Volvo Penta KAD/KAMD44P User manual

OPERATOR’S MANUAL
KAD/KAMD44P, KAD/KAMD300

CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
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1
Welcome aboard
Volvo Penta marine engines are used all over the world today. They are used in all pos-
sible operating conditions for professional as well as leisure purposes. That’s not sur-
prising.
After more than 90 years as an engine manufacturer and after delivering over 500,000
marine engines, the Volvo Penta name has become a symbol of reliability, technical in-
novation, top of the range performance and long service life. We also believe that this is
what you demand and expect of your Volvo Penta engine.
We would like you to read this operator’s manual thoroughly and consider the advice we
give on running and maintenance before you cast off on your maiden voyage so that
you will be ensured of fulfilling your expectations.
With warm regards
AB VOLVO PENTA
IMPORTANT! These instructions do not contain descriptions of controls or
operation for boats with waterjet. If your boat is equipped with Volvo Penta
waterjet, this information can be found in the operator’s manual that came
with the waterjet.

2
Safety Information ............................................. 3–7
General .................................................................... 3
Boat travel ............................................................... 4
Maintenance and service ......................................... 6
Introduction ...................................................... 8–10
Running-in ............................................................... 8
Fuel and oil types.................................................... 8
Certificated engines ................................................ 9
Warranty information ............................................... 9
Identification numbers ............................................ 10
Presentation .................................................... 11–16
Technical Description ............................................. 11
What is EDC .......................................................... 12
Orientation ............................................................. 13
Instrumentation ............................................... 17–21
Instrument panels .................................................. 17
Control panels ........................................................ 18
Warning displays .................................................... 18
Starting switch ....................................................... 19
Control panels (EDC) ............................................. 20
Controls .......................................................... 22–23
Power Trim ..................................................... 24–26
Starting the engine .......................................... 27–29
Before starting ....................................................... 27
General about starting ............................................ 27
Starting method ..................................................... 28
Operation ......................................................... 30–36
Checking instruments ............................................ 30
Diagnostic information ........................................... 31
Cruising speed ....................................................... 31
Synchronising engine speed ................................. 32
Changing control position ...................................... 32
Manoeuvering ....................................................... 33
Power Trim while running ...................................... 34
Stopping the engine ...................................... 37–38
Stopping ................................................................ 37
Laying up ............................................................... 37
Cold weather precautions ....................................... 38
Maintenance schedule .................................... 39–42
Maintenance .................................................... 42–74
Engine, general ...................................................... 42
Lubrication system ................................................. 47
Freshwater system ................................................ 49
Coolants ................................................................ 49
Seawater system ................................................... 51
Fuel injection system ............................................. 54
Electrical system ................................................... 56
Electrical components diagram .............................. 61
Reverse gear .......................................................... 63
Drive ...................................................................... 65
Steering ................................................................. 70
Propellers ............................................................... 73
Laying up/Launching ...................................... 75–77
Inhibiting ................................................................ 75
Bringing out of winter storage ................................. 76
Painting the drive and underwater hull .................... 77
Fault-tracing ..................................................... 78-84
Symptoms and possible causes ............................ 78
Starting using auxiliary batteries ............................ 79
Emergency shifting ................................................ 80
Calibrating the control unit ...................................... 81
Diagnostic function .......................................... 85-91
Diagnostic function ................................................ 85
Reading off diagnostic trouble codes (DTCs) .......... 86
Erasing diagnostic trouble codes (DTCs) ............... 87
Diagnostic trouble codes (DTCs) ............................ 88
Technical Data .................................................. 92-93
Engine ................................................................... 92
Fuel specification ................................................... 92
Drive ...................................................................... 93
Reverse gear .......................................................... 93
Power Trim ............................................................ 93
Steering ................................................................. 93
© 2002 AB VOLVO PENTA
All rights to changes or modifications reserved.
Printed on environmentally friendly paper.
(Cover: Department of transport (shipping), license 9809095)
Contents

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

4
Safety Information
Safety precautions to be taken when operating the boat
Your new boat
Read operator’s manuals and other information sup-
plied with your new boat. Learn to operate the engine,
controls and other equipment safely and correctly.
If this is your first boat, or is a boat type with which
you are not familiar, we recommend that you practice
controlling the boat in peace and quiet. Learn how the
boat behaves at different speeds, weather conditions
and loads before casting off for your “real” maiden
voyage.
Remember that the person driving a boat is legally re-
quired to know and follow the current rules regarding
traffic and safety at sea. Make sure you know the
rules that apply to you and the waters you are sailing
in by contacting the relevant authorities or organiza-
tion.
A good piece of advice is to take a course in seaman-
ship. We recommend that you contact your local boat-
ing organization to find a suitable course.
Accidents
Statistics show that poor maintenance of boats and
engines and a lack of safety equipment are often the
cause of accidents at sea.
Ensure that your boat is maintained in accordance
with the relevant Instruction Manual and that the nec-
essary safety equipment is on-board and is service-
able.
Daily checklist
Make a habit of checking the engine and engine com-
partment visually before operating the boat (before
the engine is started) and after operating the boat
(after the engine has been stopped). This will help
you to quickly detect fuel, coolant or oil leaks and
spot anything else unusual that has or is about to hap-
pen.
Maneuvering
Avoid violent and unexpected changes in course and
gear engagement. This could cause someone on the
boat to lose their balance and fall over or overboard.
A rotating propeller can cause serious injury. Check
that nobody is in the water before engaging ahead or
astern. Never drive near bathers or in areas where
people could be in the water.
Avoid trimming an outboard drive too much, as steer-
ing will be severely reduced.
Refueling
When refueling there is always a danger of fire and ex-
plosion. Smoking is forbidden and the engine must be
switched off.
Never overfill the tank. Close the fuel tank filler cap
properly.
Only use the fuel recommended in the operator’s man-
ual. The wrong grade of fuel can cause operating prob-
lems or cause the engine to stop. On a diesel engine
poor quality fuel can cause the control rod to seize
and the engine to overrev with a resultant risk of dam-
age to the engine and 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.
Safety breaker
We recommend that you install and use a safety
breaker (accessory), especially if you boat can travel
at high speeds. The safety breaker stops the engine if
the driver falls down and loses control over the boat.

5
Safety Information
Carbon monoxide poisoning
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 prevalent 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 obtaining
the best solution for your boat.
Checklist
●Safety equipment Life jackets for all passengers, communication equipment, emergency rockets,
approved fire extinguisher, first-aid equipment, life belt, anchor, paddle, torch etc.
●Replacement parts and tools: impeller, fuel filters, fuses, tape, hose clamps, engine oil, propeller
and tools for any repairs that might have to be carried out.
●Get out your charts and go over the planned route. Calculate distance and fuel consumption. Lis-
ten to the weather reports
●Make sure that relations or contact persons are informed when planning a longer voyage. Remem-
ber to inform them if your plans have changed or been delayed.
●Tell your passengers and crew where the safety equipment is stored and how to operate it. Make
sure you are not the only person on board who knows how to start the boat and operate it safely.
This list can be added to because safety equipment and other requirements vary depending on the
type of boat and how it is used. We recommend that you contact your local boating organization for
more detailed information on safety afloat.

6
Safety Information
Safety precautions for maintenance and service operations
Preparations
Knowledge
The operator’s manual contains instructions on how to
carry out general maintenance and service operations
safely and correctly. Read the instructions carefully
before starting work.
Service literature covering more complicated opera-
tions is available from your Volvo Penta dealer.
Never carry out any work on the engine if you are un-
sure of how it should be done, contact your Volvo
Penta dealer who will be glad to offer assistance.
Stop the engine
Stop the engine before opening or removing engine
hatches. Unless otherwise specified all maintenance
and service must be carried out with the engine
stopped.
To prevent accidental start of the boat engine remove
the ignition key, turn off the power supply to the en-
gine at the main switches and lock them in the OFF
position before starting work. Put up a warning sign in
the control position that work on the engine is being
carried out.
Approaching or working on an engine that is running is
a safety risk. Loose clothing, hair, fingers or a
dropped tool can be caught in the rotating parts of the
engine and cause serious personal injury. Volvo Penta
recommend that all servicing with the engine running
be undertaken by an authorized Volvo Penta work-
shop.
Lifting the engine
When lifting the engine use the lifting eyes installed
on the engine (reverse gear where installed). Always
check that lifting equipment is in good condition and
has sufficient load capacity to lift the engine (engine
weight including reverse gear and any extra equipment
installed). For safety’s sake lift the engine using an
adjustable lifting beam. All chains and cables should
run parallel to each other and as perpendicular as pos-
sible in relation to the top of the engine. Bear in mind
that extra equipment installed on the engine may alter
its center of gravity. Special lifting equipment may
then be required in order to maintain the correct bal-
ance and make the engine safe to handle. Never carry
out work on an engine suspended on a hoist.
Before starting the engine
Reinstall all protective parts removed during service
operations before starting the engine. Check that no
tools or other items have been left on the engine.
Never start a turbocharged engine without installing
the air cleaner (ACL). The rotating compressor in the
Turbocharger unit can cause serious personal injury.
Foreign objects can also be sucked in and cause me-
chanical damage to the unit.
Fire and explosion
Fuel and lubrication oil
All fuel, most lubricants and many chemicals are in-
flammable. Read and follow the instructions on the
packaging.
When carrying out work on the fuel system make sure
the engine is cold. A fuel spill onto a hot surface or
electrical components can cause a fire.
Store fuel soaked rags and other flammable material
so that there is no danger of them catching fire. Fuel-
soaked rags can self-ignite under certain conditions.
Do not smoke when filling fuel, oil or in proximity of a
filling station or in the engine room.
Non-original components
Components used in the fuel and ignition system
(gasoline engines) and electrical systems on Volvo
Penta products are designed and constructed to mini-
mize the risk of fire and explosion.
Using non-original Volvo Penta parts can result in fire
or explosion on board.
Batteries
The batteries contain and give off oxyhydrogen gas,
especially during charging. This gas is easily ignited
and highly volatile.
Do not under any circumstances smoke or use naked
flame or allow sparks in the vicinity of the batteries or
battery compartment.
Incorrectly connection a battery terminal cable or
jump-start cable can cause a spark which in its turn
can be sufficient to cause an explosion.
Start spray
Never use start spray or similar agents to start an en-
gine equipped with air pre-heating (glow plugs/starter
element). This may cause an explosion in the inlet
manifold. Danger of personal injury.

7
Safety Information
Hot surfaces and fluids
There is always a risk of burns when working with a
hot engine. Beware of hot surfaces. For example: the
exhaust pipe, Turbo unit, oil pan, charge air pipe,
starter element, hot coolant and hot oil in oil lines and
hoses.
Carbon monoxide poisoning
Only start the engine in a well-ventilated area. If oper-
ating the engine in an enclosed space, ensure that
there is proper ventilation in order to remove exhaust
gases and crankcase ventilation emissions from the
working area.
Chemicals
Most chemicals such as anti-freeze, rustproofing
agent, inhibiting oil, degreasing agent etc. are hazard-
ous to health. Read and follow the instructions on the
packaging.
Some chemicals such as inhibiting oil are inflammable
and dangerous if breathed in as well. Ensure good
ventilation and use a protective mask when spraying.
Read and follow the instructions on the packaging.
Store chemicals and other hazardous materials out of
the reach of children. To protect the environment
please dispose of used or leftover chemicals at a
properly designated disposal site for destruction.
Cooling system
There is a risk of flooding when working on the seawa-
ter system. Turn off the engine and close the sea
cock (where installed) before starting work on the sys-
tem.
Avoid opening the coolant filler cap when the engine is
hot. Steam or hot coolant can spray out and cause
burns.
If work must be carried out with the engine at operat-
ing temperature and the coolant filler cap or a cock
open or a coolant hose disconnected, open the cool-
ant filler cap carefully and slowly to release pressure
before removing the cap completely. Note that the
coolant may still be hot and can cause burns.
Lubrication system
Hot oil can cause burns. Avoid skin contact with hot
oil. Ensure that the lubrication system is not under
pressure before commencing work on it. Never start or
operate the engine with the oil filler cap removed, oil
can spray out.
Fuel system
Always use protective gloves when tracing leaks. Liq-
uids ejected under pressure can penetrate body tissue
and cause serious injury. There is a danger of blood
poisoning.
Always cover the generator if it is located under the
fuel filter. The generator can be damaged by spilled
fuel.
Electrical system
Cutting off power
Always stop the engine and break the current using
the main switches before working on the electrical
system. Isolate shore current to the engine block
heater, battery charger, or accessories mounted on
the engine.
Batteries
The batteries contain an extremely corrosive electro-
lyte. Protect your skin and clothes when charging or
handling batteries. Always use protective goggles and
gloves.
If battery electrolyte comes into contact with unpro-
tected skin wash off immediately using plenty of water
and soap. If battery acid comes into contact with the
eyes, flush immediately with plenty of water and ob-
tain medical assistance without delay.

8
Introduction
This operator’s manual has been compiled to help you get the most from your Volvo Penta engine. It contains all
the information you need in order to operate and maintain your engine safely and correctly. Please read the opera-
tor’s manual carefully and learn how to operate the engine, controls and other equipment safely.
Always have the operator’s manual available. Keep it in a safe place and do not forget to give it to the new owner
if you sell your boat.
Care of the environment
We would all like to live in a clean and healthy environ-
ment. Somewhere where we can breathe clean air, see
healthy trees, have clean water in our lakes and oce-
ans, and are able to enjoy the sunshine without being
worried about our health. Unfortunately, this cannot be
taken for granted nowadays but is something we must
work together to achieve.
As a manufacturer of marine engines, Volvo Penta has
a special responsibility, why care of the environment is
a core value in our product development. Today, Volvo
Penta has a broad range of engines where progress
has been made in reducing exhaust emissions, fuel
consumption, engine noise, etc.
We hope you will take care in preserving these quali-
ties. Always follow any advice given in the instruction
manual concerning fuel grades, operation and mainte-
nance and you will avoid causing unecessary interfe-
rence to the environment. Get in touch with your Volvo
Penta dealer if you notice any changes such as in-
creased 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 condition
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 disposal at a de-
struction plant.
Our joint efforts will make a valuable contribution
to our environment.
Running-in
The engine must be run in for its first 10 operating
hours as follows: Operate the engine normally. Do not
operate it at full load except for short periods. Never
run the engine at a constant engine speed for long peri-
ods during the running-in period.
The engine can be expected to use more engine oil
during the running-in period than would otherwise be
normal. Check the oil level more often than is normally
recommended.
A First Service Inspection must be carried out after
20–50 running hours. For further information: See the
Warranty and Service Book.
Fuel and oils
Only use the fuel and oils recommended in the chap-
ter Technical Data. Other grades of fuel and oil can
cause operating problems, increased fuel consump-
tion and, in the long-term, a shorter engine service
life.
Always change oil, oil filters and fuel filters at the re-
commended intervals.
Service and replacement 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 Volvo Penta worldwide network of authorized
dealers are at your service. They are specialists in
Volvo Penta products and have accessories and the
original replacement parts, test equipment and special
tools necessary for high quality service and repair
work.
Always follow the maintenance intervals contained in
the operator’s manual. Remember to state the engine/
transmission identification number when ordering
service and replacement parts.

9
Introduction
Warranty
Your new Volvo Penta marine engine is covered by a limited warranty according to the conditions and
instructions contained in the Warranty and Service book.
Note that AB Volvo Penta’s liability is limited to that contained in the Warranty and Service Book. Read
this book as soon as you take delivery of the engine. It contains important information about warranty
cards, service and maintenance which you, the owner, must be aware of, check and carry out. Liability
covered in the warranty may otherwise be refused by AB Volvo Penta.
Contact your Volvo Penta dealer if you have not received a Warranty and Service Book and a
customer copy of the warranty card.
Certificated engines
If you own an engine certificated for any area
where exhaust emissions are regulated by law, the
following is important:
Certification means that an engine type is inspected
and approved by the authorities. The engine manufac-
turer guarantees that all engines manufactured of that
type correspond to the certified engine.
This places special requirements for mainte-
nance and service as follows:
●The maintenance and service intervals recommen-
ded by Volvo Penta must be observed.
●Only genuine Volvo Penta replacement parts may
be used.
●The service of injection pumps and injectors or
pump settings must always be carried out by an
authorized Volvo Penta workshop.
●The engine must not be modified in any way ex-
cept with accessories and service kits approved
by Volvo Penta.
●No modifications to the exhaust pipes and air
supply ducts for the engine may be undertaken.
●Seals may only be broken by authorized person-
nel.
Otherwise the general instructions contained in the
operator’s manual concerning operation, service and
maintenance must be followed.
IMPORTANT! Late or inadequate maintenance/
service or the use of spare parts other than
Volvo Penta original spare parts will invalidate
AB Volvo Penta’s responsibility for the engine
specification being in accordance with the certifi-
cated variant.
Volvo Penta accepts no responsibility or liability
for any damage or costs arising due to the abo-
ve.

10
Introduction
Identification numbers
Always provide the engine and transmission identification numbers when ordering service or replacement compo-
nents.
The identification numbers are on an information decal located on the front edge of the engine. Note the informa-
tion below. Make a copy of the page. Store the information so that it is available in event of the boat being stolen.
Engine
Product designation (1*) ......................................................................................................
Serial number (2*) ...............................................................................................................
Product number (3*) ............................................................................................................
Drive/Reverse gear
Product designation (4*) .......................................................................................................
Gear ratio (5*) ......................................................................................................................
Serial number (6*) ................................................................................................................
Product number (7*) .............................................................................................................
Shield (Drive)
Product designation (8*) .......................................................................................................
Serial number (9*) ................................................................................................................
Product number (10*) ...........................................................................................................
* The numbers refer to the position of the identification numbers on the information decal
Location of information decal and identification plates:
Engine/Drive/Reverse gear (information decal)
XXX XXX
RATED POWER: xxx
RATED SPEED: xxxx
PART NO: xxx xxxx
DATASET: xxx xxx
ECU BATCH: xxxx
Control module (decal)
Engine (identification plate)
Certification (identification plate)
Drive/Shield (identification plate) Reverse gear
(identification plate)

11
Presentation
KAD/KAMD44P* and KAD/KAMD300* are in-line, direct injected 6-cylinder marine diesel engines, specially
developed for planing boats.
They are equipped with electronically controlled fuel injection, a mechanical supercharger, turbocharger, intercool-
er, heat exchanger for thermostatically controlled fresh water cooling, electronically controlled engine speed con-
trol and shifting.
The supercharger provides the engines with air at low speeds, and at higher speeds the turbocharger provides the
air supply. This interaction gives the engines extremely high torque at all engine speeds.
Technical description
Engine and cylinder block
– The cylinder block and cylinder head are manufac-
tured of alloyed cast iron
– 4 valve technology
– Oil cooled pistons
– Replaceable wet cylinder liners
– Replaceable valve seats
– Crankshaft carried on seven bearings
Lubrication system
– Pressure lubrication system with replaceable full
flow oil filter
– Gear driven oil pump
– Washable pipe type oil cooler
Intake and exhaust system
– Intake silencer with replaceable filter
– Seawater cooled exhaust pipe made of cast iron
with a stainless steel insert
– Exhaust driven freshwater cooled turbocharger
(TC)
– Mechanically driven compressor
Fuel system
– Rotor type fuel injection pump with electronic actu-
ator
– Microprocessor based control module for fuel con-
trol module (EDC*)
– Two step injector
– Fine fuel filter with water separator
– Feeder pump with hand pump
Cooling system
– Thermostat controlled freshwater cooling system
– Pipe heat exchanger with separate expansion tank
– Cooling system prepared for hot water outlet
Electrical system
– 12V two pole electrical system
– 14V/60A generator, adapted for marine use.
– Charge regulator with battery sensor for compen-
sating voltage drop
* KAD (engine with drive)
KAMD (engine with reverse gear)
EDC (Electronic Diesel Control), see description in next section.

12
Presentation
What is EDC
EDC stands for Electronic Diesel Control. It is an electronic system for marine diesel engine control. The system
has been developed by Volvo Penta and covers fuel control, diagnostic function and electronic engine speed
control and shifting.
The processor
The brain of the EDC system, the processor, is en-
cased in the control module and protected against
moisture and vibration.
The processor continuously receives information
about fuel supply, engine speed, charge air pressure,
engine temperature and driver commands etc, via a
number of sensors and senders.
The information provides an exact picture of the pre-
vailing operating conditions. This makes it possible for
the processor to calculate the correct fuel volume,
check the engine condition and prevent irritating stall-
ing during backward and forward manoeuvring etc.
Fuel control
The engine fuel requirement is analysed up to a 100
times per second. If necessary the fuel supply is ad-
justed by the electronic actuator in the fuel injection
pump.
This ensures that the engine always receives the
correct volume of fuel in all operating conditions. This
means lower fuel consumption and minimal exhaust
emissions.
Diagnostic function
The task of the diagnostic function is to discover and
localise any disturbances within the EDC system, to
protect the engine and to ensure operation in event of
serious disturbances.
If a disturbance is found the diagnostic button indica-
tor in the control panel begins to flash. By pressing
the diagnostic button the operator will receive a diag-
nostic trouble code (DTC) as a guide for any fault-
tracing.
Engine speed control and shifting
The operating command is transferred to the electron-
ic actuator in the fuel injection pump, the electronic
valves in the reverse gear or to the gearshift control
actuator for drive, using a potentiometer in the
operating control.
The result is fast accurate throttle response and
smooth shifts.
Changing is further protected by the processor which
prevents shifting at too high engine speeds which may
cause damage to the transmission.
1
2
3
5
4
1. Control Module
2. Injection pump
3. Control panel
4. Gearshift control actuator
5. Potentiometer
For the location of other electrical components: See the chapter
“Maintenance. Electrical components diagram”.

13
Presentation
1234 5
78
910
11
6
12
13
19
14 15 16 17 18
20
Orientation
KAMD44P/KAMD300, HS63
1. Electrical box
2. Oil filler cap, engine
3. EDC control module
4. Oil filter, engine
5. Charge air cooler
6. Dipstick, reverse gear
7. Starter motor
8. Fuel feed pump
9. Fuel filter
10. Injection pump
11. Generator
12. Sea water pump
KAMD44P/KAMD300, HS63
13. Turbocharger
14. Air Cleaner (ACL)
15. Dipstick, engine
16. Coolant filler
17. Expansion tank
18. Compressor
19. Heat exchanger
20. Oil filter, reverse gear

14
Presentation
KAD44P/Professional, DP-E
1. Seawater filter
2. Electrical box
3. Oil filler cap, engine
4. EDC control module
5. Oil filter, engine
6. Charge air cooler
7. Starter motor
8. Fuel feed pump
9. Fuel filter
10. Injection pump
11. Generator
12. Sea water pump
KAD44P/Professional, DP-E
13. Turbocharger
14. Air Cleaner (ACL)
15. Dipstick, engine
16. Coolant filler
17. Expansion tank
18. Compressor
19. Power steering pump
20. Heat exchanger
21. Trim cylinder
22. Cooling water intake
23. Guide cylinder
24. Topping up oil, drive
22
21
13
20
14 15 16 17 18
19
24
23
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4

15
Presentation
KAD44P/DPX-A
1. Seawater filter
2. Electrical box
3. Oil filler cap, engine
4. EDC control module
5. Oil filter, engine
6. Charge air cooler
7. Starter motor
8. Fuel feed pump
9. Fuel filter
10. Injection pump
11. Generator
12. Sea water pump
KAD44P/DPX-A
13. Turbocharger
14. Air Cleaner (ACL)
15. Dipstick, engine
16. Coolant filler
17. Expansion tank
18. Compressor
19. Power steering pump
20. Heat exchanger
21. Trim cylinder
22. Cooling water intake
23. Guide cylinder
24. Topping up oil, drive
25. Oil dipstick, drive
22
21
13
20
14 15 16 17 18
19
25
24
23
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78
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16
Presentation
KAD300/DP-G
1. Seawater filter
2. Electrical box
3. Oil filler cap, engine
4. EDC control module
5. Oil filter, engine
6. Charge air cooler
7. Starter motor
8. Fuel feed pump
9. Fuel filter
10. Injection pump
11. Generator
12. Sea water pump
KAD300/DP-G
13. Turbocharger
14. Air Cleaner (ACL)
15. Dipstick, engine
16. Coolant filler
17. Expansion tank
18. Compressor
19. Power steering pump
20. Heat exchanger
21. Trim cylinder
22. Cooling water intake
23. Topping up oil, drive
24. Oil dipstick, drive
22
21
13
20
14 15 16 17 18
19
24
23
123456
78
9
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17
This section contains descriptions of the instrument panels and panels available from Volvo Penta for your en-
gine, with the exception of the Power Trim instrument, which is described in the section Power Trim. Note that the
tachometer, oil pressure gauge, temperature gauge, charge indicator, ignition switch etc. which are shown here in-
stalled in the instrument panels can be installed in other positions on some boats.
If your boat is fitted with instruments not described here and you are not sure of their function, please get in touch
with your boat dealer.
Instrument panels
Instrumentation for the main control position and auxil-
iary control position.
1. Temperature gauge. Indicates the engine coolant
temperature.
2. Oil pressure gauge. Indicates the pressure of the
engine lubricant.
3. Voltmeter. Indicates the charge voltage from the
alternator when the engine is running and the bat-
tery voltage when the engine is stopped.
4. Tachometer. Indicates the speed of the engine in
rpm. (recommended cruising speed is shown in
the chapter “Operation”)
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.
Instrumentation
8910
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18
Instrumentation
1234
5678
1
2
4
3
5 6
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1
Control panels
Control panels for the main control position and auxil-
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.