Manual Volvo Penta Kad 44 ECD

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VOLVO PENTA KAD/KAMD44P OPERATOR'S

MANUAL
Quick Links
Engine
Table of Contents
Table of Contents
General
Boat travel
Maintenance and service
Running-in
Fuel and oil types
Certificated engines
Warranty information
Identification numbers
Technical Description
What is EDC
Orientation
Instrument panels
Control panels
Warning displays
Starting switch
Control panels (EDC)
Before starting
General about starting
Starting method
Checking instruments
Diagnostic information
Cruising speed
Synchronising engine speed
Changing control position
Manoeuvering
Power Trim while running
Stopping
Laying up
Cold weather precautions
Engine, general
Lubrication system
Freshwater system
Coolants
Seawater system
Fuel injection system
Electrical system
Electrical components diagram
Reverse gear
Drive
Steering
Propellers
Inhibiting
Bringing out of winter storage
Painting the drive and underwater hull
Symptoms and possible causes
Starting using auxiliary batteries
Emergency shifting
Calibrating the control unit
Reading off diagnostic trouble codes (DTCs)
Erasing diagnostic trouble codes (DTCs)
Diagnostic trouble codes (DTCs)
Engine
Fuel specification
Drive
Reverse gear
Power Trim
Steering
OPERATOR’S MANUAL
KAD/KAMD44P, KAD/KAMD300
This operator’s manual is also available in the following languages:
Diese Betriebsanleitung ist auch auf Dit instructieboek kan worden besteld
Deutsch erhältlich. in het Nederlands.
Ein Bestellcoupon ist am Ende der Betriebs- De bestelcoupon vindt u achter in het instruc-
anleitung zu finden. tieboek.
Ce manuel d’instructions peut être Denne instruktionsbog kan bestilles på

commandé en français. dansk.
Vous trouverez un bon de commande à la fin Bestillingskupon findes i slutningen af in-
du manuel d’instructions. struktionsbogen.
Este libro de instrucciones puede soli- Tämän ohjekirjan voi tilata myös suo-
citarse en español. menkielisenä.
El cupón de pedido se encuentra al final del Tilauskuponki on ohjekirjan lopussa.
libro.
Den här instruktionsboken kan bestäl- Este manual de instruções pode ser
las på svenska. encomendado em português.
Beställningskupong finns i slutet av instrukti- O talão de requerimento encontra-se no fim
onsboken. do manual.
Questo manuale d’istruzioni può esse- Áõôü ôï åã÷åéñßäéï ÷ñÞóçò

re ordinato in lingua italiana. äéáôßèåôáé óôçí áããëéêÞ ãëþóóá.
Il tagliando per l’ordinazione è riportato alla Ãéá íá ðáñáããåßëåôå Ýíá áíôßôõðï,
fine del manuale. óõìðëçñþóôå ôç öüñìá ðïõ âñßóêåôáé óôï
ôÝëïò áõôïý ôïõ åã÷åéñéäßïõ ÷ñÞóçò.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
Welcome aboard
Volvo Penta marine engines are used all over the world today. They are used in all pos-
sible operating conditions for professional as well as leisure purposes. That’s not sur-
prising.
After more than 90 years as an engine manufacturer and after delivering over 500,000
marine engines, the Volvo Penta name has become a symbol of reliability, technical in-
novation, top of the range performance and long service life. We also believe that this is
what you demand and expect of your Volvo Penta engine.
We would like you to read this operator’s manual thoroughly and consider the advice we
give on running and maintenance before you cast off on your maiden voyage so that
you will be ensured of fulfilling your expectations.
With warm regards
AB VOLVO PENTA
IMPORTANT! These instructions do not contain descriptions of controls or

operation for boats with waterjet. If your boat is equipped with Volvo Penta
waterjet, this information can be found in the operator’s manual that came
with the waterjet.
1
Contents
Safety Information ............................................. 3–7 Maintenance schedule .................................... 39–42

General .................................................................... 3
Maintenance .................................................... 42–74
Boat travel ............................................................... 4
Engine, general ...................................................... 42
Maintenance and service ......................................... 6
Lubrication system ................................................. 47
Introduction ...................................................... 8–10 Freshwater system ................................................ 49
Running-in ............................................................... 8 Coolants ................................................................ 49
Fuel and oil types .................................................... 8 Seawater system ................................................... 51
Certificated engines ................................................ 9 Fuel injection system ............................................. 54
Warranty information ............................................... 9 Electrical system ................................................... 56
Identification numbers ............................................ 10 Electrical components diagram .............................. 61
Reverse gear .......................................................... 63
Presentation .................................................... 11–16
Drive ...................................................................... 65
Technical Description ............................................. 11
Steering ................................................................. 70
What is EDC .......................................................... 12
Propellers ............................................................... 73
Orientation ............................................................. 13
Laying up/Launching ...................................... 75–77
Instrumentation ............................................... 17–21
Inhibiting ................................................................ 75
Instrument panels .................................................. 17
Bringing out of winter storage ................................. 76
Control panels ........................................................ 18
Painting the drive and underwater hull .................... 77
Warning displays .................................................... 18
Starting switch ....................................................... 19 Fault-tracing ..................................................... 78-84
Control panels (EDC) ............................................. 20 Symptoms and possible causes ............................ 78
Starting using auxiliary batteries ............................ 79
Controls .......................................................... 22–23 Emergency shifting ................................................ 80
Power Trim ..................................................... 24–26 Calibrating the control unit ...................................... 81
Starting the engine .......................................... 27–29 Diagnostic function .......................................... 85-91

Before starting ....................................................... 27 Diagnostic function ................................................ 85
General about starting ............................................ 27 Reading off diagnostic trouble codes (DTCs) .......... 86
Starting method ..................................................... 28 Erasing diagnostic trouble codes (DTCs) ............... 87
Diagnostic trouble codes (DTCs) ............................ 88
Operation ......................................................... 30–36
Checking instruments ............................................ 30 Technical Data .................................................. 92-93
Diagnostic information ........................................... 31 Engine ................................................................... 92
Cruising speed ....................................................... 31 Fuel specification ................................................... 92
Synchronising engine speed ................................. 32 Drive ...................................................................... 93
Changing control position ...................................... 32 Reverse gear .......................................................... 93
Manoeuvering ....................................................... 33 Power Trim ............................................................ 93
Power Trim while running ...................................... 34 Steering ................................................................. 93
Stopping the engine ...................................... 37–38

Stopping ................................................................ 37
Laying up ............................................................... 37
Cold weather precautions ....................................... 38
© 2002 AB VOLVO PENTA

All rights to changes or modifications reserved.
Printed on environmentally friendly paper.
2 (Cover: Department of transport (shipping), license 9809095)
Safety Information
Read this chapter carefully. It concerns your safety. This section describes how safety information is presented in
the operator’s manual and on the engine. It also gives a general account of basic safety precautions to be taken
when operating the boat and maintaining the engine.
Check that you have the correct operator’s manual before you read on. If this is not the case please con-
tact your Volvo Penta dealer.
If operations are performed incorrectly it could result in personal injury, or damage to property or
the engine. Read the operator’s manual carefully before operating or servicing the engine. If any-
thing is unclear please contact your Volvo Penta dealer for assistance.
This symbol is used in the book and on the engine to make you aware of safety information.
Always read these safety precautions very carefully.
In the operator’s manual warning texts have the following priority:
WARNING! If these instructions are not followed there is a danger of personal injury, exten-
sive damage to the product or serious mechanical malfunction.
IMPORTANT! Used to draw your attention to something that can cause damage, product
malfunction or damage to property.
NOTE! Used to draw your attention to important information that will facilitate work or operations.
This symbol is used in certain cases on our products and refers to important information in
the operator’s manual. Ensure that warning and information symbols on the engine and transmis-
sion are always visible and legible. Replace symbols that have been damaged or painted over.
3
Safety Information
Safety precautions to be taken when operating the boat
Your new boat Refueling

Read operator’s manuals and other information sup- When refueling there is always a danger of fire and ex-
plied with your new boat. Learn to operate the engine, plosion. Smoking is forbidden and the engine must be
controls and other equipment safely and correctly. switched off.
If this is your first boat, or is a boat type with which Never overfill the tank. Close the fuel tank filler cap
you are not familiar, we recommend that you practice properly.
controlling the boat in peace and quiet. Learn how the
boat behaves at different speeds, weather conditions Only use the fuel recommended in the operator’s man-
and loads before casting off for your “real” maiden ual. The wrong grade of fuel can cause operating prob-
voyage. lems or cause the engine to stop. On a diesel engine
poor quality fuel can cause the control rod to seize
Remember that the person driving a boat is legally re- and the engine to overrev with a resultant risk of dam-
quired to know and follow the current rules regarding age to the engine and personal injury.
traffic and safety at sea. Make sure you know the
rules that apply to you and the waters you are sailing
in by contacting the relevant authorities or organiza-
Do not start the engine
Do not start or run the engine with a suspected fuel or
tion. LPG leak in the boat, nor when you are close to or in
A good piece of advice is to take a course in seaman- a discharge of explosive media, etc. There is risk for
ship. We recommend that you contact your local boat- fire and/or explosion in explosive surroundings.
ing organization to find a suitable course.
Safety breaker
Accidents We recommend that you install and use a safety
Statistics show that poor maintenance of boats and breaker (accessory), especially if you boat can travel
engines and a lack of safety equipment are often the at high speeds. The safety breaker stops the engine if
cause of accidents at sea. the driver falls down and loses control over the boat.
Ensure that your boat is maintained in accordance

with the relevant Instruction Manual and that the nec-
essary safety equipment is on-board and is service-
able.
Daily checklist
Make a habit of checking the engine and engine com-
partment visually before operating the boat (before
the engine is started) and after operating the boat
(after the engine has been stopped). This will help
you to quickly detect fuel, coolant or oil leaks and
spot anything else unusual that has or is about to hap-
pen.
Maneuvering
Avoid violent and unexpected changes in course and
gear engagement. This could cause someone on the
boat to lose their balance and fall over or overboard.
A rotating propeller can cause serious injury. Check
that nobody is in the water before engaging ahead or
astern. Never drive near bathers or in areas where
people could be in the water.
Avoid trimming an outboard drive too much, as steer-
ing will be severely reduced.
4
Safety Information
Carbon monoxide poisoning

When a boat is moving forward, it will cause a certain Most modern boats, however, are designed in such a
vacuum to form behind the boat. In unfortunate cir- way that this problem is very rare. If suction should
cumstances, the suction from this vacuum can be so arise anyway, do not open hatches or portholes at the
great that the exhaust gases from the boat are drawn fore of the boat. Surprisingly, this will otherwise in-
into the cockpit or cabin and cause carbon monoxide crease the suction. Try changing speed, trim or load
poisoning. distribution instead. Try taking down/opening or in any
other way changing the setup of the cover as well.
This problem is most prevalent on high, wide boats
Get in touch with your boat dealer for help in obtaining
with abrupt stern. In certain conditions, however, this
the best solution for your boat.
suction can be a problem on other boats, e.g. when
running with the cover up. Other factors that can in-
crease the effect of the suction are wind conditions,
load distribution, swells, trim, open hatches and port-
holes, etc.
Checklist
● Safety equipment Life jackets for all passengers, communication equipment, emergency rockets,
approved fire extinguisher, first-aid equipment, life belt, anchor, paddle, torch etc.
● Replacement parts and tools: impeller, fuel filters, fuses, tape, hose clamps, engine oil, propeller
and tools for any repairs that might have to be carried out.
● Get out your charts and go over the planned route. Calculate distance and fuel consumption. Lis-
ten to the weather reports
● Make sure that relations or contact persons are informed when planning a longer voyage. Remem-
ber to inform them if your plans have changed or been delayed.
● Tell your passengers and crew where the safety equipment is stored and how to operate it. Make
sure you are not the only person on board who knows how to start the boat and operate it safely.
This list can be added to because safety equipment and other requirements vary depending on the
type of boat and how it is used. We recommend that you contact your local boating organization for
more detailed information on safety afloat.
5
Safety Information
Safety precautions for maintenance and service operations
Preparations Never start a turbocharged engine without installing

the air cleaner (ACL). The rotating compressor in the
Knowledge
Turbocharger unit can cause serious personal injury.
The operator’s manual contains instructions on how to
Foreign objects can also be sucked in and cause me-
carry out general maintenance and service operations
chanical damage to the unit.
safely and correctly. Read the instructions carefully
before starting work.
Service literature covering more complicated opera- Fire and explosion
tions is available from your Volvo Penta dealer. Fuel and lubrication oil
Never carry out any work on the engine if you are un- All fuel, most lubricants and many chemicals are in-
sure of how it should be done, contact your Volvo flammable. Read and follow the instructions on the
Penta dealer who will be glad to offer assistance. packaging.
When carrying out work on the fuel system make sure
Stop the engine the engine is cold. A fuel spill onto a hot surface or
Stop the engine before opening or removing engine electrical components can cause a fire.
hatches. Unless otherwise specified all maintenance
and service must be carried out with the engine Store fuel soaked rags and other flammable material
stopped. so that there is no danger of them catching fire. Fuel-
soaked rags can self-ignite under certain conditions.
To prevent accidental start of the boat engine remove
the ignition key, turn off the power supply to the en- Do not smoke when filling fuel, oil or in proximity of a
gine at the main switches and lock them in the OFF filling station or in the engine room.
position before starting work. Put up a warning sign in
the control position that work on the engine is being Non-original components
carried out. Components used in the fuel and ignition system
(gasoline engines) and electrical systems on Volvo
Approaching or working on an engine that is running is Penta products are designed and constructed to mini-
a safety risk. Loose clothing, hair, fingers or a mize the risk of fire and explosion.
dropped tool can be caught in the rotating parts of the
engine and cause serious personal injury. Volvo Penta Using non-original Volvo Penta parts can result in fire
recommend that all servicing with the engine running or explosion on board.
be undertaken by an authorized Volvo Penta work-
shop. Batteries
The batteries contain and give off oxyhydrogen gas,
Lifting the engine especially during charging. This gas is easily ignited
When lifting the engine use the lifting eyes installed and highly volatile.
on the engine (reverse gear where installed). Always Do not under any circumstances smoke or use naked
check that lifting equipment is in good condition and flame or allow sparks in the vicinity of the batteries or
has sufficient load capacity to lift the engine (engine battery compartment.
weight including reverse gear and any extra equipment
installed). For safety’s sake lift the engine using an Incorrectly connection a battery terminal cable or
adjustable lifting beam. All chains and cables should jump-start cable can cause a spark which in its turn
run parallel to each other and as perpendicular as pos- can be sufficient to cause an explosion.
sible in relation to the top of the engine. Bear in mind
that extra equipment installed on the engine may alter Start spray
its center of gravity. Special lifting equipment may Never use start spray or similar agents to start an en-
then be required in order to maintain the correct bal- gine equipped with air pre-heating (glow plugs/starter
ance and make the engine safe to handle. Never carry element). This may cause an explosion in the inlet
out work on an engine suspended on a hoist. manifold. Danger of personal injury.
Before starting the engine

Reinstall all protective parts removed during service
operations before starting the engine. Check that no
tools or other items have been left on the engine.
6
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 tissue
exhaust pipe, Turbo unit, oil pan, charge air pipe, and cause serious injury. There is a danger of blood
starter element, hot coolant and hot oil in oil lines and poisoning.
hoses.
Always cover the generator if it is located under the
fuel filter. The generator can be damaged by spilled
Carbon monoxide poisoning fuel.
Only start the engine in a well-ventilated area. If oper-
ating the engine in an enclosed space, ensure that
there is proper ventilation in order to remove exhaust Electrical system
gases and crankcase ventilation emissions from the Cutting off power
working area. Always stop the engine and break the current using
the main switches before working on the electrical
system. Isolate shore current to the engine block
Chemicals heater, battery charger, or accessories mounted on
Most chemicals such as anti-freeze, rustproofing the engine.
agent, inhibiting oil, degreasing agent etc. are hazard-
ous to health. Read and follow the instructions on the Batteries
packaging. The batteries contain an extremely corrosive electro-
Some chemicals such as inhibiting oil are inflammable lyte. Protect your skin and clothes when charging or
and dangerous if breathed in as well. Ensure good handling batteries. Always use protective goggles and
ventilation and use a protective mask when spraying. gloves.
Read and follow the instructions on the packaging. If battery electrolyte comes into contact with unpro-
Store chemicals and other hazardous materials out of tected skin wash off immediately using plenty of water
the reach of children. To protect the environment and soap. If battery acid comes into contact with the
please dispose of used or leftover chemicals at a eyes, flush immediately with plenty of water and ob-
properly designated disposal site for destruction. tain medical assistance without delay.
Cooling system
There is a risk of flooding when working on the seawa-
ter system. Turn off the engine and close the sea
cock (where installed) before starting work on the sys-
tem.
Avoid opening the coolant filler cap when the engine is
hot. Steam or hot coolant can spray out and cause
burns.
If work must be carried out with the engine at operat-
ing temperature and the coolant filler cap or a cock
open or a coolant hose disconnected, open the cool-
ant filler cap carefully and slowly to release pressure
before removing the cap completely. Note that the
coolant may still be hot and can cause burns.
Lubrication system
Hot oil can cause burns. Avoid skin contact with hot
oil. Ensure that the lubrication system is not under
pressure before commencing work on it. Never start or
operate the engine with the oil filler cap removed, oil
can spray out.
7
Introduction
This operator’s manual has been compiled to help you get the most from your Volvo Penta engine. It contains all
the information you need in order to operate and maintain your engine safely and correctly. Please read the opera-
tor’s manual carefully and learn how to operate the engine, controls and other equipment safely.
Always have the operator’s manual available. Keep it in a safe place and do not forget to give it to the new owner
if you sell your boat.
Care of the environment Fuel and oils

We would all like to live in a clean and healthy environ- Only use the fuel and oils recommended in the chap-
ment. Somewhere where we can breathe clean air, see ter Technical Data. Other grades of fuel and oil can
healthy trees, have clean water in our lakes and oce- cause operating problems, increased fuel consump-
ans, and are able to enjoy the sunshine without being tion and, in the long-term, a shorter engine service
worried about our health. Unfortunately, this cannot be life.
taken for granted nowadays but is something we must
work together to achieve. Always change oil, oil filters and fuel filters at the re-
commended intervals.
As a manufacturer of marine engines, Volvo Penta has
a special responsibility, why care of the environment is
a core value in our product development. Today, Volvo
Penta has a broad range of engines where progress Service and replacement parts
has been made in reducing exhaust emissions, fuel Volvo Penta marine engines are designed for high
consumption, engine noise, etc. operational reliability and long service life. They are
We hope you will take care in preserving these quali- constructed to withstand the marine environment while
ties. Always follow any advice given in the instruction also affecting it as little as possible. Through regular
manual concerning fuel grades, operation and mainte- service and the use of Volvo Penta original spare
nance and you will avoid causing unecessary interfe- parts, these qualities will be retained.
rence to the environment. Get in touch with your Volvo
Penta dealer if you notice any changes such as in- The Volvo Penta worldwide network of authorized
creased fuel consumption exhaust smoke. dealers are at your service. They are specialists in
Volvo Penta products and have accessories and the
Adapt speed and distance to avoid wash and noise
original replacement parts, test equipment and special
disturbing or injuring animal life, moored boats, jetties,
tools necessary for high quality service and repair
etc. Leave islands and harbours in the same condition
work.
as you want to find them. Remember to always leave
hazardous waste such as waste oil, coolant, paint and Always follow the maintenance intervals contained in
wash residue, flat batteries, etc., for disposal at a de- the operator’s manual. Remember to state the engine/
struction plant. transmission identification number when ordering
service and replacement parts.
Our joint efforts will make a valuable contribution
to our environment.
Running-in
The engine must be run in for its first 10 operating
hours as follows: Operate the engine normally. Do not
operate it at full load except for short periods. Never
run the engine at a constant engine speed for long peri-
ods during the running-in period.
The engine can be expected to use more engine oil
during the running-in period than would otherwise be
normal. Check the oil level more often than is normally
recommended.
A First Service Inspection must be carried out after
20–50 running hours. For further information: See the
Warranty and Service Book.
8
Introduction
Certificated engines ● The engine must not be modified in any way ex-
If you own an engine certificated for any area cept with accessories and service kits approved
where exhaust emissions are regulated by law, the by Volvo Penta.
following is important: ● No modifications to the exhaust pipes and air
supply ducts for the engine may be undertaken.
Certification means that an engine type is inspected
and approved by the authorities. The engine manufac- ● Seals may only be broken by authorized person-
turer guarantees that all engines manufactured of that nel.
type correspond to the certified engine.
Otherwise the general instructions contained in the
This places special requirements for mainte- operator’s manual concerning operation, service and
nance and service as follows: maintenance must be followed.
● The maintenance and service intervals recommen-
ded by Volvo Penta must be observed. IMPORTANT! Late or inadequate maintenance/
service or the use of spare parts other than
● Only genuine Volvo Penta replacement parts may Volvo Penta original spare parts will invalidate
be used. AB Volvo Penta’s responsibility for the engine
● The service of injection pumps and injectors or specification being in accordance with the certifi-
pump settings must always be carried out by an cated variant.
authorized Volvo Penta workshop. Volvo Penta accepts no responsibility or liability
for any damage or costs arising due to the abo-
ve.
Warranty
Your new Volvo Penta marine engine is covered by a limited warranty according to the conditions and
instructions contained in the Warranty and Service book.
Note that AB Volvo Penta’s liability is limited to that contained in the Warranty and Service Book. Read
this book as soon as you take delivery of the engine. It contains important information about warranty
cards, service and maintenance which you, the owner, must be aware of, check and carry out. Liability
covered in the warranty may otherwise be refused by AB Volvo Penta.
Contact your Volvo Penta dealer if you have not received a Warranty and Service Book and a
customer copy of the warranty card.
9
Introduction
Identification numbers
Always provide the engine and transmission identification numbers when ordering service or replacement compo-
nents.
The identification numbers are on an information decal located on the front edge of the engine. Note the informa-
tion below. Make a copy of the page. Store the information so that it is available in event of the boat being stolen.
Engine
Product designation (1*) ......................................................................................................
Serial number (2*) ...............................................................................................................
Product number (3*) ............................................................................................................
Drive/Reverse gear
Product designation (4*) .......................................................................................................
Gear ratio (5*) ......................................................................................................................
Serial number (6*) ................................................................................................................
Product number (7*) .............................................................................................................
Shield (Drive)
Product designation (8*) .......................................................................................................
Serial number (9*) ................................................................................................................
Product number (10*) ...........................................................................................................
* The numbers refer to the position of the identification numbers on the information decal
Location of information decal and identification plates:
Engine/Drive/Reverse gear (information decal)
Drive/Shield (identification plate) Reverse gear

(identification plate)
XXX XXX
RATED POWER: xxx
RATED SPEED: xxxx
PART NO: xxx xxxx
DATASET: xxx xxx
ECU BATCH: xxxx
Engine (identification plate)
Control module (decal)
Certification (identification plate)
10
Presentation
KAD/KAMD44P* and KAD/KAMD300* are in-line, direct injected 6-cylinder marine diesel engines, specially
developed for planing boats.
They are equipped with electronically controlled fuel injection, a mechanical supercharger, turbocharger, intercool-
er, heat exchanger for thermostatically controlled fresh water cooling, electronically controlled engine speed con-
trol and shifting.
The supercharger provides the engines with air at low speeds, and at higher speeds the turbocharger provides the
air supply. This interaction gives the engines extremely high torque at all engine speeds.
Technical description
Engine and cylinder block Fuel system
– The cylinder block and cylinder head are manufac- – Rotor type fuel injection pump with electronic actu-
tured of alloyed cast iron ator
– 4 valve technology – Microprocessor based control module for fuel con-
– Oil cooled pistons trol module (EDC*)
– Replaceable wet cylinder liners – Two step injector
– Replaceable valve seats – Fine fuel filter with water separator
– Crankshaft carried on seven bearings – Feeder pump with hand pump
Lubrication system Cooling system

– Pressure lubrication system with replaceable full – Thermostat controlled freshwater cooling system
flow oil filter – Pipe heat exchanger with separate expansion tank
– Gear driven oil pump – Cooling system prepared for hot water outlet
– Washable pipe type oil cooler Electrical system
Intake and exhaust system – 12V two pole electrical system
– Intake silencer with replaceable filter – 14V/60A generator, adapted for marine use.
– Seawater cooled exhaust pipe made of cast iron – Charge regulator with battery sensor for compen-
with a stainless steel insert sating voltage drop
– Exhaust driven freshwater cooled turbocharger
(TC)
– Mechanically driven compressor
* KAD (engine with drive)

KAMD (engine with reverse gear)
EDC (Electronic Diesel Control), see description in next section.
11
Presentation
What is EDC
EDC stands for Electronic Diesel Control. It is an electronic system for marine diesel engine control. The system
has been developed by Volvo Penta and covers fuel control, diagnostic function and electronic engine speed
control and shifting.
The processor Diagnostic function

The brain of the EDC system, the processor, is en- The task of the diagnostic function is to discover and
cased in the control module and protected against localise any disturbances within the EDC system, to
moisture and vibration. protect the engine and to ensure operation in event of
serious disturbances.
The processor continuously receives information
about fuel supply, engine speed, charge air pressure, If a disturbance is found the diagnostic button indica-
engine temperature and driver commands etc, via a tor in the control panel begins to flash. By pressing
number of sensors and senders. the diagnostic button the operator will receive a diag-
nostic trouble code (DTC) as a guide for any fault-
The information provides an exact picture of the pre-
tracing.
vailing operating conditions. This makes it possible for
the processor to calculate the correct fuel volume,
check the engine condition and prevent irritating stall- Engine speed control and shifting
ing during backward and forward manoeuvring etc. The operating command is transferred to the electron-
ic actuator in the fuel injection pump, the electronic
valves in the reverse gear or to the gearshift control
Fuel control
actuator for drive, using a potentiometer in the
The engine fuel requirement is analysed up to a 100
operating control.
times per second. If necessary the fuel supply is ad-
justed by the electronic actuator in the fuel injection The result is fast accurate throttle response and
pump. smooth shifts.
This ensures that the engine always receives the Changing is further protected by the processor which
correct volume of fuel in all operating conditions. This prevents shifting at too high engine speeds which may
means lower fuel consumption and minimal exhaust cause damage to the transmission.
emissions.
3
2 5
1. Control Module
2. Injection pump
3. Control panel
4. Gearshift control actuator
5. Potentiometer
For the location of other electrical components: See the chapter

“Maintenance. Electrical components diagram”.
12
Presentation
Orientation
1 2 3 4 5 KAMD44P/KAMD300, HS63
1. Electrical box
2. Oil filler cap, engine
3. EDC control module
4. Oil filter, engine
5. Charge air cooler
6. Dipstick, reverse gear
7. Starter motor
8. Fuel feed pump
9. Fuel filter
10. Injection pump
6
11. Generator
12
12. Sea water pump
11
10 9 8 7
13 14 15 16 17 18 KAMD44P/KAMD300, HS63
13. Turbocharger
14. Air Cleaner (ACL)
15. Dipstick, engine
16. Coolant filler
17. Expansion tank
18. Compressor
19. Heat exchanger
20. Oil filter, reverse gear
20
19
13
Presentation
1 2 3 4 5 6 KAD44P/Professional, DP-E
1. Seawater filter
2. Electrical box
7. Starter motor
8. Fuel feed pump
9. Fuel filter
12 10. Injection pump
11. Generator
11 10 9 8 7 12. Sea water pump
13 14 15 16 17 18 KAD44P/Professional, DP-E
13. Turbocharger
16. Coolant filler
24
17. Expansion tank
23
18. Compressor
19. Power steering pump
20. Heat exchanger
21. Trim cylinder
22. Cooling water intake
23. Guide cylinder
21 20 19 24. Topping up oil, drive
22
14
Presentation
1 2 3 4 5 6 KAD44P/DPX-A
1. Seawater filter
2. Electrical box
7. Starter motor
8. Fuel feed pump
9. Fuel filter
12 10. Injection pump
11. Generator
11 10 9 8 7
12. Sea water pump
13 14 15 16 17 18 KAD44P/DPX-A
13. Turbocharger
25 16. Coolant filler
24 17. Expansion tank
18. Compressor
23 19. Power steering pump
20. Heat exchanger
21. Trim cylinder
23. Guide cylinder
20 19 24. Topping up oil, drive
21 25. Oil dipstick, drive
22
15
Presentation
1 2 3 4 5 6 KAD300/DP-G
1. Seawater filter
2. Electrical box
7. Starter motor
8. Fuel feed pump
9. Fuel filter
10. Injection pump
11. Generator
12. Sea water pump
12 11 10 9 8 7
KAD300/DP-G
13. Turbocharger
13 14 15 16 17 18
16. Coolant filler
17. Expansion tank
18. Compressor
24
19. Power steering pump
23 20. Heat exchanger
21. Trim cylinder
23. Topping up oil, drive
24. Oil dipstick, drive
20 19
21
22
16
Instrumentation
This section contains descriptions of the instrument panels and panels available from Volvo Penta for your en-
gine, with the exception of the Power Trim instrument, which is described in the section Power Trim. Note that the
tachometer, oil pressure gauge, temperature gauge, charge indicator, ignition switch etc. which are shown here in-
stalled in the instrument panels can be installed in other positions on some boats.
If your boat is fitted with instruments not described here and you are not sure of their function, please get in touch
with your boat dealer.
1 2 3
Instrument panels
Instrumentation for the main control position and auxil-
iary control position.
1. Temperature gauge. Indicates the engine coolant
temperature.
2. Oil pressure gauge. Indicates the pressure of the
engine lubricant.
3. Voltmeter. Indicates the charge voltage from the
alternator when the engine is running and the bat-
tery voltage when the engine is stopped.
4. Tachometer. Indicates the speed of the engine in
rpm. (recommended cruising speed is shown in
the chapter “Operation”)
4 5 6 7 8 9 10 5. Hour counter. Shows the total number of engine
running hours as a decimal number.
4 6 7 6. Press button for testing and acknowledging

alarms (see next page “Warning displays”).
7. Siren for acoustic alarm that sounds if one of the
warning lamps comes on.
8. Warning display (see next page “Warning dis-
plays”, pos. 1–4).
9. Starting switch (see next page).
10. Press button for instrument illumination.
8 9 10
17
Instrumentation
Control panels
Control panels for the main control position and auxil-
iary control position.
1 1
1. Siren for acoustic alarm that sounds if one of the
warning lamps comes on.
2 3 2 3 2. Press button for instrument illumination.

3. Press button for testing and acknowledging
alarms (see “Warning displays” below).
4
5 6 4. Starting switch.
5. Start button.
6. Stop button.
Warning displays
If the acoustic alarm sounds, one of the warning dis-
play lamps will immediately start to flash to indicate
the cause of the alarm.
1. Coolant temperature too high.
2. Lubricant pressure too low.
3. Alternator not charging
4. Not used
1 2 3 4
5. Lubricant level too low* (accessory).
6. Coolant level too low* (accessory).
7. Water in fuel pre-filter (accessory).
8. Auxiliary (accessory).
* Warns for low level with stationary engine and starter key in position
I (“Drive position”). Refill to correct level before starting the engine.
5 6 7 8 After an alarm
Press the “Alarm test” button to acknowledge and
terminate the acoustic alarm. The relevant warning
lamp will continue to flash until the fault has been
rectified.
Alarm test
After pressing the “Alarm test” button, the warning
lamps will come on and the acoustic alarm will start to
sound. Make a habit of always performing an alarm
test before starting.
18
Instrumentation
Starting switch
Delivered with the starter keys is a plate containing
the key code required when ordering additional starter
keys. Do not keep the code where unauthorized per-
sons can access it.
S = Stop position.
0 = Key can be inserted and removed.
I = Voltage on (drive position).
II = Not used
III = Start position.
IMPORTANT! Read the starting instructions in

the chapter “Starting the engine”.
19
Instrumentation
Control panel EDC (type I)

If the boat has a single engine there are three buttons in the control panel. If the boat has two engines there are
six buttons in the control panel. Each button has an LED which indicates the present selection or status.
Note that certain buttons and LEDs are duplicated on the control panel for two engines. The buttons on the left
hand side of the panel apply to the port engine. The buttons on the right hand side of the panel apply to the
starboard engine.
1 1
3 3
2 3 2 2
4
1. Activation button 3. Diagnostics button

The control position is activated by pressing the but- The button is used if the diagnostic function has re-
ton in for at least one second so that the engine can gistered malfunction (indicator flashes).
be started and controlled from the control position.
By pressing the button the message is acknowledged.
Indicator (red): When the button is released a diagnostic trouble code
(DTC) flashes which guides any fault-tracing (see
No light: The control position is not activated
chapter “Diagnostic function” for more information).
Light on: The control position is activated
Indicator (yellow):
Flashing: The control position cannot be activated
because the control lever is not in the neutral posi- No light: Normal position
tion. Check all control positions. Flashing: Diagnostic function has registered a mal-
function
2. Neutral button
By pressing the button at the same time as the con- 4. Synchronisation button
trol lever is moved forward to the shifting position, the Press the button in for at least one second to engage
control lever shift function is disengaged so that the or disengage the synchronisation function (the
engine can be revved freely. function is automatically activated at start).
Indicator (green): The synchronisation function automatically adjusts
No light: Reverse gear/drive is engaged the engines to the same speed (RPM).
Light on: The control lever is in neutral position Indicator (blue):
Flashing: The control lever shift mechanism is disen- No light: The synchronisation function is not activat-
gaged ed
Light on: The synchronisation function is activated
20
Instrumentation
Control panel EDC (type II)

If the boat has a single engine there are three buttons in the control panel. If the boat has two engines there are
six buttons in the control panel. Each button has an LED which indicates the present selection or status.
Note that the neutral and diagnostic buttons are duplicated on the control panel for two engines. The buttons on
the left hand side of the panel apply to the port engine. The buttons on the right hand side of the panel apply to
the starboard engine.
2 3 3 1 3
1 2 4 2
1. Activation button (red) 3. Diagnostic button (yellow)

The control position is activated by pressing the but- The button is used if the diagnostic function has re-
ton in for at least one second so that the engine can gistered malfunction (indicator flashes).
be started and controlled from the control position.
By pressing the button the message is acknowledged.
Indicator: When the button is released a diagnostic trouble code
No light: The control position is not activated (DTC) flashes which guides any fault-tracing (see
chapter “Diagnostic function” for more information).
Light on: The control position is activated*
Flashing: The control position cannot be activated Indicator:
because the control lever is not in the neutral position. No light: Normal position
Check all control positions. Flashing: Diagnostic function has registered a mal-
function
2. Neutral button (green)
By pressing the button at the same time as the con- 4. Synchronisation button (blue)
trol lever is moved forward to the shifting position, the Press the button in for at least one second to engage
control lever shift function is disengaged so that the or disengage the synchronisation function (the func-
engine can be revved freely. tion is automatically activated at start).
Indicator: The synchronisation function automatically adjusts the
No light: Reverse gear/drive is engaged engines to the same speed (RPM).
Light on: The control lever is in neutral position Indicator:
Flashing: The control lever shift mechanism is disen- No light: The synchronisation function is not activat-
gaged ed
Light on: The synchronisation function is activated
* If the boat has two engines: The indicator only lights when the control position is activated for both engines. If the control position is
activated when there is voltage supply to one engine, only the neutral button indicator lights.
21
Controls
This chapter describes the controls available from Volvo Penta. If your boat is equipped with controls which are
not described here and you feel uncertain about the function please contact the dealer you purchased the boat
from.
Single lever control. Electronic

Operation
Both the shift function and engine speed control are con-
trolled using the single lever control.
N = Neutral position (reverse/drive is disengaged and the
engine runs at idle speed).
F = Drive/reverse gear engaged for movement ahead.
R = Drive/reverse gear engaged for movement astern.
T = Engine speed control.
NOTE! The engine can be started only if the control lever is
in the neutral position.
Disengaging the shift function

The shift function can be disengaged so that the control
lever only affects the engine speed.
1. Move the lever to the neutral position (N).
2. Press the neutral button in and hold it down while mov-
ing the control lever forward to the shift position (F).
3. Release the neutral button. The indicator begins to flash
to acknowledge that the shift function is disengaged.
The lever now only affects the engine speed (RPM). In this
position the engine speed is limited to a maximum of 1500
rpm.
When the lever is moved back to the neutral position it will
automatically re-engage.
WARNING! Take care not to engage the reverse gear/

drive unintentionally.
22
Controls
Friction brake
The control has a friction brake which can be adjusted as
necessary to provide lighter or heavier lever action.
Adjusting the friction brake:
1. Stop the engine.
2. Mover the control lever forwards so that the groove in
the hub of the control lever is accessible.
3. Position a screwdriver in the groove and remove the
plug.
4. Adjust the friction brake (8 mm wrench):
Clockwise = heavier lever action
Counter clockwise = lighter lever action.
5. Reinstall the plug.
23
Power Trim
Your Volvo Penta propulsion system is equipped with a Power Trim hydraulic trim system which makes it possi-
ble to adjust the angle of the drive in relation to the stern of the boat. This adjusts the boat’s trim to obtain maxi-
mum comfort and fuel economy in different operating conditions.
Power Trim settings and adjustment are controlled from the helm position using the controls and instruments de-
scribed in this chapter. The chapter ”Operation” provides more information on use of the Power Trim system when
operating the boat.
WARNING! Avoid over-trimming the drive system as this can adversely effect the steering of the boat se-
verely.
Trim controls
1 The drive is trimmed using the separate control panel or the
button on the control lever (option). The current trim posi-
tion of the drive is shown on the separate trim instrument.
Trimming the drive away from the stern of the boat raises
the bow in relation to the horizontal, while moving it towards
the stern will lower the bows.
Button 1: Press button to raise the bow of the boat (drive

is trimmed out).
Button 2: Press button to lower the bow of the boat (drive

is trimmed inward).
2 Button 3: Press the button* while simultaneously pressing

button (2) or (4) is pressed up to raise or trim the
drive out to Beach range.
3 Button 4: Press button up to raise bows. Press button
down to lower bows.
* Applies only to DP. This button has no function on the DPX drive.
4
Trim instrument. General

To be able to make use of the information provided by the
trim instrument it important to know about the significance
of the trim ranges and their application. There are three
ranges:
Trim range
The trim range is used to achieve maximum comfort under
normal operation at all speeds from start to maximum
speed.
Beach range
The beach range is used for operation at reduced speed in
shallow water or where water depth is uncertain.
WARNING! The maximum permitted engine speed in

the Beach range is 1 000 rpm. Always check that the
cooling water intake is below the surface of the water.
24
Power Trim
Lift range
The lift range is used for lifting the drive to its maximum
angle, however this cannot be used during normal op-
eration of the boat. The range is used mainly for trailer
transport of the boat. The Power Trim has an automatic
stop which cuts off the current when the stop position is
reached. The stop is automatically reset when trimming
down.
WARNING! The engine must not be run with the drive

in the “Lift” range.
Digital trim instrument (DP)

The display shows the current trim range and drive posi-
tion. The same information can be obtained from the LEDs
which also indicate the up or down movement of the bows.
A A. Shows the current trim range (TRIM: trim range,

B
BEACH: beach range, no text on display: lift range).
7 B. Shows the current drive position* in the range –9 to 40.
1. Yellow light indicates that the bows are above the hori-
6 zontal line. Flashes when the drive moves and the bow
1 5 is raised. Otherwise no indication.
2. Yellow light indicates that the bows are below the hori-
2
4 zontal line. Flashes when the drive moves and the bow
is lowered. Otherwise no indication.
3
3. Green light comes on in the trim range (9 to 0). Other-
wise no indication.
wise no indication.
wise no indication.
6. Red light in the beach range (6 to 40). Otherwise no indi-
cation.
7. Red light flashes to warn that the drive is in the lift range
(over 40). Otherwise no indication.
Note. A diagnostics program is initiated automatically ev-
ery time the instrument is activated (using the ignition key);
all the LCD segments light up and the display shows A-
BEACH. The instrument then returns to displaying the cur-
rent drive angle.
* This figure is the angle of the drive to perpendicular (stationary boat).
The lowest value shows that the drive is trimmed to maximum and
the highest value shows that the drive is at maximum lift. Note that
the lowest value can vary from boat to boat depending on the angle
of the boat’s stern.
25
Power Trim
3 Analogue trim instrument (DP)

The trim instrument indicates the current trim position of
2
the drive. The scale has five calibration points with the
Beach and Lift range marked in red.
1. Trim range
2. Beach range (red).
1
3. Lift range (red)
Trim instrument (DPX)

The instrument shows the current position of the drive with-
in the Trim range and the beginning of the Beach range.
The position is indicate by the scale as follows:
0–7 = Trim range.
7–10 = Beach range.
IMPORTANT! There is no automatic lockout between

the Trim and Beach ranges. Take care to observe the
instrument when trimming the drive out so that the
drive does not enter the Beach range.
Twin and triple installations

In twin and triple installations the drives may be trimmed
individually within the permitted trim range.
WARNING! When lifting drives within the Beach range

both drives must be always lifted at the same time –
in parallel – so as not to place an undue strain on the
parallel strut between the drives.
When lifting in parallel the drive must be first trimmed
to its foremost position (0). Start the lift from this posi-
tion.
When lowering the drives it is important that they are
lowered in parallel to avoid snapping the parallel strut.
26
Starting the engine
Make a habit of “visually” inspecting the engine and engine room before starting This will help you to quickly detect
abnormalities that have occurred or are about to occur. Make sure instruments and warning displays indicate nor-
mal values after starting the engine.
WARNING! Never use start spray or similar start help. Risk for explosion!
Before starting
● Open the fuel cock
● Open the seawater cock (reverse gear)
● Carry out the actions in the “Daily before the first start-
up” section in the maintenance schedule
● Switch on the main switch

IMPORTANT! Never break the circuit with the
main switches while the engine is running. This
could damage the generator.
● Start the engine compartment fan if one is installed and

let it run for at least four minutes.
● Lower the drive(s) if raised.

WARNING! Twin and triple installations (DPX): the
drives must be trimmed at the same time/ parallel.
General about starting

The engine speed control must be set to idle when the en-
gine is started. The EDC system ensures that the engine
receives the correct amount of fuel – even when the engine
is cold.
The EDC system allows the engine to run for a few revolu-
tions to heat the engine before the fuel is injected. The
lower the engine coolant temperature (ECT) sensor the more
the number of revolutions. This raises the temperature in
the combustion chamber, ensuring reliable starting and
reducing smoke during starting.
After starting, the supercharger is engaged, for accelerated
warm up when the engine temperature is low.
The idling speed is also governed by the engine coolant
temperature (ECT) and is slightly higher when starting from
cold.
27
Starting the engine
Starting method
1. Disengage the drive/gears
Disengage the drive/gears by moving the control lever(s)
to neutral at all control positions.
2. Switch on the power

Turn the start key to position “I” to switch on the power.
3. Check the warning lamps and alarm

Check that the lamps in the warning display and the
acoustic alarm are functioning by pressing the “Alarm
test” button on the instrument panel.
4. Activate the control position

Press the activation button for at least one second. The
indicator lights to confirm the control position is activat-
ed when the button is released.
NOTE! If the indicator flashes, the control position has
not been activated because the control lever(s) are not
in the neutral position.
5. Start the engine

Start using the ignition switch:
Turn the key to position “III”. Release the key and let it
key spring back to position “I” as soon as the engine
has started.
NOTE! If repeated start attempts are needed, the key
must be turned back to position “0” first (the control po-
sition must be reactivated if the key is turned to position
“S”).
28
Starting the engine
Start using the start button

Press the start button. Release the button immediately
after the engine has started (note that when starting
from the alternative control position, the starter key at
the main control position must be turned to “I”).
Overheating protection:
If the starter motor is engaged for the maximum en-
gagement time (30 seconds), the starter motor circuit is
broken automatically to prevent the starter motor from
overheating. If possible, allow the starter motor to cool
down for at least five minutes before making a new start
attempt.
Start using auxiliary batteries
Refer to the description in the chapter “Troubleshoot-
ing”.
6. Check the instruments and run the engine

warm
Let the engine idle for the first ten seconds and make
sure the instruments and warning display show normal
values.
Then run the engine at low speed and low load so it at-
tains normal operating temperature before using full
power.
IMPORTANT! Do not race the engine when it is
cold.
Check there is sufficient fuel for the planned journey.
29
Operation
It is important to learn how to operate the engine, controls and other equipment safely and properly before setting
off on a maiden voyage. Avoid violent and unexpected changes in course and gear engagement. There is a risk
that someone aboard will fall over or overboard.
WARNING! A rotating propeller can cause serious injury. Check that nobody is in the water before engaging
ahead or astern. Never drive near bathers or in areas where people could be in the water.
Check the instruments

Check the instruments and warning display directly after
start and regularly during operation.
Oil pressure
The oil pressure gauge must display 150–500 kPa during
normal operation. At engine idle this is normally lower.
The acoustic alarm sounds and the lamp in the warning dis-
play starts to flash if the oil pressure is too low.
IMPORTANT! In the event of a low oil pressure alarm:
Stop the engine immediately. Investigate and correct
the malfunction.
Engine coolant temperature (ECT)

The temperature gauge must display 75–90°C during normal
operation.
The acoustic alarm sounds and the lamp in the warning dis-
play starts to flash if the engine coolant temperature (ECT)
is too high.
IMPORTANT! In the event of a high engine coolant
temperature (ECT) alarm: Reduce engine speed to idle
(neutral). Stop the engine if the temperature does not
drop. Investigate and correct the malfunction.
Charging
The charge voltage must be at approximately 14 V.
The acoustic alarm sounds and the lamp in the warning
display starts to flash if there is no charging.
IMPORTANT! Operation if there is a charge failure will

lead to malfunctions and finally to an engine stoppage.
Investigate and attend to the fault.
30
Operation
Diagnostic information
The indicator for the diagnostic button starts to flash if the
diagnostic function registers malfunction in the EDC sys-
tem.
Corrective action:
1. Reduce engine speed to idle.
2. Acknowledge the message by pressing the diagnostic
button.
3. Release the diagnostic button and make a not of the
diagnostic trouble code (DTC) that is flashed out.
The diagnostic trouble code (DTC) remains stored as
long as there is a malfunction and can be noted later.
4. Look up the diagnostic trouble code (DTC) in the “Diag-
nostic function” chapter and carry out the recommended
remedies accordingly.
Alternatively: If the gear control, warning display and
other instrumentation is functioning normally, the opera-
tor can continue the journey and remedy the malfunction
at a later time.
NOTE! In the “Diagnostic function” chapter there is more
information about the diagnostic function, reading off diag-
nostic trouble codes (DTCs) etc.
Cruising speed
Avoid running at full speed to obtain the best operating
economy. We recommend a cruising speed of at least 10%
lower than the maximum rpm at full speed (wide open throt-
tle). The maximum rpm at full speed can vary depending
on choice of propeller, load and sea conditions, etc., but
should be within the wide open throttle range.
Wide open throttle range:

KAD/KAMD44P .................................. 3700–3900 rpm
KAD/KAMD300 ................................... 3700–3900 rpm
There could be several reasons for the engine failing to
reach the wide open throttle range, see the chapter “Trou-
bleshooting”. Use a propeller with a greater pitch if the en-
gine speed exceeds the wide open throttle range. Get in
touch with your Volvo Penta dealer for advice.
Overloading
In all parachute towing, water skiing, etc. full throttle speed
must not be less than 3600 rpm.
Towing must only be done at half throttle.
31
Operation
Synchronising the engine speed

When driving with twin engines, both the operating econo-
my and comfort can be increased if the engines are operat-
ing at the same engine speed (RPM).
If the synchronisation function is activated, the engine
speed (RPM) of the starboard engine is automatically ad-
justed to that of the port engine if:
1. The engine speed levers for both engine are in (approxi-
mately) the same position.
2. The engine speed on both engines must exceed 800
rpm.
3. The engine speed on neither engine exceeds 3800 rpm.
NOTE! The synchroniser is disengaged as soon as the
conditions are no longer met.
The synchronisation function is automatically activated at
start. However the function can also be engaged and disen-
gaged by pressing the synchronisation button for at least
one second.
Changing control position

For reasons of safety, the engine can only be changed to
the new control position if the control lever(s) are in neutral
in both the control position that was left and the new con-
trol position.
WARNING! Ensure that the control lever(s) are in neu-

tral before transffering to the new control position.
1. Set the control lever(s) to neutral at the control position

you are about to leave.
2. Set the control lever(s) to neutral at the new control po-
sition.
3. Activate the control position by pressing the activation
button for at least one second.
32
Operation
Maneuvering
Only shift between forward and astern at engine idle speed
as shifting at higher engine speeds can cause discomfort
for those on board and unnecessary strain on the drive/re-
verse gear or the engine to stop.
Attempting to shift when the engine speed is too high will
automatically result in the shift being delayed until the en-
1 gine speed drops to approximately 1000 rpm.
Always follow this procedure when carrying out for-
ward/reverse maneuvering:
1. Reduce engine speed to idling and let the boat lose

most of its speed.
WARNING! Never shift to reverse when the boat
is planing.
2
2. Move the reverse gear control lever quickly and firmly
into the neutral position. Wait for a moment.
3. Move the gear control lever quickly and firmly into

astern, then increase the speed.
IMPORTANT! If the boat has two engines, it is impor-

tant that they are both running during maneuvers
3 astern (rearward movement), otherwise water might
get into the exhaust of the engine which is not run-
ning.
Emergency shifting
If shifting is not possible with the control, the gears/drive
(intended for electronic shifting) can be engaged manually
for forward movement. See the “Fault-tracing” chapter for
additional information.
If the boat has more control positions, it may be possi-
ble to operate the reverse gear from this/these.
33
Operation
Power Trim while running

The Power Trim adjusts the drive angle to the stern of the
boat to obtain maximum comfort and fuel economy at dif-
ferent speeds, with varying loads, and in a range of wind
and sea conditions.
Power Trim settings and adjustment are controlled from the
helm position using the controls and instruments described
in the Power Trim section.
WARNING! Avoid over-trimming the drive system as

this can adversely effect the steering of the boat se-
verely.
The engine must not be run with the drive in the “Lift”
range.
IMPORTANT! Avoid running with the drive fully

trimmed for long periods (when planing). Apart from
excessive fuel consumption this can cause cavity
damage to the propeller(s).
Operating with the drive in the Trim range

The Trim range is used to achieve maximum comfort under
normal operation at all speeds from start to maximum
speed.
Since every boat has its own unique characteristics and
will be effected in different ways by the factors involved,
only general advice is given here on how to get the best
trimming angle for your boat. It can generally be said that
when the boat feels well-balanced, easy to steer and pleas-
ant to operate, then that is the optimal trim angle for the
boat.
When starting
Trim the drive. The bow will be pressed down and the boat
accelerates faster. This gives improved running and steer-
ing characteristics at speeds below the planing threshold.
At planing speed
Trim the drive out to the operating position which provides
the most stable and comfortable running.
If the boat has twin motors the drives can be trimmed with
different angles to compensate for side winds and to a cer-
tain extent compensate for uneven loading on one side of
the boat or the other.
34
Operation
For maximum fuel economy

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

Trim drive so the bows drop. This will provide more com-
fortable running.
Operating with the drive in the Beach range

The beach range is used for operation at reduced speed in
shallow water or where water depth is uncertain.
IMPORTANT! Max. permitted engine speed (rpm)

when running in the “Beach range” is 1 000 rpm.
Check that drive is never trimmed so that the cooling
water intake is out of the water.
WARNING! Twin and triple installations (DPX): When

lifting multiple drives installations within the beach
range both drives must always be lifted at the same
time – in parallel, so as not to place an undue strain
on the parallel strut between the drives.
Drives must also be lowered simultaneously/parallel.
35
Operation
Running aground
The automatic Kick-up function releases the drive if it
grounds or hits an object in the water. If the function has
been tripped and the drive released it must be trimmed
back to the original position using the control buttons.
IMPORTANT! The Kick-up function only protects the

drive when running ahead (forwards). There is no pro-
tection for the drive while running astern (backward).
Check after running aground that the drive or propeller are

not damaged or if there are vibrations from the drive. If this
is the case then the boat (if possible) should be run to har-
bor at reduced speed and taken out of the water.
Take the boat out of the water. Check the oil level in the
drive. If it is colored gray then water has entered the drive.
If this is the case or if other damage has occurred to the
drive it must be inspected at an authorized Volvo Penta
workshop. If only the propeller has been damaged it must
be replaced. Launch the boat and test drive. If there are
still vibrations it must be inspected by an authorized Volvo
Penta workshop.
IMPORTANT! To prevent galvanic corrosion any dam-

age to the paintwork on the drive and propeller must
be repaired before launching the boat: See section
“Laying up/Launching”.
DPX twin and triple installations:
WARNING! If the parallel strut shows signs of dam-

age, run at reduced speed to harbor. The parallel strut
is a vital safety component, damage may affect steer-
ing characteristics. In the worst case steering could
be lost altogether. Never align or weld a damaged par-
allel strut. Please contact your nearest authorized Vol-
vo Penta workshop for assistance.
36
Stopping the engine
The engine should be run for a few minutes at idle (in neutral) before turning it off. This will avoid boiling and even
out the temperature. This is especially important if the engine has been operated at high engine speeds and
loads.
Stopping
Turn the key to stop position “S”. Keep the key turned until
the engine stops. The key will automatically return to the
“0” position when it is released and can then be removed.
There is also an extra stop button at the junction box.
After stopping the engine

● Close the fuel cock and sea cock (reverse gear) for the
cooling water intake.
IMPORTANT! Do not forget to open the cocks be-
fore the engine is started again.
● Inspect the engine and engine compartment for any

leaks.
● Boats with drives: The drive must be trimmed in to its

maximum to protect the trim cylinders untreated surfac-
es from fouling.
IMPORTANT! If there is a risk that the drive can
run aground, it must instead be trimmed out to its
maximum lift position.
WARNING! Twin and triple installations DPX: The
drives must be lifted at the same time/parallel.
● Switch off the main switches if the boat is not to be

used for some time.
IMPORTANT! Never break the circuit with the main
switches while the engine is running. This could
damage the generator.
Laying up
If the boat is not going to be used for some time but is be-
ing left in the water, the engine must be run to operating
temperature at least once every 14 days. This prevents the
corrosion in the engine. If the boat will not be used for
more than two months then inhibiting should be carried out:
Refer to section “Laying up/Launching”.
37
Stopping the engine
Cold weather precautions

To prevent freezing damage, the seawater system must be
drained and the freshwater system coolant must have suffi-
cient antifreeze protection. Refer to the cooling system sec-
tion in chapter “Maintenance”.
IMPORTANT! A poorly charged battery may burst as

a result of freezing.
Transporting on a trailer
Before pulling boats with on to a trailer, trim the drive out to
“Lift range” (maximum lift). An automatic stop will cut off
the current to the hydraulic pump when the drive has
reached its max. lift point. The stop is automatically reset
when trimming down. NOTE! Check local legislation for
transporting boats on trailers, there are differences between
different countries’ trailer laws.
IMPORTANT! The engine must not be run with the

drive in the “Lift” range. Before transporting the boat
by trailer always secure the drive in the lift position
with a Trailer Kit (accessory) or similar, so that it can-
not drop down.
Boats with reverse gear: Drain water out the exhaust
pipes to prevent water entering the engine when trans-
porting the boat by trailer.
Laying up on land
Where boats are kept laid up on land when not in use, for
example, trailer boats, there is a lower level of galvanic cor-
rosion 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 re-
move any oxidation.
IMPORTANT! Do not use a wire brush or other steel

tools when cleaning, as these may damage the galvanic
protection.
38
Maintenance schedule
Your Volvo Penta engine and its equipment are designed for high reliability and long service life. They are built to
withstand the marine environment, and to minimise their impact on it. Given regular maintenance, as in the
schedule, these properties will be maintained and unnecessary malfunctions will be avoided.
Warranty inspection
During the first period of use, the specified warranty inspection, “First service inspection”, must be done at an
authorised Volvo Penta workshop. Instructions about when and how this must be done are found in the Warranty
and Service Book.
Extended Protection
Volvo Penta offers an Extended Protection for your marine diesel engine, including transmission, if used for plea-
sure use only. To be valid a Extended Protection service has to be performed at the owners cost and expense by
an authorized Volvo Penta distributor, dealer or workshop before the expiry of the 12 months Warranty Period.
Further directions can be found in the Warranty and Service Book.
MAINTENANCE SCHEDULE
WARNING! Before you do any maintenance work, read the “Maintenance” chapter
carefully. This contains advice on doing the work in a safe and correct manner.
IMPORTANT! Maintenance points marked must be done by an authorised Volvo

Penta workshop.
Daily, before first start:

● Engine and engine room. General inspection ..................................................page 43
● Engine oil. Checking the level ........................................................................ page 49
● Coolant. Checking the level ........................................................................... page 50
● General inspection of drive, propeller, shield. Leakage and function check.not shown
Every 14 days:
● Drive belts. Check for wear. Change as necessary ...................................... page 45.
● Sea water filter. Cleaning ............................................................................. page 52.
● Battery. Checking of the electrolyte level ..................................................... page 58.
● Fuel filter/ fuel pre-filter. Drain water ............................................................. page 56.
● Reversing gear. Checking of oil level ........................................................... page 64.
● Outboard drives. Checking corrosion protection ...................................... pages 66-67
● Outboard drives. Power Trim pump. Checking of oil level ............................ page 68.
● Outboard drive. Servo pump. Checking of oil level ....................................... page 71.
Every 100-200 hours / at least once a year, included in extended protection

● Engine oil. Change1) ................................................................................ pages 48-49
● Oil filter. Change 2) .................................................................................. pages 48-49
Every 100 hours/at least once a year, included in extended protection

● Drive (DPX). Oil change4 ................................................................................page 68
1)
Oil change intervals vary, depending on oil grade and sulfur content of the fuel. Please refer to page 46.
2)
Change the filters during each oil change.
3)
If the fresh water system is filled with a rust protection mixture, it must be changed every year. On the
other hand, if the fresh water system is filled with anti-freeze (glycol mixture), it must be changed every
second year.
4)
IMPORTANT! In operation situations where the number of forward-reverse operations averages
more than 20 per hour, the oil should be changed every 100 hours.
39
Every 200 hours / at least once a year, included in extended protection

● Air filter Change ........................................................................................... page 44.
● Exhaust pipe. Inspection .............................................................................. page 44.
● Supercharger. Checking of oil level .............................................................. page 44.
● Drive belts. Checking of belt tension ............................................................ page 45.
● Sea water pump. Checking of impeller ......................................................... page 52.
● Anti-siphon valve. Inspection ....................................................................... page 52.
● Fuel filter/ fuel pre-filter. Change .................................................................. page 56.
● Reversing gear. Change oil and filter ............................................................ page 64.
● Outboard drive (DP). Change oil 4) ................................................................ page 68.
● Outboard drive. Check universal joint and exhaust bellows .......................... page 69.
● Outboard drive (DP). Lubricate steering shaft bearings ................................. page 71.
● Clean and touch up the paintwork as necessary .......................................... page 78.
● Check the condition of all rubber hoses, and re-tighten the hose clamps .. not shown
Every 200 hours:

Valve clearance. Adjustment .................................................................... not shown
EDC system. Inspection with diagnostic tool ............................................ not shown
Outboard drive. Changing the universal joint bellows ................................. not shown
Outboard drive. Steering cable. Lubrication ............................................... not shown
Outboard drive (DP). Re-tighten the steering cap bolts .............................. not shown
Every second year:

● Coolant. Change3) ........................................................................................ page 51.
Every 600 hours / at least every 5 years:

● Drive belt, circulation pump. Change ............................................................ page 45.
● Drive belt, supercharger. Change ................................................................. page 46.
Reversing gear. Changing the propeller seal. ............................................. not shown
Turbo. Inspection/cleaning as necessary .................................................. not shown
Trim cylinders, hoses, hydraulic hoses. Leakage check ........................... not shown
Rubber valves for exhaust outlet in cavitation plate. Inspection ................ not shown
Outboard drive, check for function and wear ............................................. not shown
– Bushes/shaft stubs in shield and suspension fork.
– Steering shaft bearing and shield seal
– Propeller shaft seal
– Propeller shaft, checking straightness
– Gear change mechanism and control cable
– Steering
1)
2)
3)
second year.
4)
40
Every 1200 hours / at least every 5 years:

● Supercharger. Changing the oil .................................................................... page 44.
● Heat exchanger. Inspection/Cleaning ........................................................... page 51.
intercooler. Inspection/Cleaning ................................................................ not shown
Control cables and seals. Change ............................................................. not shown
Coolant pipes. Inspection .......................................................................... not shown
– Checking hoses, unions and hose clamps
Safety and function check ........................................................................ not shown
– In a safety and function check, the outboard drive is disassembled to check for wear
and damage. Any faults are rectified. If necessary, the complete drive is changed.
1)
2)
3)
second year.
4)
41
Maintenance
This chapter describes how to carry out the above maintenance. Read the instructions carefully before starting
work. Maintenance intervals are contained in the chapter above: Maintenance schedule
WARNING! Read the safety precautions for maintenance and service in the chapter: Safety Information,
WARNING! Unless otherwise specified all maintenance and service must be carried out with the engine
stopped. Stop the engine before opening or removing engine hatches. Immobilize the engine by removing
the ignition key, turning off the power supply with the main switch.
Engine, general
General inspection
Make a habit of “visually” inspecting the engine and
engine room before starting the engine and after stop-
ping when the engine has been turned off. This will
help you to quickly detect abnormalities that have oc-
curred or are about to occur.
Look especially carefully for oil, fuel and coolant
leaks, loose bolts, worn or slack drive belts, loose
connections, damaged hoses and electric cables.
This inspection takes only a few minutes but can pre-
vent serious operating diesturbances and costly re-
pairs.
WARNING! Accumulations of fuel, oil and grease

on the engine or in the engine room is a fire haz-
ard and must be removed immediately they are
detected.
IMPORTANT! If an oil, fuel or coolant leak is de-

tected, the cause must be investigated and the
fault rectified before the engine is started.
IMPORTANT! Never point high-pressure water

jets directly at seals, rubber hoses or electrical
components. Never use the high-pressure func-
tion when washing the engine.
42
Maintenance: Engine, general
Air Cleaner. Replacement

Remove air cleaner cover. Remove the old air filter.
Clean the air cleaner cover/housing as required. Take
care that no contaminants enter the engine. Install the
new air filter and air cleaner cover.
Compressor. Checking oil

Checking and topping up
Unscrew and remove the dipstick. Wipe off oil. Screw
the dipstick down fully and then remove it again.
Check that the level oil is between the markings. If
the dipstick is not screwed down fully the oil level will
be slightly above the MIN marking if the oil level is
correct. Ensure therefore that the dipstick is fully
MAX
screwed in to read off the oil level correctly. Top up
the oil as required (use the dip stick tube to fill). For
MIN oil quality and capacity: See the “Technical Data”
chapter.
IMPORTANT! The oil level should always be

within the MAX and MIN range marked on the
dipstick.
Oil change
Run engine to normal operating temperature. Remove
the oil dipstick. Remove the plug (1) and let the oil run
out. Reinstall the plug and fill with oil to correct level
as above.
Exhaust system. Check

The exhaust system in the drive installations must be
3 checked every year for corrosion damage between
hose (1) and the pipe (2).
WARNING! Risk of water penetration. Checking

the exhaust system should be carried out with
4
the boat on land.
5
1 If there is heavy corrosion the pipe should be re-
paired or replaced with a new one.
To check: Undo the clamp (3) and the two lower

2 clamps holding the hose (1). Raise the elbow (4) so
the hose frees off from the pipe. Check the mating
surface (5). If there is heavy corrosion the pipe should
be repaired or replaced with a new one.
43
Drive belts. Checking and adjustment

WARNING! Stop the engine before doing mainte-
nance work.
If the belts are tightened too hard, they can damage

the water pump bearings, if they are too loose, they
can slip.
For this reason, check belt tension regularly. Proce-
dure, please refer to the advice for each belt below.
Adjust as necessary. Do checks and any adjust-
ment after driving, when the belts are warm.
Check that the belts are free from cracks and other
damage. Replace worn belts.
Adjustment and replacement.

IMPORTANT! The belts must be tensioned in
the following order, to avoid uneven loading.
1. Circulation pump belt

Undo the nut (1) enough so the belt slackens off. Ten-
sion the belt by tightening the domed nut (2) on the
tensioner screw to 35–40 Nm. Use a torque wrench
and a suitable socket. Lock the tensioner screw with
1
2 the nut (1).
1
2. Alternator belt
Loosen the alternator fixing screws (1) and (2). Ten-
sion the belt with the adjustment screw (3), so that the
belt can be pressed down about 10 mm (3/8") between
the pulleys, using normal thumb pressure. Tighten
screws (1) and (2).
3
2
44
3. Compressor belt
Remove the protective cover. Undo the nut (1) enough
so the belt slackens off. Tension the belt by tightening
the domed nut (2) on the tensioner screw to 35–40
Nm. Use a torque wrench and a suitable socket. Lock
the tensioner screw with the nut (1).
2 1
1
4. Servo pump belt
Undo the fixing screw (1). Tension the belt with the
adjustment screw (2), so that the belt can be pressed
down about 10 mm (3/8") between the pulleys, using
normal thumb pressure. Tighten the screw (1).
Replacement
Slacken belt off so that it can be removed. Clean off
the pulley grooves. Install the new belt. Adjust as
above. Check belt tension again after a few hours’ op-
eration.
45
Idling speed. Adjustment

The engine idle speed is adjusted at the factory to 600
rpm. If required the idle speed can be adjusted within
the range 600–700 rpm. Any adjustment must be
700
made when the engine at operating temperature.
600 NOTE! If the boat has a number of control positions,
the adjustment can only be carried out from the main
control position (normally the control position in the
saloon).
1. Check that all control levers are in the neutral/idle
position.
2. Turn the start key to the S position (stop) and re-
lease it so that it springs back to 0.
3. Press in the neutral button. Hold it depressed until
point 5 inclusive.
4. Turn the ignition key to position l (drive position).
The indicator on the diagnostic button lights.
5. Release the neutral button when the indicator on
the diagnostic button goes out.
6. The indicators for the neutral and diagnostic but-
tons flash to confirm that the idling speed can now
be adjusted.
If the boat has two engines: Repeat the proce-
dure above so that the idling speed for both en-
gines can be adjusted at the same time.
7. Start the engine and adjust to the desired idling
speed using the control lever.
8. Confirm the set engine speed (RPM) by pressing
the neutral button.
9. Exit the adjustment by moving the control lever to
the neutral/idle position.
46
Lubrication system
IMPORTANT! With a new or reconditioned engine, the oil and oil filters must be changed after 20–50 hours
of operation. Use only the recommended grades of oil: See the chapter “Technical Data”.
Oil change intervals can vary from 100 to 200 hours, depending on oil grade and sulphur content of the fuel.
Note that oil change intervals must never exceed a period of 12 months. If you want longer oil change
intervals than given in the table below, the condition of the oil must be checked by the oil manufacturers th-
rough regular oil testing.
Sulfur content in fuel, by weight
< 0,5 – 1,0 % > 1,0 %3)
Oilgrade1) Oil change interval, reached first in operation
All engines: 200 h / 12 months 100 h / 12 months

VDS-2 and ACEA E7 2)
or VDS-2 and Global DHD-1
or VDS-2 and API CH-4
or VDS-2 and API CI-4
1)
When oil quality specifications are joined by “or” (Type 1, 2 and 3), either engine oil specification can
be used.
When oil quality specifications are joined by “and” (Type 2 and 3), the engine oil must fulfill both re-
quirements.
2)
ACEA E7 has replaced ACEA E5, but if available ACEA E5 can be used.
3)
If sulphur content is > 1.0% by weight, use oil with TBN > 15.
NOTE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the
quality requirements.
VDS = Volvo Drain Specification

ACEA = Association des Constructeurs Européenne d’Automobiles
API = American Petroleum Institute
TBN = Total Base Number
Global DHD = Global Diesel Heavy Duty
−30 −20 −10 ±0 +10 20 30 40

C
o
Viscosity
−15oC SAE 15W/40 Select the viscosity from the table below.
o
−25 C SAE 10W/30 Note. The temperature values refer to stable ambient
temperatures.
✱ SAE 5W/30
* Refers to synthetic or semi-synthetic oils.
−10oC SAE 20W/30
±0oC SAE 30
Oil change volume
+10oC SAE 40
Please refer to the “Technical Data” chapter.
−22 −4 +14 32 50 68 86 104
o
F
47
Maintenance: Lubrication system
1
Oil level. Checking and topping up
The oil level should be within the marked area on the
dipstick (1) and should be checked every day the first
time the engine is started. Topping up is done through
2 the valve cover (2). Top up oil slowly. Wait a few min-
utes before checking the oil level again to give the oil
time to run down to the oil pan. Then check the level
again. Use only the recommended grades of oil: See
the chapter “Technical Data”.
IMPORTANT! Do not fill the oil above the MAX

level.
Oil and oil filters. Changing

Run the engine to operating temperature so that the oil
is easier to suck out. Stop the engine. Suck up oil us-
ing an oil scavenging pump through the hole for the
dipstick.
WARNING! Hot oil and hot surfaces can cause

burns.
Unscrew the old filter. (To avoid oil spills put a plastic
bag over the filter before it is unscrewed). Check that
the mating surface on the engine is clean and that the
old rubber gasket is removed.
Moisten the filter rubber gasket with a little oil. Screw
on the new filter by hand until it is in contact with the
mating surface. And then a further half turn but no
more!
Top up oil to correct level. Start the engine and let it
idle. Check that the warning lamp for low oil pressure
goes out. Stop the engine. Check the oil level and top
up if necessary. Check that there are no leaks round
the oil filter.
Collect up the old oil and filter for deposit at a
proper disposal site.
48
Freshwater system
The freshwater system is the engine's internal cooling system. It is a closed system and must always be filled
with a coolant that protects it against internal corrosion and freezing when the climate demands.
The circulation pump ensures sufficient circulation in the system. The thermostat will start to open at a certain
temperature and will be fully open when the engine has attained normal operating temperature. When the thermo-
stat opens, the warm coolant passes through the heat exchanger where it is cooled by the water in the engine’s
seawater system.
Coolant. General
The freshwater system must be filled with a coolant
that protects the engine against internal corrosion and
from freezing (if the climate requires it). Never use
freshwater alone.
WARNING! Anti-corrosive agents and antifreeze

products are harmful to health (do not drink!)
If there is a risk for freezing at any time of year, the

engine coolant system must be filled with a mixture of
50% Volvo Penta antifreeze and 50% clean water (as
neutral pH as possible). This mixture prevents corrosi-
on and protects against freezing down to approx. –
40°C. It should be used all year round. NOTE! There
should be at least 40% antifreeze in the system for
complete protection against corrosion.
Where there is no risk of damage from freezing the

engine coolant can be fresh water with of Volvo Penta
anti-corrosion fluid added. Mix according to the ins-
tructionson the packaging.
IMPORTANT! Never mix antifreeze (glycol) and

anti-corrosive agents. The two combined can
produce foam and drastically reduce the
coolant’s effectiveness.
Coolant. Checking the level

WARNING! Do not open the engine coolant sys-
tem filler cap when the engine is still hot except
in an emergency. Steam or hot coolant may
spray out.
Turn the filler cap to the first stop and let any pressure
escape from the system before removing the cap. Top
up coolant if necessary. The coolant level should be
between the MAX and MIN marking on the expansion
tank when the engine is at normal operating tempera-
ture. The level is normally lower when the engine is
cold. Reinstall the filler cap.
49
Maintenance: Freshwater system
Coolant. Changing
The corrosion-proofing additives become less effec-
tive with time and the coolant must be changed. If the
freshwater system is filled with antifreeze mixture it
must be changed every other year. If the system is
filled with anti-corrosion agent mixture it must be
changed every year.
Coolant. Draining
Remove the filler cap on the expansion tank (this lets
1 the coolant run out faster). Put a container under the
drain cock on the hose without a blue marking (1).
4 Open the drain cock and drain coolant. Then continue
by draining the coolant from the other drain cocks (2–
3 4). Flush out the heat exchanger as follows before fill-
ing coolant.
2 NOTE! Deposit old coolant at a properly designated

disposal site.
Heat exchanger. Flushing out

Cooling performance is reduced by scaling in the heat
exchanger. It should therefore be flushed when the
coolant is changed.
1. Drain the coolant as above.
2. Insert a hose into the filler pipe on the expansion
tank. Flush with fresh water until the water which
runs out of the drain cocks is clean. Allow all the
water to run out.
3. Close the drain cocks. Fill with new coolant to cor-
rect level. Reinstall the filler cap.
IMPORTANT! If there is a danger of freezing

never top up with plain water, always add anti-
freeze mixture.
50
Maintenance: Seawater system
Seawater system
The sea water system is the engine’s external cooling system. On engines with stern drives, the sea water pump
sucks in water via the drive, after which the water passes the sea water filter before it is pumped through the inter-
cooler, heat exchanger and the engine oil cooler. Finally, the water is pumped out into the exhaust pipe elbow,
where it is mixed with the exhaust gas.
On engines with a reversing gear, the sea water pump sucks in water via the hull fitting, after which the water pas-
ses the sea water filter (optional equipment) before it is pumped through the intercooler, heat exchanger and the
engine oil cooler. Finally, the water is pumped out into the exhaust pipe elbow, where it is mixed with the exhaust
gas.
WARNING! There is a risk that water will enter while working on the seawater system (if the boat is in the
water). Water may flow into the boat if a hose, plug or similar object located below the waterline is removed.
So always close the seawater cock. If the boat does not have a seawater cock, the flow of water must be
stopped in a safe manner. The boat must be brought up on land if this is not possible.
Impeller. Checking/Replacing
WARNING! Risk for water penetration.
Remove the cover from the seawater pump and re-

1 move the impeller (1). If there are cracks or other de-
fects the impeller must be replaced. (If the pump shaft
can be turned by hand the flange must be replaced).
Lubricate the pump housing and the inside of the cov-
er with a little waterproof grease for rubber.
Reinstall the impeller using a rotating movement. In-
stall the seal washers on the shaft
center. Install the cover together with a new gasket.
Reverse gear: Open the sea cock.
1
Seawater filter. Cleaning
Screw off cover (1) and remove seal plate (2). Lift out
2 and clean the insert (3).
3
WARNING! Risk for water penetration.
IMPORTANT! If the boat is used in water that

has a lot of contaminants, seaweed etc. the filter
must be checked more frequently than indicated
in the maintenance schedule. Otherwise there is
a risk the filter will clog and the engine will over-
heat.
2
Anti-siphon valve. Checking
IMPORTANT! If the anti-siphon valve does not
function, there is a risk that sea water will get
into the engine. Change the anti-siphon valve as
necessary.
The anti-siphon valve (1) in reversing gear installa-

3 tions must be function checked regularly. The check
1 must be done both when the engine is stopped and
when it is running.
Undo the hose (2). Blow down the hose. When the
engine is stopped, air should pass easily through the
valve. When the engine is running, the valve is closed
and no air should pass.
Check and clean the nipple (3) on the sea water filter.
51
Seawater system. Draining

To prevent freezing damage the seawater system
must be drained in cold weather where there is a risk
of frost.
WARNING! If the boat is left in the water, the

seawater intake to the engine must be turned off
with a seawater cock (non-standard equipment)
or other method before draining the engine. If the
water is not drained properly the boat may fill
with water and sink. Check that there are no
leaks before you leave the boat.
1. Engine with drive: Remove the seawater hose

from the shield and close the intake with a plug*
(1) tightened with a hose clamp. Water will flow in
immediately the seawater hose is removed. Have
3
4 tools, plug and hose clamp ready. Bend seawater
hose down so the water runs out.
2 WARNING! To prevent freezing of the water re-
maining in the drive water galleries, the drive
must be completely trimmed down in the water.
Engine with reverse gear Close the sea cock.
Drain oil cooler by opening the plug (2). Disconnect
hose (3) and bend down so that the water runs out.
Disconnect hose (4) by the sea cock and empty it
of water.
2. Undo hose (5) and empty the water out of it. Drain
the intercooler by opening the plug (6), drain the oil
cooler by opening the plug on the hose with blue
markings (7) and drain the heat exchanger by un-
doing and emptying the hose (8).
5
3. Remove the cover from the seawater pump and let
the water run out.
6 4. Connect and tighten all hoses. Reinstall the cover

on the seawater pump and the cover plate on the
seawater filter.
When laying up the boat, remove the impeller from
the seawater pump and store it in a cool place in a
plastic bag. Reinstall the impeller when bringing
the boat out of storage.
* Make this plug from a 100 mm long piece of 30 mm diameter

hose. Plug one end of the hose with a piece of dowel or similar
and hold the dowel in place with a hose clamp.
52
Seawater system. Cleaning and inhibiting

To prevent the build up of deposits and salt crystals in
the seawater system it must be flushed with freshwa-
ter. When the boat is laid up it must also be inhibited.
WARNING! Risk of water penetration. Cleaning

and inhibiting the seawater system should be car-
ried out with the boat on land.
1. Open the seawater cock (reverse gear).

1
2 2. Detach hose (1) from the seawater pump and con-
nect a hose (2) which reaches to a bucket filled with
fresh water. Take care of filling.
3. Check that there is nothing that will get splashed
behind the exhaust outlet.
WARNING! Approaching a running engine is
dangerous. Watch out for rotating components and
hot surfaces.
IMPORTANT! The impeller will be damaged if
it runs dry.
4. Set the gear control lever in the neutral position.
Check that nobody is near the propellers. Start the
engine. Let it run at fast idle a few minutes. Stop
the engine.
5. For inhibiting fill a bucket with antifreeze mixture
(50/50 freshwater and antifreeze). Secure a contain-
er by the exhaust outlet. Repeat step 4.
6. Connect seawater hose (1).
7. The system is now inhibited. The antifreeze mixture
should be left in the system while the boat is laid
up. Drain the mixture just before the boat is
launched. Reuse the antifreeze mixture next sea-
son or deposit it at a properly designated disposal
site.
53
Maintenance: Fuel system
Fuel system
All work on the engine injection pump or injectors must be carried out at an authorized workshop. Use only the
recommended grade of fuel: See the chapter “Technical Data”.
WARNING! Fire risk. When carrying out work on the fuel system make sure the engine is cold. A fuel spill
onto a hot surface or an electrical component can cause a fire. Store fuel soaked rags so that they cannot
cause a fire.
Venting the fuel system

The fuel system must be vented after the fuel filters
1 have been replaced or after refilling the fuel tank after
it has been run dry.
1. Open vent screw (1) on the filter mounting approxi-
mately four turns. Avoid fuel spillage. Use rags
around the venting point.
2. Pump the fuel using hand pump (2) until there are
no more air bubbles visible in the fuel. Continue
pumping and at the same time tighten the venting
screw. If the pump effect is poor, turn the engine
over slightly so that the pump drive cam changes
position.
If the engine does not start continue venting as
follows:
2
3. Use the handpump (2) and pump for about half a
minute to automatically vent the fuel injection
pump.
4. Slacken off the injector delivery line nuts (3) and
set the engine speed control to neutral. Turn the
engine over with the starter motor until fuel comes
out of the delivery lines. Avoid fuel spillage. Tight-
3 en delivery line nuts.
5. Start the engine and check for leaks.
WARNING! Approaching a running engine is dan-

gerous. Watch out for rotating components and
hot surfaces.
54
Maintenance: Fuel system
Fuel filter. Replacement

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

hot surfaces.
Fuel pre-filter. Replacing filter insert

Close fuel cock at the fuel tank. Position a container
under the fuel filter.
Remove the cover by slackening off screw (1). Re-
place insert and reinstall cover. Open fuel cock. Vent
fuel system. Deposit the old filter insert at a prop-
erly designated disposal site.
Start the engine and check for leaks.

hot surfaces.
Fuel filter and fuel pre-filter. Draining

The fuel pre-filter is an accessory.
Position a container under the fuel filter. On the fuel
filter first open the venting screw (1) approximately 4
turns. Drain off water and contaminants using the
cock/plug at the bottom of the filter. Vent fuel system.
IMPORTANT! Wait a few hours after the engine

has been turned off before draining the filter.
55
Maintenance: Electrical system
Electrical system
The engine is equipped with a two-pole system electrical system which means that the voltage (minus) is returned
directly from the starter motor minus terminal with the battery negative lead. Individual components on the system
return voltage to the starter motor minus terminal via separate cables.
WARNING! Always stop the engine and break the current using the main switches before working on the
electrical system. Isolate shore current to the engine block heater, battery charger, or accessories mounted
on the engine.
Main switch
The main switch must never be turned off before the
engine has stopped. If the circuit between the genera-
tor and the battery is cut off when the engine is run-
ning the generator can be seriously damaged. For the
same reason charging circuits must never be
switched over while the engine is running.
IMPORTANT! Never break the circuit with the

main switches while the engine is running.
Fuses/circuit breakers
The engine is equipped with circuit breakers in the
electrical distribution box. The circuit breakers cut the
current if the electrical system is overloaded.
If the engine can not be started, or if the instruments
stop working when driving, a circuit breaker might
have tripped. Re-set the circuit breaker by pressing in
the button on the distribution box.
The EDC system (1) and the compressor (2) have 7.5
A fuses beneath the distribution box. (There are spare
fuses in the distribution box.)
IMPORTANT! Always investigate the reason for
the overload!
The control lever with integrated Power Trim control

button has a 5A fuse in the cable.
IMPORTANT! Always keep a stock of spare

fuses on board.
Drives with electric shift have a 5A fuse (3) in the ca-

ble, by the actuator.
56
Electrical connections
Also check that all electrical connections are dry and
free of oxidation and that there are no loose connec-
tions. If necessary, spray these connections with a
water-repellent spray (Volvo Penta Universal oil).
Battery. Maintenance
WARNING! Risk of fire and explosion. Never al-
low an open flame or electric sparks near the
battery or batteries.
WARNING! Never mix up battery positive and

negative terminals. This may cause sparks and
an explosion.
WARNING! The battery electrolyte contains ex-

tremely corrosive sulfuric acid. Protect your skin
and clothes when charging or handling batteries.
Always use protective goggles and gloves. If
battery electrolyte comes into contact with un-
protected skin wash off immediately using plenty
of water and soap. If battery acid comes into
contact with the eyes, flush immediately with
plenty of water and obtain medical assistance
without delay.
Connecting and disconnecting

First connect the red battery lead + to the battery +
terminal. Then connect the black battery lead – to the
battery – terminal.
When disconnecting the battery, disconnect the
– lead (black) first and then the + lead (red).
Cleaning
Keep batteries dry and clean. Oxidation or dirt on the
battery and battery terminals can cause short-circuits,
voltage drop and discharge especially in damp weath-
er. Clean the battery terminals and leads to remove
oxidation using a brass brush. Tighten the cable ter-
minals well and grease them with terminal grease or
petroleum jelly.
Topping up
The electrolyte should be 5–10 mm over the plates in
the battery. Top up using distilled water if neces-
sary. Charge the battery after topping up for at least
30 minutes by running the engine at fast idle.
NOTE! Certain maintenance-free batteries have spe-
cial instructions which must be followed.
57
Battery. Charging
WARNING! Danger of explosion! The batteries
give off hydrogen gas during charging which
when mixed with air can form an explosive gas –
oxyhydrogen A short-circuit, naked flame or
spark can cause a large explosion. Ensure that
the ventilation is good.
WARNING! The battery electrolyte contains ex-

tremely corrosive sulfuric acid. Protect your skin
and clothes when charging or handling batteries.
Always use protective goggles and gloves. If
battery electrolyte comes into contact with un-
protected skin wash off immediately using plenty
of water and soap. If battery acid comes into
contact with the eyes, flush immediately with
plenty of water and obtain medical assistance
without delay.
If the battery has discharged it must be charged. If

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

with the battery charger carefully. To avoid elec-
trolytic corrosion when an external charger is
connected, always disconnect the battery leads
before connecting the charger.
When charging, unscrew filler plugs but leave them in

their holes. Ventilation should be good, particularly if
the batteries are being charged in an enclosed area.
WARNING! Always switch off the charging cir-

cuit before removing the battery charger con-
nectors. Never mix up battery positive and nega-
tive terminals. This may cause sparks and an
explosion.
Special instructions apply when boost charging the

batteries. Avoid boost charging the batteries as it will
shorten their service life.
58
Electrical installations
Leakage current from the electrical system can be
caused by incorrect installation of electrical equip-
ment. Leakage current can knock out the galvanic
protection of components such as the drive, propeller,
propeller shaft, rudder stock and keel and cause dam-
age by electrolytic corrosion.
IMPORTANT! Work on the boat’s low tension

circuit should only be carried out by qualified or
experienced persons. Installation or work on the
shore power equipment must only be carried out
by electricians authorized to work with high-volt-
age installations.
The following should always be observed:

1. If shore power is connected, the protector ground
should be ashore, never in the boat. Shore power
should always have a ground fault circuit breaker.
Shore power units (transformer, rectifier, battery
chargers etc.) must be intended for marine usage
and the high tension circuit must be galvani-
cally separated from the low tension circuit.
2. Route and clamp electric cables so that they will
not be exposed to rubbing, damp or bilge water in
the keelson.
3. Engine or drive/reverse gear must never be used
as a ground point.
IMPORTANT! The engine or drive/reverse
gear must never be used as a ground or be
electrically connected to other equipment
such as the radio, navigational equipment,
the rudder, bathing steps etc.
Protective grounds for the radio, navigational
equipment, rudder, bathing steps or other equip-
ment with separate ground leads must be connect-
ed to a common ground terminal.
59
4. There must be a main switch connected to the

starter battery positive (+) terminal. The main
switch should cut off power to all power consuming
equipment and should be switched off when the
boat is not in use.
5. If an auxiliary battery is in use, a main switch
should be connected between its + terminal and
the fuse block, and the (–) terminal and the termi-
nal block for the boat’s electrical equipment. The
main switch for the auxiliary battery must cut off
all power consuming equipment connected to that
battery and be turned off when power is no longer
needed.
All equipment connected to the auxiliary battery
should have separate switches.
To simultaneously charge two independent battery
circuits, fit a Volvo Penta charge distributor (ac-
cessory) to the regular generator.
60
Maintenance: Electrical components diagram
Electrial components diagram
KAD44P, KAD300
6 15 19 4 5 7 14
16 10
3
11
20
18 21
17
12, 13
22
1. Starter motor 12. Injection pump

2. Generator 13. Stop solenoid
3. Starter relay 14. Engine speed (rpm) sensor
4. Main relay 15. Service socket
5. Stop relay 16. Needle lift sensor
6. Ground relay 17. Emergency stop
7. Semi-automatic fuses, 18. Standard fuse, EDC system/compressor
engine/instrumentation 19. Connector, instrumentation
8. EDC control module 20. DC/DC converter
9. Boost pressure sensor, connection 21. Gearshift control actuator
10. Charge air temperature sensor 22. Fuse, gearshift control actuator
11. Engine coolant temperature sensor
61
Maintenance: Electrical components diagram
KAMD44P, KAMD300
14
6 15 19 4 5 7 16 10
3
11
20
18
17
12, 13
2 21
1. Starter motor 12. Injection pump

2. Generator 13. Stop solenoid
3. Starter relay 14. Engine speed (rpm) sensor
4. Main relay 15. Service socket
5. Stop relay 16. Needle lift sensor
6. Ground relay 17. Emergency stop
7. Semi-automatic fuses, 18. Standard fuse, EDC system/compressor
engine/instrumentation 19. Connector, instrumentation
8. EDC control module 20. DC/DC converter
9. Boost pressure sensor, connection 21. Electronic valves, shifting
10. Charge air temperature sensor
11. Engine coolant temperature sensor
62
Maintenance: Reverse gear
Reverse gear
The HS63AE/HS63VE reverse gear is hydraulic, which means that ahead/astern engagement and disengagement
is hydraulically activated. The reverse gear lubrication system has an oil filter and oil cooler. The HS63AE/
HS63VE is equipped with solenoid valves for electronically controlled shifting.
IMPORTANT! Volvo Penta recommends the installation of a seawater filter to guarantee the proper coolant
water flow to the engine and reverse gear. Contaminants in the seawater will otherwise foul the reverse gear
radiator and other cooling system components.
Oil level
Remove the dipstick by turning/screwing it anti
clockwise. Dry off the dipstick and reinstall it in the
reverse gear, without screwing it into place. Re-
move the oil dipstick again and check the oil level.
The correct oil level is inside the marked area.
If necessary, top the oil up through the dipstick hole.
Please refer to the “Technical Data” chapter for oil
grades and volume.
IMPORTANT! Never over-fill the reversing gear.

The oil level must always be inside or at the rec-
ommended levels.
Oil change and filter change

1. Clean around the lid (2), so that there is no risk
that dirt could fall down into the filter housing.
2. Undo screw (1) with a 6 mm Allen key. Remove lid
(2). Replace and oil in the new O-rings in the lid.
3. Lift up the filter (3).
4. Suck up the oil with an oil drain pump, via the oil
filter housing.
5. Measure up the correct quantity of oil and fill the
reversing gear with the oil. Please refer to the
“Technical Data” chapter for oil grades and volume.
IMPORTANT! Never over-fill the reversing

gear.
6. Install the new filter (3) in the filter housing.
7. Install the lid. Tightening torque 5–8 Nm.
8. Put the control lever in neutral. Start and run the
engine at 1500 rpm for a few minutes to ensure
that the reversing gear oil cooler is filled with oil.
9. Stop the engine and check the oil level. Top up as
necessary.
63
Maintenance: Reverse gear
Propeller shaft seal

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

600 hours and changed as necessary. The seal
must be changed every five years, however.
64
Maintenance: Drive
Drive
Your drive is protected against galvanic corrosion. This protection consists of five layers of paint, sacrificial an-
odes and ground braids. The ground braids maintain a connection between the different components of the drive.
A broken connection can result in the rapid corrosion of an individual component even though the protection is
otherwise effective. Check ground braids every year. Faulty electrical installation can also cause the break down
of the galvanic protection. Damage due to electrolytic corrosion occurs rapidly and is often extensive. For further
information see the chapter: “Electrical system”.
IMPORTANT! Always repair damage to paintwork immediately. Improperly applied paint or the wrong type of
paint on the keel can put the corrosion protection system out of action. For further information on painting
see the chapter: Laying up and launching
The drive is equipped with a cone clutch for shifting using a control cable with either mechanical operation or an
electric actuator and electronic operation.
Corrosion protection. Checking/

Replacing
Check the sacrificial anodes regularly. Replace with
new anodes when approximately 1/3 of the anode has
been eroded. Tighten the new anode so that there is a
good electrical contact.
Where boats are kept laid up on land when not in use
there is a lower level of galvanic corrosion protection
due to the oxidation on the sacrificial anodes. Even a
new anode can be oxidized on the surface. Before
launching the sacrificial anodes must be cleaned/
ground using an emery cloth.
IMPORTANT! Use emery paper. Do not use a

wire brush or other steel tools when cleaning, as
these may damage the galvanic protection.
Your drive is equipped with sacrificial anodes of

zinc as standard, intended for use with salt water.
On drives used mainly in freshwater the sacrificial
anodes should be of magnesium.
IMPORTANT! Use zinc sacrificial anodes for salt

water and magnesium anodes for freshwater.
65
Maintenance: Drive
DP drive
The sacrificial anodes can be found at the lower edge
of the shield (1) and on the gear housing in front of the
propellers (2).
Undo the two screws holding the anode (1). Remove
the anode and the support plate under the anode.
Clean the mating surface. Reinstall support plate and
the new anode.
Disassemble the propellers in accordance with the in-
structions in the “Propellers” section. Undo the two
screws holding the anode (2). Remove the anode.
1 Scrape mating surface on the drive clean. Install new
anode.
DPX drive
The protective anodes are located on both sides of the
upper bevel drive housing (1), the steering cylinders
1
(2), on top of the cavitation plate (3) and underneath
the shield (4).
All anodes are fixed with screws. Undo the screws
which hold the anode. Clean the mating surface and
install the new anode.
3 There is a support plate inside the anode (4) which
2
holds the trim sensor in place. Carefully check that the
4 support plate locks the trim sensor before installing the
anode and tightening the screws.
WARNING! Risk of water entry. Check that the

support plate locks the trim sensor before install-
ing the anode.
66
Maintenance: Drive
A Oil change
A Remove the oil dipstick (A). Trim the DP drive up as
far as possible, trim the DPX drive in (forward) as far
as possible. Remove the plug on the gear housing and
let the oil run out. If oil is discolored, contact an au-
thorized Volvo Penta workshop. Reinstall plug and O
ring. Always replace a damaged O ring with a new
one.
DP-E
NOTE! Deposit the used engine oil at a properly
DP-G, DPX
designated disposal site.
Remove the protective cover and remove the oil filling

plug, together with its seal. Fill up with new oil. Please
DPX DP-E, DP-G refer to “Technical Data” for grades and quantities.
Fold the drive down.
Use the dipstick after a while, to check the oil level.
The dipstick must not be screwed down when the oil
level check is done. If the level is too high, drain
some oil off. If the level is too low, top up the oil
through the dipstick hole.
Check tightening of the dipstick and drain plug. Re-
install the protective cover.
DP-G, DPX DP-E
Oil level Power Trim

Trim the drive in as far as possible. Check the oil lev-
el is between the MAX and MIN markings on the oil
container. Top up if necessary using ATF oil. Cleanli-
ness is extremely important, no dirt must get into the
drive when topping up with oil.
If the system has been drained, fill with new oil and
trim the drive in and out 6–10 times to vent the sys-
tem. Check the oil level and top up if necessary.
67
Maintenance: Drive
Bellows. Replacement
Check the condition of the universal joint and exhaust
bellows at least once a year. If any cracks or other
defects are visible, they must be changed. The uni-
versal joint bellows must be changed every 200 hours.
The drive may need to be removed from the support
fork to replace the bellows. Removal of the drive re-
quires special knowledge and tools. If in doubt contact
your Volvo Penta workshop for assistance.
WARNING! Never work on the drive bellows or

hydraulic system without locking the drive in its
raised position so that it cannot fall down. A fall-
ing drive can cause serious personal injury.
Tool 885143-8, when properly installed, prevents the

drive falling. Install the tool as follows: Trim the drive
down to 0. Remove cotter pins and knock out trim cyl-
inder bolts.
DPX: Also remove steering cylinders by removing

pins. Tie up the steering cylinder so that they do not
hang in the way.
The drive can now be lifted by hand to its raised posi-

tion. Hold the drive steady in this position and install
the tool on the starboard side as illustrated. Carefully
check the bellows for damage. The exhaust bellows
can be replaced without removing the drive.
WARNING! Do not overload the tool by standing

on the raised drive.
68
Maintenance: Drive
DP: If the drive has been removed the steering rack

and drive controlling the trim sensor may have come
out of position. Turn the cog until the notched tooth is
visible. Install the steering rack so that the first cog
position meshes with the marked tooth.
DP, DPX: Hose clamp screws should be located as

illustrated when tightened.
69
Maintenance: Steering
Steering
The DP drive is equipped with power-assisted mechanical steering. The DPX drive is equipped with the Xact fully
hydraulic power steering system.
DP power steering pump. Oil level

Turn the filler cap counterclockwise and remove.
Check the oil level is between the MAX and MIN
markings on the dipstick. Fill with ATF. For ATF
grade, see Technical data
DP steering shaft bearing. Lubrication

Lubricate steering shaft bearing with a grease gun.
Use water resistant grease. Press in grease until it is
forced out of the bearing.
Xact Power steering, DPX IMPORTANT!

To ensure safe and reliable steering follow these
instructions:
Check steering system oil level every two weeks to
detect level changes. The oil level should not normally
change, oil consumption is negligible over a year. If
the oil level drops there is probably a leak. This leak
must immediately be localized and remedied. Please
contact your nearest authorized Volvo Penta work-
shop for repairs. The steering system is filled with au-
tomatic transmission fluid (ATF), the fluid should not
normally require changing. As long as the oil is red
and contains no visible contaminants you do not need
to change the oil. If the color of the oil changes to
black or contains visible contaminants you must
change the oil. The oil should also be changed if the
steering system has been opened for servicing.
WARNING! Always use the recommended grade

of ATF from a recognized manufacturer. Never
fill the steering system with an unknown grade of
fluid. The wrong type of oil can negatively af-
fect steering, and at worst steering can be
lost altogether. The wrong oil can also damage
steering system components.
70
DPX Hydraulic pump Oil level

Check with the engine(s) idling. The level should be
between MAX and MIN markings on the dipstick.
NOTE! The level is slightly higher with the engine
stopped. Fill with ATF. For ATF grade, see Technical
data.
DPX Hydraulic circuits Venting

If the steering system hydraulic circuit has been re-
moved or dismantled, the system must be vented.
Venting is easier if you have an assistant.
WARNING! Be extremely careful that hands,

clothes, hair, necklaces and tools do not come
into contact with engine drive belts or pulleys.
Fill the system. Start the engine(s). The steering

system engine circuit is automatically vented when
the engines have been running for 2–3 minutes. Other
parts of the system are vented as follows: Turn the
wheel 2–3 times port and starboard to full lock. Check
the oil level as the wheel is being turned and top up as
necessary. The oil level can drop rapidly when the
wheel is turned. Be ready to top up the oil immediately
so that no air is sucked into the system. Check the oil
level one last time with the dipstick and top up as
necessary. Check that there are no leaks before
running, particularly if the system has been
dismantled. Also check that all connections have
been tightened properly.
71
DPX Hydraulic hoses. Checking

Carefully check the steering system’s hydraulic hoses
for wear and cracks. Check external hoses especially
carefully, as these have been exposed to water fa-
tigue. Hoses must be replaced if at all damaged.
WARNING! A leaking hydraulic hose can nega-

tively affect steering, and at worst steering can
be lost altogether. Cleanliness is extremely im-
portant, no dirt must get into the hydraulic sys-
tem. Before removing, clean and check carefully
how hoses are routed and connected. Faulty
routing or dirt in the hydraulic system can
negatively affect steering, and at worst steer-
ing can be lost altogether. Please contact your
nearest authorized Volvo Penta workshop for as-
sistance.
DPX Parallel strut. Checking

The parallel strut (twin and triple installation) is a vital
safety component. Inspect it carefully if the drive
kick-up function has been triggered by the boat going
aground or hitting an object in the water. Check paral-
lel strut ball joints and for cracks or other damage an-
nually.
WARNING! If the parallel strut shows signs of

damage, run at reduced speed to harbor. The
parallel strut is a vital safety component, dam-
age may affect steering characteristics. In the
worst case steering could be lost altogether.
Never align or weld a damaged parallel strut.
Please contact your nearest authorized Volvo
Penta workshop for assistance.
72
Maintenance: Propellers
Propellers
For best performance and fuel economy the engine speed should be within the maximum RPM range: See chap-
ter “Operation”. If the engine speed at maximum RPM falls outside the max. RPM range then the propeller
should be changed.
WARNING! Make it impossible to start the engine when working on the propellers. Take the starter key out
of the starter switch.
IMPORTANT! Damaged propellers should be replaced immediately. Operating the boat with a damaged pro-
peller should be undertaken with extreme care and only at reduced engine speeds.
4 2 1
5
Propellers. DPX-drive Installation

NOTE! A tool for installing and removing the propel- 1. Grease both the propeller hubs. Use Volvo Penta
lers (please refer to the illustration) is provided with grease (water resistant).
the drive. 2. Switch the ignition on and put the control lever in
the forwards position. Take the starter key out of
Removal the starter switch.
1. Switch the ignition on and put the control lever in 3. Slide the front propeller (5) onto the shaft.
the reverse position. Take the starter key out of
the starter switch. 4. Install the large lock nut (4) and torque it to 50–70
Nm (37-52 lbf ft).
2. Remove the lock screw (1) and the nut (2). Re-
move the rear propeller (3). 5. Switch the ignition on and put the control lever in
the reverse position. Take the starter key out of
3. Switch the ignition on and put the control lever in the starter switch.
the starter switch. 6. Slide the rear propeller (3) onto the shaft and lock
it with nut (2). Use a 30 mm socket and torque it to
4. Remove the lock nut (4). Remove the front propel- 25–35 Nm (18-26 lbf ft).
ler (3).
7. Install lock nut (1) and torque it to 70-80 Nm (52-60
5. Dry the propellers off. lbf ft).
73
Maintenance: Propellers
8
7
9
6 4 3
2
1
Propellers. DP-drive Installation

NOTE! A tool for installing and removing the propel- 1. Apply some Volvo Penta water resistant grease to
lers (please refer to the illustration) is provided with the propeller hubs.
the drive.
2. Switch the ignition on and put the control lever in
Removal
the starter switch.
the reverse position. Take the starter key out of 3. Slide the thrust washer (9) and the front propeller
the starter switch. (8) on.
2. Remove the lock screw (1) and the washer (2). 4. Install the nut (7) and torque it to 70-80 Nm (52-60
lbf ft).
3. Remove the spinner (3). Remove the plastic wash-
er (4), the rear propeller (5) and the thrust washer 6. Switch the ignition on and put the control lever in
(6). the reverse position. Take the starter key out of
the starter switch.
the forwards position. Take the starter key out of 7. Install the thrust washer (6). Slide the rear propel-
the starter switch. ler (5) and then the plastic washer (4) on.
5. Remove the nut (7). Remove the front propeller (8) 8. Screw the spinner on (3) and tighten it hard.
and the thrust washer (9). 9. Install the washer (2) and the lock screw (1). Tight-
6. Dry the propellers off. ening torque 70–80 Nm (52-60 lbf ft).
74
Laying up/Launching
Before taking the boat out of the water for winter/out-of-season storage have an authorized Volvo Penta workshop
inspect the engine and other equipment. Have any necessary repairs or service work carried out so that your boat
is in top condition for the new season.
Inhibition should be carried out to ensure that the engine and transmission are not damaged while out of commis-
sion during the winter/off-season. It is important this is done properly and than nothing is forgotten. We have
therefore provided a checklist covering the most important points.
WARNING! Read the chapter on Maintenance carefully before starting work. It contains instructions on how
to carry out the most common maintenance and service operations safely and correctly.
Inhibiting
The following are best carried out with the boat in ● Change oil in the drive.
the water:
● Clean the seawater filter.
● Change engine oil and replace oil filter.
● Clean and inhibit the seawater system.
● Change oil in the reverse gear.
● Remove the impeller from the seawater pump.
● Replace fuel filter. Replace fuel pre-filter if in-
Store the impeller in a sealed plastic bag in a cool
stalled.
place.
● Run engine to normal operating temperature. ● Check the condition of the engine coolant anti-
freeze. Top up if required.
● Take the boat out of the water:
IMPORTANT! An anti-corrosion mixture in
the engine coolant system provides no pro-
The following should be carried out with the boat
tection against freezing. If there is any possi-
out of the water:
bility the engine will be subjected to freezing
● Clean the hull and drive directly after taking up the temperatures then the system must be
boat (before it dries). drained.
● Drain any water and contaminants from the fuel

tank. Fill the tank completely with fuel to avoid
condensation.
● Clean the outside of the engine. Do not use a high

pressure spray to clean the engine. Touch up any
damaged areas of paintwork with Volvo Penta orig-
inal paint.
● Check all control cables and treat with rust inhib-

itor.
● Repair any damaged areas of paintwork with

Volvo Penta original paint. NOTE! Read the spe-
cial instructions on painting the drive under the
heading: “Painting the drive and underwater hull”.
● Disconnect battery leads. Clean and charge the

batteries. NOTE! A poorly charged battery may
burst as a result of freezing.
IMPORTANT! Be careful when cleaning with a
high pressure water spray. The spray must not ● Spray electrical system components with moisture
be pointed toward the exhaust and drive union repellent spray.
bellows, the trim cylinder seals, the propeller
● Remove propeller for winter storage. Grease the
shaft seal, hoses etc.
propeller shaft using water repellent grease.
75
Laying up/Launching
Bringing out of storage

● Check oil level in the engine and drive/reverse ● Paint the drive and hull: See next page.
gear. Top up if necessary. If there is inhibiting oil
in the system drain and fill with new oil, change oil ● Check the sacrificial anode on the drive. If there is
filter. For correct oil grade: See the chapter “Tech- less than 2/3 of the anode left it must be replaced.
nical Data”. Clean with emery cloth just before the boat is
launched.
● Drain the antifreeze from the seawater system.
IMPORTANT! Do not use a wire brush or other
● Install the impeller in the seawater pump. Replace steel tools when cleaning, as these may damage
if the old one looks worn. Please refer to the Sea the galvanic protection.
Water System chapter.
● Close/tighten drain cocks/plugs. ● Install propellers.
● Check the tension and condition of the drive belts. ● Launch the boat. Check for leaks.
● Check the condition of rubber hoses and tighten ● Vent and lubricate the propeller shaft seal (reverse
hose clamps. gear).
● Check engine coolant level and antifreeze protec- ● Start the engine. Check that there are no fuel, en-
tion. Top up if necessary. gine coolant or exhaust gas leaks and that all con-
trol functions are operating.
● Connect the fully charged batteries.
76
Laying up/Launching
Painting the drive and underwater

hull
Drive
Before treating the drive with anti-fouling agent any
damaged paintwork must be repaired. Sand down met-
al surfaces lightly using a 120 grade paper and a finer
grade for painted surfaces. Wash off using thinners or
similar. Any pores in the surface should be filled and
sanded down. Paint using Volvo Penta original primer
and topcoat. Let the paint dry. A further two coats of
Volvo Penta anti-fouling primer should then be ap-
plied. Let them dry. A further two coats of Volvo Pen-
ta anti-fouling should then be applied.
IMPORTANT! The sacrificial anodes on the drive

must not be painted or treated with Teflon. This
also applies to stainless or bronze propellers.
Use of anti-fouling agents is not permitted in all coun-

tries. Please make sure that it is permitted where your
boat is to be used. If anti-fouling agents are not per-
mitted we recommend that a pure Teflon®* agent be
applied onto the original paintwork on the drive without
sanding it down first.
*Teflon is the registered trademark of the Du Pont Corp.
Underwater hull
All types of paints with anti-fouling properties are poi-
sonous and cause damage to the marine environment.
Avoid the use of such agents. Most countries have in-
troduced legislation controlling the use of anti-fouling
agents. Always abide by these regulations. In many
cases it is completely forbidden to use them on plea-
sure boats, for example in freshwater. For boats that
are relatively easy to get out of the water we recom-
mend only Teflon treatment combined with mechani-
cal cleaning several times per season.
For larger craft this is not practicable. If the boat is in
an area where the water quickly produces fouling then
anti-fouling paints must probably be used. If this is the
case use a copper-based paint containing copper cya-
nide and not copper oxide.
IMPORTANT! Leave an area of 10 mm around

the drive unpainted.
Tin-based agents (TBT) must not be used. Check the

legislation that applies where the boat is to be
used. Wait for the paint to dry before launching the
boat.
77
Fault-tracing
A number of symptoms and possible causes for engine disturbances are described in the table below. If faults or
hitches arise that you cannot solve alone, you must always get in touch with your Volvo Penta dealer.
WARNING! Read the safety directions for maintenance and service in the chapter “Safety information” before
starting work.
Symptom and possible cause

The diagnostic button indicator flashes See the “Diagnostic function” chapter
Starter motor not turning (or slow) 1, 2, 3, 24
Engine does not start 4, 5, 6, 7, 24
Engine starts but stops again 6, 7, 24
Engine difficult to start 4, 5, 6, 7
Engine does not reach correct speed at wide open throttle (WOT) 5, 6, 7, 8, 9, 10, 11, 15, 18, 19, 20, 21, 24
Engine knocks 4, 5, 6, 7
Engine runs unevenly 4, 5, 6, 7, 10, 11
Engine vibrates 15, 16
High fuel consumption 8, 9, 10, 12, 15
Black exhaust smoke 10
Blue or white exhaust smoke 12, 22
Low oil pressure 13, 14
Engine coolant temperature too high 17, 18, 19, 20, 21
None or poor charging 2, 23
1. Discharged battery 10. Insufficient air supply 19. Circulation pump drive belt slipping
2. Loose connection/open-circuit 11. Engine coolant temperature too high 20. Defective impeller
3. Fuse tripped 12. Engine coolant temperature is too low 21. Defective/incorrect thermostat
4. Lack of fuel 13. Lubricating oil level too low. 22. Lubricating oil level too high
5. Fouled fuel filter. 14. Blocked fuel filter 23. Generator drive belt slipping
6. Air in the fuel injection system 15. Defective/incorrect propeller 24. Stored diagnostic trouble codes
(DTCs)*
7. Water/contaminants in the fuel 16. Defective engine mounting
8. Boat abnormally loaded 17. Too little coolant
9. Fouling on underwater hull/drive/pro- 18. Blocked seawater intake/pipe/filter
peller
*See the “Diagnostic function” chapter for additional information.
78
Fault-tracing
Start using auxiliary batteries
WARNING! Ventilate well. Batteries generate ox-

yhydrogen gas, which is extremely flammable
and explosive. A short circuit, naked flame or
spark can cause a powerful explosion.
Never reverse the polarity of the battery. Risk of

sparks and explosion.
1. Make sure the rated voltage of the auxiliary battery
is the same as the system voltage of the engine.
2. Connect the red auxiliary cable to the discharged

battery’s + terminal and then to the auxiliary bat-
tery’s + terminal.
3. Connect the black jump lead to the auxiliary bat-

tery negative terminal and then to a position
slightly away from the discharged batteries, for ex-
ample at the negative cable’s connection to the
starter motor.
WARNING! The black auxiliary cable (–) must

not come in contact with the positive connec-
tion on the starter motor.
4. Start the engine and run at fast idling speed for

about ten minutes to charge the batteries.
WARNING! Working on or approaching a run-

ning engine is a safety hazard. Beware of ro-
tating parts and hot surfaces.
Do not touch the connections while attempt-

ing to start: Risk of sparks. Do not bend over
the batteries either.
5. Stop the engine. Remove the auxiliary cables in
the exact reverse order to connecting.
79
Fault-tracing
Emergency shifting
If a fault occurs which prevents the drive or reversing
gear from being operated (shifted) with the control le-
ver, it is possible to shift manually, using the descrip-
tion below.
Note. The descriptions refer to electrically shifted
drives and reversing gear.
WARNING! In manual operation, the unit is
locked in forwards operation. The drive or re-
versing gear can not then be put in neutral. For-
ward motion can only be cut off by stopping the
engine with the ignition key or stop button.
Drive
Drives are shifted electronically by means of a gear
1 actuator (3) installed in the engine bay.
1 NOTE! If the drive can not be shifted, this could be
because the fuse (4) for the gear actuator has tripped.
Check the fuse. It is mounted on, or close to the start-
3 2 er motor.
Manual engagement of the drive:
2
1. Stop the engine and remove the ignition key from
the ignition lock.
4 2. Undo the pins (1) and remove the pins (2) which fix
the gear actuator (3) to its bracket.
3. Move the gear actuator forwards or backwards to
the position which gives the desired direction of
travel.
Reversing gear
This description is for manual engagement of the re-
versing gear, for forwards travel.
A
Manual engagement of the reversing gear:
1. Stop the engine and remove the ignition key from
the ignition lock.
B
2. Undo the screw (1) on the side where the cable
2 harness marked A is connected.
3. Remove washer (2) and tighten the screw.
4. Undo cables A and B from the solenoid valves.
1
80
Fault-tracing
Calibrating the control

If a control is replaced, the new control must be cali-
brated.
During calibration, a number of predetermined control
lever positions for the EDC system are defined.
Preparations
Before the control is calibrated the EDC system must
be put into calibration mode as follows:
1. Move the control lever(s) to the neutral/idle posi-
tion.
2. Turn the start key to the S position (stop) and re-
lease it so that it springs back to 0.
3. Press in the neutral button. Hold it depressed until
point 5 inclusive.
4. Turn the ignition key to position I (drive position).
The indicator on the diagnostic button lights.
5. Release the neutral button when the indicator on
the diagnostic button goes out.
6. The indicators for the neutral and diagnostic lamps
will flash confirming that the EDC system is in cali-
bration mode.
7. Repeat the procedure for the other engine if the
boat has two engines.
NOTE! The system will not enter the calibration mode
if diagnostic trouble codes (DTCs) are stored (except
for DTC 1.6 and 1.7). Remedy any malfunctions be-
fore calibration.
81
Fault-tracing
Calibration. Electronic single lever

control
NOTE! When calibrating the control for two engines,
both the control levers must be calibrated at the same
time so that the lever positions are the same for both
engines.
1. Put the EDC system in calibration mode according

to the instructions in “Preparations”.
2. Move the control lever to the position where For-
ward movement throttle opening is to start (1).
Release the lever and confirm the position by
pressing the neutral button for at least three sec-
onds.
3. Move the lever to the position for full speed ahead
(2).
onds.
4. Move the lever to the position where reverse throt-
tle opening is to begin (3).
onds.
5. Move the lever to the position for full speed re-
verse (4).
onds.
6. Return the lever to the neutral position. Release
the lever.
7. Confirm and exit the calibration by pressing the
neutral button twice for at least three seconds.
The indicator in the neutral and diagnostic buttons
stops flashing to confirm that the calibration is
complete.
82
Fault-tracing
Calibration. Mechanical single lever

control
engines.
Some controls from third party manufacturers have a
greater throw (A) at wide open throttle (WOT) with re-
verse gear disengaged than at WOT with the reverse
gear engaged. Measure the movement (throw) at the
potentiometer bracket (A) at wide open throttle (WOT)
and with the reverse gear engaged. Note the value.

2. Disengage the shift function and move the lever
forward to the position for wide open throttle (WOT)
(1). Release the lever.
Control from third party manufacturers: Check
that the cable movement does not exceed the val-
ue obtained earlier.
3. Acknowledge the position by pressing the neutral
button for at least three seconds.
4. Move the lever to the neutral position (2). Release
the lever and confirm the position by pressing the
neutral button for at least 3 seconds.
5. Move the control lever to the position where For-
ward movement throttle opening is to start (3). Re-
lease the lever and confirm the position by press-
ing the neutral button for at least three seconds.
6. Move the lever to the position where reverse throt-
tle opening is to begin (4). Release the lever and
confirm the position by pressing the neutral button
for at least three seconds.
7. Return the lever to the neutral position. Release
the lever.
complete.
Calibration. Electronic/Mechanical dual

lever control
83
Fault-tracing

engines.

2. Move the shift lever to the neutral position (N).
3. Move the lever to the position for wide open throt-
tle (WOT) (1). Release the lever.
Acknowledge the position by pressing the neutral
4. Move the lever to the idling position (2). Release
the lever and confirm the position by pressing the
neutral button for at least three seconds.
5. Move the gear operation lever to the position at
which the reverse gear is engaged for Ahead (for-
ward) movement (3). Release the lever.
6. Move the gear operation lever to the position at
which the reverse gear is engaged for Astern (rear-
ward) movement (4). Release the lever.
7. Move the levers to the neutral and idling positions.
Release the levers.
complete.
84
Diagnostic function
Diagnostic function
The diagnostic function monitors and checks that the
EDC system is functioning correctly (including the
boost pressure and engine coolant temperature
(ECT)).
The diagnostic function has the following tasks:

● To detect and locate malfunctions
● To inform that malfunctions have been detected
● To assist in fault-tracing
● To protect the engine and ensure suitability for
manoeuvring when serious malfunctions have
been detected
Malfunction alerts
The indicator for the diagnostic button starts to flash if
the diagnostic function registers malfunction in the
EDC system.
Note! High engine coolant temperature (ECT) is only
indicated via the warning lamp and the acoustic
alarm.
Assistance when fault-tracing

A diagnostic trouble code (DTC) is flashed out if the
diagnostic button is pressed and then released. This
code can be found in the list of DTCs with information
about cause, consequences and corrective action.
The diagnostic function affects the engine as

follows when:
1. The diagnostic function has detected a minor fault
which will not damage the engine:
Consequence: The engine is unaffected
2. The diagnostic function has detected a serious
fault that will not result in immediate damage to
the engine (high engine coolant temperature (ECT)
for example):
Consequence: Engine power is reduced until the
relevant value normalises.
fault that will cause engine break down:
Consequence: Engine stops
fault that will prevent engine operation:
Consequence: The gear is disengaged and the
engine speed (RPM) is set to 1000 rpm.
Emergency shifting is still possible: See the
“Fault-tracing” chapter.
85
Diagnostic function
If the diagnostic button indicator

flashes
1. Reduce the engine speed to idle.
2. Press the diagnostic button to acknowledge the
message.
3. Release the diagnostic button and make a not of
the diagnostic trouble code (DTC) that is flashed
out. See the following section.
3. Look up the diagnostic trouble code (DTC) in the
list and take the recommended action.
Alternatively: If the gear control, warning display
and other instrumentation is functioning normally,
the operator can continue the journey and remedy
the malfunction at a later time.
Reading off diagnostic trouble

codes (DTCs)
A diagnostic trouble code (DTC) is flashed out if the
diagnostic button is pressed and then released.
The diagnostic trouble code (DTC) consists of two
groups of flashes with a break of two seconds in-be-
tween. A diagnostic trouble code (DTC) is obtained by
counting the number of flashes in each group:
Example: break = Diagnostic
trouble code (DTC) 2.4
The diagnostic trouble code (DTC) is stored and can
be read off as long as the malfunction remains.
In the next page there is a list of diagnostic trouble
codes (DTCs) with information about cause, conse-
quence and corrective action.
Read off as follows:

1. Check that the ignition key is in position I (driving
position).
2. Press the diagnostic button.
3. Release the diagnostic button and make a not of
the diagnostic trouble code (DTC) that is flashed
out.
4. Repeat points 2-3. A new diagnostic trouble code
(DTC) flashes if there are several DTCs stored.
Repeat until the first diagnostic trouble code (DTC)
reappears.
NOTE! All diagnostic trouble codes (DTCs) have
been read out when the first DTC reappears.
86
Diagnostic function
Erasing diagnostic trouble codes

(DTCs)
The DTC memory for the diagnostic function is reset
each time the power to the engine is interrupted.
NOTE! The power must be shut-off completely. Stop
the engine and check that the start key(s) are in posi-
tion 0 at all control positions.
When the power is switched back on, the diagnostic
function checks whether there are any malfunctions in
the EDC system. New diagnostic trouble codes
(DTCs) are stored if there are malfunctions.
This means that:

1. Diagnostic trouble codes (DTCs) for malfunctions
that have been remedied or are no longer present
are erased automatically.
2. Diagnostic trouble codes (DTCs) for malfunctions
that have not been remedied must be acknowl-
edged and read off each time the power is
switched on.
If the diagnostics button is pressed after diagnostic
trouble codes (DTCs) have been erased, code 1.1 (“no
fault”) will be flashed out.
87
Diagnostic function
Diagnostic trouble codes (DTCs)

WARNING! Read the safety precautions for maintenance and service in the chapter “Safety Information”
Code 1.1 No fault Code 1.6 Calibration

There are no diagnostic trouble codes (DTCs) stored and Cause: The control on the main control position (usually
no malfunctions have been registered. the control position in the saloon) is not calibrated.
Consequence: The starter motor does not activate.
Code 1.2 Calibration Corrective action:
Cause: The neutral position is incorrect in relation to the • Calibrate the control (see the “Fault-tracing” chapter).
potentiometer value.
Consequence: The calibration is not approved. Code 1.7 Calibration
Corrective action: Cause: The control on another control position is not cali-
• Erase the diagnostic trouble code (DTC). brated.
• Recalibrate the control (see the “Fault-tracing” chapter). Consequence: The starter motor does not activate.
• Check the installation of the control and the potentiome-
ter if the fault persists. Corrective action:
• Calibrate the control (see the “Fault-tracing” chapter).
Code 1.3 Calibration

Code 2.2 Fuel injection pump
Cause: The angle between the initial throttle opening and
wide open throttle (WOT) is too small. Cause: The sensor for the control rod position gives read-
ings outside the permitted range.
Consequence: The calibration is not approved.
Consequence: The engine stops.
Corrective action:
• Erase the diagnostic trouble code (DTC). Corrective action:
• Recalibrate the control (see the “Fault-tracing” chapter). • Check the connections for the injection pump (the actua-
• Check the installation of the control and the potentiome- tor) and the control module.
ter if the fault persists. • Erase the diagnostic trouble code (DTC).
• Start the engine.
• Contact an authorised workshop if the fault persists.
Code 1.4 Calibration
Cause: The neutral position is too small.
Code 2.3 Fuel injection pump
Consequence: The calibration is not approved.
Cause: The actuator is drawing excessive, too little or no
Corrective action: current.
• Erase the diagnostic trouble code (DTC). Consequence: The engine stops.
• Recalibrate the control (see the “Fault-tracing” chapter).
• Check the installation of the control and the potentiome- Corrective action:
ter if the fault persists. • Check the connections for the injection pump (the actua-
tor) and the control module.
• Erase the diagnostic trouble code (DTC).
Code 1.5 Calibration • Start the engine.
Cause: The control module is unable to identify the con- • Contact an authorised workshop if the fault persists.
trol system.
Consequence: The control cannot be calibrated.
Corrective action:
• Check the fuses, connections and wiring for the main
relay, control relay and reverse gear/actuator (drive).
• Recalibrate the control (see the “Fault-tracing” chapter).
88
Diagnostic function
Code 2.4 Engine speed (RPM) sensor Code 2.7 Potentiometer

Cause: The engine speed (RPM) sensor transmits no Cause: The control module receives no information from
signal to the control module at start. the potentiometer in the control (applies to the potentiom-
eter for the engine speed lever in dual lever controls).
Consequence: The engine does not start/The starter mo-
tor is not activated. Consequence: The gear is disengaged and the engine
speed (RPM) is set to 1000 rpm.
Corrective action:
• Check the connections for the engine speed (RPM) sen- NOTE! The fault applies to the relevant control position
sor, the starter relay and the control module. (the boat can be driven from another control position if
there are multiple control positions).
• Start the engine. Corrective action:
• Contact an authorised workshop if the fault persists. • Check the wiring and connections leading to the control.
Code 2.5 Engine speed (RPM) sensor
• Emergency shifting is possible if the fault remains: See
Cause: The engine speed (RPM) sensor transmits abnor- the “Fault-tracing” chapter.
mal values to the control module during operation.
Consequence: The engine stops. Code 3.1 Potentiometer
Corrective action: Cause: The control module receives no information from
• Check the connections for the injection pump (the actua- the potentiometer for the gear selector lever (dual lever
tor) and the control module. control only).
Consequence: The gear is disengaged and the engine
• Start the engine. speed (RPM) is set to 1000 rpm.
NOTE! The fault applies to the relevant control position
(the boat can be driven from another control position if
Code 2.6 Potentiometer there are multiple control positions).
Cause: Short-circuit or open-circuit in the power supply to Corrective action:

the potentiometer in the control. • Check the wiring and connections for the potentiometer
and the wiring and connections leading to the control
Consequence: The gear is disengaged and the engine
position.
speed (RPM) is set to 1000 rpm.
NOTE! The fault applies to the relevant control position • Start the engine.
(the boat can be driven from another control position if
there are multiple control positions).
the “Fault-tracing” chapter.
Corrective action:
• Check the wiring and connections leading to the control.
Code 3.3 Temperature sensor
• Start the engine. Cause: The control module receives no signal from the
• Emergency shifting is possible if the fault remains: See engine coolant temperature (ECT) signal.
the “Fault-tracing” chapter. Consequence: The engine is difficult to start, there is ex-
cessive smoke when the engine is cold.
Corrective action:
• Check the sensor and the connections and wiring for the
sensor and control module.
• Contact an authorised workshop if the fault persists
89
Diagnostic function
Code 3.4 Gearshift control actuator Code 5.4 Forward gear

Cause: The control module receives no position signal Cause: Short-circuit or open-circuit in the wiring for re-
from the gearshift control actuator (drive) or the signal is verse gear/gearshift control actuator (drive) for the forward
outside the permitted range. gear.
Consequence: Shifting is not possible. Consequence: Shifting is not possible.
WARNING! Forward motion can only be stopped by • Reverse gear: The gear is disengaged (if possible).
switching of the engine with the start key or the stop but- • Drive: The engine is stopped in the gear selected when
ton. the fault occurred.
Corrective action: NOTE! The engine can be started as soon as the diag-
• Check the connections and wiring for the actuator and nostic trouble code (DTC) is flashed out.
contra module. WARNING! If the engine is started with a gear en-
• Erase the diagnostic trouble code (DTC). gaged, forward motion can only be interrupted by
• Start the engine. switching off the engine with the start key or the stop
button.
the “Fault-tracing” chapter. Corrective action:
• Check the wiring and the connections for the reverse
gear/actuator.
Code 4.5 Alpha solenoid
Cause: Faulty signal from the control module for the Al- • Start the engine.
pha Solenoid in the fuel injection pump. • Emergency shifting is possible if the fault remains: See
Consequence: Engine power is reduced. the “Fault-tracing” chapter.
Corrective action:
• Check the injection pump and the control module con- Code 5.5 Reverse gear
nections. Cause: Short-circuit or open-circuit in the wiring for re-
• Erase the diagnostic trouble code (DTC). verse gear/gearshift control actuator (drive) for the reverse
• Start the engine. gear.
Consequence: Shifting is not possible.
• Reverse gear: The gear is disengaged (if possible).
Code 4.6 Starter relay • Drive: The engine is stopped in the gear selected when
Cause: Short-circuit or open-circuit in the control voltage the fault occurred.
for the starter relay. NOTE! The engine can be started as soon as the diag-
nostic trouble code (DTC) is flashed out.
Consequence: The engine cannot be started.
WARNING! If the engine is started with a gear en-
Corrective action: gaged, forward motion can only be interrupted by
• Check the fuses, connections and wiring for the starter switching off the engine with the start key or the stop
relay and control module. button.
• Erase the diagnostic trouble code (DTC). Corrective action:
• Start the engine. • Check the wiring and the connections for the reverse
• Contact an authorised workshop if the fault persists. gear/actuator.
Code 5.1 Main relay • Start the engine.
Cause: Short-circuit or open circuit in the wiring for the the “Fault-tracing” chapter.
main relay.
Consequence: The engine cannot be started or stopped.
Corrective action:
• Check the main relay and fuses, wiring and connections
for the main relay and the control module.
90
Diagnostic function
Code 5.6 Boost pressure Code 8.3 Calibration

Cause: High boost pressure. Cause: The calibration values cannot be stored by the
control module.
Consequence: The engine power is reduced until normal
values are obtained. Consequence: The control must be calibrated before
each start.
Corrective action:
• Check the air filter and the delivery pipe between the Corrective action:
intake manifold and the control module. • Erase the diagnostic trouble code (DTC).
• Erase the diagnostic trouble code (DTC). • Recalibrate the control.
• Start the engine. • Contact an authorised workshop if the fault persists.
Code 9.1 MS unit
Code 6.4 MS unit
Cause: The MS unit receives no signal from the control
Cause: Incorrect signals from the control potentiometer or unit.
the control panel on an alternative control position (or a
Consequence: The boat cannot be operated from alterna-
fault in the MS unit).
tive control positions.
Consequence: The boat cannot be operated from alterna-
Corrective action:
tive contra positions.
• Check the wiring and connections for the control module
Corrective action: and the wiring and connections leading to alternative
• Check the wiring and connections for the control, control control positions.
panel and the wiring and connections leading to alterna- • Erase the diagnostic trouble code (DTC).
tive control positions. • Start the engine.
• Erase the diagnostic trouble code (DTC). • Drive from an alternative control position if the fault per-
• Start the engine. sists.
• Drive from an alternative control position if the fault per-
sists.
Code 9.9 Program memory
Cause: Fault when the ignition is switched on or a fault in
Code 7.2 Needle lift sensor
the program memory.
Cause: Values outside the permitted range from the nee-
Consequence: The engine cannot be started.
dle lift sensor in the injector for cylinder 1.
Corrective action:
Consequence: Engine power is reduced.
• Turn off power completely and wait three minutes before
Corrective action: reconnecting.
• Check the connections and wiring for the injector for • Check the wiring and the connections for the power
cylinder 1 and the control module. supply (battery, starter motor, ignition switch, actuator
• Erase the diagnostic trouble code (DTC). etc.).
• Start the engine. • Erase the diagnostic trouble code (DTC).
• Contact an authorised workshop if the fault persists. • Start the engine.
Code 8.1 Control module
Cause: Fault in the control module
Consequence: The engine stops, cannot be started, the
control position cannot be activated.
Corrective action:
91
Technical Data
Engine
General information
Engine designation KAD44P-C, KAD44 Professional, KAMD44P-C,
KAD300-A, KAMD300-A
Idling speed. ................................................. 590-610 rpm.
Swept volume ............................................... 3.59 liter (3.8 US quart)
Injection sequence ........................................ 1-5-3-6-2-4
Direction of rotation (seen from front) ............ Clockwise
Max. forwards inclination ............................... 4°
Max. rearwards inclination in operation .......... 15°
Max. sideways inclination in operation .......... 20°
Valve clearance, inlet/exhaust, cold engine .. 0.40 mm (0.016”)
Oil pressure, hot engine ................................
Idling ........................................................... 1.5 kg/cm² (21 psi)
Full speed ................................................... 4.2–5.0 kg/cm² (60-72 psi)
Lubrication system
Oil volume, (incl. oil filter) ............................. 11.0 liter (11.6 US quart)
at 15° rearwards inclination (incl. oil filter) .. 11.5 liter (12.2 US quart)
Oil volume, oil filter ....................................... 0.5 liter (0.6 US quart)
Sulfur content in fuel, by weight
< 0,5 – 1,0 % > 1,0 %3)
Oilgrade1) Oil change interval, reached first in operation
All engines: 200 h / 12 months 100 h / 12 months

VDS-2 and ACEA E7 2)
or VDS-2 and Global DHD-1
or VDS-2 and API CH-4
or VDS-2 and API CI-4
1)
When oil quality specifications are joined by “or” (Type 1, 2 and 3), either engine oil specification can be
used.
When oil quality specifications are joined by “and” (Type 2 and 3), the engine oil must fulfill both require-
ments.
2)
ACEA E7 has replaced ACEA E5, but if available ACEA E5 can be used.
3)
If sulphur content is > 1.0% by weight, use oil with TBN > 15.
NOTE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the
quality requirements.
VDS = Volvo Drain Specification
ACEA = Association des Constructeurs Européenne d’Automobiles
API = American Petroleum Institute
TBN = Total Base Number
Global DHD = Global Diesel Heavy Duty
−30 −20 −10 ±0 +10 20 30 40

C
o
Viscosity
−15oC SAE 15W/40 Select the viscosity from the table below.
o
−25 C SAE 10W/30 Note. The temperature values refer to stable ambient
temperatures.
✱ SAE 5W/30
* Refers to synthetic or semi-synthetic oils.
−10oC SAE 20W/30
±0oC SAE 30
Oil change volume
+10oC SAE 40
Please refer to the “Technical Data” chapter.
−22 −4 +14 32 50 68 86 104
o
F
92
Technical Data
Supercharger
Oil volume .................................................... 0.1 liter (0.2 US pint)
Oil grade ....................................................... Volvo Penta, part no. 1141641-9
Cooling system
Thermostats open/fully open ......................... 81°C/94°C
Fresh water system volume, app .................. 19 liter (20 US quart)
Electrical system
System voltage ............................................. 12V
Starter motor battery, capacity ...................... 88–140Ah
Alternator, rated power, max ......................... 14V/60A
Starter motor, rated power ............................. 3.0 kW
Drive
DP-E
Oil volume .................................................... 2.7 liter (2.9 US quart)
Oil volume between min. and max. markings 0.15 liter (0.32 US pint)
Oil grade and viscosity: ................................ VP 1141634-4 (API GL5 SAE75W/90) Synthetic
Tightening torque, steering cap bolt .............. 3.5 kpm (35 Nm) (26 lbf ft)
DP-G
Tightening torque, steering cap bolt .............. 3.5 kpm (35 Nm) (26 lbf ft)
DPX-A
Reversing gear
HS63AE
Oil grade ....................................................... ATF (Dexron II)
HS63VE
Fuel specification
The fuel must comply with national and international standards for commercially supplied fuels, such as:
EN 590 (with nationally adapted environmental 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%.
93
Power Trim
Oil grade ....................................................... ATF (Dexron II, III)
Steering
Power steering (DP)
VP hydraulic steering (optional DP/HS63)

Oil grade ....................................................... Volvo Penta part no. 1141640-1 , Shell Aero 4, Texaco HO15
Esso Univis N15, Chevron Aviation Fluid A, Mobil Aero HFA
VP Xact hydraulic steering (DPX)
Oil grade ....................................................... ATF, type G
94
Notes
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95
Notes
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96
✂
Yes please,
I would like an operator’s manual in English at no charge.
Post or fax this coupon to: Publication number: 7742203-8
42200/615001/155099900192
Document & Distribution Center Name
Order Department
ARU2, Dept. 64620
SE-405 08 Göteborg Address
Sweden
Fax: +46 31 545 772
Orders can also be placed via
the Internet:
http://www.volvopenta.com/
manual/coupon Country
NB! This offer is valid for a period of 12 months from delivery of the boat.
Availability after this period will be as far as supplies admit.
✂
Ja,
ich will kostenlos eine Betriebsanleitung in deutscher Sprache erhalten.
Schicken Sie den Coupon Publikationsnummer: 7742204-6
42200/615001/155099900192
per Post oder als Fax an: Name
Document & Distribution Center
Order Department
ARU2, Dept. 64620 Anschrift
SE-405 08 Göteborg
Schweden
Fax: +46 31 545 772
Die Bestellung kann auch über
das Internet erfolgen:
http://www.volvopenta.com/ Land
manual/coupon
Bitte beachten Sie, dass dieses Angebot für die Dauer von 12 Monaten ab dem
Lieferdatum des Bootes gilt, danach bis zum Aufbrauchen des Lagerbestandes.
✂
Oui merci,
Je souhaite recevoir un manuel d’instructions gratuit en français.
Envoyez ou faxez le bon de Numéro de publication: 7742205-3
42200/615001/155099900192
commande à: Nom
Order Department
ARU2, Dept. 64620 Adresse
SE-405 08 Göteborg
Suède
Fax: +46 31 545 772
Vous pouvez également passer
la commande par Internet:
http://www.volvopenta.com/ Pays
manual/coupon
Notez que l’offre est valable pendant 12 mois à partir de la date de livrai-
son du bateau, ensuite seulement en fonction des stocks disponibles.
97
✂
Sí gracias,
deseo recibir gratuitamente un libro de instrucciones en español.
Franquear o enviar fax a: Número de publicación: 7742206-1
42200/615001/155099900192
Document & Distribution Center Nombre
Order Department
ARU2, Dept. 64620
SE-405 08 Göteborg Dirección
Suecia
Fax: +46 31 545 772
El pedido puede hacerse tam-
bién por internet:
manual/coupon País
Nótese que el ofrecimiento vale durante 12 meses después de la fecha de entrega

de la embarcación, y posteriormente solamente mientras duren las existencias.
✂
Sì, grazie,
desidero ricevere gratuitamente un manuale d’istruzioni in lingua italiana.
Spedire il tagliando per posta o Public. No.: 7742207-9
42200/615001/155099900192
per fax a: Nome e Cognome
Order Department
ARU2, Dept. 64620 Indirizzo
SE-405 08 Göteborg
Svezia
Fax: +46 31 545 772
L’ordinazione può essere fatta
anche su Internet:
http://www.volvopenta.com/ Paese
manual/coupon
Si ricorda che l’offerta è valida per 12 mesi dalla data di consegna dell’imbarcazio-
ne; dopo il suddetto periodo l’offerta resta valida solo in base alla disposizione della
pubblicazione in oggetto.
✂
Ja tack,
jag vill kostnadsfritt ha en instruktionsbok på svenska.
Posta eller faxa kupongen till: Publikationsnummer: 7742199-8
42200/615001/155099900192
Dokument & Distribution center Namn

Ordermottagningen
ARU2, Avd. 64620
SE-405 08 Göteborg Adress
Sverige
Fax: +46 31 545 772
Beställningen kan även göras
via internet:
manual/coupon Land
Observera att erbjudandet gäller i 12 månader från båtens leveransdatum,

därefter endast i mån av tillgång.
98
✂
Ja graag,
Ik wil kosteloos een instructieboek in het Nederlands ontvangen.
Stuur of fax de coupon naar: Publicatienummer: 7742213-7
42200/615001/155099900192
Document & Distribution Center Naam
Order Department
ARU2, Dept. 64620
SE-405 08 Göteborg Adres
Zweden
Fax: +46 31 545 772
U kunt ook bestellen via
internet:
manual/coupon Land
Denk eraan dat het aanbod geldt gedurende 12 maanden na de datum

waarop de boot werd afgeleverd, daarna alleen indien nog verkrijgbaar.
✂
Ja tak,
jeg vil gerne gratis have en instruktionsbog på dansk
Send kuponen med post eller Publikationsnummer: 7742208-7
42200/615001/155099900192
fax til: Navn
Order Department
ARU2, Dept. 64620 Adresse
SE-405 08 Göteborg
Sverige
Fax: +46 31 545 772
Bestillingen kan også ske på
internet:
http://www.volvopenta.com/ Land
manual/coupon
Bemærk at tilbudet gælder i 12 måneder fra bådens leveringsdato, Deref-

ter kun så længe lager haves.
✂
Kyllä kiitos,
haluan suomenkielisen ohjekirjan veloituksetta.
Postita tai faksaa kuponki Julkaisunumero: 7742209-5
42200/615001/155099900192
osoitteella: Nimi
Order Department
ARU2, Dept. 64620 Osoite
SE-405 08 Göteborg
Ruotsi
Fax: +46 31 545 772
Tilauksen voi tehdä myös
Internetissä:
http://www.volvopenta.com/ Maa
manual/coupon
Huomaa, että tarjous on voimassa 12 kuukautta veneen toimituspäivä-

määrästä lukien ja sen jälkeen vain niin kauan kuin kirjoja riittää.
99
✂
Sim, obrigado(a)!
Gostaria de receber gratuitamente um manual de instruções em português.
Envie o talão pelo correio ou Número de publicação: 7742214-5
42200/615001/155099900192
um fax para: Nome
Order Department
ARU2, Dept. 64620 Endereço
SE-405 08 Göteborg
Sweden
Fax: +46 31 545 772
A encomenda também pode
ser feita através da Internet:
http://www.volvopenta.com/ País
manual/coupon
Observar que esta oferta é válida durante um período de 12 meses a contar da

data de entrega do barco. Após este período, a oferta está dependente do número
de exemplares disponíveis.
✂
Íáé,
Èá Þèåëá Ýíá áíôßôõðï ôïõ åã÷åéñéäßïõ ÷ñÞóçò óôçí áããëéêÞ ãëþóóá ÷ùñßò êáìéÜ ÷ñÝùóç.
Ôá÷õäñïìÞóôå áõôü ôï êïõðüíé Áñéèìüò Ýêäïóçò: 7742215-2
42200/615001/155099900192
óôçí ðáñáêÜôù äéåýèõíóç Þ ¼íïìá
óôåßëôå ôï ìå öáî óôïí
ðáñáêÜôù áñéèìü öáî:
Document & Distribution Center Äéåýèõíóç
Order Department
ARU2, Dept. 64620
SE-405 08 Göteborg
Sweden
Fax: +46 31 545 772
Ìðïñåßôå åðßóçò íá äþóåôå ôçí ×þñá
ðáñáããåëßá óáò ìÝóù ôïõ Inter-
net, óôç äéåýèõíóç:
http://www.volvopenta.com/manual/ ÐÑÏÓÏ×Ç: ÁõôÞ ç ðñïóöïñÜ éó÷ýåé ãéá ÷ñïíéêÞ ðåñßïäï 12 ìçíþí áðü ôçí
coupon ðáñÜäïóç ôïõ óêÜöïõò. ÌåôÜ ôï ðÝñáò ôçò åí ëüãù ÷ñïíéêÞò ðåñéüäïõ ç
äéáèåóéìüôçôá ôùí áíôéôýðùí èá åîáñôÜôáé áðü ôçí ðïóüôçôá ôùí áðïèåìÜôùí.
100
7742203 English 03-2006

Manual Volvo Penta Kad 44 ECD

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com - Simplified Manuals

VOLVO PENTA KAD/KAMD44P OPERATOR'S

Ce manuel d’instructions peut être Denne instruktionsbog kan bestilles på

Questo manuale d’istruzioni può esse- Áõôü ôï åã÷åéñßäéï ÷ñÞóçò

IMPORTANT! These instructions do not contain descriptions of controls or

Safety Information ............................................. 3–7 Maintenance schedule .................................... 39–42

Starting the engine .......................................... 27–29 Diagnostic function .......................................... 85-91

Stopping the engine ...................................... 37–38

© 2002 AB VOLVO PENTA

Safety precautions to be taken when operating the boat

Your new boat Refueling

Ensure that your boat is maintained in accordance

Carbon monoxide poisoning

Safety precautions for maintenance and service operations

Preparations Never start a turbocharged engine without installing

Before starting the engine

Hot surfaces and fluids Fuel system

Care of the environment Fuel and oils

Location of information decal and identification plates:

Engine/Drive/Reverse gear (information decal)

Drive/Shield (identification plate) Reverse gear

Lubrication system Cooling system

* KAD (engine with drive)

The processor Diagnostic function

For the location of other electrical components: See the chapter

4 6 7 6. Press button for testing and acknowledging

2 3 2 3 2. Press button for instrument illumination.

IMPORTANT! Read the starting instructions in

Control panel EDC (type I)

1. Activation button 3. Diagnostics button

Control panel EDC (type II)

1. Activation button (red) 3. Diagnostic button (yellow)

Single lever control. Electronic

Disengaging the shift function

WARNING! Take care not to engage the reverse gear/

Button 1: Press button to raise the bow of the boat (drive

Button 2: Press button to lower the bow of the boat (drive

2 Button 3: Press the button* while simultaneously pressing

Trim instrument. General

WARNING! The maximum permitted engine speed in

WARNING! The engine must not be run with the drive

Digital trim instrument (DP)

A A. Shows the current trim range (TRIM: trim range,

3 Analogue trim instrument (DP)

Trim instrument (DPX)

IMPORTANT! There is no automatic lockout between

Twin and triple installations

WARNING! When lifting drives within the Beach range

● Open the seawater cock (reverse gear)

● Switch on the main switch

● Start the engine compartment fan if one is installed and

● Lower the drive(s) if raised.

General about starting

2. Switch on the power

3. Check the warning lamps and alarm

4. Activate the control position

5. Start the engine

Start using the start button

6. Check the instruments and run the engine