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

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OPERATOR'S MANUAL
D4, D6

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Summary of Contents for Volvo Penta D4

  • Page 1 OPERATOR’S MANUAL D4, D6...
  • Page 2 Todos los datos recibidos son almacenados de forma in- Όλες οι πληροφορίες αποθηκεύονται από την AB Volvo Pen- terna por Volvo Penta AB y no se ponen a disposición de ta και δεν θα μεταβιβαστούν σε τρίτα πρόσωπα. terceras partes.

  • Page 3: Table Of Contents

    Content Foreword ...................... 2 Safety Information ..................3 Introduction ....................8 Instruments and Controls ................ 10 Optional ..................... 29 Starting ...................... 31 Operation ....................34 Engine Shutdown ..................38 Fault Handling ................... 42 Fault Code Register .................. 45 In Case of Emergency ................54 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 instruction book before you read on. If not, please contact your Volvo Penta dealer. This symbol is used in the instruction book 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 Gauges Tachometer The tachometer displays engine speed; multiply the value shown on the dial by 1,000 to get the number of engine revolutions per minute. Boat and engine information is displayed in the tach- ometer window. Information displayed depends on engine type, the number of sensors and which acces- sories are installed.
  • Page 14 Instruments and Controls Control Panel The control panel is used for station handling, disen- gaging the gear/drive and to navigate the EVC system menu. There is one control panel for single installations and one for twin installations. Always push the buttons firmly and for at least one second.
  • Page 15 Instruments and Controls Tachometer Display Selection Boats with twin installations with one tachometer for port engine and one for starboard can choose which engine menu to handle from the station. The lamp above the button shows which engine is chosen, green lamp for starboard engine and red lamp for port engine.
  • Page 16 Instruments and Controls EVC System Display In the EVC system display it is possible to show mul- tiple windows with different information. There are four display modes which can be chosen using the buttons on the instrument. Button 1–4 shows the different display modes. Button 5 i used to adjust the contrast and to access the con- figuration menu, please refer to section Configuration menu.
  • Page 17 Instruments and Controls Contrast In the display modes Engine, Trip and Graph, it is pos- sible to adjust the contrast. Press button 5 when outside the menu and then + (button 4) and – (button 3). P0002403 Engine, button 1 Rpm and speed is shown in the upper part of the dis- ENGINE SPEED...
  • Page 18 Instruments and Controls Multi, button 2 In the multi mode the information can be shown in sev- eral windows, analogue or digital. The display can show windows with different information or be divided to show windows and system information. To handle the system information, see section Instruments and Controls page 19.
  • Page 19 Instruments and Controls Graph, button 4 The information is shown as graphs. Press button 4 repeatedly to choose which information will be shown. The time interval is set in the Configuration menu. If the connection is broken there will be a straight line 4000 in the display.
  • Page 20 Instruments and Controls - Display: Setting of intervals (unit settings are made UNITS in the EVC menu, see Instruments and Con- trols page 19): SPEED KM/H Rpm interval, 2500–9000 rpm, in steps of 500 rpm. DISTANCE Speed, on/off. OIL PRESSURE Speed interval, 10–100 knots, in steps of 10 knots.
  • Page 21 Instruments and Controls EVC Menu The EVC menu can be shown in both the EVC system display and the tachometer display. The main menu shows operating information, the settings menu and the fault menu (only shown when a fault in the system is detected).
  • Page 22 Instruments and Controls Settings Turn the control panel wheel until the start screen for the settings menu is displayed. Press the wheel to reach the sub menus. Turn to move between the available setting functions. For further information, refer to section Settings P0001015 Menu page 102.
  • Page 23 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 24 Instruments and Controls Digital trim instrument The trim instrument shows the drive trim setting. The angle of the drive is given in relation to a horizontal line. The lowest value indicates that the drive is fully trim- med down and the highest value that the drive is fully trimmed up.
  • Page 25 Instruments and Controls Trim Controls The drive can be trimmed with the Power Trim panel or with the button on the trim control. On twininstalla- tions there is a control for each drive. The Power Trim panel is used for both single and twin engine installa- tions.
  • Page 26 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 Settings Menu page 102 section PTA.
  • Page 27 ”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 28 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. Single Lever Control...
  • Page 29 Instruments and Controls Adjusting the friction brake The lever is fitted with a friction brake to allow adjust- ment for easier or stiffer movement as required. The friction brake only affects movement of the throttle con- trol lever. 1 Stop the engine. 2 Move the control lever forward so that the groove in the lever hub is accessible.
  • Page 30 Instruments and Controls Dual lever control Maneuvering A twin-lever control has separate levers for the gear- shift function (1) and rpm control (throttle) (2). The engine can only be started with the control lever in the neutral position. Control A Black lever (1) N = Neutral position.

  • Page 31: Optional

    Optional Low speed The Lowspeed function is available for engines with some hydralic reverse gear. Boats with powerful engines can have high speed even at idle. The Lowspeed function reduces the boat speed. N = Neutral. Reverse gear is disengaged and engine runs at idle speed.
  • Page 32 Optional Engaging Lowspeed 1 Move the lever to neutral position. 2 Press the neutral button (N) to activate Lowspeed. RPMX100 If the message “Lowspeed initierate” (A) followd by the snail symbol (B) in the display the lowspeed function is not ready. Normal gear shifting until Low- speed is activated.

  • Page 33: 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 34 Starting Starting the Engine Shifting, adjusting speed and performing EVC settings and calibrations 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 EVC system is started up with the ignition key(s).
  • Page 35 Starting Check lamps Each time the ignition is turned on, all lamps in the alarm instrument are illuminated. Check that all lamps light up and go out. If a lamp flashes a fault has been registred, please refer to section Fault Han- dling page 42 for further information and reco- mended actions.

  • Page 36: 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 37 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 38 Operation Helm Stations Changing stations 1 Put the gear in neutral. The lamp above the neutral button (1) is lit when the gear is in neutral. 2 Unlock, if locked, the station you leave by pushing the activation button (2). 3 Activate the station you change to by pressing the activation button (2).
  • Page 39 Fault Handling page 44 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 40: 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 41 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 42 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 laid up, please refer to Stor- age page 98.
  • Page 43 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 44: 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 Fault information from engine and EVC system If a malfunction is discovered the driver is warned by a buzzer sounding and a pop-up showing in the display.
  • Page 45 Fault Handling Acknowledge message 1 Push the knob on the control panel to ackowledge the alarm. The buzzer becomes silent. 2 Read the alarm or message in the pop-up. 3 Push the knob on the control panel again and the pop-up disappears.
  • Page 46 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 47: Fault Code Register

    Check the batteries fluid level • Check belt tension. • Please contact a Volvo Penta workshop if the fault remains. P0005024 1 Is the orange “water in fuel” lamp lit there is to much water in the water separator on the fuel pre-filter.
  • Page 48 None. Action: • Empty the water trap underneath the fuel filters. Please refer to Maintenance page 71. • Please contact a Volvo Penta workshop if the fault remains. P0001200 CAUTION! Water in Fuel See Operator's Manual Coolant Level Explanation: Coolant level too low.
  • Page 49 If the cooling water flow ceases, the exhaust hose should be inspected internally and replaced if the hose shows signs of damage. • Please contact a Volvo Penta workshop if the fault remains. Fuel Pressure Explanation: Fuel pressure too low.
  • Page 50 Check that the oil filters are not blocked. Replace filters if nec- essary. • Check that no leakage occurs. P0005018 • Please contact a Volvo Penta workshop if the fault remains. WARNING! Engine Oil Pressure See Operator's Manual Stop Engine Battery Voltage Explanation: Battery voltage too low.
  • Page 51 84. • Check belt tension. Please refer to Drive Belt, Check and Change page 66. • Please contact a Volvo Penta workshop if the fault remains. P0005026 WARNING! Primary Battery See Oper- ator's Manual Check Control Lever Explanation: Fault in control lever.
  • Page 52 Incorrect lever calibration. Symptom: Impossible to select active station. Action: • Restart engine(s). • Please contact a Volvo Penta workshop if the fault remains. P0005033 CAUTION! Lever Calibration Incorrect- See Operator's Manual Check EVC System Explanation: Internal fault in EVC system.
  • Page 53 Check Engine Explanation: Miscellaneous system faults. Symptom: None. Action: • Restart engine(s). • Please contact a Volvo Penta workshop if the fault remains. P0005036 CAUTION! Check Engine See Opera- tor's Manual Helm Restarted Explanation: Lost active helm during crank. Symptom: None.
  • Page 54 Fault in power trim system. Symptom: Not possible to control the power trim. Action: • Emergency Trimming • Please contact a Volvo Penta workshop if the fault remains. P0001198 WARNING!Power Trim FaultsSee Operator's Manual P0001205 CAUTION!Power Trim FaultsSee Operator's Manual...
  • Page 55 Fault Code Register Key Failure Explanation: Key or start panel out of order. Symptom: None. Action: Please contact a Volvo Penta workshop. P0001199 CAUTION! Key FailureSee Operator's Manual Check Multilink Explanation: Fault in multilink communication. Symptom: Possible loss of engine synchronization or loss of display(s).

  • Page 56: 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 57 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 58 In Case of Emergency Emergency Shifting If a fault occurs that prevents engaging gears with the control lever (shifting), it is possible to engage them manually. Reverse gear This description describes electronically shifted reverse gear. Manual shifting of gears 1 Stop the engine and remove the ignition key from the ignition lock.
  • Page 59 In Case of Emergency Emergency Trimming If a fault occurs that prevents the drive from being trim- med from the trim panel, the drive can be emergency trimmed. 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 60: 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 61 Maintenance Schedule Every 200 hours / at Least Every 12th Month Coolant level and antifreeze mixture Crankcase ventilation filter Luftfilter Fuel pre-filter and fuel fine filter Seawater filter Drive belts, wear Compressor, oil level Seawater pump impeller Sacrificial anodes (charge air cooler and heat exchanger) Drive-unit and transom.
  • Page 62 Every 1200 hours for Marine Leisure 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. 7748934 04-2008...

  • Page 63: Maintenance

    Care and maintenance work should be done with the engine stopped unless otherwise specified. Stop the engine before opening or removing the engine hatch/hood. Make it impossible to start the engine by removing the start key and cutting the system voltage with the main switches. D4 with reverse gear, starboard Turbocharger Crankcase ventilation filter...
  • Page 64 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...
  • Page 65 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 66 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 67 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 68 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 69 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 70 2 Wait 5 minutes to allow the oil time to reach the sump before checking the level again. 3 Then check the level again. NOTICE! The volume between MAX and MIN is about 1.5 liter (0.4 US gal) for D4 and 3.5 liter (0.9 US gal) for D6. 7748934 04-2008...
  • Page 71 Maintenance Engine Oil, Change Always follow the recommended oil change interval. Use only oils of the recommended grades; refer to Technical Data page 113. WARNING! Hot oil and hot surfaces can cause burns. 1 Run the engine until warm so that the oil is easier to pump.
  • Page 72 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 73 Maintenance Fuel System Only use the grades of fuel recommended in the fuel specification, see Technical Data page 114. 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 74 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 75 Maintenance Water in Fuel If the EVC system warns for too much water in the fuel pre-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 76 Water Quality page 115. Only coolant of this grade is suitable for, and approved by, Volvo Penta. The use of anti-corrosion agents alone is not permitted in Volvo Penta engines. Never use water alone as the coolant. IMPORTANT! Coolant of a suitable chemical composition must be used all year round.
  • Page 77 The coolant must be mixed with distilled, deionized water. The water must fulfill the requirements specified by Volvo Penta; refer to Water Quality page 115. It is extremely important that the system is filled with the correct coolant concentration. Mix in a separate clean vessel before filling the cooling system.
  • Page 78 Maintenance Coolant Level, Checking and Topping Up WARNING! Do not open the coolant filler cap when the engine is warm, except in emergencies, this could cause serious personal injury. Steam or hot fluid could spray out. 1 Turn the filler cover slowly counter-clockwise and release any pressure from the system before removing the cover completely.
  • Page 79 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 80 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 81 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 78. 3 Remove the zinc anodes from the heat exchanger (1) and intercooler (2).
  • Page 82 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 83 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 84 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. Main Switch IMPORTANT! Never disconnect the current with the main switches when the engine is running, the alternator and elec-...
  • Page 85 Volvo Penta workshop. Electrical Connections 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). 7748934 04-2008...
  • Page 86 Maintenance Battery, Maintenance WARNING! Risk of fire and explosion. Never allow an open flame or electric sparks near the battery or batteries. WARNING! P0002107 Never confuse the positive and negative poles on the batteries. Risk of arcing and explosion. WARNING! The battery electrolyte contains extremely corrosive sulfuric acid.
  • Page 87 Maintenance Filling The electrolyte level should be 5–10 mm (0.2– 0.4”) above the cell plates in the battery. Top up with distilled water as required. After filling, the battery should be charged for at least 30 minutes by running the engine at idle. Some maintenance-free batteries have special instructions, which must be followed.
  • Page 88 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 89 Maintenance 4 The start battery must have a main switch (1) con- nected to the battery's plus (+) 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 plus (+) ter- minal and the circuit breaker panel for the boat's...
  • Page 90 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 91 Maintenance Reverse Gear, Oil och Filter Change 1 Clean around the cap (2) so that there is no risk of dirt falling into the filter housing. 2 Undo the Allen bolt (1) with a 6mm Allen key. Remove the cover (2). Change the O-rings in the cap;...
  • Page 92 Maintenance 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. Purge the glands by pressing them together, at the same time as they are pressed down onto the shaft.
  • Page 93 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 94 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 95 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 96 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. 7748934 04-2008...
  • Page 97 5 Wipe dry and clean the propeller shaft. Installation 1 Grease both propeller hubs. Use Volvo Penta grease (part # 828250). 2 Turn on the ignition and move the control lever to ahead. Remove the start key from the start lock.
  • Page 98 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.
  • Page 99 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 100: 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 101 • 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 102 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 page 113.
  • Page 103 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 104: Calibration And Settings

    My view. P0001013 Depth Alarm Setting the depth alarm for the Volvo Penta echo soun- der. The setting need only be entered at one display, at one station.
  • Page 105 Calibration and Settings 2 Turn until Depth Alarm is shown in the settings menu. Press the wheel to reach the submenu. P0001028 3 Depth Alarm, press the wheel to switch the func- tion on or off. P0001027 4 Turn to Set Level. Press the wheel to access adjustment of depth level alarm.
  • Page 106 Calibration and Settings 5 Turn to Set offset. Press the wheel to access offset depth adjustment. Adjust it to correspond to the boat's deepest point or the boat's waterline, depending on the depth to be displayed. The echo-sounder can be placed anywhere between these two points.
  • Page 107 Calibration and Settings Trip Reset Zeroing trip information 1 Activate the station. 2 Turn to Trip reset in the settings menu. 3 Press the wheel twice to zero the trip information. P0001032 7748934 04-2008...
  • Page 108 Calibration and Settings My View In My view it is possible to select the operating infor- mation to be displayed in the main menu. The type of information that may be selected depends on the functions installed. P0001016 1 Turn to My View in the settings menu. Press to reach the submenu.
  • Page 109 Calibration and Settings EVC Info Information regarding accessories, components and software installed in the boat is displayed here. P0001020 1 Turn to EVC About in the settings menu and press the wheel to reach the submenu. 2 Features shows what accessories are installed. Press the wheel to access the submenu.
  • Page 110 Calibration and Settings Language It is possible to select between 10 languages. On boats with more than one station and with several displays language only need to be selected on one display for it to be shown at all stations and on all dis- plays.
  • Page 111 Calibration and Settings 3 Press the wheel at PTA Pos 1. Set the trim angle for idle and press to confirm. P0001237 Trim position being set Trim angle C Engine rpm 4 Turn to PTA Pos 2. 5 Press the wheel to set the desired rpm. P0001234 Trim position being set Engine rpm...
  • Page 112 Calibration and Settings Fuel Tank There are two alternative methods for calibrating the level sensor in the fuel tank. Full Fuel Tank Calibra- tion is an approximate method, while Fuel Multipoint Calibration provides more precise results. Multipoint calibration is a prerequisite if the trip computer is to show fully accurate information.
  • Page 113 Calibration and Settings Full Fuel Tank Calibration For this method the tank must be full and calibration of the fuel level sensor takes place in one step. This means that the fuel level value will be approximate, and therefore all trip data based on remaining fuel must be seen as approximate values.

  • Page 114: Technical Data

    Technical Data Engines Engine designation D4 — See table, below D6 — See table, below Engine model See table, below See table, below Crankshaft power kW (hp)* See table, below See table, below Propeller shaft kW (hp)* See table, below...
  • Page 115 Compressor, oil Oil volume 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 Sulphur content in fuel, by weight Oil grade < 0.5 – 1.0% more than 1.0%...
  • Page 116 2–3%. Cooling System Volume Fresh water system volume (ca) D4: 13 liter (3.4 Us gal) D6 : 16,5 liter (4.4 US gal) Thermostat The thermostats begins opening/fully open 82 °C/92 °C (179.6 °F/197.6 °F)
  • Page 117 Technical Data Water Quality ASTM D4985: Total solid particles <340 ppm Total hardness <9.5° dH Chloride <40 ppm Sulfate <100 ppm pH value 5.5–9 Silica (acc. ASTM D859) <20 mg SiO P0002094 Iron (acc. ASTM D1068) <0.10 ppm Manganese (acc. ASTM D858) <0.05 ppm Conductivity (acc.
  • Page 118 Technical Data Reverse Gear Reverse gear (excluding oil cooler) Type Designation HS45AE Oil volume 2.5 liters (0.7 US gal) Oil grade ATF (Dexron II, III) Type Designation HS63AE Oil volume 4.0 liters (1 US gal) Oil grade ATF (Dexron II, III) Type Designation HS63IVE Oil volume...
  • Page 119 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 120 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 121 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 D4-300 drive DPH ............SDVOLV002 D6-280 drive DPH ............

  • Page 122: Alphabetical Index

    Alphabetical index Impeller, Check and Change........79 Acknowledge message......... 43 Information Beep........... 108 After Engine Shutdown..........39 Air Filter, Change............ 65 Laying Up and Launching........40 Alarm handling............42 Low speed............... 29 Alarms..............34 Lubrication System.......... 68, 113 Battery, Charging..........85 Main Switch............
  • Page 123 NOTICE: The free-of-charge Operator’s Manual offer is valid for 12 months after delivery. Fill in your name, postal address, email address and desired language. Publication Reference: 7748934 Name: Address: Country: E-mail: English Dansk Svenska Suomi Deutsch Português Français Ελληνικά Español Русско...

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