Volvo Penta D3 Operator's Manual
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Volvo Penta D3 Operator's Manual

Volvo Penta D3 Operator's Manual

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OPERATOR'S MANUAL
D3

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

  • Page 3: Table Of Contents

    Content Foreword ...................... 2 Safety Information ..................3 Introduction ....................8 Instruments and Controls ................ 10 Optional ..................... 36 Starting ...................... 38 Operation ....................41 Engine Shutdown ..................45 Fault Handling ................... 49 Fault Code Register .................. 52 In Case of Emergency ................56 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 Screens 4" Screen 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 Trip, button 3 The display works as trip computer and shows: Trip Fuel, since last reset Fuel Rate, fuel consumption Trip hours, since last reset Engine hours, total amount of operating hours Reset by pressing button 3 for three seconds until a beep is heard.
  • Page 19 Instruments and Controls Configuration menu Press button 5 for five seconds to enter the Configu- ration menu. Navigate with the up and down arrows, select with the right arrow. The port engine, or both engines, must have the igni- tion on when display settings are made. System information System information shows the EVC-menu and is han- dled by the knob on the control panel.
  • Page 20 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 21 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 105.
  • Page 22 Instruments and Controls 7" screen The Volvo Penta 7" screen is controlled by means of buttons: Turn to browse through submenus and to return to the main menu, Select view. Return to the previous menu. Confirms selection; also used to access sub- menus and the Settings menu.
  • Page 23 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 24 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 25 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: Instant fuel rate, current fuel consumption per hour. Average fuel rate, average fuel consumption since the last trip computer zero reset.
  • Page 26 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 105 chapter.
  • Page 27 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 to switch between modes.
  • Page 28 Instruments and Controls Components, press to see installed compo- nents. Software, information regarding the software ID number. The following is only displayed if the function is instal- led. For further information, refer to the relevant sec- tions in the Settings Menu page 105 chapter. Speed Correction, setting the speed factor.
  • Page 29 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 30 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 31 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 32 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 105 section PTA.
  • Page 33 ”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 34 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 35 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 36 Instruments and Controls Joystick Volvo Penta IPS Joystick is a control used for docking and maneuvering in low speed. The joystick makes it possible to rotate the boat and maneuver the boat in different directions – sideways, diagonally, forward and backward.
  • Page 37 Instruments and Controls Maneuvering with joystick To maneuver the boat move the joystick forwards, back- wards, sideways or by turning the top of the joystick, see figure. IMPORTANT! The boat keeps moving even after the joystick is released, compensate this by moving the joystick in opposite direction.

  • Page 38: Optional

    Optional Low speed The Volvo Penta Lowspeed function is available for engines with 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 39 Optional Engaging Lowspeed 1 Move the lever to neutral position. 2 Press the neutral button (N) to activate Lowspeed. When Lowspeed is engaged “Lowspeed activated” (A) shows on the display. 3 Active Lowspeed is indicated by the snail symbol on the display. (B). Delay in gear shifting may occur when Lowspeed is active.

  • Page 40: 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 41 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 42 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 Turn the key to position III. Release the key and let it spring back to position I as soon as the engine has started.

  • Page 43: 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 44 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 45 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 46 Fault Handling page 51 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 47: 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 48 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. Keep the button depressed untill the enigine stops. After Engine Shutdown •...
  • Page 49 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 Short Term Storage.
  • Page 50 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 51: 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 52 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 53 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 54: Fault Code Register

    Battery voltage incorrect. Check voltage level, alternator and batteries Acknowledge fault by pressing the OK button Contact a Volvo Penta workshop if the faults remains. P0010533 7749456 01-2010...
  • Page 55 Engine power is reduced. Checking Engine Oil Level. Refer to Oil level, checking and topping up page 69. 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 56 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 77.
  • Page 57 Poor batteries or charging. Refer to Battery, Charging page 86. 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 Transmission lubri- cant, checking and topping up page 92.

  • Page 58: 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 59 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 60 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 61 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 62: 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 63 Maintenance Schedule Every 200 hours / at Least Every 12th Month Coolant level and antifreeze mixture Air Filter Fuel pre-filter and fuel fine filter Seawater filter Drive belt (tension) Impeller, raw water pump Reverse gear, oil and filter Reverse gear, propeller shaft seal Outboard drive, oil Outboard drive, corrosion protection Outboard drive, propeller shaft.
  • Page 64 Maintenance Schedule Every 1200 hours / at least every 5 years Control cables and seals Outboard drive, disassemble and check for wear. Safety and function check. Every 1400 hours / at least every 8 years Timing belt, Change 1 . Every 1200 hours 7749456 01-2010...

  • Page 65: Maintenance

    Make it impossible to start the engine by removing the start key and cutting the system voltage with the main switches. Oil filler cap, engine D3 with SX/DPS sterndrive Turbo Air Filter Coolant filler cap...
  • Page 66 Maintenance Oil filler cap, engine D3 with HS45 reverse gear Turbo Air Filter Coolant, Filling Crankcase venting Seawater Pump Charge air cooler Oil Cooler Oil filter, reverse gear P0011342 11 12 13 Relays Oil Filter Auxiliary stop Fuel feed Fuel Filter...
  • Page 67 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 68 Maintenance Crankcase Ventilation, Filter Change 1 Undo the four cover bolts. 2 Move the cover forward/up so that the hose comes loose from the air filter housing. 3 Remove the filter and insert a new one. 4 Slide the hose back into the air filter housing. Screw the cover back in place.
  • Page 69 Maintenance Drive Belt, Check and Change WARNING! Stop the engine before doing any maintenance work. Check belt tensions and condition regularly. The drive belts have automatic belt tensioners and do not need to be adjusted. Check that the belt tensioner does not bottom.
  • Page 70 Maintenance Checking exhaust line The exhaust line must be checked annually for corro- sion between the hose and the pipe. 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 71 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 72 Maintenance IMPORTANT! MAX oil level for engine installations up to 5° inclination is at the upper cross on the oil dipstick. 7749456 01-2010...
  • Page 73 Maintenance Engine oil and engine oil filter, changing Always follow the recommended oil change interval. Use only oils of the recommended grades; refer to Technical Data page 119. Change the oil filters at every oil change. WARNING! Hot oil and hot surfaces can cause burns. 1 Idle the engine for around 20 minutes so that the oil is easier to pump out.
  • Page 74 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 75 Maintenance Fuel system, bleeding The fuel system is self venting but may still require venting after e.g. fuel filter replacement, when the fuel tank has been run dry or after long breaks in opera- tions. IMPORTANT! Never disconnect the delivery pipes. 1 Pump up fuel by pressing the fuel feed button (1) for around 5 seconds.
  • Page 76 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 77 Water Quality. Only coolant of this grade is suit- able 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 78 –28°C (–18°F). At 60% glycol concentration, the freezing point is lowered to –54°C (–65°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 79 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 80 Maintenance Seawater System The seawater system is the engine's external cooling system. The seawater pump draws in water via the seawater pump intake. The water is then pumped through the charge air cooler and heat exchanger into the exhaust elbow where it is mixed with exhaust gases.
  • Page 81 Maintenance Impeller, Check and Change WARNING! Risk of water entry. Close the seawater cocks before doing any work on the seawater system. 1 Remove the protective cover, if fitted, over the drive belt and remove the drive belt (1). 2 Remove the three screws (2) keeping the seawater pump cover in place.
  • Page 82 Maintenance Seawater System, Cleaning and Inhibiting The sea water system must be flushed with fresh water to prevent the build-up of deposits and salt crystals. It must also be conserved when the boat is laid up. WARNING! Risk of water entry. Close the seawater cocks before doing any work on the seawater system.
  • 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 1-pole electrical system and an alternator. System voltage is 12V. WARNING! Always stop the engine and break the current using the main switches before working on the electrical system. Isolate shore current to the engine block heater, bat- tery charger or accessories mounted on the engine.
  • Page 85 Maintenance Electronic Steering System Engines fitted with a drive wtih electronic steering are equipped with an automatic circuit breaker for the SCU (1). The circuit breaker is located near the battery or the engine's main battery switch. The circuit breaker cuts the power if the electrical sys- tem for the SCU is overloaded.
  • Page 86 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 87 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 88 Maintenance Battery, Charging WARNING! Risk of fire and explosion. Never allow an open flame or electric sparks near the battery or batteries. WARNING! P0002107 The battery electrolyte contains extremely corrosive sulfuric acid. Protect your skin and clothes when charg- ing or handling batteries. Always use protective goggles and gloves.
  • Page 89 Maintenance Electrical Installations An incorrectly-carried-out electrical installation may generate leakage current from the electrical system. Leakage current can in turn render galvanic protection insufficient in respect of propellers, propeller shafts, rudder posts, keel etc and may cause damage through electrochemical corrosion. WARNING! Work on the low voltage circuits in the boats should be done by a person with electrical training or knowledge.
  • Page 90 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 91 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 92 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 93 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 94 3 Check O-ring on dipstick for wear; replace if needed. 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. 7749456 01-2010...
  • Page 95 Maintenance Transmission Oil, Change Draining 1 Trim the sterndrive down to the drive position. 2 Remove the propeller; refer to Mainte- nance page 96. 3 Place a container under the sterndrive. Remove the oil dipstick. 4 Remove the plug (1). Allow all the oil to drain from the sterndrive.
  • Page 96 2 Clean the area around the filler cap (1) to prevent dirt from entering the trim system. 3 Remove the filler cap. The fluid must reach all the way up to the hole. Fill with Volvo Penta Power Trim and steering fluid as necessary. Corrosion protection, checking and changing Check the anodes regularly.
  • Page 97 Maintenance Replacement of anodes 1 Remove the anode retaining screws. 2 Clean the contact surface. 3 Install the new anodes and tighten them so that they make good contact with the underlying metal. Drive Unit Bellows WARNING! Secure the drive unit in a raised position in such a way that it cannot fall when working on the drive bellows.
  • Page 98 Ask your Volvo Penta dealer for advice if you wish to switch to a propeller with a different pitch and diameter. In twin installations one propeller must have right rota- tion and the other left rotation.
  • Page 99 Remove the ignition key from the ignition switch. 2 Thoroughly lubricate the propeller hub and propel- ler shaft with Volvo Penta grease (part # 828250). 3 Install the bushing (6) with the inner cone facing the sterndrive. 4 Install the propeller (5) on the propeller shaft (7);...
  • Page 100 Maintenance DPS propeller WARNING! Make sure the engine can not start during work on pro- peller(s); remove ignition key(s) and shift drive into for- ward or reverse. Removing the propeller Lock the propeller shaft 1 Remove the five bolts and remove the cover (1) from the sterndrive.
  • Page 101 P0002510 Installation 1 Thoroughly lubricate the propeller hub and propel- ler shaft with Volvo Penta grease (part # 828250). 2 Fit the forward propeller (4). 3 Install the forward propeller nut (3) and torque to 60 4 Install the aft propeller (2).
  • Page 102 “MAX” lines. Whenever you check the engine oil, also check the steering reservoir fluid level. 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 103: 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 104 • 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 105 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 106 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 107: Calibration And Settings

    Calibration and Settings Settings Menu Settings are entered and certain calibrations are car- ried out in the Settings menu. Navigate through the menus by turning and depressing the control panel wheel. It is always possible to return to the menu above by pressing .
  • Page 108 Calibration and Settings 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. 1 Activate the station. 2 Turn until Depth Alarm is shown in the settings menu.
  • Page 109 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 110 Calibration and Settings Trip Reset Set trip information to zero 1 Activate the station. 2 Turn to Trip reset in the settings menu. 3 Press the wheel twice to zero the trip information. P0001032 My View In My view it is possible to select the operating infor- mation to be displayed in the main menu.
  • Page 111 Calibration and Settings Display Contrast Adjusting the tachometer display contrast 1 Turn to Display Contrast in the settings menu. Press to reach the submenu. 2 Turn to adjust the contrast. Press the wheel to con- firm the selection. P0001030 EVC Info Information regarding accessories, components and software installed in the boat is displayed here.
  • Page 112 Calibration and Settings Units Setting operating information and trip data units. P0001035 1 Activate the station. 2 Turn until Units is shown in the settings menu. Press to reach the units menu. 3 Turn to US or Metric; press the wheel and select US or Metric.
  • Page 113 Calibration and Settings Information Beep Adjusting the volume of the integral tachometer alarm. 1 Turn until Info Beep is shown in the settings menu. Press to access adjustment. 2 Turn to the desired volume. Press to confirm the selection; the setting will be confirmed by a beep at the set volume.
  • Page 114 Calibration and Settings 4 Turn to PTA Pos 2. 5 Press the wheel to set the desired rpm. P0001234 Trim position being set Engine rpm C Trim angle 6 Press the wheel again to set the trim angle. Press to confirm the selection. 7 Repeat steps 4–6 for Pos 3, Pos 4 and Pos 5.
  • Page 115 Calibration and Settings 2 Turn to Fuel Tank in the settings menu and press to access the calibration menu. P0001012 3 Turn to Multipoint Calibr. and press the wheel. P0001011 4 Fill the tank with the quantity shown in the display, POS 1.
  • Page 116 Calibration and Settings 3 Fill the fuel tank. Confirm that the fuel tank is full by depressing the wheel. P0001034 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.
  • Page 117 Calibration and Settings 2 Activate docking mode by depressing the docking button. 3 An audible signal will confirm that docking mode is activated and the docking button lamp will light up. 4 Simultaneously press both buttons on the joystick for 5 sec. to reach calibration mode. 5 Calibration mode is confirmed by an audible signal and by both lamps on the joystick and the neutral button lamps on the control panel flashing.
  • Page 118 Calibration and Settings 7 When the boat is moving straight abeam, depress the docking button. P0001202 8 An audible signal and both lamps on the joystick and the neutral button lamps on the control panel will light up to confirm that calibration is complete and stored.
  • Page 119 Calibration and Settings 2 An audible signal will confirm that docking mode is activated and the docking button lamp will light up. 3 Simultaneously press both buttons on the joystick for 5 seconds. 4 Calibration mode is confirmed by an audible signal and by both lamps on the joystick and the neutral button lamps on the control panel flashing.

  • Page 120: Technical Data

    Technical Data Engine Type designation After market designa- Crankshaft power kW Propeller shaft kW (hk) tion (hk) D3-110i D3-110i-D 82 (110) 79 (106) D3-150i D3-150i-D 111 (150) 107 (144) D3-170i D3-170i-D 127 (170) 122 (163) D3-200i D3-200i-D 149 (200) 143 (192)
  • Page 121 Technical Data Lubrication system Oil capacity including oil filters, approx.: For all allowed installation inclinations 6.3 liters (6.8 US quarts) Volume difference MIN – MAX 1.5 liters (1.6 US quarts) Sulphur content in fuel, by weight Oil grade < 0.5 – 1.0% more than 1.0% Oil change interval: Reached first in operation: All engines:...
  • Page 122 Technical Data Fuel specification The fuel must comply with national and international standards for commercially supplied fuels, such as: EN 590 (with national environment and cold requirements) ASTM D 975 No 1-D and 2-D JIS KK 2204 Sulfur content: Complying with legal requirements in each country. Low density fuel (urban diesel in Sweden and city diesel in Finland) can cause a loss of up to 5% of power and an increase in fuel consumption of about 2–3%.
  • Page 123 Technical Data Electrical system System voltage Alternator, rated power, max voltage/max. amperage 14V/115A output, approx. 1610W 2 connected parallelly 12V, max. 88Ah Battery capacity Battery electrolyte density at +25°C (77°F): fully charged battery 1.28 g/cm = 0.0462 lb/in (1.24 g/cm = 0.0448 lb/in battery recharged at...
  • Page 124 Technical Data Reverse Gear Type designation HS25AE-A Gear ratio 1,92:1 2,48:1 Angle, output shaft 8° Oil capacity 1.8 liter (1.9 US quarts) Oil quality ATF (Dexron II, III) Weight 32 kg (70 lb) Type designation HS45AE-C Gear ratio 2,43:1 2,03:1 Angle, output shaft 8°...
  • Page 125 Technical Data Drive Type designation DPS-A SX-A Gear ratio 1,95:1 1,66:1 2,14:1 1,78:1 Oil capacity 2.25 liter (2.38 US quarts) 2.44 liter (2.58 US quarts) Oil quality API GL5 synthetic API GL5 synthetic Viscosity SAE 75W/90 SAE 75W/90 Weight 103 kg (227 lb) 98 kg (216 lb) Power Trim Oil capacity...
  • Page 126 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 127 Declaration of Conformity for Recreational Craft Propulsion Engines with the sound and ex- haust emission requirements of Directive 94/25/EC as amended by 2003/44/EC Engine manufacturer AB Volvo Penta, Gropegårdsgatan, 405 08 Göteborg, Sweden Body for exhaust emission assessment Body for sound emission assessment...

  • Page 128: Alphabetical Index

    Alphabetical index Low speed............... 36 4" Screen..............14 Lubrication System..........69 7" screen..............20 Main Switch............82 Acknowledge message......... 50 My View............21, 108 After Engine Shutdown..........46 Oil level, checking and topping up....69, 89 Air Filter, Change............ 66 Operation Break............
  • Page 129 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: 7749456 Name: Address: Country: E-mail: English Dansk Svenska Suomi Deutsch Português Ελληνικά Français Русско Español Italiano Türkçe...

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