Volvo Penta 22 Series Instruction Book
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Volvo Penta 22 Series Instruction Book

Volvo Penta 22 Series Instruction Book

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INSTRUCTION BOOK
22 Series

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Summary of Contents for Volvo Penta 22 Series

  • Page 1 INSTRUCTION BOOK 22 Series...

  • Page 2: Table Of Contents

    Trolling operation valve ......... 21 When sailing ............21 Checking instruments ........... 21 Operating with Power Trim ........22 © 1998 AB VOLVO PENTA All rights to changes or modifications reserved. Printed on enviornmentally friendly paper. (Cover: Department of transport (shipping), license 9809095)

  • Page 3: Safety Information

    Read the Instruction Manual carefully before operating or servicing the engine. If anything is unclear please contact your Volvo Penta dealer for assistance. This symbol is used in the book and on the engine to make you aware of safety information.

  • Page 4: Voyages

    Safety precautions to be taken when operating the boat Your new boat Refueling Read Instruction Manuals and other information When refueling there is always a danger of fire and supplied with your new boat. Learn to operate the explosion. Smoking is forbidden and the engine must engine, controls and other equipment safely and be switched off.
  • Page 5 Carbon monoxide poisoning When a boat is moving forward backwash is caused Most modern boats are designed in such a way that behind the boat. Sometimes this backwash can be so problems with backwash are extremely unusual. powerful that exhaust gases can be sucked into the Should a backwash problem occur do not open cabin or seating well on the boat with the resulting risk hatches or valves in the forward part of the boat.

  • Page 6: Maintenance And Service

    Volvo Penta Using non-original Volvo Penta parts can result in fire recommend that all servicing with the engine running or explosion on board.
  • Page 7 Hot surfaces and fluids Fuel system There is always a risk of burns when working with a Always use protective gloves when tracing leaks. hot engine. Beware of hot surfaces. For example: the Liquids ejected under pressure can penetrate body exhaust pipe, turbocharger (TC), oil pan, charge air tissue and cause serious injury.

  • Page 8: Introduction

    Introduction This Instruction Manual has been compiled to help you get the most from your Volvo Penta engine. It contains all the information you need in order to operate and maintain your engine safely and correctly. Please read the Instruction Manual carefully and learn how to operate the engine, controls and other equipment safely.

  • Page 9: Certified Engines

    Warranty and Service book. Note that AB Volvo Penta’s liability is limited to that contained in the Warranty and Service Book. Read this book as soon as you take delivery of the engine. It contains important information about warranty cards, service and maintenance which you, the owner, must be aware of, check and carry out.

  • Page 10: Identification Numbers

    Identification number Your engine and transmission has identification plates with identification numbers. This information should always be quoted when ordering service and replacement parts. There are probably similar plates on your boat and its equipment. Make a note of the details below, make a copy of the page and keep it so that you have a copy should the boat be stolen.

  • Page 11: Orientation

    Orientation The orientation illustrations do not illustrate all combinations of engines and reverse gears respectively drives It is therefore possible that information about your reverse gear or drive is with another engine model than the ones covered here. 1. Coolant filler cap 2.

  • Page 12: Md22P/Ms25

    12 13 14 15 18, 19 MD22P/MS25 12 13 14 15 TMD22/MS2 12 13 14 15 18, 19 TMD22P/HS25...

  • Page 13: Tamd22P/Sx

    12 13 14 15 TAMD22P/SX 1. Turbo (TMD, TAMD) 2. Coolant filler cap 3. Heat exchanger 4. Oil cooler 5. Oil scavenging/bilge pump pipe 6. Charge air cooler (CAC) (TAMD) 7. Oil filter 8. Starter motor 9. Generator 10. Injection pump 11.

  • Page 14: Instrumentation

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

  • Page 15: Starting Lock

    Warning display If the acoustic alarm sounds, one of the three warning lamps (10-12) on the instrument panel starts to flash to indicate the source of the alarm. 11 12 10. Engine coolant temperature too high. 11. Low oil pressure. 12.

  • Page 16: Controls

    Controls This chapter only describes the controls available from Volvo Penta as standard alternatives for your engine. If your boat is equipped with controls which are not described here and you feel uncertain about the functions, contact your Volvo Penta dealership.

  • Page 17: Power Trim

    Power Trim The SX propulsion system is equipped with a Power Trim hydraulic trim system which makes it possible to adjust the angle of the drive in relation to the stern of the boat. This adjusts the boat’s trim to obtain maximum comfort and fuel economy in different operating conditions.

  • Page 18: Starting The Engine

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

  • Page 19: Starting The Engine Using Auxiliary Batteries

    4. Turn the key to position ”III” to start. Release the key as soon as the engine has started, the key will automatically spring back to the ”I” position. If the engine did not start the key must first be turned to the ”0”...

  • Page 20: Operation

    Fault-tracing. If the engine speed exceeds wide open throttle range a propeller with a higher pitch should be selected. Ask your Volvo Penta service dealer for advice. Maneuvering All shifting between ahead and astern must be done at engine idle speed.

  • Page 21: Trolling Operation Valve

    Trolling operation valve HS25 reverse gear can be equipped with a trolling operation valve which makes it possible to steplessly reduce the boats lowest speed by 1-80% at engine speeds up to 1200 rpm. IMPORTANT! At higher speed the reverse gear may overheat. When sailing When sailing the control lever should be in the neutral position if the boat is equipped with HS25 reverse gear.

  • Page 22: Operating With Power Trim

    Power Trim while running The SX propulsion system is equipped with a Power Trim hydraulic trim system which makes it possible to adjust the angle of (trim) the drive in relation to the stern of the boat. This adjusts the boat’s trim to obtain maximum comfort and fuel economy in different load, speed, wind and sea conditions.
  • Page 23 At planing speed Trim the drive out to the operating position which provides the most stable and comfortable running. If the boat has twin motors the drives can be trimmed with different angles to compensate for side winds and to a certain extent compensate for uneven loading on one side of the boat or the other.

  • Page 24: Running Aground

    Volvo Penta workshop. If only the propeller has been damaged it must be replaced. Launch the boat and test drive. If there are still vibrations it must be inspected by an authorized Volvo Penta workshop. IMPORTANT! To prevent galvanic corrosion any damage to the paintwork on the drive and propeller must be repaired before launching the boat: See section “Laying up/Launching”.

  • Page 25: Stopping The Engine

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

  • Page 26: Cold Weather Precautions

    Cold weather precautions To prevent freezing damage, the seawater system must be drained and the freshwater system coolant must have sufficient antifreeze protection. See chapter Maintenance ”Cooling systems”. IMPORTANT! A poorly charged battery may burst as a result of freezing. Laying up If the boat is not going to be used for some time but is being left in the water, the engine must be run to operating temperature at least once...

  • Page 27: Maintenance Schedule

    Maintenance schedule Your Volvo Penta engine and its equipment is designed for maximum service life and reliability. They are built to survive in a tough marine environment, but also to cause as little environmental impact as possible. Regular maintenance according to the following schedule is necessary if the engine and transmission are to operate without problems.
  • Page 28 EVERY 200 OPERATING HOURS OR AT LEAST ONCE A YEAR G Engine oil and oil filter. Replace ..............page 31 G Timing gear belt. Check ................. page 29 G Fuel filter. Replace ..................page 39 G Fuel pre-filter. Replace ...................page 40 G Fuel feed pump.

  • Page 29: Maintenance And Care

    Maintenance This chapter contains instructions regarding how the above maintenance points should be carried out together with general technical information. Read the instructions carefully before starting work. Maintenance intervals are contained in the chapter: Maintenance schedule WARNING! Read the safety precautions for maintenance and service in the chapter: Safety Precautions, before starting work.
  • Page 30 Drive belts. General WARNING! Always turn the engine off before starting maintenance work. Check the tension and condition of the belts regularly. A belt that is too tight can damage the bearings and a belt that is too loose can result in slippage. Check and adjust as necessary after operating the engine when the belts are warm.

  • Page 31: Lubrication System

    Lubrication system IMPORTANT! With a new or reconditioned engine, the oil and oil filters must be changed after 20-50 hours of operation. After that they should be changed every 200 operating hours or at least once a year. Use only the recommended grades of oil: see the chapter ”Technical Data”. Oil level.

  • Page 32: Cooling System

    In event of frost risk Use a mixture of Volvo Penta antifreeze and pure water (the mixing ratio is on the packaging). Mix the coolant in a separate container before filling.
  • Page 33 No risk of freezing When there is never a risk of freezing water may be used as coolant with addition of Volvo Penta anti corrosion agent. Mix according to the instructions on the packaging. Warm up the engine after filling to allow the additive to work as efficiently as possible.
  • Page 34 Coolant. Replacing/Draining The antifreeze additive rust-proofing properties diminish with time. It is therefore important that the coolant is replaced according to the service schedule below. To avoid reduced cooling performance caused by scaling in the coolant system it should be flushed when it has been drained.
  • Page 35 Seawater system. Draining To prevent freezing damage the seawater system must be drained in cold weather where there is a risk of frost. IMPORTANT! If the boat does not have a seacock (boats with SX for example) the boat must be standing on dry land in order to drain the entire seawater system.
  • Page 36 The seawater system is now cleaned. Continue with points 6-8 to preserve it. 6. Fill container with an antifreeze mixture of 50% Volvo Penta glycol and 50% freshwater. 7. Collect mixture from system in a suitable container. 8. Start the engine and let it idle. Stop the engine just before the mixture is finished.
  • Page 37 Vacuum valve. Cleaning Some engines have a vacuum valve installed in the seawater piping. Disassemble the valve. Unscrew the hexagonal cover. In the cover there is a membrane and a gasket. Clean all the parts. Turn the cover upside down. Install the membrane first and then the gasket.

  • Page 38: Fuel Injection System

    Fuel injection system The fuel feed pump sucks fuel from the fuel tank and pumps it through the fuel filter on to the fuel injection pump where the pressure is increased before the fuel is pumped out to the injectors. When the injectors open the fuel is sprayed in to the cylinders.
  • Page 39 Fuel filter. Draining Open vent screw (1) on the filter mounting approx. 3 turns. Then undo the drain screw (2) a few turns. Let any water in the filter run off into a container. Tighten the screws. IMPORTANT! Wait a few hours after the engine has been turned off before draining the filter.
  • Page 40 Fuel pre-filter. Replacement Fuel pre-filters and water separators are accessories and are available in two variants. Filter insert replacement Close fuel cock at the fuel tank. Position a container under the fuel filter. Remember to dispose of the old filter at a proper disposal site. Fuel pre-filter type A: Remove the glass bowl by slackening off screw (2).

  • Page 41: Electrical System

    NOTE! The Power Trim equipment also has fuses. See under heading: SX-drive. Electrical connections Also check that all electrical connections are dry and free of oxidation and that there are no loose connections. If necessary, spray these connections with a water-repellent spray (Volvo Penta Universal oil).
  • Page 42 Battery. Maintenance WARNING! Risk of fire and explosion. Never allow an open flame or electric sparks near the battery or batteries. WARNING! Never mix up battery positive and negative terminals. This may cause sparks and an explosion. WARNING! The battery electrolyte contains extremely corrosive sulfuric acid.
  • Page 43 Battery. Charging WARNING! Danger of explosion! The batteries give off hydrogen gas during charging which when mixed with air can form an explosive gas - oxyhydrogen A short-circuit, naked flame or spark can cause a large explosion. Ensure that the ventilation is good. WARNING! The battery electrolyte contains extremely corrosive sulfuric acid.
  • Page 44 All equipment connected to the auxiliary battery should have separate switches. To simultaneously charge two independent battery circuits, fit a Volvo Penta charge distributor (accessory) to the regular generator.

  • Page 45: Wiring Diagram

    Wiring diagram Engine Engine 1. Engine coolant temperature (ECT) 2. Engine coolant temperature (ECT) switch Color code PU = Purple 3. Oil pressure sensor/switch GR = Gray GN = Green 4. Glow plugs SB = Black = White 5. Relay BN = Brown = Blue 6.
  • Page 46 Instrument panels...

  • Page 47: S-Drive And Reverse Gear

    ”Technical Data”. IMPORTANT! If the oil is colored gray then water has entered the drive. Please contact your authorized Volvo Penta dealer. Oil change. MS2 Remove the oil dipstick. Suck up oil using an oil pump through the hole for the dipstick. Top up oil to correct level.
  • Page 48 Oil level. MS25 and HS25 Remove the dipstick by turning/screwing it anti clockwise. Dry off the dipstick and reinstall it in the reverse gear, without screwing it into place. Remove the oil dipstick again and check the oil level. The correct oil level is between MAX and MIN marking for the HS25 and at the level marking for the MS25.
  • Page 49 Oil change. MS25 Remove the dipstick. Suck up oil using an oil pump through the hole for the dipstick. Measure out the correct amount of oil and fill up through the hole for the oil dipstick. For oil quality and capacity: See the chapter ”Technical Data”.
  • Page 50 WARNING! The line cutter (2) has very sharp edges and must be handled with care. IMPORTANT! The tab washer (3) must be replaced every fourth year. Only a Volvo Penta original locking screw (4) may be used.
  • Page 51 Removing and installing 1. Set the control lever in the ”Ahead” position. WARNING! Immobilize the engine before starting work. 2. Remove the propeller blade by first undoing the locking screws (5) completely and then pressing out the shaft studs (1). 3.

  • Page 52: Sx-Drive

    SX-drive The drive alloy components are protected against galvanic corrosion. This protection consists of five layers of paint, sacrificial anodes and ground braids. IMPORTANT! Check the corrosion protection regularly. Used, overpainted or oxidized sacrificial anodes, a broken ground braid or a paintwork damage can result in corrosion. The corrosion protection may also be inadequate due to a faulty electrical or faulty painting (for more information see “Electrical system”...
  • Page 53 IMPORTANT! If the oil is colored gray then water has entered the drive. Please contact your authorized Volvo Penta dealer. 5. Trim the drive up slightly. Remove the rear cover (2) and remove the plug (3) and its gasket.
  • Page 54 (on the injection pump). Reset the fuse by pressing in the button (5). The control handle with integrated Power Trim controls (Volvo Penta control) has a 5 A fusible link (6) in the harness. IMPORTANT! Always investigate the reason for...
  • Page 55 The propeller shaft should be smeared with a water resistant grease once a year. Remove and install according to the instructions on the next page. Ask your Volvo Penta dealership for advice if you wish to change to a propeller with another pitch or diameter.
  • Page 56 WARNING! Removal of the drive requires special knowledge and tools. A falling drive can cause serious personal injury. Please contact your nearest authorized Volvo Penta dealer for assistance. Lubrication. CV joint Remove the drive from mounting fork. The CV joint is lubricated by the two lubricating nipples (1).
  • Page 57 WARNING! Removal of the drive requires special knowledge and tools. A falling drive can cause serious personal injury. Please contact your nearest authorized Volvo Penta dealer for assistance.

  • Page 58: Laying Up/Launching

    Laying up/Launching Before taking the boat out of the water for winter/out-of-season storage have an authorized Volvo Penta workshop inspect the engine and other equipment. Inhibition should be carried out to ensure that the engine and transmission are not damaged while out of commission during the winter/off-season.

  • Page 59: Bringing Out Of Storage

    Touch up any damaged areas of paintwork with Close/tighten drain cocks/plugs. Volvo Penta original paint. NOTE! Read the Check drive belts. special instructions on painting the drive under the Check the condition of rubber hoses and check heading: Painting the drive and underwater hull tighten hose clamps.

  • Page 60: Painting The Drive And Underwater Hull

    Most countries have introduced legislation controlling the use of anti-fouling agents. In some cases these agents are completely forbidden for use on leisure craft. In these cases ask your Volvo Penta dealer for advice about alternative methods. IMPORTANT! Find out what regulations apply to the use of anti-fouling agents.

  • Page 61: Fault-Tracing

    A number of symptoms and possible reasons for engine problems are described in the table below. In case of faults or mishaps which you cannot solve, always contact the Volvo Penta dealership. WARNING! Read the safety precautions for maintenance and service in the chapter: Safety Precautions, before starting work.

  • Page 62: Technical Data

    Technical data Engine Engine designation .......... MD22L-B, MD22P-B, TMD22-B, TMD22P-C, TAMD22P-B No. of cylinders ..........Cylinder bore/stroke ........84.5/88.9 mm Cylinder volume ..........2 liters Max. bhp ............See sales literature Idling speed ............. 800 ± 25 rpm Wide Open Throttle (WOT) range ....See chapter ”Operation”...

  • Page 63: S-Drive And Reverse Gear

    S-drive Type designation ..........120S–E Gear ratio ............2,2:1 Oil quality/Viscosity ........API GL5/SAE 75W/90 (synthetic) Oil capacity, approximately ......2,8 liters Difference between MIN and MAX markings . 0,07 liters Weight .............. 28 kg Reverse gear Type designation ..........MS2L–E MS2A–E Gear ratio ............
  • Page 64 Notes ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________...
  • Page 66 AB Volvo Penta SE-405 08 Göteborg, Sweden www.volvopenta.com...

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