2
Safety Precautions
Check that the warning or information decals on
the product are always clearly visible. Replace
decals that have been damaged or painted over.
Engine with turbocharger: Never start the en-
gine without installing the air cleaner (ACL). The
rotating compressor in the Turbo can cause se-
rious personal injury. Foreign objects entering
the intake ducts can also cause mechanical
damage.
Never use start spray or similar to start the en-
gine. The starter element may cause an explo-
sion in the inlet manifold. Danger of personal in-
jury.
Avoid opening the filler cap for engine coolant
system (freshwater cooled engines) when the
engine is still hot. Steam or hot coolant can
spray out. Open the coolant filler cap carefully
and slowly to release pressure before removing
the cap completely. Take great care if a cock,
plug or engine coolant line must be removed
from a hot engine. It is difficult to anticipate in
which direction steam or hot coolant can spray
out.
Hot oil can cause burns. Avoid skin contact
with hot oil. Ensure that the lubrication system
is not under pressure before commencing work
on it. Never start or operate the engine with the
oil filler cap removed, otherwise oil could be
ejected.
Stop the engine and close the sea cock before
carrying out operations on the engine cooling
system.
Only start the engine in a well-ventilated area. If
operating the engine in an enclosed space, en-
sure that exhaust gases and crankcase ventila-
tion emissions are ventilated out of the working
area.
Introduction
This Workshop Manual contains technical data, de-
scriptions and repair instructions for Volvo Penta
products or product versions contained in the con-
tents list. Ensure that the correct workshop literature
is being used.
Read the safety information and the Workshop
Manual “General Information” and “Repair In-
structions” carefully before starting work.
Important
In this book and on the engine you will find the follow-
ing special warning symbols.
WARNING! If these instructions are not fol-
lowed there is a danger of personal injury, ex-
tensive damage to the product or serious me-
chanical malfunction.
IMPORTANT! Used to draw your attention to
something that can cause damage, product mal-
function or damage to property.
NOTE! Used to draw your attention to important infor-
mation that will facilitate work or operations.
Below is a summary of the risks and safety precau-
tions you should always observe or carry out when
operating or servicing the engine.
Immobilize the engine by turning off the power
supply to the engine at the main switch (switch-
es) and lock it (them) in the OFF position before
starting work. Set up a warning notice at the en-
gine control point or helm.
Generally, all servicing should be carried out
with the engine switched off. Some work (carry-
ing out certain adjustments for example) re-
quires the engine to be running. Approaching a
running engine is dangerous. Loose clothing or
long hair can fasten in rotating parts and cause
serious personal injury.
If working in proximity to a running engine,
careless movements or a dropped tool can re-
sult in personal injury. Avoid burns. Take pre-
cautions to avoid hot surfaces (exhausts, turbo-
chargers, charge air pipes and starter elements
etc.) and liquids in supply lines and hoses when
the engine is running or has been turned off im-
mediately prior to starting work on it. Reinstall
all protective parts removed during service op-
erations before starting the engine.
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