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Maintenance

This chapter contains general technical information and instructions on how the prescribed maintenance items
must be carried out. Read through the instructions carefully before starting work. The times when maintenance
items must be carried are indicated in the

Service Protocol

.

Read through the safety precautions for maintenance and service in the

Safety Information page 4

chapter before

work on the engine is begun.

WARNING!

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.

D3 with SX/DPS sterndrive

2

3

5

6

8

7

9

4

1

P0011340

1

Oil filler cap, engine

2

Turbo

3

Air Filter

4

Coolant filler cap

5

Seawater filter

6

Crankcase ventilation

7

Seawater Pump

8

Charge air cooler

9

Oil cooler

10

Relays

11

Oil filter

12

Auxiliary stop

13

Fuel feed

14

Fuel Filter

15

Oil dipstick, drive

16

Trim cylinder

17

Sacrificial Anode

18

Oil draining (behind propeller)

19

Seawater intake

20

Sacrificial Anode

21

Heat exchanger

22

Oil dipstick, engine

23

Alternator

47705992 05-2015 © AB VOLVO PENTA

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Summary of Contents for D3

Page 1: ...OPERATOR S MANUAL D3 ...

Page 2: ...lvopenta com coupon Se não for possível aceder à internet contacte o seu con cessionário Volvo Penta To παρόν Βιβλίο Χρήσης μπορεί να παραγγελθεί δωρεάν σε άλλη γλώσσα μέχρι 12 μήνες μετά την παράδοση μέσω διαδικτύου http manual volvopenta com coupon Εάν δεν είναι δυνατή η πρόσβαση στο ιαδίκτυο παρακαλούμε επικοινωνήστε με το δικό σας αντιπρόσωπο της Volvo Penta Данное руководство по эксплуатации ...

Page 3: ... 10 Optional 42 Starting 52 Operation 55 Engine Shutdown 59 Fault Handling 63 Fault Code Register 66 In Case of Emergency 70 Maintenance Schedule 74 Maintenance 81 Storage 115 Calibration and Settings 119 Technical Data 130 Alphabetical index 137 47705992 05 2015 AB VOLVO PENTA 1 ...

Page 4: ...d consider the advice we give on running and maintenance before your maiden voyage so that you will be ensured of fulfilling your expectations Please pay attention to the safety instructions contained in the manual 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 requirement...

Page 5: ...e following order of priority DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious personal injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate personal injury IMPORTANT Indicates a situation which if not avoid...

Page 6: ...l The wrong grade of fuel can cause malfunctions or engine shutdown In diesel engines fuel of poor quality can cause damage to the fuels system or the engine to over speed with the risk of engine damage and personal injury Do not start the engine Do not start or run the engine if fuel or propane leaks are suspected in the boat or in the vicinity of or close to discharges of explosive media etc An ...

Page 7: ...n some other way changing the cockpit awning configuration Contact your boat dealer for the best solution for your boat P0003073 Remember Safety equipment Life jackets for everyone on board communications equipment distress rockets fire extinguishers first aid kit life buoy anchor paddles flashlights etc Spare parts and tools Impeller fuel filter fuses tape hose clamps engine oil propeller and too...

Page 8: ...be required in order to maintain the correct balance and make the engine safe to handle Never carry out work on an engine suspended on a hoist Before starting the engine Reinstall all protective parts removed during service operations before starting the engine Check that no tools or other items have been left on the engine Never start a turbocharged engine without installing the air cleaner ACL T...

Page 9: ...isconnected open the cool ant filler cap carefully and slowly to release pressure before removing the cap completely Note that the coolant may still be hot and can cause burns Lubrication system Hot oil can cause burns Avoid skin contact with hot oil Ensure that the lubrication system is not under pressure before commencing work on it Never start or operate the engine with the oil filler cap remov...

Page 10: ...for destruction at a recycling station If we all pull together we can make a valuable con tribution to the environment together Running in The engine must be run in during its first 10 hours as follows Use the engine in normal operation Full load should only be applied for short periods Never run the engine for a long period of time at constant speed during this period Higher oil consumption is no...

Page 11: ...cept for the accessories and service kits which Volvo Penta has approved for the engine Installation changes to the exhaust pipe and engine air inlet ducts must not be done No seals may be broken by unauthorised per sonnel The general advice in the Operator s manual about operation care and maintenance apply Late or inadequate maintenance service or the use of spare parts not approved by Volvo Pen...

Page 12: ...rect start proce dure e Key panel The Volvo Penta e Key consists of a panel and a key fob Hold the key fob in front of the symbol on the panel to unlock the EVC system A sound confirms the sys tem is unlocked When the electrical system is locked a red light flashes under the symbol The lamp goes out to indicate the system is unlocked Key Management Two key fobs comes at delivery It is possible to ...

Page 13: ...osition System power is connected II Not used III Start position Starter motor is engaged There is always a main helm station on a boat It is the only helm station with an ignition lock The ignition must be switched on here in order for other helm sta tions to be used Read the starting instructions in the Starting page 52 chapter to make sure you use the correct start proce dure Instruments and Co...

Page 14: ...tton down for more that 3 seconds to reach the main menu or browse back to it by pressing the button repeatedly Browse backwards and forwards through the informa tion panel menus by pressing the buttons Hold down a button to scroll through a menu Confirm a selection by pressing the button Settings Browse to the settings menu and press OK to pro ceed to the submenu For further information about set...

Page 15: ...ol panel can be used to make individual or simultaneous adjustments to the drives By trimming out the drive away from the transom the bow will be raised in relation to the horizontal axis and trimming in the drive will lower the bow of the boat Will trim the drive away from the transom the bow will be raised in relation to the horizontal axis Will trim the drive away towards the transom lower the ...

Page 16: ... Instruments and Controls page 32 Neutral button The gearshift function can be disconnected so that the control lever only operates the throttle The neutral button disengages the drive reverse gear so that engine speed may be increased without driving the boat warm up mode The drive is disengaged Drive engaged for movement ahead astern Single lever When the single lever function is activated the l...

Page 17: ... the button locks the helm station To switch off the function hold the button down for 3 seconds Twin instalation Both engines in a twin instalation must be running before the docking station can be activated The helm station is inactive The helm station is active and the docking function is switched on The helm station is locked Start Stop Press the STOP and START buttons to stop and start all en...

Page 18: ...ns in the system Fault message is displayed on the screen when the system dis covers a fault All fault messages must be acknowledged Acknowl edge by pressing the button if the fault is accompanied by an audible signal the signal will silenced Go to the information panel to get information regarding the alarm For further information on how to handle fault mes sages and recommended actions refer to ...

Page 19: ... engine coolant tempera ture During operations coolant temperature should normally be between 75 95 C 167 203 F 4 Oil pressure gauge The oil pressure gauge displays engine oil pres sure During operations the oil pressure gauge should normally show 3 6 bar At idle lower val ues are normal 5 Fresh water level sensor Freshwater tank level gauge 6 Rudder position indicator The instrument shows rudder ...

Page 20: ...te button View Selection The last selected view is shown on start To return to the main menu click Navigate to the desired screen using the arrow buttons My View operating information Engine View engine information Fuel Economy trip computer Vessel information regarding the boat s installation Settings settings display and installed functions Warning Manager shows system faults detected and descri...

Page 21: ...Transmission Oil Pressure Transmission Oil Temperature Propeller Rotation Ahead speed Power Trim angle Fuel This is the boat s trip computer and information is shown in two windows Current Fuel and Average Fuel Switch between screens by pressing the arrow but tons Current Fuel Instant Fuel Rate current fuel consumption per hour Instant Fuel Economy based on current fuel con sumption Remaining In T...

Page 22: ...p computer press the MENU button and select Trip Reset Vessel Shows information regarding the boat s installation The information shown can be set under Change gauge Functions are also switched on and off here Depending on the functions installed in the boat the following can be displayed Boat Speed Rudder Angle Depth for setting echo sounder refer to Depth Alarm page 120 Fuel Level Sea Water Temp...

Page 23: ...r that sounds when the control is in the neutral position on and off Info Beep Switches the signal that confirms when a function has been activated or deactivated on and off Info Beep Level Sets the volume of the Info Beep that confirms when a function has been activated or deactivated PTA Calibration Calibration and resetting PTA For information regard ing calibration refer to PTA Calibration pag...

Page 24: ...s installed Installed functions are checkmarked Warning Manager If the system discovers a fault the helmsman is informed by a message on the display The fault mes sage must be acknowledged by pressing OK All fault messages are stored in Warning Manager the drivetrain affected is shown the fault described and suitable actions suggested For further information on different fault messages refer to th...

Page 25: ...utton and select Replace Gauge 2 Navigate using to the gauge for replace ment and press 3 Select the gauge for replacement and press Restore Default View The display has a basic setting that it is always possi ble to return to 1 Press MENU button and select Restore Default View 2 Press Replace Gauge Restore Default View Instruments and Controls 47705992 05 2015 AB VOLVO PENTA 23 ...

Page 26: ...o sure to strong sunlight can damage the screen and cause function faults The status field 2 on the right of the screen displays the current view active functions and repaired faults Pop up A number of pre set functions can be switched on and off in a pop up Press OK and the functions will show in the lower part of the screen 1 Turn to the desired function and press OK to confirm that the function...

Page 27: ... they are distinguished by different color dials in the instruments Customize Press OK so that the Customize menu is displayed Press OK to access the submenus Add Remove Modify and Return to basic setting Use the knob to browse between menus Adding instruments Turn the knob to Add and press OK Select the desired information is displayed and confirm with OK The new instrument will position itself a...

Page 28: ...oose between Remove removes the instrument Replace changes one instrument for another Turn to the desired instrument and press OK Analogue Numeric specify whether the instru ment will be displayed as analog or digital Restore Default View The screen has a basic setting that can always be returned to by pressing Restore Default View in the Customize menu P0001184 P0001185 P0001097 Instruments and C...

Page 29: ...peed Power Trim angle for further information refer to Trim Controls page 33 and PTA calibration in the Settings Menu page 119 chapter Rudder Angle Coolant Temperature Voltage battery voltage Engine Oil Pressure Turbo Pressure Engine Hours total operating hours The information in this view cannot be changed P0012483 Instruments and Controls 47705992 05 2015 AB VOLVO PENTA 27 ...

Page 30: ...tion Time To Empty operating time with fuel remaining in the tank based on current fuel consumption Trip History Average Fuel Rate average fuel consumption since the last trip computer zero reset Average Fuel Economy average since the last trip computer zero reset Trip Distance distance travelled since the last trip computer zero rest Trip Time time travelled since the last trip computer zero rest...

Page 31: ... Fuel Level Freshwater Level ACP Info for further ACP information refer to the ACP chapter Interceptor Position for further information refer to the Volvo Penta Interceptor System chapter The information in this view cannot be changed Camera It is possible to connect a camera to the screen e g for monitoring the engine compartment or swimming platform If a camera is installed images will be displa...

Page 32: ...eys Refer to Key Management page 126 Neutral Beep switching on and off the beeper that sounds when the control is in the neutral position Info Beep Level setting the volume of the signal that confirms when a function has been activated or deac tivated Trip Computer Reset zeroes all values in the trip computer Camera for laterally inversing the image shown or showing the camera at a docking station...

Page 33: ...ions on the screen Fuel Tank fuel tank calibration Follow the instruc tions on the screen ACP Info setting the ACP protection position PTA PTA calibration Follow the instructions on the screen Warning Manager If the system discovers a fault the helmsman is informed by a message on the display The fault mes sage must be acknowledged by pressing OK All faults are stored in the Warning Manager A faul...

Page 34: ...th one engine running can result in the drives colliding with each other and suffering damage Trim Ranges To be able to use the information on the trim instru ment it is important to be aware of the three trim ranges and the way they are used Trim range The trim range are used to provide the best comfort when driving from starting to top speed Beach range The beach range is used for driving at low...

Page 35: ...us adjustments to the drives The drive s angle and position is shown on the Power Trim panel By trimming out the drive away from the transom the bow will be raised in relation to the hor izontal axis and trimming in the drive will lower the bow of the boat Trimming out the drive On the Power Trim panel press button to trim the drive out away from the transom The bow will be raised in relation to t...

Page 36: ...t value indicates that the drive is fully trim med down and the highest value that the drive is fully trimmed up Note that the lowest value can vary from boat to boat depending on the angle of the transom When the drive angle is within the trim range the text TRIM is shown on the display When the drive angle is within the beach range lamp 1 lights orange and the text BEACH is shown on the display ...

Page 37: ... down position is normally used during accel eration up to planing speed at low planing speeds or with a short sea With full bow down the boat has a tendency to self steer You may have to compensate with the wheel to keep the boat on the right course In this position the bow of the boat tries to go deeper in the water If the boat is driven at high speed or towards high waves the bow will plough do...

Page 38: ... cavitation so that the pro peller looses its grip The engine speed increases with out the boat speed increasing in fact the boat might even sink Be careful when driving in short seas Excessive bow up trim may cause the boat to bounce quickly upwards with the risk of throwing passengers over board In short seas or heavy head seas Trim the drive down so that the bow drops This makes for a more comf...

Page 39: ... 57 for further information 2 CRUISE CONTROL optional Switch on cruise control by pressing the button Fine tune the locked engine speed by increasing or reducing engine rpm with the button at the other side of the control 3 LOW SPEED optional See Optional page 42 for information 4 THROTTLE ONLY Disconnects the shift function so that the control lever only affects engine speed refer to Disengag ing...

Page 40: ...veline with the indicated fault 8 This function is not available 9 TRIM ASSIST The Power Trim Assistant PTA adjusts the trim angel automatically according to engine speed rpm see Power Trim Assistant page 34 for infor mation 10 TRIM Trim the drive out in For twin engine installations the adjustment of the drives are synchronized For further information see Instruments and Controls page 32 Instrume...

Page 41: ...th button 3 5 CRUISE CONTROL optional Switch on cruise control by pressing the button Fine tune the locked engine speed by increasing or reducing engine rpm with button 3 6 TRIM ASSIST optional The Power Trim Assistant PTA adjusts the trim angel automatically according to engine speed rpm see Power Trim Assistant page 34 for infor mation 7 THROTTLE ONLY Disconnects the shift function so that the c...

Page 42: ...d and that the lever will only affect engine revolutions To exit neutral mode press the button again Adjusting the friction brake Top mounted lever The control lever has a friction brake that can be adjusted for lighter or stiffer lever movement Resist ance in click mode can also be adjusted 1 Switch off the engine 2 Remove the cover 3 3 Adjust the friction brake 1 and or click mode 2 by turning t...

Page 43: ...h buttons on the control What buttons and functions available is depending on the installation 1 Docking For operation and further function information refer to Joystick for docking page 43 2 Dynamic Positioning System For operation and further function information refer to Dynamic Positioning System 3 Joystick Driving For operation and further function information refer to Joystick Driving page 4...

Page 44: ...ow speed disengaged The control affects engine speed and propeller revolutions P0012978 Engaging the low speed function 1 Move the lever to the neutral position 2 Press the Low Speed button on the control or on the helm station panel to activate the low speed function An audible signal and the message Lowspeed activated A will be displayed on screen to confirm that the function is on is shown on t...

Page 45: ...ks differently depending on if the docking function or steering function is active Practise using all means of steering and throttle under all conditions The docking function is designed to be used when docking or maneuvering in close quarters Use the steering wheel and throttle control levers in all other situations The boat is maneuvered by moving the joystick for ward aft abeam twisting the top...

Page 46: ...king function the following must be fulfilled engines running control levers in neutral helm station active joystick in center position Activating the docking function Activate docking mode by depressing the docking but ton A on the joystick An audible signal will confirm that docking mode is activated and the docking button lamp will light up Exiting the docking function To exit the function pres...

Page 47: ... docking button lights up 2 Activate the High Mode function by depressing but ton B on the joystick 3 An audible signal confirms that the function is acti vated and the high Mode button lights up Disengage High Model Disengage the function by pressing the button again An audible signal will sound twice to confirm that dock ing mode is deactivated and the light will go out The system is now in norm...

Page 48: ...wist the top of the joystick or move it sideways to reengage Joystick Driving If the autopilot is put in standby mode manually by means of the STBY button Joystick Driving switched off and must be reengaged using the button on the joystick Heading adjustments Twist the top of the joystick to change heading incre mentally A short twist changes the heading by a fixed increment while a twist held fir...

Page 49: ...r the last menu used When the autopilot is active the helm steering unit is locked but may always be used for e g changing course or giving way to obstacles The autopilot will then default to stand by mode and must be activated again If the Shadow Drive function is activated in the Set tings menu the autopilot is re activated automatically after a course change has been made manually with steering...

Page 50: ...nd a route or waypoint has been cre ated in the plotter The display shows the distance to the next waypoint along the plotted route Refer to GPS Steering for further information and settings Setting a course The boat s course is set by means of the arrow buttons 10 1 1 10 One click on the button changes the course 1 at a time if the button is held down longer the course is changed in larger steps ...

Page 51: ...pilot a waypoint must be activated in the plotter this point will be the pattern s central marker The selected pattern helm and any other settings are shown on the display Pattern steering is deactivated if the boat s course is changed using the helm or autopilot buttons reactiva tion is manual Orbit The boat is steered on a circular course around the active waypoint The radius of the circle is de...

Page 52: ...es The boat is steered in a circular pattern based on its position when the pattern is activated Setting the helm port or starboard and the time taken to complete a circle 180 turn The boat turns through 180 and then maintains the new course Setting the helm port or starboard for the direction of the turn Man over board MOB Turns the boat to come parallel with the position when MOB was activated S...

Page 53: ...topilot must be manually reactivated Step size Setting the number of degrees a course is changed when the Autopilot menu arrow buttons are held down Dealer autopilot settings Settings in this menu may only be changed by an authorized Volvo Penta dealer System Course Setting a reference for calculating course informa tion Magnetic calculating a course based on magnetic North True calculating a cour...

Page 54: ...to start an engine This may cause an explosion in the inlet manifold Danger of personal injury Before Starting Check the engine and transmission oil level Check the coolant level Open the sea cock where fitted Open the fuel cock Turn the main switch es on IMPORTANT Never disconnect the current with the main switches when the engine is running The alternator and elec tronics could be damaged If the...

Page 55: ...p panel if the engine s are turned off The station automati cally becomes active when the engine s is are started Make sure the ignition is on A green light in the IGNITION button indicates to igni tion is on The ignition is switched on via the e Key panel Press the IGNITION button to switch the ignition on Put the gear in neutral Put the drive reverse gear in neutral by moving the control lever s...

Page 56: ... panel Press the starter button for each engine Release the button as soon as the engine has started Read the instruments and warm the engine up Allow the engines to idle for the first ten seconds Check that instruments and warning displays show normal values Check that no messages are displayed and no warning signs are showing If a fault is registered please refer to section Fault Handling page 6...

Page 57: ...r in areas where people could be in the water Reading the Instruments Read all instruments and alarm displays directly after starting and then regularly during the voyage Alarms Alarms and messages are shown in the information display some alarms do also have a sound alarm Is there an alarm instrument installed the lamp in ques tion will flash 1 Read the message 2 Acknowledge the alarm by pressing...

Page 58: ... 1500 rpm Always do a forwards reverse operation as follows 1 Reduce engine speed to idle and let the boat more or less lose way WARNING Never shift to reverse when the boat is planing 2 Move the control lever to neutral with a rapid dis tinct movement Make a brief pause 3 Then move the control lever to reverse with a rapid distinct movement and increase engine speed IMPORTANT It is important all ...

Page 59: ... up when the helm station is active If the helm station is inactive the lamp will be extin guished If the padlock symbol 3 flashes the helm station can not be activated Another helm station is active and locked or unlocked with a drive selected not in neu tral Locking unlocking helm stations If a helm station is locked it is only possible to start and stop the engine or change helm stations from t...

Page 60: ...ual engine revolutions 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 When the synchronization function is activated the engine speed rpm of the starboard engine is auto matically adjusted to that o...

Page 61: ...everse gear by putting the control lever in neutral 2 Stop the engine s by pushing the START STOP button s Stopping with the start stop panel 1 Disengage the drive reverse gear by putting the control lever in neutral 2 Push the stop button s Release the button s when the engine s has have stopped Turning the ignition off and locking the EVC system To turn the ignition of press the IGNITION button ...

Page 62: ...d Take an hour meter reading and carry out preven tive maintenance according to the maintenance schedule Boats with stern drives Trim the stern drive down to maximum to protect the trim ram piston s untreated surfaces from fouling If there is a risk of the boat striking bottom with the stern drive the drive must instead be trimmed up to the maximum lift position Turn off the main switch before any...

Page 63: ...on due to oxidation on the sacrificial anodes Before launching the boat the sacrificial anodes on the drive and shield must be cleaned with emery paper to remove any oxidation If you expect the boat to be unused for two months or more it must be inhibited please refer to Storage page 115 IMPORTANT Use emery paper Do not use a wire brush or other steel tools when cleaning as these may damage the ga...

Page 64: ...h a trailer kit accessory or similar so that it cannot fall onto the trailer during transportation WARNING The engine must not be run with the drive in the lift range Boats with reverse gear Drain the water from the exhaust system to prevent water entering the engine while the boat is being trans ported by trailer Cold Weather Precautions If the engine bay cannot be kept frost free the raw water s...

Page 65: ...ansmission Affect on engine None Serious malfunction which will not immediately dam age the engine or transmission e g high coolant temperature Affect on engine Engine power is reduced until faulty value becomes normal Serious malfunction which will cause serious dam age to engine or transmission Affect on engine Engine power is reduced Serious malfunction which makes it impossible to control the ...

Page 66: ...he submenu 2 Browse through the fault list using the arrows if more than one fault is registered 3 Press OK twice to see information about the cause of the fault and the remedy 4 Return to the previous menu by pressing Deleting faults from the list Acknowledged faults that have been stored are deleted automatically when the ignition key is turned to the stop position Stop the engine and check that...

Page 67: ...aust smoke 10 Blue or white exhaust smoke 12 21 22 Low oil pressure 13 14 Engine coolant temperature too high 17 18 19 20 21 No charge or poor charge 2 23 1 Flat batteries 13 Lubricating oil level too low 2 Poor contact open circuit in cables 14 Blocked oil filter 3 Fuse tripped or faulty relay 15 Defective incorrect propeller 4 Lack of fuel 16 Defective engine mounting 5 Fouled fuel filter 17 Too...

Page 68: ...nal If a lamp in the alarm monitor flashes a malfunction is detected 1 Is the orange water in fuel lamp lit there is too much water in the water separator on the fuel pre filter 2 Is the charging lamp lit the alternator has stopped charging 3 Is the coolant temperature lamp lit the coolant tem perature is too high 4 Is the orange coolant level lamp lit during operation the coolant level is too low...

Page 69: ...level Refer to Battery Maintenance page 100 Fuel pressure incorrect Engine performance might be affected Communication failure Gear automatically set to neutral Engine per formance might be affected Oil pressure too low Engine power is reduced Checking Engine Oil Level Refer to Oil level checking and topping up page 86 Check that no leakage occurs Please contact a Volvo Penta workshop if the fault...

Page 70: ...gh Engine power is reduced Check coolant level Refer to Coolant Level Checking and Topping Up page 93 Check that the seawater filter is not blocked Refer to Seawater Filter Check and Cleaning page 97 Check the impeller in the seawater pump Refer to Impeller Check and Change page 95 Check that no leakage occurs Engine Oil Pressure Oil pressure too low Engine power is reduced Check the oil level in ...

Page 71: ...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 106 Steering failure Engine power is reduced Limited steering The helm station has lost communication with the steering actuator Please contact a Volvo Penta workshop Steering Oil High Temp Chec...

Page 72: ...t the drive and pro peller are not damaged and that the drive does not vibrate If there is damage vibration the boat should be driven if possible slowly to a harbor and lifted out of the water 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 t...

Page 73: ...he auxiliary battery and to a place a little distance away from the discharged bat tery e g the start motor s negative terminal WARNING Under no circumstances may the black jumper cabel come in contact with the positive connec tion on the starter motor 4 Start the engine and let it run at fast idle for approximately 10 minutes to charge the batter ies Make sure there is no extra equipment con nect...

Page 74: ... be disengaged by the control lever Emergency Shifting Drive If a fault occurs which prevents the drive from being operated shifted with the control lever it is possible to shift manually using the description below WARNING In emergency shifting the unit is locked in forwards operation Please note that the drive can not then be disengaged with the control lever Forward motion can only be cut off b...

Page 75: ...o be trim med Release the button when the trim limit is reached 2 Press the button again and hold it depressed for more than 5 seconds The drive starts trimming Start after crash stop If the engine crash stops the following routine must be performed before the engine can be started again 1 Move control lever s to neutral 2 Acknowledge any alarms and turn the ignition off 3 Wait until the system is...

Page 76: ...d unnecessary malfunctions will be avoided Warranty inspection During the initial period of use a special warranty inspection a First service inspection must be carried out by an authorized Volvo Penta workshop Instructions regarding when this must be done can be found in the Warranty and service book Volvo Penta reserves the right to adjust service interval and content after the printing of the O...

Page 77: ...up engine Engine and transmission abnormal noises I Engine and transmission oil fuel water leakage I 1 Or within 180 days of the date of delivery or the end of the first season whichever comes first S1 Every 100 200 hours at least every 12 month 1 Engine Oil and Oil Filters By pass filter R 1 Oil change intervals vary depending on oil grade and sulfur content of the fuel Change the filters during ...

Page 78: ...opellershaft Must not be painted R Propellershaft seal Lubrication of shaft splines I Exhaust hose I Seawater Inlet I Crankcase ventilation filter R Start and warm up engine Engine and transmission abnormal noises I Engine and transmission oil fuel water leakage I 1 Readout if any fault codes and LVD B Every 400 hours At least every month 12 24 48 Impeller in seawater pump R Control cables and sea...

Page 79: ...harger I D Every 1200 hours At least every month 12 24 48 Control cables and seals 1 R 1 Xact E Every 8000 hours At least every month 12 24 48 Coolant VCS yellow 1 R 1 Different types of coolant must not be mixed with each other Maintenance Schedule 47705992 05 2015 AB VOLVO PENTA 77 ...

Page 80: ...d leakage I Engine and transmission abnormal noises I Engine and transmission oil fuel water leakage I 1 Or within 180 days of the date of delivery or the end of the first season whichever comes first S1 Every 100 200 hours at least every 12 month 1 Engine Oil and Oil Filters By pass filter R 1 Oil change intervals vary depending on oil grade and sulfur content of the fuel Change the filters durin...

Page 81: ...se I Seawater Inlet I Exhaust Bellow I U Joint Bellows I U joint shaft splines and gimbal bearing I Steering Cylinder Grounding I Crankcase ventilation filter R Start and warm up engine Power steering and Power Trim function and leakage I Engine and transmission abnormal noises I Engine and transmission oil fuel water leakage I 1 Readout if any fault codes and LVD B Every 400 hours At least every ...

Page 82: ...ours At least every month 12 24 48 Control cables and seals 1 R Transmission complete overhaul incl gears shaft shifting mechanism and U joint I 1 Xact E Every 8000 hours At least every month 12 24 48 Coolant VCS yellow 1 R 1 Different types of coolant must not be mixed with each other Maintenance Schedule 80 47705992 05 2015 AB VOLVO PENTA ...

Page 83: ...s 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 D3 with SX DPS sterndrive 2 3 5 6 8 7 9 4 1 P0011340 1 Oil filler cap engine 2 Turbo 3 Air Filter 4 Coolant filler cap 5 Seawater filter 6 Crankcase ventilation 7 Seawater Pump 8 Charge air cool...

Page 84: ...6 Seawater Pump 7 Charge air cooler 8 Oil cooler 9 Oil filter reverse gear 11 12 13 14 10 18 19 17 16 15 P0011343 10 Relays 11 Oil filter 12 Auxiliary stop 13 Fuel feed 14 Fuel Filter 15 Oil cooler reverse gear 16 Oil dipstick reverse gear 17 Heat exchanger 18 Oil dipstick engine 19 Alternator Maintenance 82 47705992 05 2015 AB VOLVO PENTA ...

Page 85: ... on the engine or in the engine room is a fire hazard and must be removed immediately they are detected WARNING If an oil fuel or coolant leak is detected the cause must be investigated and the fault rectified before the engine is started Never direct the jet from a high pressure washer at seals rubber hoses or electrical components Never use the high pressure setting for engine cleaning Crankcase...

Page 86: ... hose clamp Scrap the old filter it may not be cleaned 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 IMPORTANT Always replace a belt that appears worn or is cracked Belts working in tandem mus...

Page 87: ...oned correctly in the grooves 5 Replace the protective cover accessory over the drive belts Checking exhaust line The exhaust line must be checked annually for corro sion between the hose and the pipe WARNING Risk of water entry 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 1 Undo the hose clamp...

Page 88: ... P0012085 The oil level must be within the marked area on the oil dipstick and must be checked daily before the first start IMPORTANT Do not fill over the limit for max oil level Use only oil of the recommended grade refer to Technical Data page 131 1 Fill oil slowly through the oil filler on top of the engine 1 or on the side 2 where fitted 2 Wait 20 minutes to allow time for the oil to run down ...

Page 89: ...protect it from oil spillage 4 Change the filter insert 1 Install a new O ring 2 tighten the cover by hand 25 Nm using a wrench size 36 Remove the newspaper protecting the alternator 5 Fill with oil to the correct level through the oil filler on top or to the side accessory of the engine For oil quantity refer to section Technical Data page 131 6 Start the engine Run the engine until it reaches op...

Page 90: ...Clean the filter bracket and place a suitable vessel under the filter 3 Undo the connector 1 Unscrew the filter use a filter wrench if necessary 4 Clean the sealing surfaces on the filter holder Make sure that the filter is clean and that the seal rings are undamaged Moisten the seal rings with engine oil IMPORTANT Do not fill the new filter with fuel before installation dirt may get into the syst...

Page 91: ...are present Fuel Pre filter Change WARNING Working with or approaching a running engine is a safety risk Watch out for rotating components and hot surfaces 1 Close the fuel stop cock on the fuel tank Place a container beneath the fuel filter 2 Remove the cover by loosening screw 1 3 Replace the insert and refit the cover 4 Open the fuel stop cock and bleed the fuel system see section Fuel system b...

Page 92: ...lace a container under the fuel filter and carefully unscrew the sensor 2 Let the water run out When diesel runs out screw in the water separator until it bottoms against the filter Then tighten an addi tional 1 4 to 1 2 turn 4 Refit the connecting piece 1 Draining the fuel pre filter extra equipment 1 Place a container beneath the fuel filter 2 Open the bleed screw 1 on the fuel filter about 4 tu...

Page 93: ...use water alone as the coolant The corrosion protection additives become less effec tive over time which means that the coolant must be changed at regular intervals refer to Maintenance Schedule The cooling system must be flushed when ever the coolant is changed refer to Freshwater sys tem Flushing Volvo Penta recommend Volvo Penta Coolant VCS Ready Mixed or the concentrate Volvo Penta Coolant VCS...

Page 94: ...ered to 46 C 51 F Never mix more than 60 concentrate Volvo Penta Coolant in the coolant A greater concentration pro vides reduced cooling effect with the risk for overheat ing and reduced frost protection The coolant must be mixed with distilled deionized water The water must fulfil the requirements specified by Volvo Penta refer to Technical Data page 132 It is extremely important that the system...

Page 95: ...xpansion tank 3 Screw the filler cover on Freshwater System Draining WARNING Stop the engine and let it cool before starting work on the cooling system Hot fluids and hot surfaces can cause burns WARNING All coolant is hazardous and harmful to the environ ment Do not consume Coolant is flammable 1 Remove the filler cover on the expansion tank to speed up coolant drainage 2 Connect a hose to the he...

Page 96: ...n a safe manner If this is not possible the boat must be drawn up on land before work starts Seawater System Draining WARNING Risk of water entry Close the seawater cocks before doing any work on the seawater system To prevent frost bursting the raw water system must be drained in cold weather when there is a risk of frost An alternative to draining is to keep the engine bay frost free with the ai...

Page 97: ...ller 3 If the impeller is cracked or damaged it must be replaced 4 Check if the pump shaft rotates relative to the pul ley In it does the sea water pump must be replaced 5 Lubricate the pump housing and inside of the cover with a little glycerin IMPORTANT The impeller will be damaged if other types of lubri cant than glycerin are used 6 Press the impeller in with an clockwise rotating movement 7 I...

Page 98: ... 2 Check that there is no one in the vicinity of the pro peller and that nothing risks being spattered by the exhaust outlet 3 Put the gear selector in neutral Start the engine and let it run at idle for a few minutes Stop the engine 4 Fill the bucket with a mixture of 40 glycol and 60 fresh water to conserve the system Place a bucket at the exhaust outlet to collect the mixture 5 Start the engine...

Page 99: ...ce parts as illustrated 5 Open the sea cock and check for leaks Vacuum Valve Cleaning Certain configurations have a vacuum valve installed in the raw water system WARNING Risk of water entry Close the seawater cocks before doing any work on the seawater system 1 Close the sea cock 2 Remove the valve Unscrew the hexagonal cover 1 3 The cover contains a membrane 2 and a gasket 3 Clean all components...

Page 100: ...to start the engine or if the gauges stop working during operations a circuit breaker or fuse may have deployed Reset the semi automatic circuit breakers by pressing the button IMPORTANT Always investigate the cause of the overload If the fuse trips frequently contact an authorized Volvo Penta workshop Electronic Steering System Engines fitted with a drive wtih electronic steering are equipped wit...

Page 101: ...o deposits of salt or dirt at the alternator mountings An aluminum hull and stemdrive can quickly be dam aged by stray currents in the water and carbon fiber hulls serve as good conductors of currents Also refer to Electrical Installations page 102 Relays The engine has four relays If the engine If it is not possible to start a relay can be broken and need to be changed 1 Main relay 2 Fuel pump re...

Page 102: ...ting 1 Connect the cable red to the pole on the bat tery 2 Connect the cable black to the pole on the battery Disconnecting 1 Remove the cable black 2 Remove the cable red 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 termi...

Page 103: ...carefully To avoid the risk of electrochemical corrosion when an external charger is connected the battery cables should be removed from the batteries before the charger is connected Always switch off the charging current before the charging clips are removed Charge batteries if they have become discharged During charging unscrew the cell plugs but leave them in the plug holes Ventilate well espec...

Page 104: ...be run and clamped such that there is no risk of exposure to chafing damp or bilge water 3 Ground protection for radios navigation instru ments rudder boarding ladders or other equipment where separate cables for ground protection are present must be clustered to a common ground connection that is not connected to the engine or reverser gear IMPORTANT The engine and reverse gear must never be used...

Page 105: ...sible to the weld site The clamp must never be connected to the engine or in such a way that current can pass through a bearing Also remove the connector for the EVC system from the control unit Press the locking arm down and pull out the connector IMPORTANT After finished welding re connect the EVC connector and the alternator terminals before connecting the bat tery cables Maintenance 47705992 0...

Page 106: ...ater blocking the reverse gear cooler and other cooling system components Oil level checking and topping up 1 Start the engine and let it run on idle a few minutes 2 Remove the dipstick by turning counter clockwise 3 Wipe the dipstick and reinsert it in the reverse gear without screwing it in Remove the dipstick and check the oil level The correct oil level is between the MAX and MIN markings 4 To...

Page 107: ...ity IMPORTANT Never over fill the reverse gear The oil level must always be within the recommended range 6 Install the new filter 3 in the filter housing 7 Install the cover Tightening torque 5 8 Nm 8 Put the control lever in neutral Start the engine and run it at 1500 rpm for a few minutes so that the reverse gear oil cooler fills with oil 9 Stop the engine and check the oil level Top up as neede...

Page 108: ...m out of action For further information on painting see section Storage page 118 Transmission lubricant checking and topping up IMPORTANT Never over fill the drive The oil level must always be within the recommended range 1 Screw the oil dipstick all the way down and then remove it 2 Check the oil level on the dipstick The oil must be on the flat dipstick area If the oil level is low fill a little...

Page 109: ...ll slowly to avoid the formation of air bubbles When the oil is visible in the oil level hole the stern drive is sufficiently full 3 Check the O rings on the plug and dipstick replace as necessary Reinstall the oil dipstick and oil level plug 4 Remove the oil pump and screw the plug back in 5 Check the oil level on the dipstick Oil must be visi ble on the flat part of the dipstick Top up with oil ...

Page 110: ...fluid as necessary Corrosion protection checking and changing Check the 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 anode oxidization Even new ano des may oxidize on the surface always clean sand them before launch IMPORTANT Use emery paper Do not use a wire brush or other stee...

Page 111: ...ve bellows A falling drive may cause serious injury Check that there are no splits or damage to the bel lows Replace bellows as necessary Keep the surfaces clean fouling on the bellows may puncture them Inspect the inside of the bellows for signs of contact with the universal joint when the drive is removed Internal wear is a sign that the engine has be run at too high rpm with the sterndrive in a...

Page 112: ...ot start during work on pro peller s remove ignition key s and shift drive into for ward or reverse SX 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 2 Remove the cotter pin 2 from the shi...

Page 113: ...s are visible 5 Install the spacer 4 on the propeller shaft splines 6 Install and tighten the propeller nut 3 so that the propeller and the bushing 6 bottom completely 7 Undo the propeller nut and screw it back against the spacer by hand Then tighten the propeller nut a further 1 3 to 1 2 turn Alternatively use a torque wrench and torque the propeller to 96 108 Nm 8 Align the lock washer 2 against...

Page 114: ...he shift cube 3 to which the gear shift cable 4 is fastened Remove the shift cube and washer 5 from the lever 6 without turning the cube 3 Put the sterndrive into gear by hand by pulling the lever to either the forward position F or reverse position R Alternatively the propeller can be locked by putting the transmission in neutral and placing a block of wood between the cavitation plate and one of...

Page 115: ...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 Nm 4 Install the aft propeller 2 5 Install the forward propeller nut 1 and torque to 100 Nm 75 ft lbs 6 Turn the shift lever to the neutral position Attach the wire to the shift arm Install a new cotter pin 7 Install the cover and bolt it in place 8 Check that the prop...

Page 116: ...altogether Never align or weld a damaged parallel strut Please contact your nearest authorized Volvo Penta workshop for assistance Steering System Operation Power steering reservoir fluid level The steering servo tank has a transparent reservoir which makes checking the level possible without open ing the cap The fluid level must be between the MIN and MAX lines Whenever you check the engine oil a...

Page 117: ...ION Read the chapter on Maintenance before starting work It contains instructions on how to carry out maintenance and service operations in a safe and correct manner The engine and other equipment must be laid up to prevent damage if they are not to be used for two months or more It is important that this is done in the correct manner and nothing is forgotten For this rea son we have compiled a ch...

Page 118: ...ry IMPORTANT The use of anti corrosion agent alone in the engine cooling system does not protect against freeze dam age If there is a risk of the engine being exposed to sub freezing temperatures the system must be drained Open the drainage tap on the charge air cooler to release any condensation Empty the fuel tank of fuel dirt and sludge Fill the fuel tank completely to avoid condensation Clean ...

Page 119: ...nsions and conditions Check rubber hoses for condition and tighten hose clamps Check the engine coolant and antifreeze Top up as necessary Connect the fully charged batteries Painting the sterndrive and hull bottom Check the sacrificial anode on the stern drive If less than 2 3 of the anode remain it must be replaced Clean with emery cloth shortly before launch IMPORTANT Use emery paper Do not use...

Page 120: ...es on the drive must not be painted or treated with Teflon This also applies to stainless or bronze propellers Teflon is a registered trademark from Du Pont Corp Underwater hull All types of paints with anti fouling properties are poi sonous and cause damage to the marine environment Avoid the use of such agents Most countries have introduced legislation controlling the use of anti fouling agents ...

Page 121: ...n menu can be adapted to suit personal preferences in My View 1 Navigate from the settings menu to My View Press to get to the submenu 2 Navigate through the menu using to see available operating information 3 Press to add or remove information for display in the main menu Neutral Beep The neutral beep is an audible signal that sounds when the control is in the neutral position The setting must be...

Page 122: ... to Trip Reset in the settings menu 2 Press twice to zero the trip information Depth Alarm Setting the level for the depth alarm on Volvo Penta echo sounders The setting need only be made at one helm station 1 Navigate to Depth Alarm in the settings menu Press to proceed to the submenu 2 Depth Alarm Off On A Press to switch the alarm on or off 3 Proceed to Set Level B and press Use to set the limi...

Page 123: ...en the echo sounder B and the boat s lowest point C has a negative num ber Press to confirm the setting Depth Alarm When the depth is less than the alarm setting a mes sage will be shown on the display followed by an audi ble signal The message will be displayed every 30 seconds until the depth exceeds the alarm level Confirm the alarm by pressing Signal fault If the signal from the depth alarm is...

Page 124: ...e settings menu Side Selection Set from which engine information is to be show in dis play Units Setting the units information will be shown in 1 Navigate to Units in the settings menu Press to open the settings menu 2 Open US or Metric press and select Ameri can or metric units 3 Navigate to Distance press and then select kilometers nautical miles or miles 4 Press to confirm the selection Display...

Page 125: ...irm the selection The screen will return automatically to the settings menu EVC Info Information regarding accessories components and the type of software installed in the boat is displayed here 1 Navigate to EVC Info in the settings menu and press to open the submenu 2 Features shows the accessories that are installed Press to open the submenu 3 Components shows what hardware components are insta...

Page 126: ...ibration needs to be made for each engine 1 Navigate from the settings menu to PTA Calibra tion Press to get to the submenu 2 Use to set the trim angle for idle PTA Pos 1 Press to confirm the setting 3 Proceed to PTA Pos 2 Use to set the rpm Press to confirm the setting 4 Use to set the trim angle Press to confirm the setting 5 Repeat steps 4 to 5 for Pos 3 Pos 4 and Pos 5 6 To return to basic set...

Page 127: ...evel 4 Fill the tank with the quantity shown in the display POS 2 Wait 10 seconds Press to confirm that the tank has been filled to the indicated level 5 Repeat the procedure for POS 3 POS 4 and POS 5 Confirm by pressing the wheel at each position 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 fu...

Page 128: ...will check that the key ID corresponds to a key registered in the system 3 Select Add a key 4 When the text Show e Key To Add is shown hold the new key in front of the panel The system will store the key ID 5 The addition of the key is confirmed on the display Removing a key 1 Go to Settings Key Management 2 When the text Show e Key For Authorization is shown hold a registered key in front of the ...

Page 129: ...to joystick movements When calibrating the joystick the boat must be driven on open waters in safe conditions Avoid calibrating in high winds or currents that can influence the result of the calibration Allow the boat to run for a fairly long distance during the calibration Hold the joystick firmly in position Calibration can only be carried out at a helm station that is equipped with both a joyst...

Page 130: ...ection Correct boat movements by moving the joystick up and down and by turning it 4 When the boat is moving straight abeam depress the docking button once again 5 An audible signal will sound and both lower button lamps on the joystick will flash to confirm that cali bration is complete and stored The system is now in docking mode When the joystick returns to the central position the lamps will s...

Page 131: ...y depressing the dock ing button for 5 seconds An audible signal will confirm that docking mode is activated and the docking button lamp will light up 3 Press the docking button Calibration is now reset which is confirmed by an audible signal The system is now in docking mode Calibration and Settings 47705992 05 2015 AB VOLVO PENTA 129 ...

Page 132: ...00i D3 200i H 149 200 143 192 D3 220i D3 220i H 164 220 157 211 D3 140A D3 140A H 104 140 99 135 D3 170A D3 170A H 127 170 120 161 D3 200A D3 200A H 149 200 142 190 D3 220A D3 220A H 164 220 156 209 1 According to ISO 8665 2 According to ISO 8665 No of cylinders 5 Bore 81 mm Displacement 2401 cm Stroke 93 2 mm Compression ratio 16 5 1 Engine dry weight 260 kg Idling speed 700 rpm 130 47705992 05 2...

Page 133: ... oil either fully or semi synthetic can be used on condition that it complies with the quality requirements above Viscosity Select the viscosity according to the table The temperature values refer to stable ambient tem peratures SAE 5W 30 refers to synthetic or semi synthetic oils Fuel System Fuel specification The fuel must comply with national and international standards for commercially supplie...

Page 134: ...anganese acc ASTM D858 0 05 ppm Conductivity acc ASTM D1125 500 µS cm Organic content CODMn acc ISO8467 15 mg KMnO4 l Electrical system System voltage 12V Alternator rated power max voltage max amperage 14V 180A output approx 2520W Battery capacity min 750CCA 75Ah max 800CCA 110Ah Battery electrolyte density at 25 C 77 F fully charged battery 1 28 g cm3 0 0462 lb in3 1 24 g cm3 0 0448 lb in3 batte...

Page 135: ... Type designation HS45AE C Gear ratio 2 43 1 2 03 1 Angle output shaft 8 Oil capacity 2 5 liters 2 6 US quarts Oil quality ATF Dexron II III Weight 37 kg 81 lb Type designation HS63IVE D Gear ratio 1 99 1 2 48 1 Angle output shaft 12 Oil capacity 4 8 liter 5 1 US quarts Oil quality ATF Dexron II III Weight 66 kg 145 lb Technical Data 47705992 05 2015 AB VOLVO PENTA 133 ...

Page 136: ... 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 1 6 liter 1 7 US quarts Oil quality ATF Dexron II III Steering power steering Oil quality ATF Dexron II III Technical Data 134 47705992 05 2015 AB VOLVO PENTA ...

Page 137: ... used with fixed pitch propellers This engine type complies with 94 25 EC amended by directive 2003 44 EC Emission approved accordance to the Bodensee schiffarts ordnung anlage C AB VOLVO PENTA SWEDEN MADE IN SWEDEN Emission Control Information This marine engine complies with US EPA regulations for Model Year Model Rated Power Speed EPA Engine Family Emissions Standards Engine Family Serial No Da...

Page 138: ...pe for which above mentioned EC type examination certificate s has been issued LR 07 15 Name and function Tom Tveitan Laws and Regulations identification of the person empowered to sign on behalf of the en gine manufacturer or his authorised representative Signature and title or an equivalent marking Date and place of issue yr month day 2015 03 25 Göteborg Engine model s covered by this declaratio...

Page 139: ...hwater System 91 Freshwater System Draining 93 Fuel Pre filter Change 89 Fuel System 88 Fuel system bleeding 89 Fuses 98 H Helm Stations 57 I Identification Numbers 135 Ignition Lock 10 Ignition switch 11 Impeller Check and Change 95 Information Beep 120 Information Panel 12 J Joystick for docking 43 L Laying Up and Launching 61 Lowspeed 42 Lubrication System 86 O Oil level checking and topping up...

Page 140: ...Trim Controls 33 Trim Instruments 34 Trim Ranges 32 V Vacuum Valve Cleaning 97 Viscosity 131 W Water Quality 132 138 ...

Page 141: ... 2015 AB VOLVO PENTA Volvo reserves the right to make changes Printed on environmentally friendly paper ...

Page 142: ...47705992 English 05 2015 ...

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