be deployed. Check what applies where you
intend to use the boat. Where anti-fouling agents are
not permitted, we recommend brushing pure Teflon®*
on the original stern drive paint without prior sanding.
1 Lightly sand metal surfaces using emery paper
grade 120. Use a finer grade of paper on painted
surfaces.
2 Wash with cellulose thinners or an equivalent.
3 Spackle and sand smooth any pores in the surface.
4 Paint with Volvo Penta original primer and paint.

Allow to dry.
5 Paint the stern drive with anti-fouling agent for alu-
minum drives according to the manufacturer's rec-
ommendations.
IMPORTANT!
The sacrificial anodes on the drive must not be painted
or treated with Teflon. This also applies to stainless or
bronze propellers.
*Teflon is a registered trademark of the DuPont Corporation.
Boat hull
All paints containing anti-fouling agents are poisonous
and damage the marine environment. Avoid these
preparations. Most countries have introduced legisla-
tion that regulates the use of anti-fouling agents.
Always follow these regulations. In many cases it is
strictly forbidden to use anti-fouling agents on leisure
craft.
On boats that are relatively easy to take out of water
we recommend treatment using Teflon alone, in con-
junction with mechanical cleaning several times per
season. However, for larger boats this is not practica-
ble. If the boat is in an area where the water causes
fast fouling, paints with anti-fouling agents will most
likely be necessary. In such cases, use copper-based
paint that contains cuprous cyanide and not copper
oxide.
Tin-based agents (TBT paints) may not be used. Find
out about legislation applicable in the area where the
boat is used. Allow the paint to dry before launching
the boat.
47702088 05-2011 67
Technical Data
Engine designation D1-13 D1-20 D1-30 D2-40
Crankshaft power, kW* 9.0 13.8 20.9 29.1
Propeller shaft, power, kW* 8.6 13.3 20.1 27.9
After sales designation D1-13 F D1-20 F D1-30 F D2-40 F
Swept volume, l 0.51 0.76 1.13 1.51
No. of cylinders 2 3 3 4
Cylinder diameter/stroke, mm 67/72 67/72 77/81 77/81
Compression ratio 23.5:1 23.5:1 23.5:1 23.5:1
Engine revolutions, rpm 2800-3200 2800-3200 2800-3200 2800-3200
Idle revolutions, rpm 850 ±25 850 ±25 850 ±25 850 ±25
Direction of rotation (seen from front) Clockwise Clockwise Clockwise Clockwise
Max. permissible rearward inclination in opera- 20° 20° 20° 20°
tion
Max. side inclination in operation 30° 30° 30° 30°
Weight, engine less oil and water 96 kg 118 kg 127 kg 148 kg
* According to ISO 8665

68 47702088 05-2011
Technical Data
Lubrication System
Engine Designation D1-13 D1-20 D1-30 D2-40

Oil capacity including oil filters, approx.: 1,9 litre 2,8 litre 3,5 litre 6,5 litre
Viscosity SAE 15W/40, SAE 15W/40, SAE 15W/40, SAE 15W/40,
SAE 20W/50 SAE 20W/50 SAE 20W/50 SAE 20W/50
Tightening torque, oil drain plug 30–40 Nm 30–40 Nm 30–40 Nm 30–40 Nm
Oil change interval: Reached first in operation: 2)

Oil grade 1) D1–13, D1–20, D1–30 D2–40
VDS-3
VDS-2 and ACEA E7 3), 4)
VDS-2 and Global DHD-1 3) 200 hours or 12 months. 500 hours or 12 months.
VDS-2 and API CH-4 3)
VDS-2 and API CI-4 3)
NOTICE! Mineral based oil, either fully or semi-synthetic, may be used on condition that it complies with the quality
requirements above.
1) Lowest recommended oil grade. Higher grades oil may always be used.
2) If sulfur content is >1.0 % by weight, oil with TBN >15 must be used.
3) The lubricating oil must fulfill both requirements.
4) ACEA E7 has replaced ACEA E5, if the former is not available ACEA E5 may be used.
5) ACEA E3 may be replaced by ACEA E4, E5 or E7.
6) API CG-4 may be replaced with API CI-4.
VDS = Volvo Drain Specification

ACEA = Association des Constructeurs Européens d’Automobiles
API = American Petroleum Institute
TBN = Total Base Number
Global DHD = Global Diesel Heavy Duty
Viscosity
Select the viscosity according to the table.
The temperature values refer to stable ambient tem-

peratures.
* SAE 5W/30 refers to synthetic or semi-synthetic oils.
47702088 05-2011 69
Technical Data
Fuel System
Fuel specification
The fuel must comply with national and international standards for commercially supplied fuels, such as:
EN 590 (with national environment and cold requirements)
ASTM D 975 No 1-D and 2-D
JIS KK 2204
Sulfur content: Complying with legal requirements in each country.
Low density fuel (urban diesel in Sweden and city diesel in Finland) can cause a loss of up to 5% of power and
an increase in fuel consumption of about 2–3%.
Cooling System
Engine Designation D1-13 D1-20 D1-30 D2-40

Freshwater system volume, approx 2.7 litre 3.0 litre 4.0 litre 6.4 litre
0.7 US gals 0.8 US gals 1.0 US gal 1.7 US gals
Thermostat
starts to open at 90±2°C 90±2°C 90±2°C 90±2°C
190-198°F 190-198°F 190-198°F 190-198°F

fully open at 102°C 102°C 102°C 102°C
215°F 215°F 215°F 215°F
Coolant
Volvo Penta Coolant VCS and VCS Ready Mixed (yel-

low colour) are based on Organic Acid Technology,
OAT.
Volvo Penta Coolant and Coolant Ready Mixed (green

colour) are silicate based.
70 47702088 05-2011
Technical Data
Water Quality
ASTM D4985:
Total solid particles <340 ppm

Total hardness <9,5° dH
Chloride <40 ppm
Sulfate <100 ppm
pH value 5.5–9
Silica (acc. ASTM D859) <20 mg SiO2/l
P0002094
Iron (acc. ASTM D1068) <0.10 ppm
Manganese (acc. ASTM D858) <0.05 ppm
Conductivity (acc. ASTM D1125) <500 µS/cm
Organic content, CODMn (acc. <15 mg KMnO4/l
ISO8467)
Electrical System
System voltage 12 V
Battery capacity (starter battery) 70 Ah
Alternator
voltage/max. current 14 V/115 A
power, approx. 1610 W
Starter motor, power, approx. 2.0 kW
Reverse Gear
Type designation MS10A-B ; MS10L-B MS15A-B ; MS15L-B

Gear ratio 2,35:1, 2,72:1 2,14:1, 2,63:1
Angle, output shaft
MS10A, MS15A 8° 8°
MS10L, MS15L 0° 0°
Oil capacity 0,35 litre 0,56 litre
Oil quality SAE 15W-40 SAE 15W-40
Weight 11 kg 16 kg
S-drive
Type designation 130S-B, 130SR-B

Gear ratio 2.19:1
Gear ratio 2.9 litre
Oil quality SAE 15W–40
Weight 26.5 kg
Tightening torque, oil drain plug 10 ±5 Nm
47702088 05-2011 71
Technical Data
Identification Numbers
There are type plates on the engine and transmission, marked with identification numbers. This information must
always be used as reference when service and spare parts are ordered. You will probably find similar plates on
your boat and its equipment. Note this information below, make a copy of the page and store it in a safe place,
so that you can have the information available if the boat is stolen.
The appearance and location of the type plates is shown below. The figures in brackets refer to the location of
the identification number on the type plate.
Engine A
Product designation (1): ......................................
Product number (2): ......................................
Serial number (3): ......................................
Transmission
Product designation (4): ......................................
B
Gear ratio (5): ......................................
Serial number (6): ......................................
Product number (7): ...................................... C
P0007541
A Engine and transmission decal A A

B Engine plate
C Transmission plate C
p0007825
72 47702088 05-2011
Declaration of Conformity for Recreational Craft Propulsion Engines with the exhaust
emission requirements of Directive 94/25/EC as amended by 2003/44/EC
D1, D2
Engine manufacturer: Body for exhaust emission assessment:
AB Volvo Penta TÜV SÜD Product Service Gmbh
Gropegårdsgatan Ridlerstrasse 65
405 08 Göteborg 80339 München
Sweden Germany
ID Number: 0123
Modules used for exhaust emission assessment ........ B + C

Other Community Directives applied ............................ EMC 89/336/EEC
Description of engine(s) and essential requirements

Engine Type .................................................................... 4 stroke diesel engine
Engine model(s) covered by this declaration EC Type certificate number

D1-13.................................................................................. SB5 08 07 66019 005
D1-20.................................................................................. SB5 08 07 66019 005
D1-30.................................................................................. SB5 08 07 66019 006
D2-40.................................................................................. SB5 08 07 66019 006
Other normative
Essential requirements Standards Used document used
Annex I.B – Exhaust Emissions
Engine identification Volvo Penta std Annex 1.B.1
Exhaust emission requirements EN ISO 8178 Annex 1.B.2
Durability Volvo Penta std Annex 1.B.3
Operator’s manual ISO 10240:2004 Annex 1.B.4
EMC Directive EN 61000-3-2,

EN 61000-3-3,
CISPR 25
This declaration of conformity is issued under the sole responsibility of the manufacturer. I declare on behalf of the engine manufacturer that
the engine(s) will meet the requirements of above mentioned directives when installed in a recreational craft, in accordance with the engine
manufacturer’s supplied instructions and that this (these) engine(s) must not be put into service until the recreational craft into which it is
(they are) to be installed has been declared in conformity with the relevant provisions of the above mentioned Directives.
Name and function: Tom Tveitan Product Liability Signature and title:
(identification of the person empowered to sign on behalf (or an equivalent marking)
of the engine manufacturer or his authorised representative)
Date and place of issue: (yr/month/day) 2008/08/29 Göteborg PL-103/08, issue 01

Operator's Manual Order
This Operator’s Manual may be ordered in a different
language free of charge up to 12 months after delivery,
via internet.
Please refer to the link below. On the web page, type

in the publication number found in the bottom of this
page (7–8 digits).
http://vppneuapps.volvo.com/manual/coupon/
If internet access isn't possible, please contact your

Volvo Penta dealer.
All order information is stored internally at AB Volvo

Penta and will not be shared with third parties.
74 47702088 05-2011
Alphabetical index
Air Filter, Change................................................... 36
Alarms...................................................................... 20
Battery, Charging................................................... 54
Battery, Maintenance............................................... 53
Bringing Out of Storage............................................ 66
Cold Weather Precautions..................................... 24
Control Panel............................................................ 10
Controls.................................................................... 17
Coolant Level, Checking and Topping Up................ 45
Coolant, Draining...................................................... 45
Corrosion protection, checking and changing.......... 61
Cruising Speed......................................................... 22
Declaration of Conformity..................................... 73
Drive......................................................................... 59
Drive Belt, Check and Change................................. 37
Electrical Connections........................................... 53
Electrical Installations............................................... 55
Electrical System...................................................... 52
Engine Fuel Filter Replacement............................... 41
Engine oil and engine oil filter, changing.................. 40

Engine, General....................................................... 36
EVC System Display................................................ 13
Fault Tracing........................................................... 28
Freshwater System.................................................. 43
Fuel pre-filter............................................................ 42
Fuel System............................................................. 41
Fuel system, bleeding.............................................. 42
Fuses........................................................................ 52
Gauges.................................................................... 11
Heat Exchanger, Cleaning..................................... 46
Identification Numbers.......................................... 72
Idling, adjustment..................................................... 38
Impeller, Check and Change.................................... 49
Lubrication System................................................ 39
Main switch............................................................. 52
Oil level, checking and topping up........... 39, 57, 59
Painting the Drive and Underwater Hull............... 67
Propeller................................................................... 62
Propeller Shaft Sealing, Check................................ 58
Reading the Instruments....................................... 20
Reverse Gear........................................................... 57
Reverse Gear, Oil Change....................................... 57
Rubber Sealing......................................................... 61
Seawater System.................................................... 47
Seawater System, Cleaning and Inhibiting............... 50
Seawater System, Draining...................................... 48
Start/Stop Panel....................................................... 10
Starting the Engine................................................... 18
Starting Using Auxiliary Batteries............................. 29
Stop the Engine........................................................ 23
Transmission Oil, Change..................................... 60
47702088 05-2011 76
05-2011
English
47702088
AB Volvo Penta
SE-405 08 Göteborg, Sweden
www.volvopenta.com

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OPERATOR’S MANUAL

CALIFORNIA PROPOSITION 65 WARNING

Your new boat Fuel filling

Daily checks Do not start the engine

Manoeuvring Accidents and near misses

Carbon monoxide poisoning

Preparations Before starting the engine

Knowledge Reinstall all protective parts removed during service

tion before starting work. Put up a warning sign in the

Hot surfaces and fluids Fuel system

Always stop the engine and break the current using

If work must be carried out with the engine at operat-

Service and spare parts Certified engines

• Installation changes to the exhaust pipe and

The general advice in the Operator's manual about

Late or inadequate maintenance/service or the use of

On/Off button (1)

Start button (4)

Multi-function button (2)

Stop button (3)

Operating information symbols

EVC System Display

Before the display is put to use certain settings must

It is also possible to bring up a menu identical to that

A self-test is performed at start; the display will emit a

Only installed functions are shown in the display.

If speed information is lacking, coolant temperature will

If the selected information is lacking, the symbol “—”

The type of information accessible depends on the

Engine ignition must be switched on when changing

display settings or calibrating functions.

Navigate through the menu using the up and down

Bleep: setting button bleep On or Off.

Engine: setting the installation the display forms part

Eng. series: setting the engine series for the display

Display: setting speed indicator and tachometer inter-

- Rpm intervals, 2500–9000 rpm in 500 rpm stages.

Units: Selection of operational information units to be

Calibration: the engine must be switched on during

N = Neutral position. Reverse gear/drive disengaged

Disconnecting the gearshift function

The gear shift function is reconnected automatically

Adjusting the friction brake

Starting the Engine

Check the tachometer

0 4 ! ! Check the alarm instrument (accessory).

Start the engine

below 50° (122° F).

Read off the instruments and warm up the

Reading the Instruments

0 4 1 Reduce engine speed to idle.

Always shift between ahead and astern in

Avoid operations at full throttle for best fuel economy.

Stop the Engine

If the engine is stopped and the ignition still turned on,

After Engine Shutdown

Operation break with the boat in water

Operation break with the boat out of water

Cold Weather Precautions

If an operational fault arises an audible alarm will