Volvo Penta TAMD63L Operator's Manual

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. This operator’s manual is also available in the following languages: Diese Betriebsanleitung ist auch auf Deutsch erhältlich. Ein Bestellcoupon ist am Ende der Betriebs- anleitung zu finden. Ce manuel d’instructions peut être commandé en français. Vous trouverez un bon de commande à la fin du manuel d’instructions. Este libro de instrucciones puede soli- citarse en español. El cupón de pedido se encuentra al final del libro. Den här instruktionsboken kan bestäl- las på svenska. Beställningskupong finns i slutet av instrukti- onsboken. Questo manuale d’istruzioni può esse- re ordinato in lingua italiana. Il tagliando per l’ordinazione è riportato alla fine del manuale. Dit instructieboek kan worden besteld in het Nederlands. De bestelcoupon vindt u achter in het instruc- tieboek. Denne instruktionsbog kan bestilles på dansk. Bestillingskupon findes i slutningen af instruk- tionsbogen. Tämän ohjekirjan voi tilata myös suo- menkielisenä. Tilauskuponki on ohjekirjan lopussa. Este manual de instruções pode ser encomendado em português. O talão de requerimento encontra-se no fim do manual. Áõôü ôï åã÷åéñßäéï ÷ñÞóçò äéáôßèåôáé óôçí áããëéêÞ ãëþóóá. Ãéá íá ðáñáããåßëåôå Ýíá áíôßôõðï, óõìðëçñþóôå ôç öüñìá ðïõ âñßóêåôáé óôï ôÝëïò áõôïý ôïõ åã÷åéñéäßïõ ÷ñÞóçò.

possible operating conditions for professional as well as leisure purposes. That’s not surprising. 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 innovation, top of the range performance and long service life. We also be- lieve 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.

3 Boat trips ............................................................ 4 Maintenance and service.................................... 6 Introduction ........................................................ 8 Environmental responsibility ............................... 8 Running in .......................................................... 8 Fuel and oil ......................................................... 8 Service and spare parts...................................... 8 Certified engines................................................. 9 Warranty............................................................. 9 Identification number .......................................... 11 Presentation........................................................ 11 Instruments......................................................... 13 Instrument panels ............................................... 13 Control panels .................................................... 14 Warning displays ................................................ 14 Starting switch .................................................... 15 Controls............................................................... 16 Single lever control ............................................. 16 Dual lever control................................................ 17 Starting the engine ............................................. 18 Measures before start......................................... 18 Starting procedure .............................................. 18 Operation ............................................................ 20 Check the instruments ........................................ 20 Alarms and fault indication.................................. 20 Cruising speed ................................................... 21 Manoeuvring....................................................... 21 Accessories ........................................................ 23 Stopping the engine ........................................... 24 Before stopping .................................................. 24 Stop .................................................................... 24 Emergency stop ................................................. 24 After stopping ..................................................... 25 Anti-freezing measures....................................... 25 Breaks in operation............................................. 25 Maintenance schedule ....................................... 26 Maintenance........................................................ 29 Engine, general .................................................. 29 Lubricating system.............................................. 32 Freshwater system ............................................. 35 Seawater system ................................................ 43 Fuel system ........................................................ 47 Electrical system ................................................ 52 Electrical component diagrams........................... 56 Reverse gear ...................................................... 58 Inhibiting ............................................................. 60 Troubleshooting ................................................. 62 Start using auxiliary batteries.............................. 63 Technical Data .................................................... 64 Engine ................................................................ 64 Reverse gear ...................................................... 65 © 2001 AB VOLVO PENTA We reserve the right to make revisions. Printed on environment-friendly paper (Cover: National Administration of Shipping and Navigation, permit 9809095)

in this manual and on the product. It also includes a summary of basic safety regulations for boat trips and main- tenance of the engine. Make sure you are in possession of the right operator’s manual before reading on. If this is not the case, please get in touch with your Volvo Penta dealer. Incorrect handling can cause personal injury or damage to the product and/or property. Consequently, please read this operator’s manual thoroughly before starting the engine or carrying out maintenance and service. If anything is still not clear or if you are not sure of any points, please get in touch with your Volvo Penta dealer for assistance. This symbol is used throughout the operator’s manual and on the product to bring your atten- tion to points of safety-related information. Always read such information thoroughly. Warnings in the operator’s manual have the following order of priority: WARNING! Warns for the risk of physical injury, severe damage to the product or other property or serious malfunctions that may occur if the instructions are not followed. IMPORTANT! Used to call your attention to points that may cause malfunctions or damage to the product or other property. NOTE! Used to call your attention to important information that can facilitate working meth- ods or handling. This symbol is used in certain cases on our products to refer to important information found in the operator’s manual. Make sure all warning and information symbols on the engine and transmission are easily visible and legible. Replace symbols that have been damaged or painted over.

The new boat Read operator’s manuals and other information ac- companying the new boat thoroughly. Accustom yourself with handling the engine, controls and other equipment in a safe and correct manner. If this is your first boat or if it is a type you are not used to, we recommend practising manoeuvring the boat in a peaceful environment. Learn the sea-going and manoeuvring characteristics at different speeds and in varying weather and load conditions before casting off on your “real” maiden voyage. Remember that when operating a boat, you have a legal responsibility to be aware of and follow regula- tions concerning traffic and safety at sea. Inform yourself of the regulations that apply to you and your waters by getting in touch with the relevant authorities or marine safety organisation. Attending some kind of boat handling course is a good idea. We recommend getting in touch with a re- gional boat or marine safety organisation to help you locate a suitable course. Accidents and other incidents Sea rescue statistics show that deficient maintenance of boats and engines together with defective safety equipment often causes accidents and other incidents at sea. Make sure your boat and engine are maintained in accordance with directions in the operator’s manuals and that the safety equipment on board is in good working order. Daily inspection Make a habit of visually inspecting the engine and en- gine room before starting (before starting the en- gine) and after stopping (when the engine has been turned off). This will help you to quickly detect any fuel, coolant or oil leaks and any other abnormalities that have occurred or are about to occur. Manoeuvring Avoid violent and rapid rudder movement and gear shifting. There is a risk of the passengers falling down or falling overboard. A rotating propeller can cause serious injury. Make sure there is nobody in the water before engaging for- ward/reverse. Never run close to bathers or in places where you have reason to believe there are people in the water. Filling fuel There is a risk of fire and explosion when filling fuel. Smoking is prohibited and the engine must be turned off. Never overfill the tank. Close the filler cap securely. Use only fuel recommended in the operator’s manual. The incorrect grade of fuel can disturb operation or cause breakdown. This can also lead to the control rod jamming on diesel engines, which will overrev the engine and risk damaging machinery and causing personal injury. Do not start the engine Do not start or run the engine with a suspected fuel or LPG leak in the boat, nor when you are close to or in a discharge of explosive media, etc. There is risk for fire and/or explosion in explosive surroundings.

When a boat is moving forward, it will cause a certain vacuum to form behind the boat. In unfortunate cir- cumstances, the suction from this vacuum can be so great that the exhaust gases from the boat are drawn into the cockpit or cabin and cause carbon monoxide poisoning. This problem is most prevailant on high, wide boats with abrupt stern. In certain conditions, however, this 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. Most modern boats, however, are designed in such a way that this problem is very rare. If suction should arise anyway, do not open hatches or portholes at the fore of the boat. Surprisingly, this will otherwise in- crease the suction. Try changing speed, trim or load distribution instead. Try taking down/opening or in any other way changing the setup of the cover as well. Get in touch with your boat dealer for help in ob- taining the best solution for your boat. Remember Safety equipment: life jackets for everyone on board, communication equipment, distress rockets, approved fire extinguisher, bandages, life buoy, anchor, paddle, torch, etc. l Spare parts and tools: Impeller, fuel filter, fuses, adhesive tape, hose clips, engine oil, propeller and tools for tasks it may be necessary to perform. l Plan your desired route from the charts. Calculate distance and fuel consumption. Listen to weather reports. l Inform relations of your planned route for long trips. Remember to inform of changed plans or de- lays. l Inform the people on board of where the safety equipment is located and how it works. Make sure there is more than one person on board that knows how to start and manoeuvre the boat safely. This list should be supplemented with necessary safety equipment depending on the type of boat, where and how it is being used, etc. We recommend you get in touch with a regional boat or marine safety organisation to obtain more detailed marine safety information.

Preparations Knowledge The operator’s manual contains directions for per- forming normal maintenance and service in a safe and correct manner. Read the directions carefully be- fore starting work. More detailed service literature is available from your Volvo Penta dealer. Never perform a task unless you are absolutely sure how it is to be carried out, call your Volvo Penta deal- er for assistance instead. Stop the engine Stop the engine before opening or dismantling the en- gine hatch/hood. Maintenance and service must be carried out with the engine stationary unless stated otherwise in the instructions. Prevent inadvertent start of the engine by removing the starter key and turning off the power with the main switch, locking it in the off position. Place a warning sign in the driver position stating that service is in progress. Working on or approaching a running engine is a safety hazard. Loose clothing, hair, fingers or a dropped tool can fasten in rotating parts and cause serious bodily injury. Volvo Penta recommend leaving all work requiring the engine to be running to an authorised Volvo Penta service centre. Lifting the engine Always use the lifting eyes mounted on the engine (or reverse gear) when lifting the engine. Always make sure lifting equipment is in good condition and con- structed for the lift (engine weight together with possi- ble reverse gear and extra equipment). Use an ad- justable lifting boom to ensure safe handling when lift- ing the engine. All chains and wires must run parallel with each other and as much at right-angle as possi- ble to the top of the engine. Note that any extra equip- ment mounted on the engine can change the centre of gravity. Special lifting devices may be required to obtain the right balance and safe handling. Never per- form service on an engine suspended only from a lift- ing device. Before starting Refit all guards and covers that have been removed before starting the engine. Make sure there are no tools or other objects left on the engine. A turbocharged engine must never be started without the air filter fitted. The rotating compressor wheel in the turbocharger can cause severe personal injury. There is also a risk of foreign objects being drawn in and causing mechanical damage. Fire and explosion Fuel and lubricants All fuel, most lubricants and many chemicals are flammable substances. Always read and follow the di- rections on the packaging. Work performed on the fuel system must be done on a cold engine. Fuel leaks and spills on hot surfaces or electrical components can cause fires. Keep oil- and fuel-drenched rags and other hazard- ous materials where they are safe in case of fire. Oil drenched rags can self-ignite in certain conditions. Never smoke when refuelling, topping up with oil or when in the vicinity of the fuel station or engine room. Non-original parts Components in fuel, ignition and electrical systems on Volvo Penta engines are designed and manufactured to minimize the risk of explosion and fire in compli- ance with existing legislation. The use of non-original parts can result in explosion or fire. Batteries Batteries contain and generate oxyhydrogen gas, es- pecially when charging. Oxyhydrogen is easily ignited and extremely explosive. Smoking, naked flames and sparks must never occur in or close to the batteries or battery compartment. A faulty battery connection or jumper cable can gen- erate sparks which can cause the battery to explode. Start spray Never use start spray or similar start help. Explosions can occur in the intake manifold. Risk for personal in- jury.

A hot engine always involves risk for burn injuries. Take care with hot surfaces. E.g.: exhaust manifold, turbocharger, oil pan, charge air pipe, starting heater, hot coolant and warm lubricant in pipes and hoses. Carbon monoxide poisoning Start the engine in well ventilated spaces only. When running in confined spaces, the exhaust gases and crankcase gases must be evacuated. Chemicals Most chemicals such as glycol, anti-corrosion agent, preservatives, degreasing agent, etc., are hazardous to health. Always read and follow the directions on the packaging. Certain chemicals such as preservatives are flamma- ble and harmful to inhale. Provide good ventilation and use breathing protection when spraying. Always read and follow the directions on the packaging. Store chemicals and other hazardous materials out of reach of children. Leave left over or used chemicals to a destruction plant. Cooling system There is a risk of water entering when working on the seawater system. Therefore, stop the engine and close the sea cock before starting work. Avoid opening the coolant filler cap when the engine is warm. Steam or hot coolant may spurt out and cause burn injuries. If the filler cap, coolant pipe, cock, etc., must never- theless be opened or dismantled while the engine is warm, the filler cap must be opened carefully to re- lease the pressure before removing it completely and starting work. Note that the coolant can still be hot and cause burn injuries. Lubricating system Hot oil can cause burn injuries. Avoid skin contact with warm oil. Make sure the lubricating system is depressurised before starting work. Never start or run the engine with the oil filler cap removed or there will be a risk of the oil being thrown out. Fuel system Always protect your hands when carrying out leak de- tection. Escaping fluids under pressure can pierce bodily tissue and cause serious injury. Risk of blood poisoning. Always cover the alternator if it is located under the fuel filter. Fuel spills can damage the alternator. Electrical system Turn off the power Before starting work on the electrical system, the en- gine must be stopped and the powered turned off with the main switch/switches. Shore power to the engine heater, battery charger or other extra equipment fitted to the engine must be disconnected. Batteries Batteries contain a highly corrosive electrolyte. Pro- tect your eyes, skin and clothing when charging and handing batteries. Always use protective goggles and gloves. In case of splashes on the skin, wash with soap and plenty of water. In case of splashes in the eyes, rinse immediately with plenty of water and call a doctor.

contains the information necessary to handle and maintain your engine in a safe and correct manner. We would like you to read this operator’s manual thoroughly and learn how to handle the engine, controls and other equip- ment in a safe manner before casting off for your maiden voyage. Keep the operator’s manual handy at all times. Keep it safe and do not forget to hand it over to the new owner if you ever sell your boat. Care of the environment We would all like to live in a clean and healthy envi- ronment. Somewhere where we can breathe clean air, see healthy trees, have clean water in our lakes and oceans, and are able to enjoy the sunshine with- out being worried about our health. Unfortunately, this cannot be taken for granted nowadays but is some- thing we must work together to achieve. As a manufacturer of marine engines, Volvo Penta has a special responsibility, why care of the environ- ment is a core value in our product development. To- day, Volvo Penta has a broad range of engines where progress has been made in reducing exhaust emis- sions, fuel consumption, engine noise, etc. We hope you will take care in preserving these quali- ties. Always follow any advice given in the operator’s manual concerning fuel grades, operation and main- tenance and you will avoid causing unnecessary in- terference to the environment. Get in touch with your Volvo Penta dealer if you notice any changes such as increased fuel consumption exhaust smoke. Adapt speed and distance to avoid wash and noise disturbing or injuring animal life, moored boats, jetties, etc. Leave islands and harbours in the same condi- tion as you want to find them. Remember to always leave hazardous waste such as waste oil, coolant, paint and wash residue, flat batteries, etc., for dis- posal at a destruction plant. Our joint efforts will make a valuable contribution to our environment. Running in The engine must be “run in” during the first 10 hours of operation as follows: Run the engine under normal operation. Do not run it at full power except for short periods. Never run the engine for long periods at constant rpm during this time. A high consumption of lubricant is normal during the running in period. Therefore, check the oil level more often than recommended. The prescribed warranty inspection “First Service In- spection” must be carried out during this first period of operation. For more information: See Warranty and Service Book. Fuel and oil Use only fuel and oil grades as recommended in the operator’s manual. Other grades can cause opera- tional problems, increase fuel consumption and have long-range effects on engine service life. Always change oil, oil filter and fuel filter according to prescribed intervals. Service and spare parts Volvo Penta marine engines are designed for high operational reliability and long service life. They are constructed to withstand the marine environment while also affecting it as little as possible. Through regular service and the use of Volvo Penta original spare parts, these qualities will be retained. The worldwide Volvo Penta network of authorised dealers is at your service. They are specialists in Volvo Penta products and stock accessories, original spare parts, test equipment and the special tools re- quired to perform high-quality service and repairs. Always follow the maintenance intervals specified in the operator’s manual and remember to specify the engine/transmission number when ordering service and spare parts.

certified engines used in areas where exhaust emis- sions are regulated by law are aware of the following points: A certification involves the engine type being checked and approved by applicable authorities. En- gine manufacturers guarantee that all engines of the same type correspond with the certified engine. This puts special demands on the maintenance and service of your engine: l Maintenance and service intervals recommended by Volvo Penta must be followed. l Only Volvo Penta original spare parts may be used. l Service of injector pumps, pump settings and in- jectors must always be performed at an authorised Volvo Penta workshop. l The engine must not be modified in any way with the exception of accessories and service kits ap- proved by Volvo Penta for use on the engine. l Installation modifications must not be made to the engine exhaust pipe or inlet channels. l Any sealed sections must not be broken by any- one other than authorised personnel. Otherwise, the general directions concerning running, care and maintenance given in the operator’s manual apply. IMPORTANT! Neglected or deficient mainte- nance/service and the use of non-original spare parts will entail Volvo Penta renouncing any re- sponsibility for the engine corresponding to the certified version. Volvo Penta will not compen- sate for damage and/or costs arising from the above. Warranty Your new Volvo Penta marine engine is covered by a limited warranty complying with the conditions and instructions given in the Warranty and Service Book. Note that AB Volvo Penta’s responsibility is limited to what is specified in the Warranty and Service Book. Read it carefully as soon as possible after delivery. It contains important information concerning the warranty card, service, maintenance and what the owner is responsible to be aware of, check and perform. Warranty liability will otherwise be declined completely or fully by AB Volvo Penta. Get in touch with your Volvo Penta dealer if you have not received a Warranty and Service Book or a copy of the warranty card.

ways be used as a reference when ordering service and spare parts. Similar plates can probably be found on your boat and its equipment. Make a note of the information in the space below and make a copy of this page so the information is available even if the boat should be stolen. The appearance and location of the type plates is shown below. The numbers in brackets refer to the location of the identification number on the type plate. Engine Product designation (1) ...................................................................................................... Serial and basic engine number (2) .................................................................................... Product number (3)............................................................................................................. Certification, IMO Decal, part No. (4) ............................................................................................................... Approval No. (5) .................................................................................................................. Transmission Product designation (6) ....................................................................................................... Serial number (7) ................................................................................................................. Product number (8).............................................................................................................. Engine and transmission decal Reverse gear plate Certification decal Engine plate Certification plate (6) (7) (8) XXXX (6) XXXXXXXXXX (7) IMPORTANT ENGINE INFORMATION AB Volvo Penta, Sweden VP xxxx (4) IMO ENGINE FAMILY xxxx ENGINE MODEL xxxx (1) TEST CYCLES xxxx POWER (kW/RPM) xxxx IMO APP NO. MTC xxxx (5) IMO APP NO. EPA – ENGINE SERIAL NO. AVAILABLE ON ENGINE IDENTIFICATION PLATE CERTIFICATE AND TECHNICAL FILE: AVAILABLE ON WWW.PENTA.VOLVO.SE THIS ENGINE IS CERTIFIED BY SWEDISH ACCREDITED ORGANISATION MTC IN ACCORDANCE WITH IMO NOX TECHNICAL CODE ANNEX VI MARPOL 73/78

direct injection, 6-cylinder, 4-stroke marine diesel engines. They are equipped with turbocharger and fit- ted with either a heat exchanger for thermostat- regulated freshwater cooling or connections for keel cooling. The engines are equipped with a seawater cooled charge air cooler. The charge air cooler lowers the temperature of the inlet air to the engine after it has been compressed in the turbocharger. This allows high power output while keeping combustion and exhaust temperatures at a suitable level. The exhaust manifold and turbocharger are fresh- water cooled to reduce heat radiation to the engine room. These engines are equipped with mechanical fuel control. TAMD63L-A, TAMD63L-B, TAMD63P-A 1. Fuel fine filters 2. Smoke limiter 3. Coolant filler cap 4. Injection pump 5. Oil filler cap 6. Distribution box with semi-automatic fuses 7. Turbocharger 8. Water cooled exhaust pipe elbow (option) 9. Reverse gear (ZF (MPM) IRM 220A-1) 10. Wastegate valve (TAMD63P) 11. Oil dipstick, engine 12. Fuel shut-off valve 13. Oil cooler, engine 14. Flexible engine mounting (option) TAMD63L-A, TAMD63L-B, TAMD63P-A 1. Filter for crankcase ventilation 2. Air filter 3. Charge air cooler 4. Oil filler cap 5. Expansion tank 6. Coolant filler cap 7. Heat exchanger 8. Alternator 9. Sea water pump 10. By-pass filter for engine oil 11. Oil filter, engine 12. Starter motor 13. Oil dipstick, engine 14. Oil dipstick, reverse gear 14 13 12 11 10 9 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 14 13 12 11 10 9

2. Smoke limiter 3. Oil filler cap 4. Coolant filler cap 5. Injection pump 6. Distribution box with semi-automatic fuses 7. Turbocharger* 8. Exhaust pipe elbow 9. Oil dipstick, engine 10. Fuel shut-off valve 11. Oil cooler, engine 12. Flexible engine mounting (option) 13. Reverse gear (TD MG5091DC) * TAMD74A-B: With wastegate. TAMD74A-A, TAMD74A-B 1. Air filter 2. Charge air cooler 3. Expansion tank 4. Heat exchanger 5. Coolant filler cap 6. Oil filler cap 7. Alternator 8. Starter motor 9. Oil sump 10. Oil filter, engine 11. By-pass filter for engine oil 12. Sea water pump 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 13

oil gauge, temperature gauge, charge gauge, starting switch, etc., that are shown here as panel mounted may be mounted separately in 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. Instrument panels Instrumentation for the main control position and aux- iliary 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. 5. Hour counter. Shows the total number of engine running hours as a decimal number. 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. 11. Oil pressure gauge. Indicates the oil pressure in the reverse gear. 12. Charge air pressure gauge. Indicates the turbo- charger boost pressure. 1 2 3 4 5 6 7 8 9 10 8 5 9 10 4 6 7 11 12

iary control position. 1. Siren for acoustic alarm that sounds if one of the warning lamps comes on. 2. Press button for instrument illumination. 3. Press button for testing and acknowledging alarms (see “Warning displays” below). 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 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. 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. 1 2 4 3 5 6 7 8 5 6 2 3 1 1 2 3 4

the key code required when ordering additional start- er keys. Do not keep the code where unauthorized persons 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”.

Manoeuvring Single lever control operates shifting and engine speed from the same lever (1). N = Neutral position (reverse disengaged and engine idling). F = Reverse gear engaged for moving forwards. R = Reverse gear engaged for moving backward. = Engine speed control. A neutral position switch is available as an accessory that allows the engine to be started only when the reverse gear is disengaged. Controls This chapter describes the Volvo Penta controls that are available for your engine. If your boat is fitted with con- trols not described here and you are not sure of their function, please get in touch with your boat dealer. Disengaging the shifting function The shifting function can easily be disengaged to that the lever only affects the engine speed. 1. Put the lever (1) in neutral position (N). 2. Press the button (2) while moving the lever forward. 3. Release the button. The lever now affects the engine speed only. The disengagement will cease automatically when the le- ver is moved back to neutral position. IMPORTANT! Take care not to engage the reverse gear unintentionally. T T 2 1

engine speed control. 1. Remove the cover on the control. 2. Set the lever to half acceleration/reverse. 3. Adjust the friction brake. Turn clockwise for stiffer lever movement and anticlockwise for lighter movement. 4. Refit the cover. Dual lever control Manoeuvring The dual lever control has separate levers for shifting (1) and engine speed control (2). Control A has a mechanic detent so that shifting can be performed only when the engine speed lever is in idle speed position. A neutral position switch is available that allows the engine to be started only when the reverse gear is disengaged. Black lever (1): N = Neutral position. Reverse gear disengaged. F = Reverse gear engaged for moving forwards. R = Reverse gear engaged for moving backward. Red lever (2): Engine speed control. Friction brake The controls are fitted with an adjustable friction brake for engine speed control. Adjust the friction brake by turning the screw (control A) or the lever (control B). Turn clockwise (+) for stiffer lever movement and anticlockwise (–) for lighter movement. B A 2 1

Make a habit of “visually” inspecting the engine and engine room before starting This will help you to quickly de- tect abnormalities that have occurred or are about to occur. Make sure instruments and warning displays indicate normal values after starting the engine. We recommend installing a heater for the engine room to minimize start smoke when cold starting at tempera- tures below +5oC (41oF). WARNING! Never use start spray or similar start help. Risk for explosion! Measures before start l Open the fuel cock l Open the seawater cock where appropriate l Carry out the measures described in “Daily before first start” in the maintenance schedule. l Turn on the main switch IMPORTANT! Never turn the power off using the main switch while the engine is running. This can damage the alternator. l Make sure there is enough fuel for the planned trip. Starting procedure 1. Disengage the reverse gear Put the control lever into neutral and idle on all control positions WARNING! If the boat is equipped with controls that allow starting the engine in gear, it is essential to check all control positions to make sure a gear is not engaged. Single lever control Make sure the lever is in neutral position “N”. This means the accelerator is in idle position and the re- verse gear is disengaged. Dual lever control Put the forward/reverse lever in neutral position to en- able starting. Move the accelerator all the way back (idle position).

2. Turn on the power Turn on the power by putting the starter key in position “I”. 3. Check warning lamps and alarms Press the “Alarm test” button on the instrument panel to make sure the warning lamps come on and the acoustic alarm sounds. 4. Start the engine Start using the starting switch Turn the key to position “III”. Release the key so it re- turns to “I” immediately after the engine has started. IMPORTANT! If the starter motor has been en- gaged for the maximum time (30 seconds), it must be allowed to cool down for at least one minute before a new attempt is made at starting. NOTE! The key must first be turned to “S” before mak- ing a new attempt at starting. 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”). Start using auxiliary batteries Refer to the description in the chapter “Troubleshoot- ing”. 5. 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 attains normal operating temperature before using full power. IMPORTANT! Do not race the engine when it is cold. 6. Check the oil level in the reverse gear The oil level should be checked once the reverse gear has attained operating temperature (see the description in the chapter “Maintenance” under the heading “Re- verse gear”).

your maiden voyage. WARNING! Avoid violent and rapid rudder movement and gear shifting. There is a risk of the passengers falling down or falling overboard. WARNING! A rotating propeller can cause serious injury. Make sure there is nobody in the water before en- gaging forward/reverse. Never run close to bathers or in places where you have reason to believe there are people in the water. Check the instruments Check the instruments and warning display directly after start and regularly during operation. Oil pressure During operation, the oil pressure gauge should show a reading of 300–550 kPa (43.5–79.8 psi) or 450–650 kPa (65.3–94 psi) for TAMD63 respectively TAMD74. A lower value is normal at idling speed. The acoustic alarm will sound automatically in case of low oil pressure. Coolant temperature During operation, the temperature gauge should show a reading of 75–90°C (167–194°F). The acoustic alarm will sound automatically in case the coolant temperature is too high. Charging During operation, the charge voltage gauge should show a reading of 14V or 28V for a 12 respectively 24V system. The acoustic alarm will sound automatically in case the charge voltage is missing. Alarms and fault indication If the acoustic alarm sounds, one of the warning display lamps will immediately start to flash to indicate the cause of the alarm: High coolant temperature (1), low oil pressure (2) and no charge voltage (3). IMPORTANT! Stop the engine immediately after an alarm for low oil pressure. Investigate the cause and rectify it. Slow the engine speed to idle/disengaged after an alarm for high coolant temperature. If temperature does not drop, the engine must be stopped. Investigate the cause and rectify it. 1 2 3

economy. We recommend a cruising speed of at least 200 rpm lower than the maximum rpm at full speed (wide open throttle). 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: TAMD63L-A/L-B (Rating 2) ..................... 2400–2500 rpm TAMD63L-A/L-B (Rating 3) ..................... 2700–2800 rpm TAMD63P-A (Rating 4, 5)........................ 2700–2800 rpm TAMD74A-A (Rating 1, 154 kW*) ............ 1700–1800 rpm TAMD74A-A (Rating 1, 160 kW*) ............ 1900–2000 rpm TAMD74A-A (Rating 1, 184 kW*) ............ 2000–2100 rpm TAMD74A-A (Rating 2)............................ 2100–2200 rpm TAMD74A-B (Rating 2)............................ 2100–2200 rpm * Max. motor effect. 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. Manoeuvring The chapter contains functional descriptions of the controls available from Volvo Penta. The reverse gear must be engaged at low idling speed. There must be a brief pause after engaging reverse gear before increasing the engine speed. The pause must be approximately two seconds long to ensure the reverse gear clutch plates are properly engaged. IMPORTANT! If the boat is equipped with two en- gines, they must both be running while in reverse or there will be a risk of water entering the stationary en- gine (through the exhaust passage). Pulling away 1. Move the lever from neutral to the engagement position for the desired direction of travel. Wait for approximate- ly two seconds. 2. Increase gradually to the desired engine speed.

loose most of its speed. 2. Move the lever to neutral. Wait for approximately two seconds. 3. Move the lever to reverse. Wait for approximately two seconds and then increase the engine speed gradually. IMPORTANT! A direct forward–reverse manoeuvre can damage the transmission and engine. It is there- fore always necessary to stop with the lever in neutral for a few seconds. Allow the boat to loose most of its speed as well before engaging. If the speed of the boat is too high, there is a risk of the propeller torque being so high that the engine will stop and start re- versing, causing the engine to break down. Forced propeller rotation (E.g. when towing) When towing, sailing, anchoring in strong currents, etc., the propeller can make the propeller shaft rotate even though the engine is stationary. This rotation may be un- comfortable and can damage the reverse gear. IMPORTANT! The propeller shaft can be allowed to rotate with a stationary engine for up to 6–8 hours. After that period, the engine must be started and run for at least 5 minutes to enable lubrication and cooling of the reverse gear. In cases where the propeller shaft may rotate faster than during normal operation, e.g. when sailing, a temperature gauge should be fitted to monitor the oil temperature. Max. permitted temperature is 110°C (230°F) for Twin Disc and 95°C (203°F) for ZF (MPM) reverse gear. A shaft brake must be fitted if the above directions cannot be followed or if it is necessary to stop the shaft for rea- sons of comfort. On isolated occasions, the propeller shaft flange can be locked mechanically in a suitable manner.

valve so that the lowest speed of the boat can be variably reduced by 1–80% at engine speeds up to 1100 rpm. IMPORTANT! Risk of overheating the reverse gear if the trolling valve is used at higher engine speeds than 1100 rpm. Manoeuvring Disengage the reverse gear and set the trolling valve for maximum slip. Engage “Forward” or “Reverse” and set the desired slip position within the permitted engine speed range. In order to attain full propeller output, the trolling valve lever must always be in “disengaged” position when not being used. Flush and bilge pump The bilge pump has a vacuum switch (1) that automatically disengages the pump when water is no longer being drawn into the pump. The scavenging and bilge pump is engaged and disen- gaged from a switch that is normally located at the main control position. The bilge pump can also be engaged manually by holding down the lever 2 for about 20 sec- onds.

Let the engine run at low idling speed (in neutral) for at least three minutes before turning it off. This will keep the engine temperature in balance and prevent it boiling. IMPORTANT! The procedure described above is especially important if the engine has been run hard and/ or exerted to heavy loads. Stop 1. Disengage the reverse gear by moving the lever to neu- tral position. 2. Turn the key to stop position “S” or press the stop but- ton. 3. Hold the key/button in position until the engine has stopped (the key will return to “0” automatically when released and can then be removed). Emergency stop If a fault occurs that prevents the engine being stopped by the normal method, it can be stopped manually using the lever on the injection pump. Pull back on the lever until the engine is stationary. WARNING! Working on or approaching a running en- gine is a safety hazard. Beware of rotating parts and hot surfaces. After stopping l Check the engine and engine room for leaks. l Close the fuel cock and seawater cock. IMPORTANT! Do not forget to open the cocks before starting the engine again. l Read off the hour counter and carry out preventive maintenance according to the maintenance schedule. l Turn off the main switch if the engine is not to be used for long periods. IMPORTANT! Never turn the power off using the main switch while the engine is running. This can damage the alternator.

Anti-freezing measures If the engine room cannot be protected from frost, the sea- water system must be drained and the coolant in the fresh- water system must contain sufficient anti-freeze to prevent it from freezing. Refer to chapter Maintenance “Seawater system” and “Freshwater system” respectively. WARNING! If the seawater system bursts due to freezing, it is possible for the boat to sink. IMPORTANT! If the coolant does not give sufficient anti-freeze protection, it may cause costly damage to the engine. Check the charge of the battery. A poorly charged battery can freeze and break. Breaks in operation During breaks in operation when the boat is in the water, the engine must be run warm once a fortnight. This will prevent the engine from corroding. IMPORTANT! The engine must be conserved if it is not to be used for longer than two months: Refer to: Inhibiting

service life. They are constructed to withstand the marine environment while also affecting it as little as possible. Preventive maintenance in accordance with the maintenance schedule will ensure that it retains these qualities and avoid unnecessary operational disturbances. Warranty inspection The prescribed warranty inspection “First Service Inspection” must be carried out at an authorised Volvo Penta workshop during this first period of operation. Directions for when and where this is to be carried out can be found in the Warranty and Service Book. MAINTENANCE SCHEDULE WARNING! Read the chapter “Maintenance” thoroughly before starting any mainte- nance work. It contains directions for performing maintenance in a safe and correct manner. IMPORTANT! When both operating time and calendar time is given, the one occur- ring first is to apply. Maintenance points marked with are to be carried out at an authorised Volvo Penta workshop. Daily before first start l Engine and engine room. General inspection ............................................... page 29 l Engine oil. Check level ................................................................................. page 33 l Coolant. Check level..................................................................................... page 37 l Charge air cooler. Check the drain hole ....................................................... page 46 l Reverse gear. Checking oil level (after start) ................................................ page 58 After the first 10 operating hours l Reverse gear (ZF/MPM). Clean oil strainer.................................................. page 58 After the first 50 operating hours l Reverse gear (Twin Disc and ZF/MPM). Clean oil strainer .......................... page 58 l Reverse gear (Twin Disc and ZF/MPM). Changing oil ................................. page 59 Every 50 operating hours / at least every 12 months l Fuel pre-filter. Check and drain .................................................................... page 50

l Engine oil. Change 1) .................................................................................... page 33 l Oil filter. Change 2) ........................................................................................ page 34 1) The oil change interval varies depending on the engine type, oil grade and sulphur content of the fuel. See page 32. 2) The oil filter is changed in every second oil change. After the first 100 operating hours Valve clearances. Check ...................................................................... not illustrated Every 250 operating hours / at least every 12 months l Crankcase ventilation(TAMD63). Change filter ............................................. page 30 l Drive belts (not Poly-V). Check / Adjustment ................................................ page 30 l Air filter (TAMD63). Clean ............................................................................ page 31 l Seawater filter. Check/clean ......................................................................... page 45 l Zinc anodes. Check/Change ........................................................................ page 45 l Fuel pre-filter(Double filter). Check1) ............................................................. page 49 l Electrical connections. Check/clean ............................................................. page 52 l Reverse gear (ZF/MPM). Clean oil strainer.................................................. page 58 1) Concerns only double filters: Check the manometer and change filter if necessary, but change filter at least every 1000 operating hours or at least once at year. Every 500 operating hours / at least every 12 months l Drive belts(Poly V). Check / Adjustment ....................................................... page 30 l Coolant (Anti-corrosion mixture). Topping up1) ............................................. page 36 l Battery. Ceck of electrolyte........................................................................... page 53 l Reverse gear (ZF/MPM). Changing oil......................................................... page 59 1) This applies only if the cooling system is filled with an anti-corrosion mixture. Every 1000 operating hours / at least every 12 months Valve clearances. Check/Adjust ........................................................... not illustrated l Air filter (TAMD74). Change ......................................................................... page 31 l Fuel filter. Change ........................................................................................ page 48 l Fuel pre-filter. Change filter element ............................................................. page 50 l Reverse gear (Twin Disc). Clean oil strainer ................................................ page 58 l Reverse gear (Twin Disc). Changing oil ....................................................... page 59

Injectors. Pressure test ......................................................................... not illustrated Every 12 months Turbocharger. Check ............................................................................ not illustrated Wastegate (TAMD63P, TAMD74A-B). Check ...................................... not illustrated Engine and reverse gear. General check ............................................. not illustrated Heat exchanger. Check / Clean ............................................................ not illustrated Charge air cooler. Check / Clean.......................................................... not illustrated Oil cooler (Reverse gear). Check / Clean ............................................. not illustrated l Impeller (Seawater pump). Check / Change ................................................. page 44 l Impeller (Flush pump/Bilge pump). Check / Change ............................ not illustrated l Engine and reverse gear. Clean / Paint ................................................ not illustrated Every 24 months l Coolant. Change........................................................................................... page 37 l Cooling system. Flushing ............................................................................. page 39 Renovated engine: After the first 100 operating hours Valve clearances. Check ...................................................................... not illustrated

points. Read the directions carefully before starting work. The times at which the maintenance points are to be carried out can be found in the previous chapter “Maintenance schedule”. WARNING! Read the safety directions for maintenance and service in the chapter “Safety information” be- fore starting work. WARNING! Maintenance and service must be carried out on a stationary engine unless specified other- wise. Stop the engine before opening or dismantling the engine hatch/hood. Prevent inadvertent start of the engine by removing the starter key and turning off the power with the main switch. Engine, general General inspection Make a habit of “visually” inspecting the engine and engine room before starting the engine and after stopping when the engine has been turned off. This will help you to quickly detect abnormalities that have occurred or are about to occur. Look especially carefully for oil, fuel and coolant leaks, loose bolts, worn or slack drive belts, loose connections, damaged hoses and electric cables. This inspection takes only a few minutes but can pre- vent serious operating disturbances and costly re- pairs. WARNING! Accumulations of fuel, oil and grease on the engine or in the engine room is a fire hazard and must be removed immediately they are detected. IMPORTANT! If an oil, fuel or coolant leak is de- tected, the cause must be investigated and the fault rectified before the engine is started. IMPORTANT! Never point high-pressure water jets directly at seals, rubber hoses or electrical components. Never use the high-pressure func- tion when washing the engine.

Crankcase ventilation. Change filter (TAMD63) Change the filter (1) earlier than recommended if oil is forced out of the relief valve (2). 1. Dismantle the filter (1) by screwing it anti-clock- wise. 2. Check the rubber gasket in the bracket and change if necessary. Screw on the new filter by hand. Drive belts. Check/Adjust/Change WARNING! Stop the engine before commenc- ing maintenance work. General Check belt tension and condition regularly. If the belt is too taut it can damage bearings and if it is too loose it may slip. Check and adjust after operation when the belt is warm. IMPORTANT! Always change a belt that ap- pears worn or is cracked (belts working in pairs must be replaced together). Poly-V belt The alternator and circulation pump are driven by a Poly-V belt for best function and service life. A torque wrench must be used for adjustment. 1. Undo screws (A) before you tension the belt. 2. Change the belt as necessary. 3. Put the torque wrench stub into the square hole in the jockey wheel bracket. Tension the belt with 60 ±3 Nm (6 ±0.3 kpm/44 ± 2 lbf.ft). 4. Tighten screws (A). Other belts Also check the belts for the bilge and flushing pump, extra alternator etc. These are usually driven by con- ventional V- belts. Adjust and change as necessary. It can generally be said that these belts are correctly tensioned if they can be pressed down 10 mm (3/8") by thumb pres- sure. Clean the belt grooves before fitting a new belt.

Air filter. Cleaning (TAMD63) 1. Remove the lid from the air filter housing. 2. Remove the insert and wash it in clean diesel oil. 3. Squeeze the insert out and put it back in the filter housing. Fix the insert by pressing the O-ring into the groove around the outside edge of the insert. IMPORTANT! Change the insert if it is dam- aged. Air filter. Changing (TAMD74) 1. Remove the old filter. Be careful to ensure that no contamination gets into the engine. 2. Install a new filter and tighten the hose clamps. IMPORTANT! Scrap the old filter. It must not be cleaned.

SAE5W/30 −−−−−30 −−−−−20 −−−−−10 ±0 +10 20 30 40 −−−−−22 −−−−−4 +++++14 32 50 68 86 104 −−−−−15oC SAE15W/40 −−−−−25oC SAE10W/30 −−−−−10oC SAE20W/30 ±0oC SAE30 SAE40 +10oC oC oF ,,,,, Lubricating system Oil change intervals can vary from 25 to 200 hours depending on engine type, grade of lubricant and the sulphur content in the fuel. IMPORTANT! Oil change intervals must never exceed 12 months. If you would like longer oil change intervals than those specified in the table below, samples of the lubricant must be sent regularly to the oil manufacturer for checking. Viscosity Select the viscosity from the table for constant exterior temperatures. *Refers to synthetic or semi-synthetic oil Oil change volume See “Technical data” NOTE! Mineral based synthetic or semi-synthetic oil can be used on condition that it meets the oil grades above. 1) If the sulphur content in the fuel exceeds 1.0 wt.%, an oil with TBN14–20 must be used (TBN=Total Base Number) 2) The oil must be changed at least once a year VDS = Volvo Drain Specification ACEA = Association des Constructeurs Européenne d'Automobiles API = American Petroleum Institute Oil grade Fuel sulphur content in wt.% up to 0.5 % 0.5 – 1.0 % above 1.0 % 1) Oil change interval 2) VDS, VDS-2 200 hours 100 hours 50 hours 100 hours 50 hours 25 hours ACEA E3–96, E2–96 API CD, CE, CF, CF–4, CG–4

Engine oil. Check level The oil level must be within the marked range on the dipstick and must be checked daily before starting the first time. Engine oil. Change Always observe the recommended oil change in- terval. Use a manual or electric oil scavenging pump (optional equipment) to suck the oil out of the sump. IMPORTANT! Only use recommended grades of oil (see previous page). 1. Warm the engine up (this makes it easier to suck the oil up from the sump). Then stop the engine. WARNING! Hot oil and hot surfaces can cause burns. 2. TAMD63 (electric oil scavenging pump): Remove the dipstick. Connect the suction hose of the oil scavenging pump to the dipstick tube (1). Suck the oil out. TAMD74 (manual oil scavenging pump): Connect a hose to the outlet pipe of the oil scav- enging pump. Suck the oil out. 3. Change the oil filter and the by-pass filter at every second oil change (please refer to the instruction on the next page). 4. Fill up with oil to the correct level. Engine oil. Filling Top up the oil through the filler opening (1) in the ven- tilation cover. Make sure the correct level is attained but wait a few minutes to allow the oil to run into the oil sump. IMPORTANT! Do not fill above the maximum oil level. Use only oil of the recommended grade (see the previous page). 1 1 TAMD63 TAMD74

5. Start the engine and allow it to idle. Check that the low oil pressure warning lamp goes out and that there is no leakage by the filter. WARNING! Approaching or working with a running engine is a safety risk. Be careful to avoid rotating components and hot surfaces. 6. Stop the engine. Wait a few minutes before you check the oil level. Top up as necessary. NOTE! Process the old oil filter in accordance with lo- cal regulations. Oil filter and by-pass filter. Changing Change the oil filter and by-pass filter every second oil change. Standard filter location is on the right side, but they can be located at the rear of the engine if necessary (option). WARNING! Hot oil and hot surfaces can cause burns! 1. Drain the oil as in the “Engine oil changing” in- struction on the previous page. 2. Put a vessel underneath the filter to avoid oil spill- age. Unscrew the oil filter (1) and by-pass filter (2). 3. Check that the mating surfaces on the filter bracket are clean, and that no traces of the seal from the old oil filter remain. 4. Wipe some oil on the rubber seal for the new filter. 5. Screw the filters on by hand until the rubber seal just touches the mating surface of the filter bracket. Then turn it another half turn, and no more! 6. Fill up with oil as in the “Engine oil, changing” in- struction on the previous page. 1 2

Freshwater system The freshwater system is the internal engine 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 ensure good circulation in the system. The thermostat will start to open at a certain temper- ature and will be fully open when the engine has attained normal operating temperature. When the thermostat opens, the warm coolant passes through the heat exchanger where it is cooled by the water in the engine’s sea- water system. In its standard version, the engine is fitted with an internal freshwater system. Volvo Penta also supply engines with the cooling system prepared for external cooling, e.g. keel cooling. Coolant. General The freshwater system must always be filled with a coolant that protects it against internal corrosion and freezing when the climate demands. Anti-corrosive additives become less efficient with age and the coolant must therefore be changed. IMPORTANT ! Never use only water as a cool- ant and change the coolant in accordance with the recommendations in the maintenance schedule. Water quality To avoid clogging the system, the coolant must be mixed with pure water in accordance with ASTM D4985. If there are doubts about the purity of the wa- ter, use distilled water or ready-mixed coolant in- stead. ASTM D4985: Total solid particles ....................................... < 340 ppm Total hardness................................................ < 9.5° dH Chloride ........................................................... < 40 ppm Sulphate .......................................................... < 100 ppm pH-value .......................................................... 5.5–9 Silicon ............................................................. < 20 mg SiO2/l Iron................................................................... < 0.10 ppm Manganese ...................................................... < 0.05 ppm Conductivity ................................................... < 500 µS/cm Organic content, CODMn ................................ < 15 mg KMnO4/l

Anti-freeze mixture When there is risk of freezing, a mixture of 50% Volvo Penta anti-freeze (glycol) and 50% water (complying with ASTM D4985) must be used. This mixture will protect against freezing down to approx. –40°C (–40°F) and is to be used all year round. IMPORTANT! Even if the temperature never falls as low as –40°C (–40°F), the mixture speci- fied above should still be used to provide ade- quate anti-corrosive properties. Mix the glycol with water in a separate container be- fore filling the cooling system. WARNING! Glycol is a health hazard (poison!). IMPORTANT! Alcohol must not be used in the cooling system. Anti-corrosion mixture Water (complying to ASTM D4985) mixed with Volvo Penta anti-corrosion agent can be used as a coolant when there is no risk of freezing. Using an anti-freeze mixture all year round is recom- mended, however, whatever the climate. Mix as directed on the packaging. Run the engine warm after filling to obtain the best effect of the addi- tive. If the operating time exceeds 500 hours a year, the anti-corrosive protection in the coolant must be sup- plemented with 1/2 litre anti-corrosion agent every 500 hours. WARNING! Anti-corrosion agent is a health haz- ard (poison!). IMPORTANT! Never mix anti-corrosion agent with anti-freeze (glycol). Frothing can occur and severley impair the cooling properties.

Coolant level. Check WARNING! Never open the pressure cap when the engine is warm. Steam or hot fluid may spurt out. IMPORTANT! Check the coolant level on a cold stationary engine. Make sure the coolant level is approx. 5 cm (2") below the sealing surface of the filling cap. Fill as nec- essary as described below. Coolant. Filling CAUTION! Stop the engine and allow it to cool down before filling. Hot oil and hot surfaces can cause burns. Topping up Fill with coolant to the correct level through the filler opening on the expansion tank. Fill slowly so that the evacuated air is able to pass through the filler open- ing. IMPORTANT! Use the same type of coolant that is already in the system. IMPORTANT! If the heat exchanger is empty, the coolant must be filled according to the de- scription “Filling the cooling system when emp- ty”. Filling the system when empty 1. Open the ventilation cocks by the turbocharger and the heat exchanger. 2. Make sure any other systems such as heater, wa- ter heater, etc., connected to the cooling system are also ventilated. 3. Fill with coolant through the filler opening on the expansion tank. 4. Fill slowly so that the evacuated air is able to pass through the ventilation cock/cocks and the filler opening.

5. When coolant that is free from air flows out, the ventilation cocks must be closed. 6. Cease filling when the correct level is attained. 7. Start the engine and run it until it reaches operat- ing temperature. IMPORTANT! The engine must not be start- ed before the system has been bled and filled. 8. Stop the engine and allow it to cool down. Check the coolant level and top up if needed. Coolant. Drain WARNING! Stop the engine and allow it to cool down before draining. Hot coolant and hot sur- faces can cause burns. WARNING! Glycol is a health hazard (poison). Collect the old coolant and leave it to a destruc- tion plant. IMPORTANT! The coolant is drained via the taps (1–3) and the plugs (4, 5). Most of the cool- ant is drained via tap (1) but all drain points must be opened for all coolant to be drained. 1. Remove the filler cap on the expansion tank. 2. Open vent cock (A) and vent cocks (B) by the heat exchanger. 3. Connect a suitable hose to tap (1) on the cylinder block. Open the tap and let the coolant run out into a suitable vessel. IMPORTANT! Check that the coolant really runs out. Deposits may need to be removed inside the drain plugs/taps. 4. Continue with the other drain points until all five have been opened and all coolant has been drained off. 5. Drain any other systems such as heater, water heater, etc., connected to the freshwater system too. 6. Close all drainage points. 1 2 4 A 5 3 B

Freshwater system. Flushing The system should be flushed before changing cool- ant to avoid inferior cooling performance due to de- posits in the cooling system. IMPORTANT! Certain parts of the system are made of light alloy. Chemical additives must therefore not be used when cleaning. 1. Drain the coolant as described earlier. 2. Insert a hose into the filler opening on the expan- sion tank and flush with fresh water. 3. Flush until the water running out of the drainage points is clean. 4. Close all drainage points when all the fresh water has run out. 5. Fill with coolant.

Cooling system, external cooling Introduction A cooling system with external cooling does not have a heat exchanger but is cooled by heat being transferred via one or two external cooling circuits. A single circuit system serves all the components being cooled. A dual circuit system has either two freshwater circuits or one freshwater circuit together with one seawater circuit. In both cases, one of the circuits cools the engine and the other circuit cools the charge air cooler and the oil cool- ers. Coolant level. Check WARNING! Never open the filler cap when the engine is warm. Steam or hot fluid may spurt out. Make sure the level ends up between the MIN and MAX marks. If there are no marks, the coolant level should be approx. 5 cm (2") below the sealing surface of the filling cap (1). Fill if necessary with the same type of coolant that is already in the system. IMPORTANT! Check the coolant level on a cold stationary engine. 1 Two circuits Two circuits One circuit One or two circuits

Coolant. Filling WARNING! Stop the engine and allow it to cool down before filling. Hot oil and hot surfaces can cause burns. Topping up Fill with coolant to the correct level through the filler opening (1) on the expansion tank. Fill slowly so that the evacuated air is able to pass through the filler opening. IMPORTANT! Use the same type of coolant that is already in the system. IMPORTANT! If the heat exchanger is empty, the coolant must be filled according to the de- scription “Filling the cooling system when emp- ty”. Filling the system when empty 1. Open the vent tap by the turbocharger (2) and at the keel cooler circuit return pipe (3). NOTE! Do not open the bleed screw by the charge air cooler if the circuit is part of the seawater sys- tem. 2. Make sure any other systems such as heater, wa- ter heater, etc., connected to the cooling system are also ventilated. 3. Fill with coolant via the filler opening on the expan- sion tank. 4. Fill slowly so that the evacuated air is able to pass through the ventilation cock/cocks and the filler opening. 5. Close the ventilation cocks/cocks as coolant that is free from air runs out of them. 6. Cease filling when the correct level is attained. 7. Start the engine and run it until it reaches operat- ing temperature. IMPORTANT! The engine must not be start- ed before the system has been bled and filled. 8. Stop the engine and allow it to cool down. Check the coolant level and top up if needed. 3 2

Coolant. Drain WARNING! Stop the engine and allow it to cool down before draining. Hot oil and hot surfaces can cause burns. WARNING! Glycol is a health hazard (poison). Collect the old coolant and leave it to a destruc- tion plant. 1. Remove the filler cap. 2. Open the vent tap (2) by the turbocharger and at the keel cooling circuit return hose union (3). 3. Open the cocks shown in “Coolant. Drain” (stan- dard system). Open also the cocks shown in “Sea- water system. Drain” on systems without seawater circuit. Collect the fluid in a suitable receptacle. IMPORTANT! Make sure the coolant really runs out. It may be necessary to clean away deposits inside the drain cocks. 4. Drain any other systems such as heater, water heater, etc., connected to the freshwater system too. 5. Close all cocks. 2 3

Seawater system The seawater system is the engine’s external cooling system. The seawater pump draws in water via the sea- water intake and pump it on through the charge air cooler, heat exchanger and the reverse gear oil cooler. The system is protected against galvanic corrosion by zinc anodes located in the charge air cooler, heat exchanger and the reverse gear oil cooler. 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. 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. Seawater system. Drain The seawater system must be drained during cold weather when there is a risk of freezing to prevent the system from bursting. An alternative to draining is to keep the engine room free from frost using an approved heater fan. WARNING! Risk of water entering. Close the seawater cock before starting work on the sea- water system. 1. Close the seawater cock. 2. Remove the cover on the seawater pump and al- low the water to run out. 3. Remove one drain plug (S) at a time and allow the water to run out until all drain points on the engine have been dismantled. IMPORTANT! Make sure the coolant really runs out. It may be necessary to clean away deposits inside the drain cocks. 4. Drain the water from the reverse gear oil cooler by opening tap (1). 5. TAMD63: Undo the hose (A) between the heat ex- changer and the reverse gear oil cooler, and empty out the water. 6. Drain/empty any extra equipment such as the sea water filter, bilge/flushing pump etc. 7. Install the cover on the sea water pump, connect all hoses and close/install all drain taps and plugs before you leave the boat. TAMD63 S S A S S S S S TAMD74 S 1

Impeller. Check/Change WARNING! Risk of water entering. Close the seawater cock before starting work on the sea- water system. In some installations, it can be easier to first remove the sea water pump from the engine (see next chap- ter) and then change the impeller. 1. Remove the end cover of the pump. Pull and twist out the impeller with adjustable pliers. 2. Inspect the impeller. Change the impeller if there are any visible cracks or other defects. 3. Clean the inside of the housing. Lubricate the pump housing and the inside of the cover with a water-resistant grease (that is not aggressive on rubber). 4. Press in the impeller while rotating it (clockwise). 5. Fit the cover with a new gasket. 6. Open the seawater cock. IMPORTANT! Always carry a spare impeller and gasket. Sea water pump. Removal and assembly WARNING! Risk of water entry. Close the sea cocks before doing any work on the sea water system. 1. Drain the water from the sea water system (please refer to previous page). 2. Undo the coolant pipes to and from the pump and remove the stay (1) on the TAMD74. 3. Remove the pump from the timing housing. 4. Check that the O-ring is undamaged and that it is correctly located on the pump. 5. Install the pump, tighten it and install the stay (1) on the TAMD74. 6. Grease the seal rings and install the coolant pipes to and from the pump. 7. TAMD74: Check that seal (2) seals correctly against the charge air cooler. 2 1

Zinc anodes. Check/Change WARNING! Risk of water entering. Close the sea- water cock before starting work on the seawater system. 1. Close the seawater cock. 2. Open drain tap (1) on the reverse gear oil cooler and drain off the sea water. 3. Remove the zinc anode in the reverse gear oil cooler (2), in the heat exchanger (3) and in the in- tercooler (4). NOTE! The sea water in the heat exchanger and intercooler is drained at the same time. 4. Change the anode if less than 50% of its original size. Otherwise, clean the anode with emery cloth to remove the layer of oxide. IMPORTANT! Do not use a wire brush or other metal tool for cleaning as this can im- pair the galvanic protection. 5. Fit the zinc anodes. Make sure there is good con- tact between the anode and the metal goods. 6. Close the drain cock (S). 7. Open the seawater cock before starting the en- gine. 8. Make sure there are no leaks. Seawater filter. Check/Clean The seawater filter is an accessory and is available in two models. If the water the boat is in is severely polluted, con- tains large amounts of seaweed, etc., the filter must be checked more often than is specified in the main- tenance schedule. The filter can otherwise become clogged and the engine overheat. WARNING! Risk of water entering. Close the seawater cock before starting work on the sea- water system. 1. Close the seawater cock. 2. Remove the cover (1) and lift up the insert. 3. Clean the insert and the housing (2). 4. Assemble the parts as illustrated below. Inspect gaskets and O-ring. Change if necessary. 5. Open the seawater valve and check for leaks. 3 1 2 4

Charge air cooler. Check the drain hole Condensation can form in the charge air cooler during operation. The condensation can be drained from a nipple (1) on the bottom of the charge air cooler. Make sure the nipple is not blocked. IMPORTANT ! If considerable amounts of water run out of the drain hole, the insert must be re- moved and test pressurized. This must be done by an authorised workshop.

Fuel system Use only fuel recommended in the fuel specifications below. Always observe cleanliness when refuelling and working with the fuel system. All work concerning the engine injection pump or injectors is to be carried out at an authorised workshop. Break- ing the seal on the injection pump will void the warranty. WARNING! Fire hazard. Work performed on the fuel system must be done on a cold engine. Fuel spill on hot surfaces or electrical components can cause fires. Keep fuel-drenched rags where they are safe in case of fire. Fuel specification Fuel must comply with national and international stan- dards at the least, e.g.: EN590 (with national environment and cold require- ments) ASTM-D975-No 1-D, 2-D JIS KK 2204 Sulphur content Complying with legal requirements in each country. If the sulphur content exceeds 0.5 wt%, service inter- vals must be changed, see “Maintenance: Lubricating system”. Fuels with low density (city diesel) can result in a loss of power by approx. 5% and an increase in fuel con- sumption of approx. 2–3 %. Fuel delivery pipes The delivery pipes must not be bent, twisted or ex- erted to any other forces. Change delivery pipes that are damaged. WARNING! Fire hazard! The fuel delivery pipes must not be bent, twisted or exerted to any other forces.

Fuel filters. Change Clean the filter bracket and place a receptacle under the filters. NOTE! Leave the old filters to a destruction plant. Standard fuel filters 1. Unscrew the filters. 2. Make sure the new filters are absolutely clean and that the gaskets are free from faults. Apply a little oil to the gaskets. 3. Screw on the filters by hand until they make con- tact with the sealing surface. Then screw a further half turn, not any more! 4. Bleed the fuel system as described above. 5. Start the engine and check for leaks. Fuel system. Bleeding The fuel system must be bled e.g. after changing fuel filter, if the fuel tank has been run dry and after long stops. Refer to the next page for bleeding when re- placing a switchable fuel filter during operation. 1. Place a receptacle under the fuel filter and open the bleed screw (1) on the filter bracket. 2. Pump fuel using the hand pump (2) until the fuel running out is free from air bubbles. Tighten the bleed screw while fuel is running out. 3. Pump another 10–20 times with the bleed screw closed to attain a good feed pressure. 4. Make sure there are no leaks. No other bleeding is normally required but if the en- gine will not start, the injection pump must be bled as follows: 1. Detach the connection (3) and pump with the hand pump until the fuel running out is free from air. 2. Tighten the conection while fuel is running out. 3. Pump another 10–20 times to attain a good feed pressure.

Switchable type fuel filters Switchable fuel filters can be changed while running as the flow of fuel can be cut off to one filter at a time. WARNING! Working on or approaching a run- ning engine is a safety hazard. Beware of rotat- ing parts and hot surfaces. 1. Put the lever (2) in its right-hand end position. 2. Unscrew the left-hand fuel filter. Use a filter wrench if necessary. 3. Screw on the filters by hand until they make con- tact with the sealing surface. Then screw a further half turn, not any more! 4. Open the left-hand bleed screw (1) on the filter bracket. Put the lever in operating position (straight up). Close the bleed screw when the fuel running out is free from air. 5. Put the lever in its left-hand end position and change the right-hand fuel filter in the same way. Fuel pre-filter. Check WARNING! Working on or approaching a run- ning engine is a safety hazard. Beware of rotat- ing parts and hot surfaces. The fuel pre-filter/water separator are accessories and available as single or dual models. The dual filter is equipped with a pressure gauge (1) indicating when it is time to change the filter insert. The filter inserts must be changed according to the maintenance schedule recommendations or ealier if the pressure gauge indicates a vacuum of 6–10 in. Hg at idling speed or 16–20 in. Hg at full engine speed/load. 1

Fuel pre-filter. Drainage Place a receptacle under the filter. Drain off water and contaminants through the plug (1) in the bottom of the glass bowl. IMPORTANT! Do not drain until a few hours af- ter stopping. Fuel pre-filter. Change filter elements The fuel pre-filter/water separator are accessories and available as single or dual models. The dual filter inserts can be changed while running as the flow of fuel can be cut off to one filter container at a time. The flow of fuel is governed by putting the knob (1) in the following positions: A: Normal running (both filters connected). B: Left filter insert can be changed. C: Right filter insert can be changed. D: Both filters turned off. 1 A D B C 1

Change filter elements: Close the fuel cocks on the tank or cut off the flow of fuel with the knob (1) for the filter insert to change if running. WARNING! Working on or approaching a run- ning engine is a safety hazard. Beware of rotat- ing parts and hot surfaces. 1. Place a receptacle under the filter. 2. Undo the T-bolt (2) and remove the cover (3). 3. Take out the insert carefully while turning it. 4. Drain off water and contaminants through the drain plug (4). 5. Fit a new filter insert and fill the container with clean fuel. IMPORTANT! Cleanliness! No contami- nants must be allowed in the fuel system. 6. Change the gasket on the cover and the O-ring on the T-bolt. Moisten the gasket and O-ring with fuel before assembling. 7. Fit the cover and tighten it by hand. 8. Wipe off any fuel from the heat shield. 9. Dual filter: Change the other filter insert in the same way. 10. Open the fuel cocks and put the knob (1) in posi- tion for normal running. Make sure there are no leaks. 1 4 3 2 4 3 2

Electrical system The engines are equipped with a bi-polar electrical system with alternating current generator. System voltage is 12 alternativly 24V. WARNING! Before starting work on the electrical system, the engine must be stopped and the powered turned off with the main switch/switches. Shore power to the engine heater, battery charger or other extra equipment fitted on the engine must be disconnected. Main switches The main switches must never be turned off until the engine has been stopped. Breaking the circuit be- tween the alternator and the batteries while the en- gine is running can damage the alternator. For the same reason, the charge circuits must never be switched while the engine is running. IMPORTANT! Never turn the power off using the main switches while the engine is running. Electrical connections Make sure electrical connections are tightened, dry and free from oxide. If necessary, spray these con- nections with water-repellant (Volvo Penta all-round oil). Fuses Two semi-automatic 8A fuses are located in the main electric terminal box. Fuses cut the current when there is an overload and are reset by pressing the buttons on the side of the main electrical terminal box. Determine the cause of the overload before re- setting the fuses.

Battery. Maintenance WARNING! Risk for fire and explosion. Never expose the battery to naked flames or sparks. WARNING! Never reverse the polarity of the battery. Risk of sparks and explosion. WARNING! Battery electrolyte is extremely cor- rosive. Protect eyes, skin and clothes when handling batteries. Always use protective goggles and gloves. In case of splashes on the skin, wash with soap and plenty of water. In case of splashes in the eyes, rinse immediately with plenty of water and call a doctor. Connecting and disconnecting Connect the (+) cable (red) to the (+) terminal of the battery first. Then connect the (–) cable (black) to the (–) pole of the battery. Disconnect the (–) cable (black) first and then the (+) cable (red). Cleaning Keep batteries dry and clean. Contaminants and ox- ide on batteries and battery terminals can cause short-circuits, voltage drops and discharging, espe- cially in damp weather. Clean oxide from battery ter- minals and cable shoes with a brass brush. Tighten cable shoes well and grease them with terminal grease or petroleum jelly. Electrolyte level The electrolyte should be 5–10 mm (0.2–0.4") above the cell plates in the battery. If necessary, top up with distilled water. The battery should be charged for at least 30 minutes after filling by running the engine at idling speed. NOTE! Special instructions must be followed for cer- tain maintenance-free batteries.

Battery. Charging WARNING! Risk for explosion. Charging gener- ates hydrogen gas (oxyhydrogen gas). A short circuit, naked flam or spark can cause a power- ful explosion. Ventilate well. WARNING! Battery electrolyte is extremely cor- rosive. Protect eyes, skin and clothes. Always use protective goggles and gloves. In case of splashes on the skin, wash with soap and plenty of water. In case of splashes in the eyes, rinse immediately with plenty of water and call a doc- tor. Charge the battery if it has been discharged. If the boat is not to be used for a long time, the battery must be fully charged and then trickle-charged (refer to battery manufacturer’s recommendations). The battery will be harmed if left discharged and can also freeze and crack in cold weather. IMPORTANT! Follow the battery charger user instructions carefully. Disconnect the battery cables before connecting the battery charger to avoid electrochemical corrosion when using an external battery charger. The battery plugs must be unscrewed but left in the holes while charging is in progress. Ventilate well, es- pecially if batteries are being charged in confined spaces. WARNING! Always cut the charging current be- fore disconnecting the charger cables. Never re- verse the polarity of the battery. Risk of sparks and explosion. Special directions apply for rapid charging. Rapid charging can impair the service life of the battery and should be avoided. Electric welding Disconnect the positive and negative battery cables. Then disconnect all the leads to the alternator. Always connect the weld clamp to the component be- ing welded and as close to the welding point as pos- sible. Never connect the clamp to the engine or in such a way as current can pass across a bearing. IMPORTANT! When welding has ceased, con- nect the leads to the alternator before recon- necting the battery cables.

Electrical installations Defective electrical insallations can generate stray current from the electrical system. Stray current can impair the galvanic protection for the propeller, pro- peller shaft, rudder, keel, etc. and cause damage due to electrochemical corrosion. IMPORTANT! Service on the boat’s low-cur- rent circuit should be carried out by a person with electrical training and experience. Installa- tions or work with shore power equipment must only be performed by an electrician qualified for high-current installations. The following points must always be taken into account: 1. If the shore power line is connected, it must have a protective earth on land, never in the boat. The shore power equipment must also be equipped with an earth fault breaker. The shore power equipment (transformer, con- verter, battery charger, etc.) must be intended for marine use where the high-voltage section is gal- vanically isolated from the low-voltage section. 2. Electric cables must be run and clamped so there is no risk of it being exposed to chafing, moisture or bilge water in the keelson. 3. Protective earth for e.g. radio, navigation equip- ment, rudder, bathing ladder or other equipment in which there are separate cables for protective earth must be collected on an earth connection that is not connected to the engine, gear wheels or reverse gear. IMPORTANT! The engine or reverse gear must never be used as an earth connection. 4. The battery must have a main switch connected on the positive (+) side of the battery. The main switch isolates all consumers and is turned off when the boat is not in use. 5. If an extra consumer battery is used, there must be a main switch (1) between the (+) terminal of the consumer battery and the fuse strip for the boat’s electric equipment. The main switch iso- lates all consumers connected to the consumer battery and is turned off when no longer needed. Equipment connected to the consumer battery must have separate switches. For simultaneous charging of two independent battery circuits, there should be a separate charge distributor (accessory) fitted to the stan- dard alternator. 1

Electrical component diagrams TAMD63L, TAMD63P 3. Starter motor 4. Alternator 5. Starter relay 6. Circuit breakers 7. Oil pressure sensor, Reverse gear 8. Pressure sensor, turbo pressure 9. Solenoid valve (fuel shut-off valve) 10. Coolant temperature monitor 11. Coolant temperature sensor 12. Oil pressure monitor, engine 13. Oil pressure sensor, engine 14. Engine speed sensor

TAMD74A 3. Alternator 4. Starter motor 5. Starter relay 9. Circuit breakers 10. Oil pressure sensor, reverse gear 11. Turbo pressure sensor 12. Oil pressure monitor, engine 13. Oil pressure sensor, engine 14. Coolant temperature sensor 16. Fuel shut-off valve (solenoid valve) 17. Coolant temperature monitor 22. Engine speed sensor

Reverse gear Oil level. Check and filling Check The oil level should be checked once the reverse gear has attained operating temperature with the en- gine idling and the controls in neutral. WARNING! Working on or approaching a run- ning engine is a safety hazard. Beware of rotat- ing parts and hot surfaces. Pull out the dipstick, wipe it off and insert it back into the reverse gear. Pull out the dipstick again and check the oil level. The correct oil level is between the MAX and MIN marks. Filling If necessary, top up with oil in the filler opening on top of the reverse gear. Oil grades and capacity: See Technical Data. IMPORTANT! Never overfill the reverse gear. The oil level must always lie within the recom- mended levels. Oil strainer. Cleaning WARNING! Working on or approaching a run- ning engine is a safety hazard. Beware of rotat- ing parts and hot surfaces. 1. Remove the plug/screw and carefully take out the filter (1) from the filter housing. IMPORTANT! Always observe the greatest cleanliness. Dirt must not enter the filter housing. 2. Clean the filter and other parts with paraffin. 3. Carefully refit all the parts. 4. Tighten the plug/screw. 5. Start the engine and check for leaks. Twin Disc 1 ZF (MPM) 1

Oil. Change Drain 1. Remove the dipstick. Connect a hose from the oil bilge pump (where applicable, the electric oil pump) to the dipstick pipe. Set the knob under the pump housing in position for pumping the reverse gear. 2. Pump the oil into a receptacle. 3. Replace the dipstick. Alternatively, the oil can be drained after removing the drain plug. Filling 1. Fill with oil through the filler opening on top of the reverse gear. Oil grades and capacity, see Tech- nical Data. IMPORTANT! Never overfill the reverse gear. 2. Start the engine and run it until the reverse gear has attained operating temperature. 3. Check the oil level with the engine at low idling speed and the controls in neutral position. The oil level must reach to the upper mark on the dipstick. Top up oil if needed. Seal. Lubrication Applies only to Twin Disc reverse gear* Lubricate the seal on the output shaft bearing using a hand gun and lithium-based grease such as Mobilux EP2, Statoil Uniway EP2N, Texaco Multifak EP2, Q8 Rembrandt EP2. * If a grease nipple is fitted.

er, it must be conserved. It is essential that it be performed correctly and nothing must be left out. This is why we have compiled a checklist of the most important points. Before taking the boat out of service for long periods, it should be left to a Volvo Penta workshop for an overhaul of the engine and other equipment. Have any faults and defects seen to so that the equipment is in good order when next started. WARNING! Read the chapter “Maintenance” thoroughly before starting any maintenance work. It contains directions for performing maintenance in a safe and correct manner. Certain preservatives are flammable. Some are also dangerous to inhale. Provide good ventilation. Use a protective mask when spraying. IMPORTANT! The following must be considered when cleaning with a high-pressure water jet: Never point high-pressure water jets directly at seals, rubber hoses or electrical components. Never use the high-pres- sure function when washing the engine Inhibiting l Run the engine warm and make sure the oil level in the reverse gear reaches the MAX mark on the dipstick. Stop the engine. l Stop up to eight months: Change oil and oil filter on the engine and then run it warm Stop over eight months: Treat the lubricating and fuel systems with preservative. See directions on next page. l Make sure there is enough anti-freeze in the cool- ant. Add more if necessary. An alternative is to drain the coolant. l Close the seawater cock and drain off the water in the seawater system. l Remove the impeller from the seawater pump. Keep the impeller in a cool place in a closed plas- tic bag. l Drain off any water and contaminant from the fuel tank. Fill the tank with fuel to avoid condensation. l Disconnect the battery cables and clean and charge the batteries. Trickle charge during the storage period. A poorly charged battery can freeze and break. l Clean the engine externally. Do not use high-pres- sure jets when cleaning the engine. Touch up any paint damage with Volvo Penta original paint. l Spray electric system components with water re- pellant. l Inspect all control cables and apply anti-corrosion agent. l Affix a label on the engine giving the date, type of conservation and the preservative that was used. l Cover the air intake to the engine, the exhaust aperture and the engine if necessary.

l Remove any protection on the engine, air intake and exhaust pipe. l Top up with lubricant of the correct grade in the engine if necessary. Fit a new oil filter if this was not done during conservation. l Make sure there is oil in the reverse gear. l Fit a new fuel filter and bleed the fuel system. l Check drive belts. l Check the condition of rubber hoses and check the tightness of all hose clips. l Close the drain cocks and fit the drain plugs. l Fit the impeller in the seawater pump. l Check the coolant level and anti-freeze. Top up as necessary. l Connect the fully charged batteries. l Open the seawater cock. l Start the engine (if the boat is in the water) and run the engine warm at idling speed before loading it. l Check for oil, fuel or coolant leaks. l Check the oil level in the reverse gear. Top up if necessary. Conserving the lubricating and fuel systems for stops longer than eight months: l Drain the oil from the engine and fill with pre- servative* to just over the MIN mark on the dip- stick. l Connect suction (1) and return fuel lines (2) to a fuel can filled with 1/3 preservative* and 2/3 diesel fuel. l Bleed the fuel system. l Start the engine and run it at fast idling speed until approximately two litres of fuel have been consumed. Stop the engine and connect the normal fuel lines. l Empty the preservative from the engine. l Follow the directions on the previous page in other respects. * Preservatives are available from oil companies. 1 2

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” be- fore starting work. Symptom and possible cause Engine can not be stopped 1, 2, 3, 5 Starter motor does not rotate 1, 2, 3, 4, 5 Starter motor rotates slowly 1, 2 Engine does not start 6, 7, 8, 9 Engine starts but stops again 7, 8 , 9, 13 Engine is difficult to start 7, 8 , 9, 13 Engine does not reach correct operating speed at full throttle 7, 8, 9, 10, 11, 12, 13, 18 Engine knocks 14 Engine run unevenly 7, 8, 9, 13, 14 Engine vibrates 18, 19 High fuel consumption 10, 11, 13, 15 Black exhaust smoke 13, 15, 18 Blue or white exhaust smoke 14, 15, 26 Oil pressure too low 16, 17 Coolant temperature too high 20, 21, 22, 23, 24, 25, 26 No charge, or poor charge 2, 27 1. Flat batteries 2. Poor contact/broken electrical cable 3. Main switch turned off 4. Engine control not in neutral 5. A fuse/circuit breaker has tripped 6. Lack of fuel 7. Blocked fuel filter/supply pump 8. Air in fuel system 9. Water/contamination in fuel 10. Boat abnormally loaded 11. Fouled hull/propeller 12. Engine speed control wrongly adjusted 13. Insufficient air supply 14. Too high coolant temperature 15. Too low coolant temperature 16. Too low lubrication oil level 17. Blocked oil filter 18. Defective/wrong propeller 19. Faulty engine mounting 20. Not enough coolant 21. Air in fresh water system 22. Blocked sea water inlet/pipe/filter 23. Circulation pump drive belt slips 24. Defective impeller 25. Defective/wrong thermostat 26. Too high lubrication oil level 27. Alternator drive belt slips

WARNING! Ventilate well. Batteries generate oxyhydrogen 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 bat- tery is the same as the system voltage of the en- gine. 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 auxiliary cable to the auxiliary battery’s – terminal and ultimately to a place away from the discharged batteries, e.g. on the main switch negative lead or the negative lead connection on the starter motor. WARNING! The black auxiliary cable (–) must not come in contact with the positive connection 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 running engine is a safety hazard. Beware of rotating 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.

6 6 Displacement ............................................................ 5.48 dm3 (334 in3) 7.28 dm3 (444 in3) Low idling speed ....................................................... 600 ±20 rpm 600 ±30 rpm Valve clearance, inlet* ....................................................................... 0.50 mm (0.0197") 0.50 mm (0.0197") outlet* ..................................................................... 0.65 mm (0.0256") 0.65 mm (0.0256") Compression pressure** ........................................... 2.2 MPa (319 psi) 2.2 MPa (319 psi) Weight*** ................................................................... 745 kg (1642 lbs) 860 kg (1896 lbs) * Applies to cold or warm engine (stopped). ** At starter motor speed (300 rpm). *** With heat exchanger, without reverse gear or clutch. Lubricating system Oil capacity, without oil filters*, No engine inclination ................................................. 20 liters (5.3 US gals) 24 liters (6.3 US gals) volume difference min.–max. ................................ 7 liters (1.8 US gals) 7 liters (1.8 US gals) Engine inclination 5° ................................................. 16 liters (4.2 US gals) 20 liters (5.3 US gals) volume difference min.–max. ................................ 6 liters (1.6 US gals) 5 liters (1.3 US gals) Engine inclination 10° ............................................... 12 liters (3.23 US gals) 14 liters (3.7 US gals) volume difference min.–max. ................................ 5 liters (1.3 US gals) 4 liters (1.1 US gals) Oil pressure at operating speed ................................ 300–550 kPa (43.5–79.8 psi) 450–650 kPa (65.3–94 psi) Oil pressure at idling speed ...................................... 150 kPa (21.8 psi) 150 kPa (21.8 psi) * Note. Engine oil filter and by-pass filter have each a capacity of approx. 0.5 liter (0.5 quart). Fuel system Engine designation TAMD63L-A TAMD74A-A TAMD63L-B Injection pump, setting .............................................. 16° ±0.5° BTDC. 15° ±0.5° BTDC. Engine designation TAMD63P-A TAMD74A-B Injection pump, setting .............................................. 15° ±0.5° BTDC. 12° ±0.5° BTDC. Cooling system Capacity .................................................................... 27 liters (7.1 US gals) 34 liters (9.0 US gals)

4.0 liters 5.3 liters 5.5 liters (1.06 US gals) (1.40 US gals) (1.45 US gals) Oil grade (to API system) .......................................... CC, CD, CE CC, CD, CE CC, CD, CE Viscosity .................................................................... SAE30* SAE30* SAE30* alt. in tropical regions ................................ SAE40* SAE40* SAE40* Working oil pressure ................................................. 2.0–2.2 MPa 2.5 MPa 2.3–2.4 MPa (290–319 psi) (363 psi) (334–348 psi) Weight, approx .......................................................... 53 kg 70 kg 86 kg (117 lbs) (154 lbs) (190 lbs) Twin Disc Type designation MG 5061A MG 5062V MG5075SC Oil capacity, approx .................................................. 3.2 liters 5.6 liters 5.9 liters (0.85 US gals) (1.48 US gals) (1.6 US gals) Oil grade (to API system) .......................................... CC, CD, CE CC, CD, CE CC, CD, CE Viscosity .................................................................... SAE30* SAE30* SAE40* alt. in tropical regions ................................ SAE40* SAE40* Oil pressure at oil temperature 82°C (180°F), engaged, 1800 rpm ................................................ 2.3 MPa 2.05–2.2 MPa 2.28 MPa (334 psi) (297–319 psi) (331 psi) at cruising speed, min. ........................................... 2.07 MPa 1.9 MPa (300 psi) (276 psi) Weight, approx. ......................................................... 113 kg 142 kg 140 kg (249 lbs) (313 lbs) (309 lbs) Type designation MG5091SC MG5091DC Oil capacity, approx. ................................................. 9 liters 18 liters (2.38 US gals) (4.75 US gals) Oil grade (to API system) .......................................... CC, CD, CE CC, CD, CE Viscosity .................................................................... SAE30* SAE30* alt. in tropical regions .................................. SAE40* SAE40* Working oil pressure ** “Neutral” ............................... 0.207–0.634 MPa (30–92 psi) Working oil pressure ** “Forward” ............................. 1.57–1.63 MPa (228–236 psi) Weight, approx. ......................................................... 220 kg 250 kg (485 lbs) (550 lbs) * Note! Only single-grade lubricating oil (only one viscosity number) may be used in the reverse gear. ** At oil temperature 82°C (180°F) and 1800 rpm. Electrical system Engine designation TAMD63L-A TAMD74A-A TAMD63L-B TAMD74A-B TAMD63P-A System voltage ......................................................... 12V (or 24V) 24V (or 12V) Battery capacity, 12V system ............................................................ 2 pcs. coupled parallel 12V, max. 110 Ah/battery 24V system ............................................................ 2 pcs. coupled in series 12V, max. 143 Ah

66 Notes ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ...........................................................................................................................................................................................

67 Notes ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ...........................................................................................................................................................................................

68 Notes ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ...........................................................................................................................................................................................

Availability after this period will be as far as supplies admit. Post or fax this coupon to: Document & Distribution Center Order Department ARU2, Dept. 64620 SE-405 08 Göteborg Sweden Fax: +46 31 545 772 Orders can also be placed via the Internet: http://www.volvopenta.com/ manual/coupon Yes please, I would like an operator’s manual in English at no charge. Publication number: 7740714-6 Name Address Country 42200/615001/155099900192 " Bitte beachten Sie, dass dieses Angebot für die Dauer von 12 Monaten ab dem Lieferdatum des Bootes gilt, danach bis zum Aufbrauchen des Lagerbestandes. Schicken Sie den Coupon per Post oder als Fax an: Document & Distribution Center Order Department ARU2, Dept. 64620 SE-405 08 Göteborg Schweden Fax: +46 31 545 772 Die Bestellung kann auch über das Internet erfolgen: http://www.volvopenta.com/ manual/coupon Ja, ich will kostenlos eine Betriebsanleitung in deutscher Sprache erhalten. Publikationsnummer: 7740715-3 Name Anschrift Land 42200/615001/155099900192 " 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. Envoyez ou faxez le bon de commande à: Document & Distribution Center Order Department ARU2, Dept. 64620 SE-405 08 Göteborg Suède Fax: +46 31 545 772 Vous pouvez également pas- ser la commande par Internet: http://www.volvopenta.com/ manual/coupon Oui merci, Je souhaite recevoir un manuel d’instructions gratuit en français. Numéro de publication: 7740716-1 Nom Adresse Pays 42200/615001/155099900192 "

ne; dopo il suddetto periodo l’offerta resta valida solo in base alla disposizione della pubblicazione in oggetto. Spedire il tagliando per posta o per fax a: Document & Distribution Center Order Department ARU2, Dept. 64620 SE-405 08 Göteborg Svezia Fax: +46 31 545 772 L’ordinazione può essere fatta anche su Internet: http://www.volvopenta.com/ manual/coupon Sì, grazie, desidero ricevere gratuitamente un manuale d’istruzioni in lingua italiana. Public. No.: 7740718-7 Nome e Cognome Indirizzo Paese 42200/615001/155099900192 " Nótese que el ofrecimiento vale durante 12 meses después de la fecha de entrega de la embarcación, y posteriormente solamente mientras duren las existencias. Franquear o enviar fax a: Document & Distribution Center Order Department ARU2, Dept. 64620 SE-405 08 Göteborg Suecia Fax: +46 31 545 772 El pedido puede hacerse tam- bién por internet: http://www.volvopenta.com/ manual/coupon Sí gracias, deseo recibir gratuitamente un libro de instrucciones en español. Número de publicación: 7740717-9 Nombre Dirección País 42200/615001/155099900192 " Observera att erbjudandet gäller i 12 månader från båtens leveransdatum, därefter endast i mån av tillgång. Posta eller faxa kupongen till: Dokument & Distribution center Ordermottagningen ARU2, Avd. 64620 SE-405 08 Göteborg Sverige Fax: +46 31 545 772 Beställningen kan även göras via internet: http://www.volvopenta.com/ manual/coupon Ja tack, jag vill kostnadsfritt ha en instruktionsbok på svenska. Publikationsnummer: 7740713-8 Namn Adress Land 42200/615001/155099900192 "

waarop de boot werd afgeleverd, daarna alleen indien nog verkrijgbaar. Stuur of fax de coupon naar: Document & Distribution Center Order Department ARU2, Dept. 64620 SE-405 08 Göteborg Zweden Fax: +46 31 545 772 U kunt ook bestellen via internet: http://www.volvopenta.com/ manual/coupon Ja graag, Ik wil kosteloos een instructieboek in het Nederlands ontvangen. Publicatienummer: 7740724-5 Naam Adres Land 42200/615001/155099900192 " Bemærk at tilbudet gælder i 12 måneder fra bådens leveringsdato, Deref- ter kun så længe lager haves. Send kuponen med post eller fax til: Document & Distribution Center Order Department ARU2, Dept. 64620 SE-405 08 Göteborg Sverige Fax: +46 31 545 772 Bestillingen kan også ske på internet: http://www.volvopenta.com/ manual/coupon Ja tak, jeg vil gerne gratis have en instruktionsbog på dansk Publikationsnummer: 7740719-5 Navn Adresse Land 42200/615001/155099900192 " Huomaa, että tarjous on voimassa 12 kuukautta veneen toimituspäivä- määrästä lukien ja sen jälkeen vain niin kauan kuin kirjoja riittää. Postita tai faksaa kuponki osoitteella: Document & Distribution Center Order Department ARU2, Dept. 64620 SE-405 08 Göteborg Ruotsi Fax: +46 31 545 772 Tilauksen voi tehdä myös Internetissä: http://www.volvopenta.com/ manual/coupon Kyllä kiitos, haluan suomenkielisen ohjekirjan veloituksetta. Julkaisunumero: 7740722-9 Nimi Osoite Maa 42200/615001/155099900192 "

ðáñÜäïóç ôïõ óêÜöïõò. ÌåôÜ ôï ðÝñáò ôçò åí ëüãù ÷ñïíéêÞò ðåñéüäïõ ç äéáèåóéìüôçôá ôùí áíôéôýðùí èá åîáñôÜôáé áðü ôçí ðïóüôçôá ôùí áðïèåìÜôùí. Ôá÷õäñïìÞóôå áõôü ôï êïõðüíé óôçí ðáñáêÜôù äéåýèõíóç Þ óôåßëôå ôï ìå öáî óôïí ðáñáêÜôù áñéèìü öáî: Document & Distribution Center Order Department ARU2, Dept. 64620 SE-405 08 Göteborg Sweden Fax: +46 31 545 772 Ìðïñåßôå åðßóçò íá äþóåôå ôçí ðáñáããåëßá óáò ìÝóù ôïõ Inter- net, óôç äéåýèõíóç: http://www.volvopenta.com/manual/ coupon Íáé, Èá Þèåëá Ýíá áíôßôõðï ôïõ åã÷åéñéäßïõ ÷ñÞóçò óôçí áããëéêÞ ãëþóóá ÷ùñßò êáìéÜ ÷ñÝùóç. Áñéèìüò Ýêäïóçò: 7740726-0 ¼íïìá Äéåýèõíóç ×þñá 42200/615001/155099900192 " 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. Envie o talão pelo correio ou um fax para: Document & Distribution Center Order Department ARU2, Dept. 64620 SE-405 08 Göteborg Suécia Fax: +46 31 545 772 A encomenda também pode ser feita através da Internet: http://www.volvopenta.com/ manual/coupon Sim, obrigado(a)! Gostaria de receber gratuitamente um manual de instruções em português. Número de publicação: 7740725-2 Nome Endereço País 42200/615001/155099900192 "