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Volvo Penta D4, Operator'S Manual

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Volvo Penta D4 Operator'S Manual Download Page 63

Primary Battery

Poor batteries or charging. Refer to 

Battery, Charging page 95

.

Sensor failure

Engine performance might be affected.
Please contact a Volvo Penta workshop if the fault remains.

Steering failure

Limited functionality.
Self test failed. Verify hydraulic steering oil level. Refer to 

Oil level, checking

and topping up page 100

.

Steering failure

Engine power is reduced. Limited steering
The helm station has lost communication with the steering actuator.
Please contact a Volvo Penta workshop.

Water in Fuel

Empty the water trap underneath the fuel filters. Refer to 

Mainte-

nance page 81

.

Fault Code Register

47702599 12-2011

61

47702599 - Downloaded from www.volvopenta.com 23/11/2015 22:01:35

Summary of Contents for D4

Page 1: ...OPERATOR S MANUAL D4 D6 ...

Page 2: ... Volvo Penta jälleenmyyjään Este Manual do Operador pode ser encomendad em idiomas diferentes isento de custos até 12 meses após entrega via internet http vppneuapps volvo com manual coupon Se não for possível aceder à internet contacte o seu concessionário Volvo Penta To παρόν Βιβλίο Χρήσης μπορεί να παραγγελθεί δωρεάν σε άλλη γλώσσα μέχρι 12 μήνες μετά την παράδοση μέσω διαδικτύου http vppneuapp...

Page 3: ...eration 47 Engine Shutdown 51 Fault Handling 55 Fault Code Register 58 In Case of Emergency 62 Maintenance Schedule 67 Maintenance 70 Storage 110 Calibration and Settings 114 Technical Data 124 Operator s Manual Order 131 Alphabetical index 133 1 47702599 Downloaded from www volvopenta com 23 11 2015 22 01 35 ...

Page 4: ... 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 requirements and replacement parts ...

Page 5: ...rity 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 avoided could result in proper...

Page 6: ...t to give the engine and engine bay a visual inspection before operation before starting the engine and after operation once the engine has stop ped This helps you to quickly discover fuel coolant or oil leakages or any other abnormal event that has or is about to happen 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 ...

Page 7: ...g 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 tools for those jobs you mi...

Page 8: ...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 The rotating compressor i...

Page 9: ... 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 removed oil can spray out Fuel...

Page 10: ...cular responsibility and for this reason envi ronmental care is a core value in our product devel opment Volvo Penta has a wide engine programme these days where considerable progress has been made in reducing exhaust fumes fuel consumption engine noise etc We hope that you will be want to preserve these val ues Always observe the advice in the Operator s Manual about fuel grades operation and mai...

Page 11: ...l engines made of the same type are equivalent to the certified engine This makes special demands on the care and maintenance you give your engine as follows Maintenance and service intervals recom mended by Volvo Penta must be complied with Only Volvo Penta original spares may be used Service on injection pumps pump settings and injectors must always be done by an authorised Volvo Penta workshop ...

Page 12: ...ystem 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 Start ing page 44 chapter to make sure you use the correct start procedure Control Panels Volvo Penta ...

Page 13: ...ns 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 settings refer to Settings Menu page 114 To adapt information shown in the main menu to suit your personal preferences refer to My View page 114 Fault messages If the system discovers a fault the word Fa...

Page 14: ...ndividual 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 bow of the boat For further in...

Page 15: ...ls page 31 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 lever that is moved from...

Page 16: ...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 engines The circles above the engine symbols show which engines are running An empty circle means an engine is running Contrast and backlighting The button on the far right is used to adjust con...

Page 17: ... 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 the Fault Handling page 55 and Fault Code Register chapters P0001308 Instruments and Controls 47702599 12 2011 15 47702599 Downloaded from www volvopenta com 23 11 2015 22 01 35 ...

Page 18: ...e The instrument shows engine coolant temperature During operations coolant temperature should nor mally 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 5 bar At idle lower values are normal 5 Fresh water level sensor Freshwater tank level gauge 6 Rudder position indicator The ins...

Page 19: ... 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 describes remedial actions My ...

Page 20: ...rmation shown can be set under Change gauge Depending on the functions installed in the boat the following can be displayed Engine speed Engine hours Engine Coolant Temperature Battery Voltage Engine oil pressure Turbo pressure Exhaust Temperature Transmission Oil Pressure Transmission oil temperature Propeller Rotation Ahead speed Power Trim angle Engine View Instruments and Controls 18 47702599 ...

Page 21: ...based on current fuel consumption Average fuel 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 Average fuel consumption per unit of distance since the last trip computer zero reset Trip fuel fuel consumption per unit since the last trip computer zero reset Trip hours Time travelled...

Page 22: ...ht background and Night light text against a dark background Fuel Tank Fuel tank calibration and settings For information regarding calibration refer to Fuel Tank page 120 Drive Type The setting may only be made by authorized Volvo Penta personnel Toe In Toe Out Adjustment The setting may only be made by authorized Volvo Penta personnel Neutral Beep Switches the beeper that sounds when the control...

Page 23: ...ge Setting the language information will be shown in Speed Factor Setting the velocity factor refer to Speed Fac tor page 121 EVC Information Information about components software and functions 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 ...

Page 24: ...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 the MENU button and select Restore Default View 2 Press Replace gauge Restore Default View Instruments and Controls 22 47702599 12 2011 47702599 Downloaded from www volvopenta com 23 11 2015...

Page 25: ... 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 is to be switched on or ...

Page 26: ...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 at the bottom right corne...

Page 27: ...ves 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 Controls 47702599 12 2011...

Page 28: ...e for further information refer to Trim Controls and PTA calibration in the Settings Menu page 114 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 26 47702599 12 2011 47702599 Downloaded from www volvopenta com 23 11 2015 22 01 35 ...

Page 29: ...ing 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 To zero all values in th...

Page 30: ...oat Speed Rudder angle Fuel level Freshwater level ACP Info for further ACP information refer to the ACP 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 displayed in this view P0012480 P0001175 Instruments and Controls 28 47702599 12 ...

Page 31: ...fo 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 choose to reverse image or show camera at dockingstation Display Type select the engines for which operating data will be displayed and the type of installation the engines is part of Infodisplay Contrast adjusts the scree...

Page 32: ...ion PTA PTA calibration Follow the instructions on the screen Warning Manager If the system discovers a fault the operator is informed by a message on the screen The fault message must be confirmed by pressing OK All faults are stored in the Warning Manager The fault message indicates the drivetrain affected describes the fault and suggests suitable actions For further information on fault message...

Page 33: ...t comfort when driving from starting to top speed Beach range The beach range is used for driving at low speed in shallow water or where the depth is unknown The highest permitted engine speed when in the beach range is 1500 rpm IMPORTANT Make sure the drive s coolant inlet is never trimmed out of the water when operating in the beach range Lift range The lift range is never used when sailing It l...

Page 34: ...ives 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 the horizontal axis Trimm...

Page 35: ...e 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 When the drive is in the ...

Page 36: ...ly 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 downwards into the water T...

Page 37: ...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 comfortable journey Refer to...

Page 38: ...on 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 shift function in this c...

Page 39: ...tment of the drives are synchronized For further information on Power Trim see Instru ments and Controls page 31 2 Neutral position The symbol shows that the drive reverse gear is disengaged The warning triangle lights up if the system discov ers a fault refer to Fault Handling page 55 for information This function is not available 3 Fine tune the locked engine speed for tow mode 4 or cruise contr...

Page 40: ...tomatically re engage when the control handle is returned to the neutral position Disengaging the Shift Function The gearshift function can be disconnected so that the control lever only operates the throttle 1 Put the control levers in neutral 2 Press the control Throttle Only button or the neu tral button N on the helm station panel 3 Release the button The N symbol on the control will light up ...

Page 41: ...er lever move ment and counterclockwise for lighter lever move ment 4 Replace the cover Side mounted control Adjust the resistance in the lever click mode 1 Switch off the engine 2 Unscrew the screw 1 and remove the cover 2 3 Adjust the detention by turning the screw 3 with a 2 5 mm hex wrench Turn the screw clockwise for an increased detent and counterclockwise to decrease the detent 4 Replace th...

Page 42: ...neuvering with the joystick The boat is maneuvered by moving the joystick for ward aft abeam or by twisting the top of the joystick see illustration IMPORTANT The boat will continue to move in the selected direc tion even when the joystick has been released com pensate for this by moving the joystick in the opposite direction Instruments and Controls 40 47702599 12 2011 47702599 Downloaded from ww...

Page 43: ...ce to confirm that docking mode is deactivated and the docking light will go out The docking function is also deactivated if the controls are moved from the neutral position High Mode If extra power e g when there is a strong wind or strong current the High Mode function may be engaged Activate High Mode Activate the High Mode function by depressing button B on the joy stick An audible signal conf...

Page 44: ...is engaged for operations ahead and the engine is at idle this involves maximum trolling in the transmission R Reverse at idle The transmission is engaged for operations astern and the engine is at idle this involves maximum trolling in the transmission A Low speed engaged The transmission affects propeller revolutions The engine is not affected B Low speed disengaged The control affects engine sp...

Page 45: ...creen if the low speed function is active B When the low speed function is engaged a delay may occur when shifting Disengage 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 disengage the low speed function Two audible signals confirm that the function is switched off and the Lowspeed deactivated C message i...

Page 46: ...NG Never use start spray or similar products as starting aid Explosion risk 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 Start the engine bay fan ...

Page 47: ...tive instead Put the reverse gear in neutral Put the drive in neutral by moving the control lever s to neutral at all stations Two lever control Also check that the engine speed lever is in the idling position Turn the ignition on Turn the starter key to position I to switch the ignition on Check the information display If a fault is registered it will be shown in the information display please re...

Page 48: ...rotection If the starter motor is engaged for its maximum activa tion time 30 seconds the starter motor circuit is cut automatically to protect the starter motor from over heating If possible leave the starter motor to cool for at least five minutes before making a new start attempt Read the instruments and warm the engine up Allow the engines to idle for the first ten seconds Check that instrumen...

Page 49: ...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 OK 3 Take the indicated...

Page 50: ...wards 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 engines are running durin...

Page 51: ... 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 there Lock or unlock an ac...

Page 52: ...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 of the port engine The s...

Page 53: ...e starter key is in 0 position or removed before main switches are switched off Otherwise the alternator and electronics could be damaged Stop with key 1 Disengage the drive reverse gear by putting the control lever in neutral 2 Turn the key to stop position S Keep the key turned until the engine stops The key will automat ically return to the 0 position when it is released and can then be removed...

Page 54: ...ry 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 long stoppage A U X S T O P P000370...

Page 55: ...e 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 Short Term Storage IMPORTANT Use emery paper Do not use a wire brush or other steel tools when cleaning as these may damage the galvanic protection Layin...

Page 56: ...y 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 system must be drained an...

Page 57: ...e varies Minor malfunction which does not damage the engine or transmission 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 redu...

Page 58: ...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 the ignition key is in position 0 at all helm stations When system power is reconnected the diagnostic function checks if there are any faults in the EVC sys tem If ...

Page 59: ...te 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 little coolant 6 Water c...

Page 60: ...larm monitor flashes a malfunction is detected 1 Is the orange water in fuel lamp lit there is to 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 to high 4 Is the orange coolant level lamp lit during operation the coolant level is to low 5 Is the orange oil leve...

Page 61: ...ing up page 78 Check that no leakage occurs Please contact a Volvo Penta workshop if the fault remains Check EVC System Internal fault in EVC system Engine performance might be affected Some possible explanations to the disturbance listed Limited or no steering Please contact a Volvo Penta workshop Shift and throttle unavailale Gear automatically set to neutral Engine power is reduced Helm station...

Page 62: ...s or head seas the system can incorrectly sense that the engine oil level is too low If this happens acknowledge the fault and check the points below for safety reasons Check the oil level in the engine Refer to Oil level checking and topping up page 78 Check that no leakage occurs Engine Oil Pressure Oil pressure too low Engine power is reduced Check the oil level in the engine Refer to Oil level...

Page 63: ...erify hydraulic steering oil level Refer to Oil level checking and topping up page 100 Steering failure Engine power is reduced Limited steering The helm station has lost communication with the steering actuator Please contact a Volvo Penta workshop Water in Fuel Empty the water trap underneath the fuel filters Refer to Mainte nance page 81 Fault Code Register 47702599 12 2011 61 47702599 Download...

Page 64: ...r 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 to the drive Replace the p...

Page 65: ... as the engine system voltage 2 Connect the red positive cable to the plus ter minal on the discharged battery and then to the plus terminal on the auxiliary battery 3 Connect the black start cable to the minus ter minal on the auxiliary battery and to a place a little distance away from the discharged battery e g the start motor s negative terminal WARNING Under no circumstances may the black jum...

Page 66: ...n 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 2 Unscrew the screw 1 on the side where the cable harness marked A is connected 3 Remove th...

Page 67: ...aged with the control lever Forward motion can only be cut off by stopping the engine with the ignition key or stop button Manual drive engagement 1 Stop the engine and take the starter key out of the starter switch 2 Pull out the split pin 1 and lift the adapter 2 from the pin 3 3 Place a screwdriver or similar tool in the adapter 2 hole and move the control wire horizontally 3 1 2 2 P0006565 In ...

Page 68: ...e 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 completely shut down an...

Page 69: ...ontained in the Warranty and service book C R A L I Clean Replace Adjust Lubricate Inspect Clean Adjust Lubricate or Replace if nec essary FSI First Service Inspection A B C D Type of service regular service FSI First Service Inspection after 50 100 running hours 1 Coolant level and antifreeze mixture I Fuel pre filter draining water contamination I Drive belt tension I Outboard drive corrosion pr...

Page 70: ...er bellow and ground strap I Outboard drive steering positioning sensors I Outboard drive Hydraulic cylinders hoses and fittings I Outboard drive rubber hoses and clamps I Outboard drive exhaust bellow I Exhaust pipe hose I Engine and transmission oil fuel water leakage at least 1200 rpm I Engine and transmission touch up paint as required I Batteries electrolyte level I 1 Once every year B Every ...

Page 71: ...00 Hours for Marine Commercial use Every 800 hours for joystick installations Every 1200 hours for Marine Leisure use without joystick Outboard drive complete over haul incl gears shaft and U joints I Outboard drive shift cable 1 R Outboard drive shift sliding sleeve R Outboard drive shift yoke and linkage rod R 1 Only use Volvo Penta XACT cable Maintenance Schedule 47702599 12 2011 69 47702599 Do...

Page 72: ...ne with the engine stopped unless otherwise specified Stop the engine before opening or removing the engine hatch hood Make it impossible to start the engine by removing the start key and cutting the system voltage with the main switches D4 with reverse gear starboard p0006492 1 2 3 4 5 6 1 Turbocharger 2 Crankcase ventilation filter 3 Air filter 4 Oil filler cap 5 Alternator 6 Control unit D4 wit...

Page 73: ...or 8 Compressor 9 Zinc anode 10 Cooling water intake D4 with drive port 11 Expansion tank 12 Aux stop 13 Oil dipstick 14 Oil filter bypass 15 Oil filter 16 Charge air cooler 17 Starter motor 18 Fuel filter 19 Sea water pump 20 Sea water filter Maintenance 47702599 12 2011 71 47702599 Downloaded from www volvopenta com 23 11 2015 22 01 35 ...

Page 74: ...lternator 6 Control unit D6 with reverse gear port 7 Expansion tank 8 Fuel filter 9 Aux stop 10 Oil dipstick engine 11 Oil filter by pass 12 Oil filter 13 Charge air cooler 14 Oil dipstick reverse gear 15 Starter motor 16 Sea water pump Maintenance 72 47702599 12 2011 47702599 Downloaded from www volvopenta com 23 11 2015 22 01 35 ...

Page 75: ...s inspection only takes a few minutes and can prevent serious malfunctions and expensive repairs WARNING Accumulations of fuel oil and grease 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...

Page 76: ... IMPORTANT Scrap the old filter They may not be cleaned Air Filter Change 1 Unscrew the air filter cover and remove the old filter 2 Clean the air filter cover housing as necessary Be careful to prevent contamination from entering the engine 3 Install the new filter and air filter cover IMPORTANT Scrap the old filter They may not be cleaned p0003704 Maintenance 74 47702599 12 2011 47702599 Downloa...

Page 77: ...justing replacement of drive belts The standard alternator and water pump are driven by a poly V belt for the best function and lifespan Replace tension the belt as follows 1 Loosen the screws 1 on the tension roller bracket Remove and replace the belt as required 2 Tension the belt by applying a torque to the ten sioning roller square fitting 2 of 70 Nm 52 lbf ft Lock the tensioning roller using ...

Page 78: ...serious corrosion damage the pipe must be repaired or replaced with a new one The exhaust pipe sacrificial anode 2 must be checked yearly 1 Loosen the sacrificial anode holding fixture 1 from the exhaust pipe 2 Check the sacrificial anode 2 Replace with new anode when approximately 1 3 of the anode has corroded away 3 Mount the sacrificial anode to the holding fixture Install the holding fixture w...

Page 79: ...will be above the MIN mark even if the oil level is correct 3 Fill with oil as required use the dipstick hole Oil quantity and grade see section Technical Data Lubrication System IMPORTANT The oil level shall be between the MAX and MIN marks on the dipstick Compressor oil change 1 Run the engine until it reaches normal operating temperature 2 Pull up the oil dipstick 3 Remove the plug and let the ...

Page 80: ...o the sump before a correct oil level check can be performed Wait 15 minutes if the engine has been run at normal operating temperature Wait an hour if the engine has been idling The oil level shall be between the MAX and MIN marks on the dipstick Levels that are higher or lower than these marks can damage the engine IMPORTANT Do not fill over the limit for max oil level Use only oil of the recomm...

Page 81: ...Filter By pass Filter Change page 80 4 Fill with oil to the correct level through the filling hole on the top of the engine Oil quantity see section Technical Data Lubrication System 5 Start the engine Run the engine until it reaches normal operating temperature The oil level shall be checked with the engine warm Check that the low oil pressure lamp goes out and that there are no leaks around the ...

Page 82: ...lter 2 with a suitable filter puller 4 Check that the mating surfaces on the filter bracket are clean and that no remnants of the old gaskets are left 5 Moisten the gaskets on the new filters with engine oil 6 Screw on the filter by hand until the rubber gasket touches the filter bracket mating surface Then tighten an additional 3 4 turn 7 Start the engine run at low idle and check that no leakage...

Page 83: ... under the filter 3 Remove the connector piece 1 from the water separator 2 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 sealing 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 system and cause d...

Page 84: ...is is completely normal and necessary to bleed the sys tem 4 Remove the hose and fit the protective cap to the bleed nipple Fuel Pre filter Change WARNING Working with or going close to 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 R...

Page 85: ...er the fuel filter and carefully unscrew the water separator 2 Let the water run out When diesel runs out screw in the water sep arator until it bottoms against the filter Then tighten an additional 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 turns 3 Drain...

Page 86: ...ter 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 page 67 The cooling system must be flushed whenever the coolant is changed refer to Freshwater system Flushing Volvo Penta recommend Volvo Penta Coolant VCS Ready Mixed or the concentrate Volvo Penta Coolant VCS...

Page 87: ... water The water must fulfil the requirements specified by Volvo Penta refer to Water Quality It is extremely important that the system is filled with the correct coolant concentration Mix in a separate clean vessel before filling the cooling system Make sure that the liquids mix Coolant Level Checking and Topping Up WARNING Do not open the coolant filler cap when the engine is warm except in emer...

Page 88: ...oolant drainage 2 Loosen the hose 1 mounted on the intercooler and connect to the drain cock 2 on the heat exchanger Open the cock 2 Let all the coolant run out into a container 3 Screw in the stop cock 4 Move the hose to the drain cock 3 on the engine block and continue draining the coolant 5 Close the cock and put the hose back on the inter cooler 6 Collect the old coolant and hand it to a re cy...

Page 89: ... via a raw water intake after which the water passes a raw water filter extra equipment before being pumped through the intercooler heat exchanger engine oil cooler and gearbox oil cooler Finally the water is fed out through the exhaust elbow where it is mixed with the exhaust gases WARNING Risk of water entry Water will flow into the boat if any hose plug etc located below the waterline is remove...

Page 90: ...Close the sea cock where fitted 2 Open the drain stop cock 1 by unscrewing it care fully 3 Drain the coolant into a container Screw in the stop cock by hand 4 Move the hose on the stop cock 1 and connect to stop cock 2 Open stop cock 2 and drain all coolant Close the stop cock 5 Move the hose to stop cock 3 Open stop cock 3 and drain all coolant Close the stop cock 6 Refit the drain hose to stop c...

Page 91: ...and the metal contact point 6 Close the drain cocks 7 Open the sea cock s before starting the engine 8 Check that there are no leaks Impeller Check and Change WARNING Risk of water entry Close the seawater cocks before doing any work on the seawater system 1 Remove the cover from the raw water pump and remove the impeller If the impeller is cracked or damaged it must be replaced 2 If the pump shaf...

Page 92: ...esh water Arrange re filling IMPORTANT The impeller will be damaged if it is run dry 3 Check that there is no one near the propeller and no one will be splashed by the exhaust outlet 4 Set the control lever to neutral and start the engine Let it run at fast idle for a few minutes Stop the engine 5 Fill a bucket with a mixture of 40 glycol and 60 fresh water to conserve the system Fix a container a...

Page 93: ...checked more frequently than stated in the maintenance schedule Otherwise there is a risk that the filter may be blocked resulting engine overheating 1 Close the sea cock 2 Unscrew the cover 1 and remove the sealing plate 2 3 Lift out the insert 3 and clean it 4 Replace parts as illustrated 5 Open the sea cock and check for leaks Maintenance 47702599 12 2011 91 47702599 Downloaded from www volvope...

Page 94: ...ng while running the circuit breaker may have been activated Resetting will take place automatically 24 volt system engine The engine is fitted with two automatic circuit breakers 1 The circuit breakers cut the power if the system is overloaded If it is not possible to start the engine or if the instrument stops working while running the circuit breaker may have been activated Reset by pressing in...

Page 95: ...em 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 Reset by pressing in the circuit breaker 2 IMPORTANT Always investigate the cause of the overload If the fuse tr...

Page 96: ...ulfuric acid Protect your skin and clothes when charg ing or handling batteries Always use protective goggles and gloves If battery electrolyte comes into contact with unprotected skin whas off immediately using plenty of water and soap If battery acid comes in contact with the eyes flush immediately with plenty of water and obtain medical assistance without delay Connecting and disconnecting the ...

Page 97: ...teries WARNING 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 If battery electrolyte comes into contact with unprotected skin whas off immediately using plenty of water and soap If battery acid comes in contact with the eyes flush immediately with plenty of water and obta...

Page 98: ...uld be done by a person with electrical training or knowledge Installation or work on land current equipment must only be done by a competent electrician in accordance with local regulations for mains electricity The following must always be heeded 1 If shore power is connected it must always be ground protected ashore never in the boat Fur thermore the shore power installation should be equipped ...

Page 99: ...ging of two independent battery circuits a separate charging distributor accessory should be installed on the standard alternator Electrical Welding Remove the positive and negative cables from the bat teries then disconnect all cables connected to the alternator Always connect the welder ground clamp to the com ponent to be welded and as close as possible to the weld site The clamp must never be ...

Page 100: ...e 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 Top up the oil as required...

Page 101: ... 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 needed Propeller Shaft Sealin...

Page 102: ... the wrong type of paint on the keel can put the corrosion protection system out of action For further information on painting see section Storage page 113 Oil level checking and topping up IMPORTANT Never over fill the drive The oil level must always be within the recommended range 1 Trim up the drive to 35 Remove the cover 1 and the plug 2 2 The oil level must always reach the oil filler cap 3 u...

Page 103: ... Fill with oil if the oil filler cap is not completely full 11 Check that the plug is tightened Fit the cover 12 Hand the waste oil to a recycling depot The oil must have a golden brown nuance If the oil is gray water has entered the stern drive In this case let a Volvo Penta workshop carry out checks on the stern drive Checking oil level power trim The Power Trim system is a closed center hydraul...

Page 104: ...mage the galvanic protection The stern drive is fitted with zinc anodes as standard intended for use in salt water If the stern drive is to be used principally in freshwater the sacrificial anodes must be magnesium Use sacrificial anodes thus Zinc in salt water Magnesium in freshwater Aluminum when the boat is used primarily in salt water and sometimes in brackish water Replacing corrosion protect...

Page 105: ... tool 885800 1 Trim the drive out to maximum and install the spe cial tool 2 Inspect the bellows for damage Replace bellows as necessary U joint bellows The U joint bellows must be inspected annually The bellows must be replaced if there are signs of cracks or other defects In order to replace the U joint bellows it is necessary to remove the stern drive from its sup port bracket Removing the ster...

Page 106: ...ol for removing and reinstalling propellers is sup plied with the transom shield kit Removal 1 Lock the propeller shaft This may be done in one of two ways a Remove the gear shift cable from the stern drive Remove the six bolts and remove the cover 1 from the sterndrive Remove the cotter pin 2 from the wire swivel pin 3 to which the gear shift cable 4 is fastened Remove the swivel pin and washer 5...

Page 107: ...is installed Brush Volvo Penta propeller shaft grease 828250 onto the entire propeller shaft and the inside of the propeller hub Install the forward propeller 5 and nut 4 Tighten the nut using the special tool supplied to 200 Nm 150 lbf ft 6 DPH Install the forward propeller 3 propeller cone 2 and nut 1 Tighten the nut using a 30 mm 1 18 socket to 100 Nm 75 lbf ft DPR Install the aft propeller 3 a...

Page 108: ... so that any changes are discovered Check the helm pump level The minimum level is 12 mm 0 47 below the filler hole lower edge If the boat has a flybridge the lower helm pump must not be opened only check the level at the upper helm station The fluid level does not normally alter annual con sumption is negligible If the level drops it is probably due to leakage or air in the system The leakage mus...

Page 109: ...d level checks servo pump The steering servo tank has a transparent reservoir which makes checking the level possible without open ing the cap The fluid level must be just below the res ervoir neck If fluid filling is required the snap connector must be removed before the cap is opened Maintenance 47702599 12 2011 107 47702599 Downloaded from www volvopenta com 23 11 2015 22 01 35 ...

Page 110: ...is a vital safety component damage may effect steering char acteristics In the worst case steering could be lost altogether Never align or weld a damaged parallel strut Please contact your nearest authorized Volvo Penta workshop for assistance Check the parallel rods connecting the two stern drives together especially after running aground or striking an underwater object If a parallel rod is bent...

Page 111: ...ue 30 Nm 22 lbf ft securely Install the lock bolt A This procedure ensures the stern drives are in par allel to one another straight ahead Boat ashore 1 Remove the lock bolt A Loosen the adjuster bolt B 1 2 turns 2 Align the stern drives in the desired direction straight ahead recommended 3 Tighten the adjuster bolt B tightening torque 30 Nm 22 lbf ft securely Install the lock bolt A Maintenance 4...

Page 112: ...ntenance 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 inhibited 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 that nothing is forgotten For this reason we have compiled a check list of the most ...

Page 113: ... use of anti corrosion agent alone in the engine cooling system does not protect against frost dam age If there is a risk of the engine being exposed to sub freezing temperatures the system must be drained Empty the fuel tank of fuel dirt and sludge Fill the fuel tank completely to avoid condensation Clean the outside of the engine Do not use a high pressure washer to clean the engine Touch up any...

Page 114: ...ck 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 a wire brush or other st...

Page 115: ...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 Always abide by these reg...

Page 116: ...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 entered at each helm sta...

Page 117: ...ttings 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 limit where the alarm must b...

Page 118: ... 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 lost e g if the sensor i...

Page 119: ...ection 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 Contrast Side Selection...

Page 120: ...reen 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 installed Press to open the s...

Page 121: ...e 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 settings select Defaults an...

Page 122: ...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 fuel level value w...

Page 123: ...be carried out if boat movements do not correspond 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 a...

Page 124: ... 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 lamps on the joystick will flash to confirm that calibration is com plete and stored The system is now in docking mode When the joystick returns to the central position the lamps will stop flashing and will inste...

Page 125: ... 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 47702599 12 2011 123 47702599 Downloaded from www volvopenta com 23 11 2015 22 01 35 ...

Page 126: ...260I E 191 260 186 253 D4 260A D4 260A E 191 260 184 250 D4 300I D4 300I E 221 300 212 289 HS 63 214 292 HS 80 D4 300A D4 300A E 221 300 214 292 D6 280I D6 280I E 206 280 201 274 D6 280A D6 280A E 206 280 198 269 D6 310I D6 310I E 228 310 223 303 D6 310A D6 310A E 228 310 219 298 D6 330I D6 330I E 243 330 237 323 D6 330 A D6 330A E 243 330 233 317 D6 370I D6 370I E 272 370 267 363 D6 370A D6 370 E...

Page 127: ...ths 100 hr or 12 months NOTICE Mineral based oil either fully or semi synthetic can be used on condition that it complies with the quality requirements above 1 Lowest recommended oil grade Engine oil with higher oil grade is always possible to use 2 If sulphur content is 1 0 by weight use oil with TBN 15 3 When oil quality specifications are joined by and the engine oil must fulfill both requireme...

Page 128: ...l 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 ...

Page 129: ...5 mg KMnO4 l Electrical System System voltage 12V 24V Alternator rated power max voltage max amperage 14V 150A 28V 80A output approx 2100W 2240W Battery capacity 2 connected parallelly 12V max 88Ah 2 connected in series 12V max 88Ah 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 1 28 g cm3 0 0462 lb in3 1 24 g cm3 0 0448 lb in3 batt...

Page 130: ...n II III Type designation HS80 85IVE Oil capacity 7 0 litre 1 8 US gal Oil quality ATF Dexron II III Sterndrive Drive Type DPH B DPH C DPR Oil capacity 5 2 litre 1 37 US gal 5 2 litre 1 37 US gal 4 2 litre 1 11 US gal Oil volume difference MIN MAX 0 2 litre 0 4 US gal 0 2 litre 0 4 US gal 0 2 litre 0 4 US gal Oil quality VP 1141634 API GL5 synthetic Viscosity SAE 75W 90 SAE 75W 90 SAE 75W 90 Visco...

Page 131: ...s stolen The appearance and location of the type plates is shown below The figures in brackets refer to the location of the identification number on the type plate Engine P0006356 Product designation 1 Serial number 2 Product number 3 Transmission Product designation 4 Gear ratio 5 Serial number 6 Product number 7 Shield drive Product designation 8 Serial number 9 Product number 10 A Engine Plate ...

Page 132: ...ential requirements Engine type 4 stroke diesel engine with stern drive with integral exhaust Engine model s covered by this declaration EC Type certificate number D4 180 EXVOLV001 D4 210 EXVOLV001 D4 225 EXVOLV001 D4 260 EXVOLV001 D4 300 EXVOLV001 D6 280 EXVOLV001 D6 310 EXVOLV001 D6 330 EXVOLV001 D6 350 EXVOLV001 D6 370 EXVOLV001 D6 400 EXVOLV001 D6 435 EXVOLV001 D4 D6 Essential requirements Ann...

Page 133: ...overed by this declaration EC Type certificate number D4 210 drive DPH SDVOLV002 D4 225 drive DPH SDVOLV002 D4 260 drive DPH SDVOLV002 D4 300 drive DPH SDVOLV002 D6 280 drive DPH SDVOLV003 D6 310 drive DPR DPH SDVOLV003 D6 330 drive DPR DPH SDVOLV003 D6 350 drive DPR DPH SDVOLV003 D6 370 drive DPR DPH SDVOLV003 D6 400 drive DPH SDVOLV003 Body for sound emission assessment International Marine Cert...

Page 134: ...web page type in the publication number found in the bottom of this page 7 8 digits http vppneuapps volvo com manual coupon If internet access isn t possible please contact your Volvo Penta dealer All order information is stored internally at AB Volvo Penta and will not be shared with third parties 47702599 12 2011 131 47702599 Downloaded from www volvopenta com 23 11 2015 22 01 35 ...

Page 135: ... 56 Freshwater System 84 Freshwater System Draining 86 Fuel Pre filter Change 82 Fuel System 81 Fuel system bleeding 82 Fuses 92 H Helm Stations 49 High Mode 41 Hydraulic hoses 108 I Identification Numbers 129 Ignition Lock 10 Impeller Check and Change 89 Information Beep 115 Information Panel 11 J Joystick 40 L Laying Up and Launching 53 Low speed 42 Lubrication System 78 O Oil Filter By pass Fil...

Page 136: ...Trim Instruments 33 Trim Ranges 31 V Viscosity 126 Z Zinc Anodes Check and Change 89 134 47702599 Downloaded from www volvopenta com 23 11 2015 22 01 35 ...

Page 137: ...47702599 Downloaded from www volvopenta com 23 11 2015 22 01 35 ...

Page 138: ...47702599 English 12 2011 AB Volvo Penta SE 405 08 Göteborg Sweden www volvopenta com ...

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