Volvo D4 Operator's Manual
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Volvo D4 Operator's Manual

Volvo D4 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 This operator’s manual is also available in the following languages: Diese Betriebsanleitung ist auch auf Dit instructieboek kan worden besteld Deutsch erhältlich. in het Nederlands. Ein Bestellcoupon ist am Ende der Betriebs- De bestelcoupon vindt u achter in het instruc- anleitung zu finden.
  • Page 3 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.

  • Page 4: Table Of Contents

    Stopping the engine ........58-59 Stopping .............. 58 Laying up ............. 58 Cold weather precautions ........59 © 2005 AB VOLVO PENTA All rights to changes or modifications reserved. Printed on environmentally friendly paper. (Cover: Department of transport (shipping), license 9809095)

  • Page 5: Safety Information

    Read the operator’s 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 6: Boat Travel

    Safety Information Safety precautions to be taken when operating the boat Your new boat Refueling Read operator’s manuals and other information When refueling there is always a danger of fire and supplied with your new boat. Learn to operate the explosion.
  • Page 7 Safety Information Carbon monoxide poisoning When a boat is moving forward, it will cause a certain Most modern boats, however, are designed in such vacuum to form behind the boat. In unfortunate cir- a way that this problem is very rare. If suction should arise anyway, do not open hatches or portholes at cumstances, the suction from this vacuum can be so the fore of the boat.

  • Page 8: Maintenance And Service

    All fuel, most lubricants and many chemicals are Never carry out any work on the engine if you are inflammable. Read and follow the instructions on the unsure of how it should be done, contact your Volvo packaging. Penta dealer who will be glad to offer assistance.
  • Page 9 Safety Information Hot surfaces and fluids Fuel system There is always a risk of burns when working with Always use protective gloves when tracing leaks. a hot engine. Beware of hot surfaces. For example: Liquids ejected under pressure can penetrate body the exhaust pipe, Turbo unit, oil pan, charge air pipe, tissue and cause serious injury.

  • Page 10: Introduction

    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 operator’s manual carefully and learn how to operate the engine, controls and other equipment safely.

  • Page 11: Certificated 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 12 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 13 Engine type............4 stroke diesel engine with stern drive with integral exhaust Engine model(s) covered by this declaration EC Type certificate number D4-210 drive DPH ............SDVOLV002 D4-225 drive DPH ............SDVOLV002 D4-260 drive DPH ............SDVOLV002 D6-280 drive DPH ............SDVOLV003 D6-310 drive DPR ............

  • Page 14: Identification Numbers

    Introduction Identification numbers Always provide the engine and transmission identification numbers when ordering service or replacement com- ponents. The identification numbers are on an information decal located on the front edge of the engine. Note the infor- mation below. Make a copy of the page. Store the information so that it is available in event of the boat being stolen.

  • Page 15: Presentation

    Presentation Volvo Penta’s D4 and D6 is developed from the latest design in modern diesel technology. The engine has com- mon rail fuel injection system, double overhead camshafts, 4 valves per cylinder, turbocharger, compressor, and aftercooler. The interaction of these, the large swept volume, and the EVC system results in exceptional diesel performance combined with low emissions.

  • Page 16: Engine Monitoring And Evc

    Presentation Engine Management and EVC system Helm station Con- trol Unit (HCU)) Helm station Con- trol Unit (HCU) CAN bus Power train Control Unit (PCU) Engine Management System (EMS) Engine Management System To protect the engine at too high coolant or charge air The engines are equipped with common rail system temperatures and boost pressure as well as oil pres- and electronically controlled injectors with an elec-...
  • Page 17 Presentation Power Trim The EVC system The function is considerably improved compared The Electronic Vessel Control (EVC) system is a so to non EVC governed PowerTrim systems. EVC in- called distributed system. The principle of a distrib- troduces a new trim panel with the same design as uted system is to have many small electonic units, other EVC control panels.

  • Page 18: Orientation

    Presentation Orientation D4 with drive, starboard 1. Zinc anode 2. Cooling water intake 3. Zinc anode 4. Turbocharger 5. Crankcase ventilation filter 6. Aux Stop 7. Air filter 8. Compressor 9. EDC control module 10. Generator 11. Oil filler cap...
  • Page 19 Presentation D4 with reverse gear, starboard 1. Turbocharger 2. Crankcase ventilation filter 3. Aux Stop 4. Air filter 5. EDC control module 6. Generator 7. Oil filler cap D4 with reverse gear, port 8. Sea water pump 9. Fuel filter 10.
  • Page 20 Presentation D6 with drive, starboard 1. Zinc anode 2. Cooling water intake 3. Zinc anode 4. Turbocharger 5. Crankcase ventilation filter 6. Aux Stop 7. Air filter 8. Compressor 9. EDC control module 10. Generator 11. Oil filler cap 15 16 D6 with drive, port 11.
  • Page 21 Presentation D6 with reverse gear, starboard 1. Turbocharger 2. Crankcase ventilation filter 3. Air filter 4. Aux Stop 5. EDC control module 6. Generator 7. Oil filler cap D6 with reverse gear, port 8. Sea water pump 9. Fuel filter 10.

  • Page 22: Instrumentation

    Instruments This chapter describes the instrument and control panels sold by Volvo Penta for your engine. If you want to supplement the instrumentation, or if your boat is equipped with instruments not described here, or you are not sure about their function, please contact your Volvo Penta dealer.

  • Page 23: Start/Stop Panel

    Instruments Ignition lock A tab with the key code accompanies the ignition keys, and is used to order extra ignition keys. Do not store the code where it is accessible to unauthorized persons. S = Stop position. 0 = Key can be inserted and removed. I = System voltage on (drive position).

  • Page 24: Alarm Display

    Instruments Alarm display The following warning lamps should never light up during operation. On the other hand, the warning lamps light up when the starter key is first turned to the drive position. Check that all lamps function. When the engine has started, all lamps should have gone out.
  • Page 25 Instruments Battery. (orange indication) The battery lamp lights up if the alternator is not charging. Stop the engine if this lamp lights up during operation. If the lamp lights up, this can be due to a fault in the electrical system or because the alternator drive belt is slack.
  • Page 26 Instruments Coolant level (orange indication) The coolant lamp lights up when the coolant level is too low. Check coolant level. Please refer to “Maintenan- ce: Fresh water system”. Red warning indication, serious fault If the red warning indication is shown during opera- tion, a serious fault has occured.

  • Page 27: Evc Control Panels

    Instruments EVC control panel There are two versions of the EVC control panel, one for single engine installations and another for twin installa- tions. Synchronization indication Activation button Used to activate the control panel, so that the engine The synchronization function automatically adjusts can be started and stopped.

  • Page 28: Evc-Display

    Instruments EVC-Display Introduction The Volvo Penta EVC-display is an instrument for indi- cation of engine operating values. The display consists of a computerised unit for fixed installation in a control panel. Indications are presented on a LCD-screen. The ope- rator selects presentation mode using five white keys on the front of the instrument.
  • Page 29 Instruments EVC data parameter names and icons Engine RPM Inlet manifold temperature Coolant temperature Exhauste temperature Voltage Engine oil temperature Transmission oil pressure Fuel pressure Transmission oil temperature Engine oil pressure Fuel level Coolant pressure Navigation based vehicle speed Engine oil filter differential pressure Fuel rate Turbo pressure (actual) Using the instrument...
  • Page 30 Instruments Engine page This page is always displayed after the start-up screen. It shows the engine rpm value and boat speed as standard gauges, a fuel computer and the fuel tank level. The fuel tank level will only be displayed if the relevant data is received.
  • Page 31 Instruments Configuration menu, key 5 (the rightmost key), held for > 3s The configuration menu allows the user to; - adjust various functions/settings - calibrate various parameters - get various kind of information from the EVC system Note! The port engine or both engines have to have ignition on when settings are made or when resetting data.
  • Page 32 Instruments Settings The settings page allows the user to set various op- tions for the functional operation of the unit and to calibrate various parameters. Language: 8 different languages are available Bleep: Keys are bleeping when pressed (on/off) Engine: Defines the engine source (Port, Stbd or Twin)* Display: Set the range of boat speed and engine rpm gauges.
  • Page 33 (imperial Chk: Flash memory checksum or metric). Sends the request to change settings Part no: Volvo software part number message with a set of valid pre-determined values Source: Display the source of received data for the configuration.
  • Page 34 Instruments Engine page, key 1 This page is always displayed after the start-up screen. It shows the engine rpm value and boat speed as standard gauges, a fuel computer and the fuel tank level. The fuel tank level will only be displayed if the relevant data is received.
  • Page 35 Instruments Multi page, key 2 The page shows data parameters displayed in four data windows. The display parameters are user selectable. The information can be displayed either digitally or graphically. The display toggles between the two when key 2 is pressed repeatedly. If a data parameter is not available, the unit will display “—“...
  • Page 36 Instruments Adjusting display parameters This page has an adjust mode which provides for any available parameter to be displayed in any of the four data windows. The adjust mode is entered by pressing key 5 (the rightmost key) when the pop-up menu is visible. Note! If the data is not available the parameter will not be selectable.
  • Page 37 Instruments Trip page, key 3 The page displays: - Trip fuel used since last reset - Instantaneous fuel rate (volume of fuel used per hours) Or instantaneous fuel rate (volume of fuel used per distance, if speed available) - Trip engine hours since last reset - Total engine hours (non re-settable) Single engine screen To reset the trip values (trip fuel and trip hours) just...
  • Page 38 Instruments Graph page, key 4 By repeatedly pressing key 4, the data parameters will be displayed with a historic graph: If a data parameter is not available, that particular screen will not be selectable. If the data is lost, whilst in the screen, then the graph line will just stop drawing but continue to scroll across the screen.
  • Page 39 Instruments Depth alarm functions All deph alarm functions are accessed through the CONFIG SETTINGS CALIBRATION menu as des- cribed below. Note! The port engine or both engines have to have ignition on when settings are made or when resetting data. Depth alarm Depth alarm can be switched ON/OFF.
  • Page 40 Instruments Depth alarm unacknowledged pop-up The depth alarm un-acknowledged pop-up will appear and flash if the depth alarm is enabled and enabled active state is transmitted from the EVC-unit. The display buzzer will also sound as for standard EVC alarms. All standard EVC-system alarms will have priority over the depth alarm.
  • Page 41 Instruments Fuel level/ alarm functions All fuel alarm functions are accessed through the CONFIG SETTINGS CALIBRATION menu as described below. Note! The port engine or both engines have to have ignition on when settings are made or when resetting data. Fuel alarm The Fuel Alarm can be switched ON/OFF.
  • Page 42 Instruments Fuel alarm un-acknowledged Pop up The fuel level alarm un-acknowledged pop-up will ap- pear and flash if the fuel level alarm is enabled and enabled active state is transmitted from the EVC- unit. The display buzzer will also sound as for stan- dard EVC alarms.
  • Page 43 Instruments Speed Calibration Speed Calibration function are accessed via the CO NFIG SETTINGS CALIBRATION menu described below. Note! The port engine or both engines have to have ignition on when settings are made or when resetting data. Calibration The calibration factor for the boat’s paddle wheel speed sensor can be adjusted + or –...

  • Page 44: Controls

    Controls This chapter describes the instrument panels sold by Volvo Penta for your engine. If your boat is equipped with controls which are not described here and you feel uncertain about the function, please contact the dealer you purchased the boat from.
  • Page 45 Controls Friction brake The control has a friction brake which can be adjusted as necessary to provide lighter or heavier lever action. Adjusting the friction brake: 1. Stop the engine. 2. Mover the control lever forwards so that the groove in the hub of the control lever is accessible.
  • Page 46 Controls Two lever control. Mechanical Operation The two lever control has separate levers for shifting (1) and speed control (2). The control has a neutral position switch that only allows the engine to be started with the reversing gear in neutral. Black lever (1): N = Neutral position.

  • Page 47: Power Trim

    Power Trim Your Volvo Penta drive is equipped with a hydraulic trim system, Power Trim, with which you can change the angle of the drive in relation to the transom. This will affect the running position of the boat and make it possible to optimize boat handling in various conditions.
  • Page 48 Power Trim Trim ranges In order to utilize the information gained from the trim instrument, it is essential to know about the dif- ferent trim ranges and their uses. There are three trim ranges: Trim range The trim range is used to obtain the best comfort at all running speeds (from start to maximum speed).
  • Page 49 Power Trim Analogue trim instrument This instrument shows the current position of the drive. Beach range is marked with an orange zone and lift range with a red zone. 1. Trim range. 2. Beach range (orange). 3. Lift range (red).

  • Page 50: Starting The Engine

    Starting the engine Make it a habit to give the engine and engine bay a visual check before starting. This will help you to discover quickly if anything abnormal has happened, or is about to happen. Also check that instruments and warning dis- plays show normal values after you have started the engine.

  • Page 51: Starting Method

    Starting the engine Starting method Put the reverse gear/stern drive in neutral Put the reverse gear in neutral by moving the control lever(s) to neutral at all control positions. Two lever control: Also check that the engine speed lever is in the idling position. Turn the ignition on Turn the starter key to position I to switch the ignition on.
  • Page 52 Starting the engine Start the engine Start using the ignition switch Turn the key to position III. Release the key and let it key spring back to position I as soon as the engine has started. Starting with the starter button Press the starter button.

  • Page 53: Operation

    Operation Learn to handle the engine, controls and other equipment in a safe and correct manner before you cast off on your maiden voyage. Remember to avoid sudden or surprising rudder movements and gear shifting. There is a risk that passengers could fall over, or overboard. WARNING! A rotating propeller can cause severe injury.

  • Page 54: Cruising Speed

    “Fault tracing” chapter. If the engine speed exceeds the full throttle range, select a coarser pitch propeller. Ask your Volvo Penta dealer for advice. Synchronizing engine speed When driving with twin engines, both the operating eco- nomy and comfort can be increased when the engines are operating at the same engine speed (rpm).

  • Page 55: Changing Helm Station

    This function must be enabled to permit the control panel to be changed during operation. The function can only be enabled by authorized Volvo Penta personnel. Please contact your Volvo Penta dealer. 1. Press the activation button (1) to unlock the system.

  • Page 56: Operation

    Operation Operation Shifting between forward and reverse should be done at idling. Shifting at higher engine speeds can be uncom- fortable for passengers and cause unnecessary stress on the stern drive/reversing gear, 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 57 “bow-up” or “bow- down” positions. Boat stability and steering torque can also vary due to changing water conditions. If you experience boat instability and/or high ste- ering torque, see your Volvo Penta dealer to cor- rect these conditions.
  • Page 58 Operation At planing speed Trim the drive out to the operating position which pro- vides 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 load- ing on one side of the boat or the other.

  • Page 59: Running Aground

    If this is the case or if other damage has occurred to the drive it must be inspected at an autho- rized Volvo Penta workshop. If only the propeller has been damaged it must be replaced. Launch the boat and test drive.

  • Page 60: 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.

  • Page 61: Cold Weather Precautions

    Stopping the engine Cold weather precautions To prevent freezing damage, the seawater system must be drained and the freshwater system coolant must have sufficient antifreeze protection. Refer to the cooling system section in chapter “Maintenance”. IMPORTANT! A poorly charged battery may burst as a result of freezing.

  • Page 62: Maintenance Schedule

    Maintenance schedule General information Your Volvo Penta engine and its equipment are designed for high reliability and long life. They are built to withstand a marine environment, but also to have the smallest possible environmental impact. If given preventive maintenance, according to the maintenance schedule, and if Volvo Penta original spares are used, these quali- ties are retained and unnecessary malfunctions can be avoided.
  • Page 63 Maintenance schedule Every 200 hours / at least once a year, included in extended protection: Crankcase ventilation filter. Change .............. page 64 Air filter. Change .................... page 64 Exhaust pipe. Check..................page 65 Drive belts. Check belt tension ..............page 65 Compressor.
  • Page 64 Maintenance schedule Every 1200 hours / at least every 5 years: Drive belts. Change ..................page 65 Drive belt, compressor. Change ..............not shown Compressor. Change oil ................page 66 Heat exchanger. Inspect/Clean..............not shown Intercooler. Inspect/Clean................not shown Control cables and seals. Change..............not shown Inspect exhaust hose and cooling water hoses.

  • Page 65: Maintenance

    Maintenance This chapter describes how to carry out the above maintenance. Read the instructions carefully before starting work. Maintenance intervals are contained in the chapter above: Maintenance schedule WARNING! Read the safety precautions for maintenance and service in the chapter: Safety Information, before starting work.
  • Page 66 Maintenance: Engine general Changing air filter Remove the air filter cover. Remove the old air filter. Clean the air filter cover/housing if necessary. Take care not to allow impurities to enter the engine. Fit the new air filter and the air filter cover. Changing crankcase ventilation filter Unscrew the lid and remove the old filter.
  • Page 67 Maintenance. Engine general Checking exhaust line The exhaust line of drive installations must be in- spected every year with respect to corrosion between the hose (1) and the 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 68 Maintenance: Engine general Compressor. Checking oil Checking and topping up Unscrew and remove the dipstick. Wipe off oil. Screw the dipstick down fully and then remove it again. Check that the level oil is between the markings. If the dipstick is not screwed down fully the oil level will be slightly above the MIN marking if the oil level is cor- rect.

  • Page 69: Lubrication System

    If sulphur content is > 1.0 % by weight, use oil with TBN >15. NOTE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the quality requirements above. VDS =Volvo Drain Specification ACEA = Association des Constructeurs Européenne d’Automobiles API = American Petroleum Institute...
  • Page 70 IMPORTANT! Do not fill the oil above the MAX level. NOTE! Between MAX and MIN there are apporx. 1,5 liter (0,4 US gals) for D4 and 3,5 liter ( 0,9 US gals) for D6. Changing engine oil Always observe the recommended oil change interval.
  • Page 71 Maintenance. Lubrication system Changing oil filter and bypass filter. Change the oil filter and bypass filter during each oil change. Remember to hand the old filters in to a re-cycling station. WARNING! Hot oil and hot surfaces can cause burns. 1.

  • Page 72: Freshwater System

    The coolant should contain ethylene glycol of a good quality with a suitable chemical consistency for an ade- quate protection of the engine. Using anti-corrosion aditive exclusively is not permitted in Volvo Penta’s engines. Never use water by itself as coolant.
  • Page 73 (18°F). (Using 60 % glycol lowers the freezing point to -54 °C (65°F)). Never mix more than 60 % concen- trate (Volvo Penta Coolant) in the cooling liquid, this will give reduced cooling effect and increase the risk of overheating, and will give reduced freezing protec- tion.
  • Page 74 Maintenance. Freshwater system Checking coolant level WARNING! Do not open the engine coolant system filler cap when the engine is still hot ex- cept in an emergency. Steam or hot coolant may spray out. Turn the filler cap slowly counter clockwise and let any pressure escape from the system before remov- ing the cap.

  • Page 75: Seawater System

    Seawater system The seawater system is the boat’s external cooling system. On engines with drives, the seawater pump draws in water via the drive, through the control system oil cooler to the seawater pump, after which the water passes the seawater filter before being pumped through the fuel cooler, intercooler, engine oil cooler and heat exchanger.
  • Page 76 Maintenance. Seawater system Cleaning seawater filter. WARNING! Risk for water penetration. Screw off cover (1) and remove seal plate (2). Lift out and clean the insert (3). IMPORTANT! If the boat is used in water that has a lot of contaminants, seaweed etc. the filter must be checked more frequently than indicated in the maintenance schedule.
  • Page 77 Maintenance. Seawater system Checking/Changing sacrificial anodes WARNING! Risk of water entering. Close the se- awater cock before starting work on the seawater system. 1. Close the seawater cock. 2. Drain the seawater as described in ”Draining the seawater system”. 3. Remove the sacrificial anodes in the heat exchan- ger and the intercooler.
  • Page 78 Maintenance. Seawater system Seawater system. Cleaning and inhibiting To prevent the build up of deposits and salt crystals in the seawater system it must be flushed with freshwa- ter. When the boat is laid up it must also be inhibited. WARNING! Risk of water penetration.

  • Page 79: Fuel System

    Fuel system The engine fuel system is a so-called common rail-system. The advantage of the common rail-system is that the engine control unit controls the timing and fuel amount, this mean better emission control and a smooth running engine. All work on the engine common rail-system must be carried out at an authorized workshop. Use only the recom- mended grade of fuel: See the chapter “Technical Data”.
  • Page 80 Maintenance. Fuel system Bleeding the fuel system The fuel system must be bled e.g. after changing fuel filter, if the fuel tank has been run dry and after long stops. WARNING! Never detach the pressure pipes. 1. Attach a transparent hose to the air vent valve (1). Lead the hose to a suitable receptacle to avoid spillage.
  • Page 81 Maintenance. Fuel system Fuel pre-filter. Changing filter insert Close fuel cock at the fuel tank. Position a container under the fuel filter. Remove the cover by slackening off screw (1). Replace insert and reinstall cover. Open fuel cock. Vent fuel system.

  • Page 82: Electrical System

    Electrical system The engine is equipped with a two-pole system electrical system which means that the voltage (minus) is re- turned directly from the starter motor minus terminal with the battery negative lead. Individual components on the system return voltage to the starter motor minus terminal via separate cables. WARNING! Always stop the engine and break the current using the main switches before working on the electrical system.
  • Page 83 Also check that all electrical connections are dry and free of oxidation and that there are no loose connec- tions. If necessary, spray these connections with a 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...
  • Page 84 Maintenance: Electrical system 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.
  • Page 85 Maintenance: Electrical system Electrical installations Leakage current from the electrical system can be caused by incorrect installation of electrical equip- ment. Leakage current can knock out the galvanic protection of components such as the drive, propel- ler, propeller shaft, rudder stock and keel and cause damage by electrolytic corrosion.
  • Page 86 All equipment connected to the auxiliary battery should have separate switches. To simultaneously charge two independent battery circuits, fit a Volvo Penta charge distributor (ac- cessory) to the regular generator.

  • Page 87: Reverse Gear

    The reverse gears is equipped with solenoid valves for electronically controlled shifting. IMPORTANT! Volvo Penta recommends the installation of a seawater filter to guarantee the proper cool- ant water flow to the engine and reverse gear. Contaminants in the seawater will otherwise foul the reverse gear radiator and other cooling system components.
  • Page 88 Maintenance. Reverse gear Propeller shaft seal. Checking If the boat has a Volvo Penta shaft the shaft seal must be vented and lubricated directly after launching. Vent the bushing by pressing it together while pressing down on the shaft until water appears. Then press in approx.

  • Page 89: Drive

    Drive Your drive is protected against galvanic corrosion. This protection consists of two-three layers of paint, sacrificial anodes and ground braids. The ground braids maintain a connection between the different components of the drive. A broken connection can result in the rapid corrosion of an individual component even though the protec- tion is otherwise effective.
  • Page 90 Dismantle the propeller and remove the oil drain plug (4) together with its gasket from the gear housing and allow the oil to run out. If the oil is discolored, contact an authorised Volvo Penta service centre. Refit the plug with gasket. A damaged gasket must al- ways be replaced with a new one.
  • Page 91 The drive must be dismantled from the suspension fork in order to change the joint bellows. Dismantling the drive requires knowledge and special tools. Contact your Volvo Penta service centre. Checking exhaust bellows Check the condition of the exhaust bellows once a year.

  • Page 92: Steering

    The leak must be located and rectified immediately. Contact your Volvo Penta service centre for repair. The steering system is filled with ATF and does not normally require changing. As long as the fluid is red in colour and does not contain any visible contami- nants, it need not be changed.
  • Page 93 Before removing, clean and check carefully how hoses are routed and connected. Faulty routing or dirt in the hydraulic system can negatively affect steering, and at worst steer- ing can be lost altogether. Please contact your nearest authorized Volvo Penta workshop for as- sistance.
  • Page 94 In the worst case steering could be lost altogether. Never align or weld a damaged parallel strut. Please contact your nearest authorized Volvo Penta workshop for assistance. Hydraulic tie-bar. Adjusting The tie-bar can be adjusted both with the boat in the 30 Nm water and with the boat up on land.

  • Page 95: Propellers

    Propellers. DPR/DPH drive Assembly 1. Lubricate both propeller hubs. Use Volvo Penta NB! A tool for removing and fitting the propellers is grease 828250. supplied together with the Transom shield kit (see figure).

  • Page 96: 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 work- shop inspect the engine and other equipment. Have any necessary repairs or service work carried out so that your boat is in top condition for the new season.

  • Page 97: Bringing Out Of Winter Storage

    Laying up/Launching Bringing out of storage Check oil level in the engine and drive/reverse Paint the drive and hull: See next page. gear. Top up if necessary. If there is inhibiting oil in the system drain and fill with new oil, change oil Check the sacrificial anode on the drive.

  • Page 98: Painting The Drive And Underwater Hull

    finer grade for painted surfaces. Wash off using thin- ners or similar. Any pores in the surface should be filled and sanded down. Paint using Volvo Penta ori- ginal primer and topcoat. Let the paint dry. A further two coats of Volvo Penta anti-fouling primer should then be applied.

  • Page 99: In Case Of Emergency

    In case of emergency Despite regular maintenance according to the maintenance schedule and perfect operation, it may occur that a fault occurs which must be attended to before the boat can travel further. This chapter contains tips for rectifying some of the possible faults. There are safety functions which are activated when certain faults occur, to protect the engine.

  • Page 100: Emergency Shifting

    In case of emergency Emergency shifting If a fault occurs which prevents the drive or the revers gear from being operated (shifted) with the control lever, it is possible to shift manually, using the des- cription below. WARNING! In emergency shifting, the unit is locked in forwards operation.

  • Page 101: Emergency Trimming

    In case of emergency Emergency trimming If a fault occurs which prevents the drive from being timmed with the trim panel, it is possible to trim manu- ally, using the description below. WARNING! In emergency triming, the automa- tic stop will not work. The drive can be trimmed outside the trim ranges, this can damage boat or drive.

  • Page 102: Water In Fuel

    In case of emergency Water in fuel Draining the fuel filter If the light on the lamp panel comes on, there is toomuch water in the water separator on the fuel filter. Proceed as follows to rectify this: 1. Stop the engine and take the starter key out of the starter switch.

  • Page 103: Fault-Tracing

    A number of symptoms and possible causes for engine disturbances are described in the table below. If faults or hitches arise that you cannot solve alone, you must always get in touch with your Volvo Penta dealer. WARNING! Read the safety directions for maintenance and service in the chapter “Safety information” be- fore starting work.

  • Page 104: Diagnostic Function

    In case of emergency Diagnostic function The diagnostic function monitors and checks that the engine, stern drive/reversing gear and EVC system func- tion normally. The diagnostic function has the following tasks: Discover and localize malfunctions Notify that malfunctions have been discovered Give advice in fault finding Protect the engine and ensure continued operation when serious malfunctions are discovered.

  • Page 105: Malfunction Message Engine And Evc-System

    In case of emergency Malfunction message engine and EVC- system If the diagnostic function discovers a malfunction, it warns the driver by starting to flash the indicator on the diagnostic button, a pop-up window will appear in the display and the buzzer will not sound. To acknowledge the alarm, press any key on the dis- play .

  • Page 106: Alarm List

    In case of emergency Alarm list The alarm list screen contain all previously acknow- ledged alarms (black text on grey background) and new unacknowledged alarms (grey text on black back- ground) as shown. - Alarm index number (in order of receipt). - Which engine the alarm is from (Port, Stbd).

  • Page 107: Fault Codes

    In case of emergency Fault codes Before the fault codes can be read out enter Service mode by pressing button D for about 5 sec. The D indication gives a steady light and indicator on alarm panel flashes with a orange/red light. The codes are flashed out on the D button indication.

  • Page 108: Erasing Fault Codes

    In case of emergency Erasing fault codes Any fault codes in the diagnostic function are auto- matically erased every time the starter key is turned to the stop position (S). NOTE! Stop the engine and check that the ignition key(s) is(are) in position 0 in all control positions. When system voltage is switched on again, the diag- nostic function checks to see whether there are any faults in the EVC system.

  • Page 109: Fault Code Register

    Empty the water trap underneath the fuel filters, please refer to the “In case of emergency” chapter ”Water in fuel” • Contact a Volvo Penta workshop if the fault remains. 1.2.4 Explanation: Fault in engine speed sensor on flywheel. Reaction: Engine power is reduced. Engine is difficult to start.
  • Page 110 Check that the sea water filter is not blocked. Please refer to “Maintenance: Sea water system”. • Check the impeller in the sea water pump. Please refer to “Maintenance: Sea water system”. • Check that no leakage occurs. • Contact a Volvo Penta workshop if the fault remains.
  • Page 111 • Open the fuel taps and check that no leakage occurs. • Check that the fuel filters are not blocked. Please refer to “Maintenance: Fuel system” • Contact a Volvo Penta workshop if the fault remains. 1.7.1–1.7.6 Explanation: Injector system failure, injector 1–6.
  • Page 112 Check the fuel level. • Check fuel cooler. • Check that no leakage occurs. • Please contact a Volvo Penta workshop if the fault remains. 1.9.9 Explanation: Internal system fault in engine. Reaction: Action: • If the engine can not be operated from the chosen control panel, use an alternative control panel.
  • Page 113 Reaction: Cannot engage gears. Engine in emergency mode. Action: • Emergency shifting, see chapter "In case of emergeny". • Please contact a Volvo Penta workshop if the fault remains. 2.4.5 Explanation: Faulty solenoid, primary. Reaction: Cannot engage gears. Engine in emergency mode. Action: •...
  • Page 114 Action: • Switch the ignition off, and repeat the calibration procedure. • Check that the control levers are approved by Volvo Penta and correctly installed. • Please contact a Volvo Penta workshop if the fault remains. • Check that the control levers are approved by Volvo Penta.
  • Page 115 If the engine can not be operated from the chosen control panel, use an alternative control panel. • Switch the ignition off, and repeat the calibration procedure. • Check that the control levers are approved by Volvo Penta and correctly installed. • Please contact a Volvo Penta workshop. 3.9.9 Explanation: Internal fault in the EVC system.

  • Page 116: Technical Data

    4.5 bars (65 psi) Compressor Oil volume..............0.1 liter (0.2 US pint) 0.1 liter (0.2 US pint) Oil grade..............Volvo Penta, part no. 1141641-9 Cooling system Thermostats open/fully open ........82°C/92°C 82°C/92°C Fresh water system volume, app......13 liter (3.4 US gals) 16.5 liter (4.4 US gals)

  • Page 117: Fuel Specification

    If sulphur content is > 1.0 % by weight, use oil with TBN >15. Note! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the quality requirements above. VDS =Volvo Drain Specification ACEA = Association des Constructeurs Européenne d’Automobiles API = American Petroleum Institute...

  • Page 118: Drive

    Technical Data Drive Oil volume............5.4 liters (1.4 US gals) Oil volume between min. and max. markings ............. 0.2 liter (0.4 US pint) Oil grade and viscosity ........VP 1141634 (API GL5 SAE 75W /90) Synthetic* Oil volume............4.2 liter (1.1 US qals) Oil volume between min.
  • Page 119 Notes...
  • Page 120 Yes please, I would like an operator’s manual in English at no charge. Publication number: 7745861 Post or fax this coupon to: Document & Distribution Center Name Order Department ARU 2, Dept. 64620 Address SE-405 08 Göteborg Sweden Fax: +46 31 545 772 Orders can also be placed via the Internet: http://www.volvopenta.com/...
  • Page 121 Sí gracias, deseo recibir gratuitamente un libro de instrucciones en español. Número de publicación: 7745008 Franquear o enviar fax a: Document & Distribution Center Nombre Order Department ARU 2, Dept. 64620 Dirección SE-405 08 Göteborg Suecia Fax: +46 31 545 772 El pedido puede hacerse tam- bién por internet: http://www.volvopenta.com/...
  • Page 122 Ja graag, Ik wil kosteloos een instructieboek in het Nederlands ontvangen. Publicatienummer: 7745018 Stuur of fax de coupon naar: Document & Distribution Center Naam Order Department ARU 2, Dept. 64620 Adres SE-405 08 Göteborg Zweden Fax: +46 31 545 772 U kunt ook bestellen via internet: http://www.volvopenta.com/...
  • Page 123 Sim, obrigado(a)! Gostaria de receber gratuitamente um manual de instruções em português. Número de publicação: 7745028 Envie o talão pelo correio ou um fax para: Nome Document & Distribution Center Order Department Endereço ARU 2, Dept. 64620 SE-405 08 Göteborg Sweden Fax: +46 31 545 772 A encomenda também pode...

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