Safety directions for maintenance and service
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 turbochar-
ged engine must never be started without the air filter
fitted. The rotating compressor wheel in the turbo-
charger can cause severe personal injur y.
There is also a risk of foreign objects being drawn in
and causing mechanical damage.
Fire and explosion
Fuel and lubricants
All fuels, most lubricants, and many chemicals are
flammable substances. Always read and follow the
directions 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 compo-
nents can cause fires.
Keep oil- and fuel drenched rags and other hazar-
dous materials where they are safe in case of fire.
Oil drenched rags can selfignite in certain conditions.
Never smoke when refueling, topping up with oil or
when in the vicinity of the fuel station or the engine
room.
Non-original parts
Components in fuel, lubrication, ignition and electrical
systems on Volvo Penta engines are designed and
manufactured to minimize the risk of explosion and
fire in compliance 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, open flames and
sparks must never occur in, or close to, the batteries
or battery compartment. A faulty battery connection
or jumper cable can generate sparks that 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
injury.
Preparations
Knowledge
The operator’s manual contains directions for perfor-
ming nor mal maintenance and service in a safe and
correct manner. Read the directions carefully before
starting work. More detailed service literature is av-
ailable 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 dealer for assis-
tance instead.
Stop the engine
Stop the engine before opening or dismantling the
engine hatch/hood. Maintenance and service must
be carried out with the engine stationary unless sta-
ted otherwise in the instructions. Prevent inadvertent
start of the engine by removing the starter key and
tur ning off the power with the main switch, locking it
in the off position. Place warning signs stating that
service is in progress in ever y position from which the
engine can be started. Working on or approaching
a running engine is a safety hazard. Loose clothing,
hair, fingers or a dropped tool can be caught in rota-
ting parts and cause ser ious bodily injury. Volvo Pen-
ta recommend leaving all work requiring the engine
to be running to an authorized Volvo Penta dealer.
Lifting the engine
Always use the lifting eyes mounted on the engine
when lifting the engine. Always make sure lifting
equipment is in good condition and constructed for
the lift (engine weight together with possible reverse
gear and extra equipment). Use an adjustable lifting
boom to ensure safe handling when lifting the engine.
All chains and wires must run parallel with each other
and as much at right angle as possible to the top of
the engine. Note that any extra equipment mounted
on the engine can change the center of gravity. Spe-
cial lifting devices may be required to obtain the right
balance and safe handling. Never perform service on
an engine suspended only from a lifting device.
IMPORTANT! Engine must only be lifted horizon-
tally.
IMPORTANT! Engine lifting eyes are designed
only for lifting an engine. Do not use the engine
lifting eyes when lifting an engine with a gearbox
mounted.
8
Safety infor mation
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