Volvo Penta D4 Series Operator's Manual
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Volvo Penta D4 Series Operator's Manual

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OPERATOR'S MANUAL
D4, D6

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  • Page 1 OPERATOR’S MANUAL D4, D6...
  • Page 2 12 kuukauden ajan toimituksen jälkeen. Sprache bestellt werden. http://vppneuapps.volvo.com/manual/coupon/a http://vppneuapps.volvo.com/manual/coupon/ Jos sinulla ei ole Internet-yhteyttä, ota yhteys lähimpään Volvo Penta jälleenmyyjään. Wenn Sie keinen Internet-Zugriff haben, kontaktieren Sie bitte Ihren Volvo Penta-Händler. Ce manuel d‘utilisation peut être commandé gratu- Este Manual do Operador pode ser encomendad em idiomas itement sur Internet en différentes langues, jusqu‘à...

  • Page 3: Table Of Contents

    Content Foreword ...................... 2 Safety Information ..................3 Introduction ....................8 Instruments and Controls ................ 10 Optional ..................... 42 Starting ...................... 44 Operation ....................47 Engine Shutdown ..................51 Fault Handling ................... 55 Fault Code Register .................. 58 In Case of Emergency ................62 Maintenance Schedule ................

  • Page 4: Foreword

    As owner of a Volvo Penta marine engine, we would also like to welcome you to a worldwide network of dealers and service workshops to assist you with technical advice, service requirements and replacement parts. Please contact your nearest authorized Volvo Penta dealer for assistance.

  • Page 5: Safety Information

    Check that you heave received the correct operator’s manual before you read on. If not, please contact your Volvo Penta dealer. This symbol is used in the operator’s manual and on the product, to call your attention to the fact that this is safety information.
  • Page 6 Safety Information Your new boat Fuel filling Carefully read through the instructions and other infor- There is always a risk of fire and explosion when fuel- mation that come with the new boat. Learn to handle ing. Smoking is forbidden, and the engine must be the engine, controls and other equipment in a safe stopped.
  • Page 7 Safety Information Carbon monoxide poisoning When a boat moves forward an area of lower air pres- Most modern boats are however designed so that the sure is formed behind the boat, so-called turbulence. turbulence problem is very rare. Should turbulence In certain conditions, this turbulence can be powerful nevertheless occur, forward hatches and ventilators enough to draw the boat's own exhaust fumes into the...
  • Page 8 Turbocharger unit can cause serious personal injury. Service literature covering more complicated opera- Foreign objects can also be sucked in and cause tions is available from your Volvo Penta dealer. mechanical damage to the unit. Never carry out any work on the engine if you are...
  • Page 9 Chemicals Installing non Volvo Penta components may cause the system to malfunction. Most chemicals such as anti-freeze, rustproofing agent, inhibiting oil, degreasing agent etc. are haz- Service must be done by approved workshops.

  • Page 10: Introduction

    Introduction This Operator's Manual has been prepared to give you the greatest possible benefit from your Volvo Penta marine engine. It contains the information you need to be able to operate and maintain the engine safely and correctly. Please read the Operator's Manual carefully and learn to handle the engine, controls and other equipment in a safe manner before you cast off on your maiden voyage.
  • Page 11 Certification means that an engine type has been possible environmental impact. Through regular serv- checked and approved by the relevant authority. The ice and use of by Volvo Penta approved spare parts, engine manufacturer guarantees that all engines these qualities are retained.

  • Page 12: Instruments And Controls

    Instruments and Controls This chapter describes the instruments, panels and controls Volvo Penta sells for your engine. If you would like to complement your instrumentation, or if your boat is equipped with instruments not described here, we ask that you contact your Volvo Penta dealer.
  • Page 13 Instruments and Controls Information Panel The information panel shows engine and operational information, messages and alarms. There is one information panel per driveline and helm station if no 7" screen is installed. The information shown can be set up according to per- sonal preferences.
  • Page 14 Instruments and Controls Start/Stop Panel The start/stop panel is used for starting and stopping the engine frpm other stations than the main station. To start the engine it is necessary for the start key at the main station to be in the ”I” operating position. Read the starting instructions in chapter Start- ing page 44 and Engine Shutdown page 51 to ensure you use the correct start procedure.
  • Page 15 Instruments and Controls Station Panel Activation Activate the helm station with a single press of the but- ton. Further pressure locks the helm station. To render the helm station inactive, hold the button down for 3 seconds. Inactive helm station Active helm station Locked helm station P0012495...
  • Page 16 Instruments and Controls Docking Panel When the boat is operated from a docking station engines, can be stopped and started and messages can be managed using the docking panel. The joystick can be used for maneuvering when the docking station is activated; refer to the Joy- stick page 40 section for further information.
  • Page 17 Instruments and Controls Fault message is displayed on the screen when the system dis- covers a fault. All fault messages must be acknowledged. Acknowl- edge by pressing the button; if the fault is accompanied by an audible signal, the signal will silenced. Go to the information panel to get information regarding the alarm.
  • Page 18 Instruments and Controls Gauges These instruments are sold as engine options by Volvo Penta. RPMX1000 The tachometer displays engine speed; multiply the value shown on the dial by 1,000 to get the number of engine revolutions per minute. Engine hours is displayed in the tachometer window. When a function is activated a symbol shows shortly in the dispaly.
  • Page 19 Prolonged expo- sure to strong sunlight can damage the screen and cause function faults. The Volvo Penta 4" screen is controlled by means of buttons on the panel: Return to the previous menu by pressing the button.
  • Page 20 Instruments and Controls Engine View Information concerning the engine and its transmission is shown in Engine View. The information is shown in two windows; switch between the windows by pressing the arrow buttons. Up to six different pieces of operations data can be shown on the display.
  • Page 21 Instruments and Controls Fuel This is the boat's trip computer and information is shown in two windows, Current Fuel and Average fuel. Switch between screens by pressing the arrow but- tons. Current Fuel • Instant fuel rateCurrent fuel consumption per hour. Instant fuel economy Based on current fuel con- •...
  • Page 22 Instruments and Controls Vessel Shows information regarding the boat's installation. The information shown can be set under Change gauge. Functions are also switched on and off here. Depending on the functions installed in the boat, the following can be displayed: •...
  • Page 23 Instruments and Controls Trip Reset Zeroes all values in the trip computer. ACP Mode Setting the ACP protection position. For information on the ACP function, refer to ACP. Depth Alarm Setting the depth alarm function; refer to Depth Alarm page 115. Display Contrast Contrast adjustments affect all displays in the system.
  • Page 24 Instruments and Controls Replace gauge In My View, Engine View and Vessel the owner can decide what information will be shown and where on the display. The procedure is the same for all views. 1 Press the MENU button and select Replace gauge. 2 Navigate using to the gauge for replace- ment and press...
  • Page 25 Instruments and Controls 7" Display The Volvo Penta 7" screen is controlled by means of buttons: Turn to browse through submenus and to return to the main menu. Return to the previous menu. Confirms selection; also used to access sub- menus and the Settings page 29.
  • Page 26 Instruments and Controls My View Boat, engine and transmission data are displayed in My View as analog or digital instruments. Selection of instruments to be displayed and their appearance is made under the Customize menu. Information for up to three engines can be displayed on the same screen in boats with multiple engine instal- lations;...
  • Page 27 Instruments and Controls Removing instruments Turn to the Remove menu and press Turn to the instrument that is to be removed and con- firm with P0001184 Changing instruments Turn to the Modify menu and press Select the instrument that is to be changed and press Choose between: Remove, removes the instrument.
  • Page 28 Instruments and Controls Engine Information concerning the engine and its transmission is displayed in this view. Depending on the functions installed in the boat, the following can be displayed: - Engine Speed - Power Trim angle, for further information refer to Trim Controls and PTA calibration in the Settings Menu page 114 chapter.
  • Page 29 Instruments and Controls Fuel economy This view functions as the boat's trip computer. Depending on the functions installed in the boat, the following can be displayed: Current Fuel Instant fuel rate, based on current fuel consump- tion Instant fuel economy, current fuel consumption per hour.
  • Page 30 Instruments and Controls Vessel Information concerning boat installations is displayed in this view. Depending on the functions installed in the boat, the following can be displayed: - Sea water temperature - Depth, to set the echo sounder refer to Depth Alarm in the Settings Menu page 114 chapter.
  • Page 31 Instruments and Controls Settings Screen settings and different function settings are made in this view. Turn to the desired menu and press to access the submenus. Mode Choose between the modes Day ((dark text on a white background) or Night (light text on a dark background). Press switch between modes.
  • Page 32 Instruments and Controls Features, installed functions are marked blue. Components, press to see installed compo- nents. Software, information regarding the software ID number. Calibration The following is only displayed if the function is instal- led. For further information, refer to the relevant sec- tions in theSettings Menu page 114 chapter.
  • Page 33 Instruments and Controls Power Trim Your Volvo Penta drive is equipped with a hydraulic trim system, Power Trim, that allows you to adjust the angle of the drive with respect to the transom from the helm station. The angle of the drive effects the boat's passage through the water and other characteristics, e.g.
  • Page 34 Instruments and Controls Trim Controls The drive can be trimmed with the Power Trim panel or with the button at the side of the control (1). For twin engine installations, the button at the side adjust the drives simultaneous. There is also a button for individuall adjustments to the drives (2) on the con- trol for twin installations.
  • Page 35 Instruments and Controls Power Trim Assistant The Power Trim Assistant, PTA, adjusts the trim angel automatically according to engine speed (rpm). It is possible to set five trim angles at five different engine speeds, idle speed included. To set the angles, please refer to PTA Calibration page 119.
  • Page 36 ”bow up” or ”bow down” positions. The stability and steering characteristics of the boat can also vary depending on the sea conditions. Contact your Volvo Penta dealer to correct these tendencies if your boat shows instability an/or self-steering tenden- cies.
  • Page 37 Instruments and Controls At planing speed Trim the drive to the angle that gives the most stable and comfortable feeling. If the boat has a twin instal- lation, the drive can be trimmed to different angles to compensate for side winds and, to a certain degree, uneven load distribution.
  • Page 38 Instruments and Controls Controls This section describes the controls Volvo Penta sells for your engine. Contact your dealer if your boat is equipped with controls other than those described here, and you feel uncertain about their function. A single-lever control operates both gearshift and throttle functions with the same lever.
  • Page 39 Instruments and Controls Neutral position. The symbol shows that the drive/ reverse gear is disengaged. The warning triangle lights up if the system discov- ers a fault; refer to Fault Handling page 55 for information. The warning triangle lights up on the same side as the driveline with the indicated fault.
  • Page 40 Instruments and Controls 6 TRIM ASSIST (optional) The Power Trim Assistant, PTA, adjusts the trim angel automatically according to engine speed (rpm), see Power Trim Assistant page 33 for infor- mation. 7 THROTTLE ONLY Disconnects the shift function so that the control lever only affects engine speed;...
  • Page 41 Instruments and Controls Adjusting the friction brake Top mounted controls The control lever has a friction brake that can be adjusted for lighter or stiffer lever movement. Resist- ance in click mode can also be adjusted. 1 Switch off the engine. 2 Remove the cover (3).
  • Page 42 Instruments and Controls Joystick The Volvo Penta Joystick is a control used for docking and maneuvering at low speed. Learn to use the joystick and its functions in a safe and proper manner before beginning to use the func- tion in confined marinas.
  • Page 43 Instruments and Controls Docking When the docking function is activated, engine revo- lutions are limited and the boat can only be steered by the joystick. In order to activate the docking function, the following must be fulfilled: • engines running •...

  • Page 44: Optional

    Optional Low speed The Volvo Penta low speed function is available for engines with hydraulic transmissions. Boats with powerful engines can have high speeds even at low revolutions; the low speed function reduces speed. N = Neutral position. Transmission is disengaged and engine revolu- tions are at idle.
  • Page 45 Optional Engaging the low speed function 1 Move the lever to the neutral position. 2 Press the Low Speed button on the control or on the helm station panel to activate the low speed function. An audible signal and the message “Lowspeed acti- vated”...

  • Page 46: Starting

    Starting Make a habit of visually checking the engine, engine bay and transmission before start. This will help you to discover quickly if anything abnormal has happened, or is about to happen. Also check that instruments and warning displays show normal values when you have started the engine. To minimize cold start smoke we recommend the installation of an engine heater or engine bay heater if temper- atures below +5°C (41°F) are encountered.
  • Page 47 Starting Starting the Engine Shifting and adjusting speed is only possible at an active station. On a boat with one station the station is always active. On a boat with two or more stations the main station automatically becomes active when the engine is started up with the ignition key(s).
  • Page 48 Starting Start the engine If a station is locked the engines can only be started and stopped from this station. Start using the ignition switch Start using the ignition switch III. Release the key and let it spring back to position I as soon as the engine has started.

  • Page 49: Operation

    Operation Learn to handle the engine, controls and other equipment in a safe and proper manner before casting off on your maiden voyage. Remember to avoid sudden and extreme rudder maneuvers and gear shifts. There is a risk for passengers and crew falling over or falling overboard. WARNING! A rotating propeller can cause serious injury.
  • Page 50 Operation Maneuvering Shifting between forward and reverse should be done at idling. Shifting at higher engine speeds can be uncomfortable for passengers and cause unnecessary stress on the transmission or cause the engine to stop. If you attempt to shift gear at an excessive engine speed, a safety function cuts in automatically, and delays shifting until engine speed has fallen to 1500 rpm.
  • Page 51 Operation Helm Stations Changing and activating helm stations Helm station change 1 Move the control lever(s) to neutral. The neutral lamp (1) on the control lights up when the drive is in neutral. 2 Unlock the helm station being vacated, if it is locked, by pressing (2).
  • Page 52 Fault Handling page 57 section. Select a propeller with greater pitch if actual enginer- evolutions exceed the full throttle range. Contact your Volvo Penta dealer for advice. Synchronizing Engine Speed When driving with twin engines, both the operating economy and comfort will be increased when the engines are operating at the same engine speed (rpm).

  • Page 53: Engine Shutdown

    Engine Shutdown Allow the engine to run at low idle, in neutral, for a few minutes after operations are completed. In this way after- boiling is avoided at the same time as temperature equalization takes place. This is especially important when the engine has been run at high rpm or under heavy load.
  • Page 54 Engine Shutdown Auxiliary stop If the engine cannot be stopped in a normal procedure, it is possible to stop the engine via the auxiliary stop mounted on the side of the engine. P0003709 After Engine Shutdown • Check the engine and engine bay for leakages. •...
  • Page 55 Engine Shutdown Operation Break Operation break with the boat in water If the boat is not used, but left in the water, the engine must be warmed up at least once every fortnight. This prevents corrosion damage in the engine. If you expect the boat to be unused for two months or more, it must be inhibited, please refer to Short Term Storage.
  • Page 56 Engine Shutdown Trailering Your Boat Check local legislation in respect of boat transportation by trailer - there are differences in various national trailer regulations. Boats with stern drives Trim the stern drive up to its "lift position" (maximum lift) before the boat is pulled onto the trailer for trans- portation.

  • Page 57: Fault Handling

    Fault Handling Despite regular maintenance according to the maintenance schedule and perfect operation conditions faults may occur which must be attended to before the boat can travel further. This chapter describes alarms and fault handling. Alarm handling Message from engine and EVC system If a malfunction is discovered the driver is warned by a buzzer sounding and a message showing in the dis- play.
  • Page 58 Fault Handling Acknowledge message 1 Push OK to ackowledge the alarm. The buzzer becomes silent. 2 Read the message. 3 Push OK again and the message disappears. The alarm has to be acknowledged before the engine can be started. Faults list If a fault is registered Faults (Faults) is displayed in the information panel together with the number of faults.
  • Page 59 A number of symptoms and possible causes of engine malfunctions are described in the table below. Always contact your Volvo Penta dealer if problems occur which you can not solve by yourself. Read through the safety advice for care and maintenance work in chapter Safety Information page 6 before starting work.

  • Page 60: Fault Code Register

    Fault Code Register CAUTION! Read the safety precautions for maintenance and service in the Safety Information chapter before starting work. When a malfunction is discovered the helmsman is warned by a sound alarm and at the same time a message is shown in the display.
  • Page 61 Engine power is reduced. Checking Engine Oil Level. Refer to Oil level, checking and topping up page 78. Check that no leakage occurs. Please contact a Volvo Penta workshop if the fault remains. Check EVC System Internal fault in EVC system. Engine performance might be affected.
  • Page 62 Acknowledge fault by moving control to neutral and press OK-button. Check Steering Wheel Limited or no steering. Please contact a Volvo Penta workshop. Coolant Level Low coolant level. Check coolant level. Refer to Coolant Level, Checking and Topping Up page 85.
  • Page 63 Poor batteries or charging. Refer to Battery, Charging page 95. Sensor failure Engine performance might be affected. Please contact a Volvo Penta workshop if the fault remains. Steering failure Limited functionality. Self test failed. Verify hydraulic steering oil level. Refer to Oil level, checking and topping up page 100.

  • Page 64: In Case Of Emergency

    Lift the boat ashore. Check the oil level in the drive. If the oil is gray-colored, water has entered and the drive must be inspected by an authorized Volvo Penta work- shop. The same applies if there is damage to the drive.
  • Page 65 In Case of Emergency Starting Using Auxiliary Batteries WARNING! Explosion hazard. Batteries contain and give off an explosive gas which is highly flammable and explosive. A short circuit, open flame or spark could cause a vio- lent explosion. Ventilate well. WARNING! Never confuse the positive and negative poles on the batteries.
  • Page 66 In Case of Emergency 4 Start the engine and let it run at fast idle for approx- imately 10 minutes to charge the batteries. Make sure there is no extra equipment connected to the electrical system. WARNING! Working with or going close to a running engine is a safety risk.
  • Page 67 In Case of Emergency Emergency Shifting, Drive If a fault occurs which prevents the drive from being operated (shifted) with the control lever, it is possible to shift manually, using the description below. WARNING! In emergency shifting, the unit is locked in forwards operation.
  • Page 68 In Case of Emergency Emergency Trimming If a situation occurs that needs the drive to be trimmed over the trim limit, the drive can be emergency trim- med. IMPORTANT! When emergency trimming is performed, the auto- matic stop will not work. The drive can be trimmed out- side the trim ranges, this can damage the boat and drive.

  • Page 69: Maintenance Schedule

    Maintenance Schedule Your Volvo Penta engine and its equipment are designed for high reliability and long life. The engines are built to withstand the marine environment, but also to have the smallest possible environmental impact. If the engine and transmission are serviced regularly according to the schedule, these qualities will be retained and unnecessary malfunctions will be avoided.
  • Page 70 Maintenance Schedule Every 200 hours / at Least Every 12th Month Coolant level and antifreeze mixture Crankcase ventilation filter Air Filter Fuel pre-filter and fuel fine filter Drive belts, wear and tension Compressor, oil level Seawater pump impeller Sacrificial anodes: charge air cooler, heat exchanger and exhaust pipe Drive-unit and transom.
  • Page 71 Every 1200 hours for Marine Leisure use (without joystick) Outboard drive, complete over haul incl. gears, shaft and U-joints Outboard drive, shift cable Outboard drive, shift sliding sleeve Outboard drive, shift yoke and linkage rod 1) Only use Volvo Penta XACT cable. 47702599 12-2011...

  • Page 72: Maintenance

    Maintenance This chapter contains general technical information and instructions on how the prescribed maintenance items must be carried out. Read through the instructions carefully before starting work. The times when maintenance items must be carried are indicated in the Maintenance Schedule page 67. Read through the safety precautions for maintenance and service in the Safety Information page 4 chapter before work on the engine is begun.
  • Page 73 Maintenance D4 with drive, starboard Zinc anode Turbocharger Crankcase ventilation filter Air filter Oil filler cap Control unit Alternator Compressor Zinc anode Cooling water intake D4 with drive, port Expansion tank Aux stop Oil dipstick Oil filter bypass Oil filter Charge air cooler Starter motor Fuel filter...
  • Page 74 Maintenance D6 with reverse gear, starboard Turbocharger Crankcase ventilation filter Air filter Oil filler cap Alternator Control unit P0006497 D6 with reverse gear, port Expansion tank Fuel filter Aux stop Oil dipstick (engine) Oil filter by-pass Oil filter Charge air cooler Oil dipstick (reverse gear) Starter motor Sea water pump...
  • Page 75 Maintenance Engine, General General inspection Make a habit of visually checking the engine and engine bay before starting, and after operations when you have stopped the engine. This will help you to dis- cover abnormalities quickly, or if something is about to happen.
  • Page 76 Maintenance Crankcase Ventilation, Filter Change 1 Unscrew the cover and remove the old filter. 2 Clean the filter cover/housing as necessary. Be careful to prevent contamination from entering the engine. 3 Install the new filter. 4 Screw the cover back in place. IMPORTANT! Scrap the old filter.
  • Page 77 Maintenance Drive Belt, Check and Change WARNING! Stop the engine before doing any maintenance work. General Check belt tensions and condition regularly. A belt that is tensioned too tightly may damage bearings, while a belt too-loosely tensioned may slip. Check and adjust the belt after operation, while the belt is still warm.
  • Page 78 Maintenance Checking exhaust line The exhaust line must be inspected every year, due to corrosion between the hose (1) and pipe (2). WARNING! Risk of water entering. The exhaust line must be inspected while the boat is on land. In case of serious corrosion damage, the pipe must be repaired or replaced with a new one.
  • Page 79 Maintenance Compressor, checking oil Checking and filling 1 Unscrew and lift up the oil dipstick. Dry the oil off. Screw the oil dipstick down as far as it will go and then unscrew and lift up. 2 Check that the oil level is between the MAX and MIN marks.
  • Page 80 Maintenance Lubrication System Oil change intervals can vary depending on oil grade and sulphur content of the fuel, please refer toTechni- cal Data, Lubrication System. Oil change intervals must never exceed a period of 12 months. If you want longer oil change intervals than given in the table Oil Grade and Oil Change Interval, the condition of the oil must be checked by the oil manufacturers through regular oil testing.
  • Page 81 Maintenance Engine Oil, Change Always follow the recommended oil change interval. Use only oils of the recommended grades; refer to Oil Grade and Oil Change Interval. WARNING! Hot oil and hot surfaces can cause burns. 1 Run the engine until warm so that the oil is easier to pump.
  • Page 82 Maintenance Oil Filter/By-pass Filter, Change The oil filter and by-pass filter must be replaced at every oil change. Deposit the old filter at a waste management facility. WARNING! Hot oil and hot surfaces can cause burns. 1 Put a suitable container under the filter to collect any spilled oil.
  • Page 83 Maintenance Fuel System Only use the grades of fuel recommended in the fuel specification, see Technical Data, Fuel System. Always observe the greatest cleanliness during re- fuelling and work on the fuel system. All work on the unit injectors of the engine must be carried out by an authorized workshop.
  • Page 84 Maintenance Fuel system, bleeding The fuel system must be bled after a filter change, if the fuel tank has been run dry and after a long-term stoppage. IMPORTANT! Never disconnect the pressure pipe. 1 Connect a transparent hose to the bleed nipple (1). Feed the hose to a container to avoid spillage.
  • Page 85 Maintenance Water in Fuel If the EVC system warns for too much water in the fuel filter, the water separator needs emptying. IMPORTANT! Do not continue operating if there is water in the water separator, it can damage the engine. Draining the fuel filter 1 Stop the engine and remove the ignition key from the ignition lock.
  • Page 86 The use of anti-corrosion agents alone is not permitted in Volvo Penta engines. Never use water alone as the coolant. The corrosion protection additives become less effec- tive over time, which means that the coolant must be changed at regular intervals;...
  • Page 87 –24°C (–11°F). At 60% glycol concentration, the freezing point is lowered to –46°C (–51°F). Never mix more than 60% concentrate (Volvo Penta Coolant) in the coolant. A greater concentration pro- vides reduced cooling effect with the risk for overheat- ing and reduced frost protection.
  • Page 88 Maintenance Freshwater System, Draining WARNING! Stop the engine and let it cool before starting work on the cooling system. Hot fluids and hot surfaces can cause burns. WARNING! All coolant is hazardous and harmful to the environ- ment. Do not consume. Coolant is flammable. 1 Remove the filler cover on the expansion tank to speed up the coolant drainage.
  • Page 89 Maintenance Seawater System The raw water system is the engine's external cooling system. On engines with drives, the raw water pump sucks in water via the drive, through the control sys- tem's oil cooler to the raw water pump. The water then passes through the raw water filter before being pumped through the fuel cooler, intercooler, engine oil cooler and heat exchanger.
  • Page 90 Maintenance Seawater System, Draining WARNING! Risk of water entry. Close the seawater cocks before doing any work on the seawater system. To prevent frost damage, the raw water system must be drained during cold weather if there is a risk for frost. An alternative to draining is to keep the engine room warm using an approved heater fan.
  • Page 91 Maintenance Zinc Anodes, Check and Change WARNING! Risk of water entry. Close the seawater cocks before doing any work on the seawater system. 1 Close the sea cock(s). 2 Drain the raw water as described in Seawater Sys- tem, Draining page 88. 3 Remove the zinc anodes from the heat exchanger (1) and intercooler (2).
  • Page 92 Maintenance Seawater System, Cleaning and Inhibiting The raw water system must be flushed with fresh water, to prevent deposits and salt crystals from build- ing up inside it. It must also be conserved when the boat is laid up for winter/out of season storage so that it is protected from internal corrosion.
  • Page 93 Maintenance Seawater Filter, Check and Cleaning WARNING! Risk of water entry. Close the seawater cocks before doing any work on the seawater system. If the water where the boat is used contains contami- nants, seaweed, etc. the filter should be checked more frequently than stated in the maintenance schedule.
  • Page 94 Maintenance Electrical System The engine is equipped with a 2-pole electrical system and an alternator. System voltage is 12V or 24V. WARNING! Always stop the engine and break the current using the main switches before working on the engine. Fuses 12–volt system (engine) The engine is fitted with automatic circuit breakers.
  • Page 95 Maintenance Power Trim Engines fitted with a drive have an automatic circuit breaker for the Power Trim engine. The circuit breaker cuts the power if the Power Trim system is overloaded. Reset by pressing in the circuit breaker. IMPORTANT! Always investigate the cause of the overload. If the fuse trips frequently, contact an authorized Volvo Penta workshop.
  • Page 96 Check that electrical connections are dry, free from oxide, and that they are securely tightened. Spray the connections as necessary with water-repellent spray (Volvo Penta universal oil). Battery, Maintenance WARNING! Risk of fire and explosion. Never allow an open flame or electric sparks near the battery or batteries.
  • Page 97 Maintenance Cleaning Keep the batteries clean and dry. Contamination and oxide on the batteries and battery poles can cause stray currents, voltage drop and discharge, especially in wet weather. Remove oxidation from the battery poles and terminals, using a brass brush. Tighten the terminals securely and grease them with terminal grease or petroleum jelly.
  • Page 98 Maintenance • Charge batteries if they have become discharged. During charging, unscrew the cell plugs but leave them in the plug holes. Ventilate well, especially if the batteries are charged in an enclosed space. • If the engine is not used for a longer period of time, the batteries should be fully charged, then possibly trickle charged (please refer to the battery manu- facturer’s recommendations).
  • Page 99 Maintenance 4 The start battery must have a main switch (1) con- nected to the battery's positive (+) side. The main switch must break the circuit to all equipment and be switched off when the boat is not in use. 5 If an auxiliary battery is used, a main switch must be placed between the auxiliary battery's positive (+) terminal and the circuit breaker panel for the...
  • Page 100 The reverse gear uses solenoid valves for electronically controlled shifting. Volvo Penta recommends that a seawater filter be fit- ted to guarantee the correct cooling water flow to the engine and reverse gear. Otherwise there is a risk of contaminants in the seawater blocking the reverse gear cooler and other cooling system components.
  • Page 101 9 Stop the engine and check the oil level. Top up as needed Propeller Shaft Sealing, Check If the boat is fitted with a Volvo Penta propeller shaft, the propeller shaft seals must be lubricated before launch and purged directly after launching.
  • Page 102 4 Tighten the plug and installed cover. The oil must have a golden brown nuance. If the oil is gray, water has entered the stern drive. In this case let a Volvo Penta workshop carry out checks on the stern drive. P0003467...
  • Page 103 P0003467 The oil must have a golden brown nuance. If the oil is gray, water has entered the stern drive. In this case let a Volvo Penta workshop carry out checks on the stern drive. Checking oil level, power trim The Power Trim system is a closed center hydraulic system.
  • Page 104 Maintenance Corrosion protection, checking and changing Check the sacrificial anodes regularly. Replace with new anodes when approximately 1/3 of an anode has corroded away. When the boat is stored ashore, corrosion protection deteriorates due to sacrificial anode oxidization. Even new anodes may have surface oxidation. Before launching the sacrificial anodes must be cleaned or polished with emery cloth.
  • Page 105 In order to replace the U-joint bellows it is necessary to remove the stern drive from its sup- port bracket. Removing the stern drive requires exper- tise and special tools. Contact your Volvo Penta work- shop. 47702599 12-2011...
  • Page 106 Maintenance Propeller For best performance and fuel economy, keep engine rpm within the maximum revolution range; refer to the Engines section. If maximum engine rpm exceeds the maximum recommended engine rpm the propeller must be replaced. Damaged propellers must be replaced as soon as pos- sible.
  • Page 107 5 The propeller shaft must be locked according to items 1a or 1b once the forward propeller (5) is installed. Brush Volvo Penta propeller shaft grease # 828250 onto the entire propeller shaft and the inside of the propeller hub.
  • Page 108 The leakage must be traced and remedied immediately. Contact your Volvo Penta service center for repairs. The steering system is filled with ATF oil. If the oil is red and does not contain visible contamination it does not need to be changed.
  • Page 109 Maintenance WARNING! Use only by Volvo Penta recommended fluid and grade. Any non-appproved fluid may cause loss of steering or result in damage to the components used in the steering system. Fluid level checks, servo pump The steering servo tank has a transparent reservoir which makes checking the level possible without open- ing the cap.
  • Page 110 If a parallel rod is bent, loose or damaged it must be checked by your Volvo Penta workshop. Parallel rod (hydraulic), adjustment The parallel rod can be adjusted when the boat is in the water or on land.
  • Page 111 Maintenance Boat in the water: 1 Remove the lock bolt (A). Loosen the adjuster bolt (B) 1-2 turns. 2 With the engines running, turn the helm hard to one side, until the helm pump reaches the stop position. Both stern drives are then fully turned to one side. 3 Tighten the adjuster bolt (B), tightening torque 30 Nm (22 lbf.ft) securely.

  • Page 112: Storage

    Storage Have an authorized Volvo Penta workshop carry out checks on the engine and other equipment before the boat is put into winter storage. Make sure all necessary repairs and service are completed so that the boat is in top condition before the next season.
  • Page 113 • Clean the outside of the engine. Do not use a high pressure washer to clean the engine. Touch up any paint damage with Volvo Penta original paint. • Check all control cables and treat with conservation agent.
  • Page 114 Storage Bringing Out of Storage Check the oil level in the engine and stern drive/ • reverse gear. Top up as necessary. If the system contains conservation oil this must be drained, and the system must then be filled with oil. For the cor- rect oil grade, refer to Technical Data, Lubrication System.
  • Page 115 2 Wash off with thinner or similar. 3 Glaze over and sand down possible pits. 4 Paint with Volvo Penta original primer and varnish. Let the paint dry. 5 Paint the drive with anti-fouling agent for aluminum drives according to the paint manufacturers instruc- tion.

  • Page 116: Calibration And Settings

    Calibration and Settings Settings Menu Settings and calibrations are managed in the Settings menu. 1 Navigate to the Settings menu. 2 Press to open the settings menu. 3 Navigate backwards and forwards in the settings menu by pressing Return to the previous menu by pressing the button. Settings Hold the button down for more than 3 seconds to get to the main menu.
  • Page 117 P0012516 Trip Reset Depth Alarm Setting the level for the depth alarm on Volvo Penta echo sounders. The setting need only be made at one helm station. 1 Navigate to Depth Alarm in the settings menu.
  • Page 118 Calibration and Settings Set Offset 1 Go from the settings menu to Set Offset and press to reach the setting. 2 Use to set the depth compensation value so that it corresponds to the boat's lowest point or the waterline. The echo-sounder can be placed anywhere between these two points.
  • Page 119 Calibration and Settings Display Contrast Adjust the screen contrast. The adjustment will affect all screens. Backlighting Contrast 1 Navigate to Display Contrast in the settings menu and press to open the submenu. 2 Use + and – to increase or reduce the contrast or backlighting.
  • Page 120 Calibration and Settings Language Setting the language the information of the screen will be shown in. There are 10 languages to choose from. On boats with several helm stations and several screens it is enough to select a language in one station for it to be displayed at all of them.
  • Page 121 Calibration and Settings PTA Calibration PTA (Power Trim Assistant) automatically adjusts the trim angle to boat speed. The system has a basic set- ting, but it is possible to set five different angles for five different speeds. On boats with more than one station and with several displays it is enough to do the calibration on one dis- play for it to be shown at all stations and on all displays.
  • Page 122 3 Fill the fuel tank. Confirm that the fuel tank is full by pressing Full Fuel Tank Calibration IMPORTANT! Settings for Fuel Tank Volume, Empty Tank Calibra- tion and Fuel Alarm Level should only be carried out by an authorized Volvo Penta workshop. 47702599 12-2011...
  • Page 123 Calibration and Settings Speed Factor The speed factor must be set while the boat is under way. Compare the displayed boat speed value with GPS data (or another boat) and adjust the speed factor until the values agree. The setting just needs to be done on one display for it to be shown at all stations and on all displays 1 Go from the settings menu to Speed Factor and press...
  • Page 124 Calibration and Settings 1 Turn the ignition on and move the control levers to neutral. 2 Start the engines. Activate calibration mode by depressing the dock- ing button for 5 seconds. An audible signal confirms that docking mode is activated and both lamps on the joystick lights up. 3 Move the joystick sideways as far as it will go in one direction.
  • Page 125 Calibration and Settings Resetting the calibration 1 Turn the ignition on and move the control levers to neutral. Start the engines. 2 Activate calibration mode by depressing the dock- ing button for 5 seconds. An audible signal will confirm that docking mode is activated and the docking button lamp will light up.

  • Page 126: Technical Data

    Technical Data Engine Type designation No. of cylinders Displacement, dm³ Bore, mm Stroke, mm Compression ratio 17.5:1 17.5:1 Engine, dry weight, kg Idling speed, rpm Type designation After market designa- Crankshaft power kW Propeller shaft kW (hk) tion (hk) D4-180I D4-180I-E 132 (180) 128 (174)
  • Page 127 Technical Data Lubrication System Engine: Oil volume, (incl. oil filter) for all allowed installation inclinations 12 liters (3.2 US gals) 20 liters (5.3 US gals) volume difference MIN – MAX 1.2 liters (0.3 US gals) 3.5 liters (0.9 US gals) Oil pressure, hot engine, idling 125 kPa (18.1 PSI)
  • Page 128 0.1 liters (0.2 US pint) 0.1 liters (0.2 US pint) Oil grade Volvo Penta, part no. 1141641 Volvo Penta, part no. 1141641 Fuel System Fuel specification The fuel must comply with national and international standards for commercially supplied fuels, such as:...
  • Page 129 Technical Data Cooling System Volume Fresh water system volume (ca) D4: 13 litre (3.4 US gal) D6: 16.5 litre (4.4 US gal) Thermostat The thermostats begins opening/fully open 82°C / 92°C (179.6°F / 197.6°F) Water Quality ASTM D4985: Total solid particles <340 ppm Total hardness <9,5°...
  • Page 130 Technical Data Reverse gear (excluding oil cooler) Type designation HS45AE Oil capacity 2.5 litre (0.7 US gal) Oil quality ATF (Dexron II, III) Type designation HS63AE Oil capacity 4.0 litre (1.0 US gal) Oil quality ATF (Dexron II, III) Type designation HS63IVE Oil capacity 4.0 litre (1.0 US gal)
  • Page 131 Technical Data Identification Numbers There are type plates on the engine and transmission, marked with identification numbers. This information must always be used as reference when service and spare parts are ordered. You will probably find similar plates on your boat and its equipment. Note this information below, make a copy of the page and store it in a safe place, so that you can have the information available if the boat is stolen.
  • Page 132 Declaration of Conformity for Recreational Craft Propulsion Engines with the exhaust emission requirements of Directive 94/25/EC as amended by 2003/44/EC D4, D6 Engine manufacturer: Body for exhaust emission assessment AB Volvo Penta International Marine Certification Institute Gropegårdsgatan Rue Abbé Cuypres 3 405 08 Göteborg...
  • Page 133 Declaration of Conformity for Recreational Craft Propulsion Engines with the sound emission requirements of Directive 94/25/EC as amended by 2003/44/EC D4, D6 Engine manufacturer: Body for sound emission assessment AB Volvo Penta International Marine Certification Institute Gropegårdsgatan Rue Abbé Cuypres 3 405 08 Göteborg...

  • Page 134: Operator's Manual Order

    (7–8 digits). http://vppneuapps.volvo.com/manual/coupon/ If internet access isn't possible, please contact your Volvo Penta dealer. All order information is stored internally at AB Volvo Penta and will not be shared with third parties. 47702599 12-2011...

  • Page 135: Alphabetical Index

    Alphabetical index Fuel Pre-filter, Change..........82 Fuel System............. 81 4" Display..............17 Fuel system, bleeding..........82 Fuses................ 92 7" Display..............23 Helm Stations............49 Acknowledge message..........56 High Mode..............41 Adjusting the friction brake........39 Hydraulic hoses............108 After Engine Shutdown..........52 Air Filter, Change.............
  • Page 136 Trim Instruments............33 Trim Ranges............. 31 Viscosity..............126 Zinc Anodes, Check and Change......89...
  • Page 138 AB Volvo Penta SE-405 08 Göteborg, Sweden www.volvopenta.com...

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