Volvo D4 Operator'S Manual Download Page 88

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Maintenance. Reverse gear

Propeller shaft seal. Checking

If the boat has a Volvo Penta shaft the shaft seal must
be vented and lubricated directly after launching.

Vent the bushing by pressing it together while pressing
down on the shaft until water appears. Then press in
approx. 1 cc

water repellent grease

into the seal.

IMPORTANT!

The seal must be checked every

600 hours and changed as required. The seal
must be changed every ﬁve years, however.

Summary of Contents for D4

Page 1: ...OPERATOR SMANUAL D4 D6 ...

Page 2: ... instruktionsboken kan bestäl las på svenska Beställningskupong finns i slutet av instrukti onsboken Questo manuale d istruzioni può esse re ordinato in lingua italiana Il tagliando per l ordinazione è riportato alla fine del manuale Dit instructieboek kan worden besteld in het Nederlands De bestelcoupon vindt u achter in het instruc tieboek Denne instruktionsbog kan bestilles på dansk Bestillings...

Page 3: ...g service life We also believe that this is what you demand and expect of your Volvo Penta engine We would like you to read this operator s manual thoroughly and consider the advice we give on running and maintenance before you cast off on your maiden voyage so that you will be ensured of fulﬁlling your expectations With warm regards AB VOLVO PENTA IMPORTANT These instructions do not contain descr...

Page 4: ...her precautions 59 Maintenance schedule 60 62 Maintenance 63 93 Engine general 63 Lubrication system 67 Freshwater system 70 Seawater system 73 Fuel system 77 Electrical system 80 Reverse gear 85 Drive 87 Steering 90 Propellers 93 Laying up Launching 94 96 Inhibiting 94 Bringing out of winter storage 95 Painting the drive and underwater hull 96 In case of emergency 97 104 Starting using auxiliary ...

Page 5: ...ta dealer for assistance This symbol is used in the book and on the engine to make you aware of safety information Always read these safety precautions very carefully In the operator s manual warning texts have the following priority WARNING If these instructions are not followed there is a danger of personal injury exten sive damage to the product or serious mechanical malfunction IMPORTANT Used ...

Page 6: ...ting the boat after the engine has been stopped This will help you to quickly detect fuel coolant or oil leaks and spot anything else unusual that has or is about to happen Maneuvering Avoid violent and unexpected changes in course and gear engagement This could cause someone on the boat to lose their balance and fall over or overboard A rotating propeller can cause serious injury Check that nobod...

Page 7: ...cover as well Get in touch with your boat dealer for help in obtain ing the best solution for your boat Checklist L Safety equipment Life jackets for all passengers communication equipment emergency rockets approved ﬁre extinguisher ﬁrst aid equipment life belt anchor paddle torch etc L Replacement parts and tools impeller fuel ﬁlters fuses tape hose clamps engine oil propeller and tools for any r...

Page 8: ...avity Special lifting equipment may then be required in order to maintain the correct balance and make the engine safe to han dle 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 engin...

Page 9: ...d cause burns If work must be carried out with the engine at operat ing temperature and the coolant ﬁller cap or a cock open or a coolant hose disconnected 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...

Page 10: ...them Remember to always leave hazardous waste such as waste oil coolant paint and wash residue ﬂat batteries etc for disposal at a de struction plant Our joint efforts will make a valuable contribution to our environment Running in The engine must be run in for its ﬁrst 10 operating hours as follows Operate the engine normally Do not operate it at full load except for short periods Never run the e...

Page 11: ...actured of that type correspond to the certiﬁed engine This places special requirements for maintenance and service as follows L The maintenance and service intervals recom mended by Volvo Penta must be observed L Only genuine Volvo Penta replacement parts may be used L The service of injection pumps and injectors or pump settings must always be carried out by an authorized Volvo Penta workshop L ...

Page 12: ...ctives applied EMC 89 336 EEC Description of engine s and essential 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 D6 280 EXVOLV001 D6 310 EXVOLV001 D6 350 EXVOLV001 D6 370 EXVOLV001 D6 435 EXVOLV001 D4 D6 Essential require...

Page 13: ...oke diesel engine with stern drive with integral exhaust Engine model s covered by this declaration EC Type certiﬁcate number D4 210 drive DPH SDVOLV002 D4 225 drive DPH SDVOLV002 D4 260 drive DPH SDVOLV002 D6 280 drive DPH SDVOLV003 D6 310 drive DPR SDVOLV003 D6 310 drive DPH SDVOLV003 D6 350 drive DPR SDVOLV003 D6 350 drive DPH SDVOLV003 Body for sound emission assessment International Marine Ce...

Page 14: ...esignation 1 Serial number 2 Product number 3 Drive Reverse gear Product designation 4 Gear ratio 5 Serial number 6 Product number 7 Shield Drive Product designation 8 Serial number 9 Product number 10 The numbers refer to the position of the identiﬁcation numbers on the information decal Introduction Engine plate Warranty decal IMO decal and EPA decal Drive plate Reverse gear plate Transom shield...

Page 15: ...olant system prepared for hot water outlet Seawater strainer and easily accessible impeller pump Electrical system 12V two pole electrical system 115A marine alternator with Zener diodes to pro tect the system from peak voltage and integrated charging regulator with battery sensor cable for maximum use of alternator Fuses with automatic reset Instruments control Complete instrumentation including ...

Page 16: ...at the engine speed registered to protect the engine from overload Engine Management and EVC system To protect the engine at too high coolant or charge air temperatures and boost pressure as well as oil pres sure the monitoring system reduces the amount of fuel reduced engine output until the current values normalises The engine monitoring system also has a diagnostic system which assists users an...

Page 17: ... results in better comfort good fuel ecomomy and minimized wear due to less vibration and reduced noise level To enable syn chronization the master port and slave starboard systems must be able to communicate Therefore a synchronization cable has to be installed at the each helm Instrumentation New types of instruments are introduced with EVC The instruments use a serial communication bus The seri...

Page 18: ...ss ﬁlter 16 Oil ﬁlter 17 Starter 18 Charge air cooler 19 Expansion tank D4 with drive starboard 1 Zinc anode 2 Cooling water intake 3 Zinc anode 4 Turbocharger 5 Crankcase ventilation ﬁlter 6 Aux Stop 7 Air ﬁlter 8 Compressor 9 EDC control module 10 Generator 11 Oil ﬁller cap 1 2 3 4 5 6 7 8 9 11 10 11 12 13 14 15 16 17 18 19 ...

Page 19: ...1 Oil bypass ﬁlter 12 Oil ﬁlter 13 Starter 14 Charge air cooler 15 Oil dipstick reverse gear 16 Expansion tank D4 with reverse gear starboard 1 Turbocharger 2 Crankcase ventilation ﬁlter 3 Aux Stop 4 Air ﬁlter 5 EDC control module 6 Generator 7 Oil ﬁller cap 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 ...

Page 20: ...kcase ventilation ﬁlter 6 Aux Stop 7 Air ﬁlter 8 Compressor 9 EDC control module 10 Generator 11 Oil ﬁller cap D6 with drive port 11 Sea water ﬁlter 12 Sea water pump 13 Fuel ﬁlter 14 Oil dipstick 15 Oil bypass ﬁlter 16 Oil ﬁlter 17 Starter 18 Charge air cooler 1 2 3 4 5 7 6 8 9 11 11 12 13 14 15 16 17 18 19 10 ...

Page 21: ...r ﬁlter 4 Aux Stop 5 EDC control module 6 Generator 7 Oil ﬁller cap D6 with reverse gear port 8 Sea water pump 9 Fuel ﬁlter 10 Oil dipstick engine 11 Oil bypass ﬁlter 12 Oil ﬁlter 13 Starter 14 Charge air cooler 15 Oil dipstick reverse gear 16 Expansion tank 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 ...

Page 22: ...entation or if your boat is equipped with instruments not described here or you are not sure about their function please contact your Volvo Penta dealer 2 Voltmeter 3 Oil pressure gauge 4 Temperature gauge 5 Hours counter 2 3 4 5 1 Instruments 1 Tachometer Extra optional instruments 6 Rudder indicator 7 Fuel level gauge 8 Water level gauge 7 8 6 ...

Page 23: ...stem voltage on drive position II Not used III Start position IMPORTANT Read the starting instructions in the Engine starting chapter Start stop panel The start stop panel is used to start or stop the engi ne The starter key on the main helm station must be in position I driving position for the engine to start The engine can only be stopped if the control panel is activated IMPORTANT Read the sta...

Page 24: ... operation the oil pressure in the engine is too low Stop the engine at once Check the oil level in the engine Please refer to Maintenance Lubrication to check and top the oil up Also check that the oil ﬁlters are not blocked Plea se refer to Maintenance Lubrication system Please refer to the In case of emergency chapter and you will ﬁnd detailed information about recommen ded action in the Diagno...

Page 25: ... serious engine damage Coolant temperature red indication The coolant temperature lamp lights up when the coolant temperature is too high Stop the engine if this lamp lights up during operation Check the coolant level Please refer to Maintenan ce Fresh water system Check that the sea water ﬁlter is not blocked Please refer to Maintenance Sea water system Also check the impeller in the sea water pu...

Page 26: ...n during opera tion a serious fault has occured Please refer to the In case of emergency chapter and you will ﬁnd detailed information about recom mended action in the Diagnostic function section Orange alarm indication fault If the orange alarm indication is shown during opera tion a fault has occured Please refer to the In case of emergency chapter and you will ﬁnd detailed information about rec...

Page 27: ... button Used to activate de activate the reversing gear stern drive so that the engine can be revved up Indicator green No light Reversing gear stern drive is engaged Light on The Control lever is in neutral position Flashing Reversing gear stern drive is in neutral Synchronization indication The synchronization function automatically adjusts the engines to the same speed rpm Indication blue No li...

Page 28: ...There is a 12 pin connector on the rear of the instru ment The cable between the EVC display and the helm control unit HCU is connected here EVC display top level menu structure Key 1 Engine 3 diffrent fuel data Key 2 Multi 3 diffrent data views Key 3 Trip Reset trip Key 4 Graph 16 diffrent Graph data Fuel rate Fuel con sumption Trip fuel Digital data view Gauge data view 1 Gauge data view 2 Reset...

Page 29: ...emperature Fuel level Engine oil ﬁlter differential pressure Using the instrument Start up screen This is the start up screen for the EVC display If the unit bleeps with a long continuos bleep at start up the self test function has failed The unit will still function but erratic behaviour may be observed as a result Conﬁguration defaults When the EVC display ﬁrst is connected to the EVC system the...

Page 30: ...bed on the following pages The lower display window provides access to fuel computer data and also shows fuel tank level s Vari ous data can be displayed by repeated pressing of the engine key key 1 For twin engine option the data is a total measurement for both engines Data available is similar to an automotive in car fuel computer Only metric units shown but other units can be displayed if selec...

Page 31: ...ewer Prog tx About EVC About Language 8 available Bleep On off Engine PORT STBD TWIN SINGLE Display Calibration Depth Fuel Speed Speed calib page Settings Alarm status Service System Alarm status page Depth alarm Alarm depth Depth offset Fuel alarm Fuel level Engine 2500rpm 9000rpm step 500 rpm Speed On off Speed 10KTS 100KTS steps of 10 in current speed unit Graph range 2MNS 10MNS 30MNS 60MNS 2 H...

Page 32: ...rce Port Stbd or Twin Speed Switches boat speed display on off Speed 10 KTS 100 KTS step 10 in current speed unit Graph range 2 MNS 10 MNS 30 MNS 60 MNS 2 HRS 4 HRS 8 HRS Calibration Calibration settings for Depth Fuel and Speed These functions is described more later on in this chapter Depth Depth alarm alarm depth depth offset Fuel Fuel alarm fuel level Speed Speed calibration Service The servic...

Page 33: ...est messages received on communication ports Prog tx Transfers the contents of the application program on ﬂash memory to other CANtrak units on the same CANbus link About Displays the following information ID no Serial number of the display Eeprom Number of write on Eeprom Vers Software version number Chk Flash memory checksum Part no Volvo software part number Source Display the source of receive...

Page 34: ...ous data can be displayed by repeated pressing of the engine key key 1 For twin engine option the data is a total measurement for both engines Data available is similar to an automotive in car fuel computer Only metric units shown but other units can be displayed if selected in conﬁguration menu If boat speed is not available the display will show coolant temperature rather than no data Fuel rate ...

Page 35: ...ows The display parameters are user selectable The information can be displayed either digitally or graphically The display toggles between the two when key 2 is pressed repeatedly If a data parameter is not available the unit will display and the analogue gauge needle will not be displayed ...

Page 36: ...e maximum range for engine rpm can be adjusted in the conﬁguration menu The voltage range can be 8V 16V or 16V 32V and will change automatically depending on the latest data value Depending on engine alternative further settings are available in the graph menu and the multi menu The se are seawater depth seawater temperature and boat speed engine trim angle rudder angel Press key 5 to enter the ad...

Page 37: ... hours non re settable To reset the trip values trip fuel and trip hours just press and hold key 3 for one second The unit will bleep and the values are reset Note For twin engine display conﬁguration the data for each engine will be a sum of the data from both engines except for engine hours Engine hours for twin engines will be shown separately Engine hours digit size is reduced if the number be...

Page 38: ... graph line will just stop drawing but continue to scroll across the screen Port or single engine data will be drawn as a black line Starboard engine data will be drawn as grey line The maximum time range can be adjusted in the con ﬁguration menu to either 2mins 10mins 30mins 1hr 2hrs 4hrs 8 hrs Range on Y axis is automatically adjusted to give a better view Single engine graph screen showing engi...

Page 39: ...elow Note The port engine or both engines have to have ignition on when settings are made or when resetting data Depth alarm Depth alarm can be switched ON OFF Alarm depth and depth of set Depth alarm and offset values can be adjusted at a resolution of 0 1 units Once adjustment value is reached the data is stored by pressing BACK key ...

Page 40: ...larm acknowledged pop up The depth alarm acknowledged pop up will appear constantly if the depth alarm is enabled This will show the depth value until the enabled inactive mes sage is received from the EVC unit Depth alarm signal loss If the depth alarm is enabled and the depth signal is lost for instance in the case of sensor malfunction the depth alarm signal loss pop up will appear and ﬂash at ...

Page 41: ...0 key then store the calibra tion point value by pressing the store key Repeat the procedure with the level sensor in the appro priate full position using the 100 key instead To conﬁrm that the calibration data is stored in the EVC the text STORED is displayed for 2s the buzzer sounds If the display is conﬁgured for a twin engine instal lation then the PORT STBD key is displayed to allow the tank ...

Page 42: ...el tank alarm level in the window as a percentage of fuel remaining If both port starboard alarms are active in a dual engine system then the alarm with the lowest fuel level is displayed in the pop up Fuel level signal lost If the fuel level alarm is enabled and the fuel level signal is lost for instance in the case of sensor mal function the fuel level alarm signal loss pop up will appear and ﬂa...

Page 43: ...etting data Calibration The calibration factor for the boat s paddle wheel speed sensor can be adjusted or 0 01 units or 1 and is used by the EVC to apply a correction to the output from the speed sensor Calibrate while driving the boat Compare displayed speed with speed data from GPS or other boat and adjust the calibration factor until they correnspond Once adjustment value is reached the data i...

Page 44: ...ins to ﬂash to acknowledge that the shift function is disen gaged The lever now only controls engine speed When the lever is moved back to the neutral position it will automatically re engage This is conﬁrmed by the green indication which gives constant light WARNING Take care not to engage the reversing gear stern drive unintentionally Single lever control Electronic Operation Both the shift func...

Page 45: ... 4 Adjust the friction brake 8 mm wrench Clockwise heavier lever action Counter clockwise lighter lever action 5 Reinstall the plug Side mounted control lever Electronic Operation Both the shift function and engine speed control are con trolled using the control lever N Neutral position stern drive is disengaged and the engine runs at idle speed F Stern drive engaged for movement ahead R Stern dri...

Page 46: ... neutral Black lever 1 N Neutral position Reversing gear is disengaged F Reversing gear engaged for movement ahead R Reversing gear engaged for movement astern Red lever 2 Engine speed control Friction brake The control has an adjustable friction brake for speed con trol Adjust the friction brake by turning the screw control A or lever control B Turn clockwise for heavier lever movement or anti cl...

Page 47: ...in engine installations the control panel can be used to make individual or simultaneous adjustments to the drives By trimming out the drive away from the transom the height of the bow will be raised in relation to the ho rizontal axis and trimming in the drive will lower the bow of the boat Trimming out the drive Press in button 1 on the control panel to raise the bow of the boat drive trimmed ou...

Page 48: ...The range is used e g for trai ling Power Trim has an automatic stop that cuts the power when its end limit has been reached The stop is reset automatically when activating down trimming WARNING Never run the engine with the drive in lift range Digital trim instrument The display window will show TRIM while the drive angle is between 5 and 6 Trim range The display window will show BEACH while the ...

Page 49: ...im Analogue trim instrument This instrument shows the current position of the drive Beach range is marked with an orange zone and lift range with a red zone 1 Trim range 2 Beach range orange 3 Lift range red 2 1 3 ...

Page 50: ...t with the main switches when the engine is running This can damage the alternator L Start the engine bay fan if one is installed and let it run for at least four minutes L Check that the amount of fuel aboard is enough for your planned voyage L Check the oil level L Lower the drive s if raised General information about starting The engine control lever must always be in neutral before starting Th...

Page 51: ...e the ignition is turned on all bulbs and LEDs are illuminated on the main control panel Check that all bulbs and LEDs function If the boat has more than one control panel the lamps on the other panel s are not checked until the control panel s is are activated Lock the system If the boat has more than one control panel the sys tem can be locked so that the engine can only be controlled from the a...

Page 52: ...n 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 Leave the starter motor to cool for at least ﬁve minutes if possible before making a new start attempt Read the instruments and warm the engine up Allow the engine to idle for the ﬁrst ten seconds and check that instruments and ...

Page 53: ...in normal operation If the coolant temperature is too high the audible warning will sound automatically at the same time as the lamp in the warning display will ﬂash Charging During operation system voltage should be about 14V If there is a charge failure the lamp in the warning display will ﬂash Alarm If a fault occurs the audible warning will sound and the re levant warning lamp on the alarm pan...

Page 54: ...ser pitch propeller Ask your Volvo Penta dealer for advice Synchronizing engine speed When driving with twin engines both the operating eco nomy and comfort can be increased when the engines are operating at the same engine speed rpm The synchronization function is indicated by a blue equals sign 1 on the EVC control panel When the synchronization function is activated the engine speed rpm of the ...

Page 55: ...ctivation button 1 gives constant light to conﬁrm that the control panel is activated The sys tem is now locked which is indicated by the padlock sign which lights up NOTE If the correct gear or engine speed is not demanded within 15 sec the system ramps engine speed down to neutral and the gearbox engages neu tral Changing the helm station The ﬁrst time you change control panel after starting the...

Page 56: ...ever to reverse with a rapid distinct movement and increase engine speed IMPORTANT If the boat has twin engines it is important that both should be running during reversing maneuvers to avoid the risk of water entry via the exhaust pipe into the stationary engine Power Trim while running The Power Trim adjusts the drive angle to the stern of the boat to obtain maximum comfort and fuel econ omy at ...

Page 57: ...s at speeds below the planing threshold Operating in Bow down Position The bow down B position is normally used for acce leration onto plane operating at slow planing speeds and running against a choppy wave condition In the fully bow down position the boat may tend to selfs teer You may have to compensate with the steering wheel to keep the boat in a straight ahead path In this position the boat ...

Page 58: ...eed will not increase and may even drop IMPORTANT Use caution when operating in rough water or crossing another boat s wake Excessive bow up trim may result in the boat s bow rising rapidly and possibly throwing the boat s occupants into the water For maximum fuel economy Operate engine at a steady throttle opening Trim the drive out in slightly The boat is most easily propelled and speed will inc...

Page 59: ...f it is colored gray then water has entered the drive If this is the case or if other damage has occurred to the drive it must be inspected at an autho rized Volvo Penta workshop If only the propeller has been damaged it must be replaced Launch the boat and test drive If there are still vibrations it must be in spected by an authorized Volvo Penta workshop IMPORTANT To prevent galvanic corrosion a...

Page 60: ...Do not forget to open the cocks be fore the engine is started again L Inspect the engine and engine compartment for any leaks L Boats with drives The drive must be trimmed in to its maximum to protect the trim cylinders untreated sur faces from fouling IMPORTANT If there is a risk that the drive can run aground it must instead be trimmed out to its maximum lift position L Switch off the main switc...

Page 61: ...rged battery may burst as a result of freezing Transporting on a trailer Before pulling boats with on to a trailer trim the drive out to Lift range maximum lift An automatic stop will cut off the current to the hydraulic pump when the drive has reached its max lift point The stop is automatically reset when trimming down NOTE Check local legislation for transporting boats on trailers there are dif...

Page 62: ...12 months Warranty Period Further directions can be found in the Warranty and Service Book MAINTENANCE SCHEDULE WARNING Before you do any maintenance work read the Maintenance chapter carefully This contains advice on doing the work in a safe and correct manner IMPORTANT Maintenance points marked must be done by an authorised Volvo Penta workshop Daily before ﬁrst start L Engine and engine room Ge...

Page 63: ...s not shown Outboard drive Change universal joint bellows not shown Thoroughly inspect all hydraulic hoses and ﬁttings for signs of leaks wear cracks or ageing not shown Every second year L Coolant Change page 70 Every 600 hours at least every 5 years Reverse gear Change propeller seal not shown Turbo Inspect clean as required not shown Trim steering cylinders hoses hydraulic hoses Check for leaka...

Page 64: ...wear and damage Any faults are rectiﬁed If necessary the complete drive is changed Every 1500 hours commercial use Outboard drive Change gears bearings all bushings and sealing rings not shown Outboard drive Rebuild or change U joint not shown Outboard drive Check propellershaft wear and strightness Change as required not shown Outboard drive Perform pressure check not shown 1 Oil change intervals...

Page 65: ...e room before starting the engine and after stopping when the engine has been turned off This will help you to quickly detect abnormalities that have occurred or are about to occur Look especially carefully for oil fuel and coolant leaks loose bolts worn or slack drive belts loose connections damaged hoses and electric cables This inspection takes only a few minutes but can prevent serious operati...

Page 66: ... cover housing if necessary Take care not to allow impurities to enter the engine Fit the new air ﬁlter and the air ﬁlter cover Changing crankcase ventilation ﬁlter Unscrew the lid and remove the old ﬁlter Clean the ﬁlter cover housing if necessary Take care not to al low impurities to enter the engine Fit the new ﬁlter ...

Page 67: ...lt tension and condition regularly If the belt is too taut it can damage bearings and if it is too loose it may slip Therefore check the belt tension regularly Check and adjust after operation when the belt is warm IMPORTANT Always change a belt that ap pears worn or is cracked belts working in pairs must be replaced together Adjusting changing drive belts The standard generator and water pump are...

Page 68: ...rking if the oil level is cor rect Ensure therefore that the dipstick is fully screwed in to read off the oil level correctly Top up the oil as required use the dip stick tube to ﬁll For oil quality and capacity See the Technical Data chapter IMPORTANT The oil level should always be within the MAX and MIN range marked on the dipstick Oil change Run engine to normal operating temperature Remove the...

Page 69: ...the oil manufacturers through regular oil testing SAE5W 30 30 20 10 0 10 20 30 40 22 4 14 32 50 68 86 104 15o C SAE15W 40 25o C SAE10W 30 10o C SAE20W 30 0o C SAE30 SAE40 10o C o C o F 1 1 1 1 1 Viscosity Select the viscosity from the table below Note The temperature values refer to stable ambient temperatures Refers to synthetic or semi synthetic oils Oil change volume Please refer to the Technic...

Page 70: ...tes before draining the oil WARNING Hot oil and hot surfaces can cause burns 2 Connect the oil bilge pump to the drain pipe Pump up the oil 3 Change the oil ﬁlter and bypass ﬁlter at each oil change please refer to chapter Changing oil ﬁlter and bypass ﬁlter 4 Fill up with oil to the correct level through the ﬁlling hole on the top of the engine please refer to the Technical Data chapter for oil v...

Page 71: ... the ﬁlter bracket 3 Unscrew the bypass ﬁlter 1 and the oil ﬁlters 2 with a suitable extractor 4 Check that the mating surfaces on the ﬁlter brack ets are clean and that no residue from the old seals remains 5 Moisten the seals on the new ﬁlters with engine oil 6 Screw the ﬁlters on by hand until the rubber seals just touch the mating surface on the ﬁlter brackets Then tighten a further 1 2 to 3 4...

Page 72: ...IMPORTANT Coolant must be used all year round This applies even if there is never any risk for frost to ensure that the engine has an adequate protection against corrosion Future warranty claims on the engine and additional equipment may be rejected if an unsuitable coolant has been used or if the instructions concerning coolant mixing have not been followed NOTE The anti corrosive agents become l...

Page 73: ... increase the risk of overheating and will give reduced freezing protec tion IMPORTANT Coolant must be mixed with pure water use distilled de ionized water The water must fulﬁll the requirements speciﬁed by Volvo Penta see Water quality IMPORTANT It is extremely important that the correct concentration of coolant is added to the system Mix in a separate clean vessel before adding into the cooling ...

Page 74: ...and screw in the nipple by hand Move the hose and then continue to drain the coolant from the drain nipple 2 on the engine block NOTE Leave the old coolant to a facility for destruc tion Checking coolant level WARNING Do not open the engine coolant system ﬁller cap when the engine is still hot ex cept in an emergency Steam or hot coolant may spray out Turn the ﬁller cap slowly counter clockwise an...

Page 75: ...er passes the seawater ﬁlter before being pumped through the fuel cooler intercooler engine oil cooler and heat exchanger Finally the water is pumped into the exhaust pipe elbow where it is mixed with the exhaust gases On engines with reverse gear the seawater pump draws in water via the seawater inlet after which it passes the seawater ﬁlter extra equipment before being pumped through the interco...

Page 76: ...must be checked more frequently than indicated in the maintenance schedule Otherwise there is a risk the ﬁlter will clog and the engine will overheat Draining seawater system Use a suitable receptacle while draining Open the drain nipple 1 by carefully screwing the nipple Use a no 17 block spanner if the nipple sticks Drain all coolant and screw in the nipple by hand Move the hose and then continu...

Page 77: ...nd the intercooler 4 Check the sacriﬁcial anodes and change them if they are less than 50 of their original size Other wise clean the sacriﬁcial anodes with sandpaper to remove the layer of oxide before reﬁtting them IMPORTANT Clean with sandpaper Use no steel tools as this will impair electrical protection 5 Fit the sacriﬁcial anodes Make sure there is good contact between the anode and the metal...

Page 78: ...hed behind the exhaust outlet WARNING Approaching a running engine is dangerous Watch out for rotating components and hot surfaces IMPORTANT The impeller will be damaged if it runs dry 4 Set the gear control lever in the neutral position Check that nobody is near the propellers Start the engine Let it run at fast idle a few minutes Stop the engine 5 For inhibiting ﬁll a bucket with antifreeze mixt...

Page 79: ...lose the fuel valve valves 2 Clean the ﬁlter bracket and put a suitable vessel under the ﬁlter 3 Remove the cables from the water trap 1 4 Unscrew the ﬁlter use a ﬁlter wrench if needed 5 Clean the sealing surfaces of the ﬁlter bracket Make sure the ﬁlter is absolutely clean and the sealing surfaces are undamaged Moisten the sealing rings with engine oil including the inner rubber seal located ins...

Page 80: ... avoid spillage 2 Open the air vent valve and pump fuel using the hand pump 2 until the fuel running out is free from air bubbles Close and tighten the air vent valve 3 Pump another 10 strokes with the hand pump The resistance in the hand pump may seem quite high and is normal and necessary for bleeding the sys tem 4 Remove the hose and reﬁt the protective cap on the air vent valve WARNING Working...

Page 81: ...fuel ﬁlter Remove the cover by slackening off screw 1 Replace insert and reinstall cover Open fuel cock Vent fuel system Deposit the old ﬁlter insert at a properly designated disposal site Start the engine and check for leaks WARNING Approaching a running engine is dan gerous Watch out for rotating components and hot surfaces 1 ...

Page 82: ...tches while the engine is running Fuses 12 volt system The engine is ﬁtted with fully automatic circuit breakers The circuit breakers cut the power if the electrical 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 If the fault is intermittent resetting will take place automatically If the fa...

Page 83: ... black battery lead to the battery terminal When disconnecting the battery disconnect the lead black ﬁrst and then the lead red Cleaning Keep batteries dry and clean Oxidation or dirt on the battery and battery terminals can cause short circuits voltage drop and discharge especially in damp weather Clean the battery terminals and leads to remove oxidation using a brass brush Tighten the cable term...

Page 84: ...e battery has discharged it must be charged If the boat has not been used for some time charge the battery and then trickle charge it see manufacturer s recommendations A poorly charged battery will be damaged and may burst in cold weather IMPORTANT Follow the instructions supplied with the battery charger carefully To avoid elec trolytic corrosion when an external charger is connected always disc...

Page 85: ...s connected the protector ground should be ashore never in the boat Shore power should always have a ground fault circuit breaker Shore power units transformer rectiﬁer battery chargers etc must be intended for marine usage and the high tension circuit must be galvani cally separated from the low tension circuit 2 Route and clamp electric cables so that they will not be exposed to rubbing damp or ...

Page 86: ...be connected between its terminal and the fuse block and the terminal and the termi nal block for the boat s electrical equipment The main switch for the auxiliary battery must cut off all power consuming equipment connected to that battery and be turned off when power is no longer needed All equipment connected to the auxiliary battery should have separate switches To simultaneously charge two in...

Page 87: ... dipstick hole Please refer to the Technical Data chapter for oil grades and volume IMPORTANT Never over ﬁll the reversing gear The oil level must always be inside or at the rec ommended levels Changing oil and ﬁlter 1 Clean around the lid 2 so that there is no risk that dirt could fall down into the ﬁlter housing 2 Undo screw 1 with a 6 mm Allen key Remove lid 2 Replace and oil in the new O rings...

Page 88: ...ed and lubricated directly after launching Vent the bushing by pressing it together while pressing down on the shaft until water appears Then press in approx 1 cc water repellent grease into the seal IMPORTANT The seal must be checked every 600 hours and changed as required The seal must be changed every ﬁve years however ...

Page 89: ...ion or an electric actuator and electronic operation Corrosion protection Checking Changing Check the sacriﬁcial anodes regularly Change with new anodes when approximately 1 3 of the anode has been eroded Tighten the new anode so that there is a good electrical contact Where boats are kept laid up on land when not in use there is a lower level of galvanic corrosion protection due to the oxidation ...

Page 90: ...m the gear housing and allow the oil to run out If the oil is discolored contact an authorised Volvo Penta service centre Reﬁt the plug with gasket A damaged gasket must al ways be replaced with a new one Check the tightness of the plug before ﬁtting the propeller Fill with new oil Refer to Technical Data concerning grade and capacity Top up with oil until the oil ﬁller cap is completely ﬁlled The...

Page 91: ...rating hours The drive must be dismantled from the suspension fork in order to change the joint bellows Dismantling the drive requires knowledge and special tools Contact your Volvo Penta service centre Checking exhaust bellows Check the condition of the exhaust bellows once a year It must be changed if there are any visible cracks or other defects WARNING Never work on the drive bellows or hydrau...

Page 92: ...probable indication that there is a leak or that there are air in the system The leak must be located and rectiﬁed immediately Contact your Volvo Penta service centre for repair The steering system is ﬁlled with ATF and does not normally require changing As long as the ﬂuid is red in colour and does not contain any visible contami nants it need not be changed If the ﬂuid has started to turn black ...

Page 93: ...or wear and cracks Check external hoses especially carefully as these have been exposed to water fa tigue Hoses must be replaced if at all damaged WARNING A leaking hydraulic hose can nega tively affect steering and at worst steering can be lost altogether Cleanliness is extremely im portant no dirt must get into the hydraulic sys tem Before removing clean and check carefully how hoses are routed ...

Page 94: ...0 Nm A B 30 Nm Hydraulic tie bar Adjusting The tie bar can be adjusted both with the boat in the water and with the boat up on land With the boat in the water 1 Remove protective cap screw A Loosen adjust ment screw B 1 2 turns 2 With the engines running turn the steering wheel hard over to one side until the helm pump goes against a lock Both stern drives will then steer out fully to one side 3 T...

Page 95: ...ing 1 Turn on the power and move the control lever to reverse Take the starter key out of the starter switch 2 Undo the lock nut 1 and remove the rear propel ler 3 Turn on the power and move the control lever to forward Take the starter key out of the starter switch 4 Undo the large lock nut 2 using the special tool supplied Remove the front propeller 5 Wipe the propeller shafts clean Assembly 1 L...

Page 96: ...an and inhibit the seawater system L Remove the impeller from the seawater pump Store the impeller in a sealed plastic bag in a cool place L Check the condition of the engine coolant anti freeze Top up if required IMPORTANT An anti corrosion mixture in the engine coolant system provides no protection against freezing If there is any possibility the engine will be subjected to freezing temperatures...

Page 97: ... the condition of rubber hoses and tighten hose clamps L Check engine coolant level and antifreeze protec tion Top up if necessary L Connect the fully charged batteries L Paint the drive and hull See next page L Check the sacriﬁcial anode on the drive If there is less than 2 3 of the anode left it must be replaced Clean with emery cloth just before the boat is launched IMPORTANT Do not use a wire ...

Page 98: ...gent be applied onto the original paintwork on the drive without sanding it down ﬁrst Teﬂon is the registered trademark of the Du Pont Corp Underwater hull All types of paints with anti fouling properties are poisonous and cause damage to the marine environ ment Avoid the use of such agents Most countries have introduced legislation controlling the use of anti fouling agents Always abide by these ...

Page 99: ...er cable to the negative pole of the help start battery and then to a place some distance from the ﬂat batteries such as the negative connection on the starter motor WARNING Under no circumstances may the black jumper cable come into contact with the positive connection on the starter motor 4 Start the engine and run at a fast idle for about ten minutes to charge the batteries Make sure that there...

Page 100: ...he engine compart ment 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 Reverse gear This description is for manual engagement of the re verse gear for forward travel Note The descriptions ref...

Page 101: ...ntrol panel and hold 2 Trim the drive using the trim panel Engine stop after crash stop If the engine has stopped after a crash stop the fol lowing procedure has to be done before the boat can be manoeuvered 1 Put the control levers in neutral position 2 Acknowledge the alarm and stop the engine s 3 Wait until the system is shutdown proberly all lamps has gone out Then start the system not the eng...

Page 102: ...ully unscrew the water separator 2 enough to allow the water to run out Screw in the water separator until it bottoms against the ﬁlter Then screw a further 1 4 to 1 2 of a turn 4 Fasten the cable from the water separator 1 Draining of fuel pre ﬁlter The fuel pre ﬁlter is an accessory Position a container under the fuel ﬁlter On the fuel ﬁlter ﬁrst open the venting screw 1 approximately 4 turns Dr...

Page 103: ...orrect propeller 16 Defective engine mounting 17 Too little coolant 18 Blocked seawater intake pipe ﬁlter 19 Circulation pump drive belt slipping 20 Defective impeller 21 Defective incorrect thermostat 22 Lubricating oil level too high 23 Generator drive belt slipping 24 Stored diagnostic trouble codes DTCs Symptom and possible cause The diagnostic button indicator ﬂashes See the Diagnostic functi...

Page 104: ...ed a minor malfunction which does not damage the engine Reaction The engine is not affected 2 The diagnostic function has discovered a serious malfunction which will not immediately damage the engine e g high coolant temperature Reaction Engine power is reduced till the rele vant value is normalized 3 The diagnostic function has discovered a serious malfunction which will cause serious engine da m...

Page 105: ...ck nowledged STOP pop up If the STOP pop up is shown during operation a seri ous fault has occured NOTE Acknowledge the alarm and stop the engine at once Go to the alarm list and read out the fault code It is also recommended to ﬂash out the fault code via the control panel More information regarding cause and effect about the fault codes is found in chapter Fault code register Warning pop up If t...

Page 106: ...alarm list will be able to be scrolled up and down if the list is longer than the screen size The acknowledge button will send an acknowledge message for all alarms at the same time The screen cannot be exited until all alarms have been acknow ledged When pressing the acknowledge button the buzzer goes silent In the following frame the exit button will be activated Alarms will not be automatically...

Page 107: ...ning If the engine is stopped check that the starter key is in position I drive position 2 Press the diagnostic button D for at least 5 sec onds Release the D button and the yellow indica tion lamp will give constant light which means that you are in Service mode and fault codes can be read 3 The diagnostic button must be depressed to make the codes ﬂash Make a note of the three digit fault code t...

Page 108: ... on again the diag nostic function checks to see whether there are any faults in the EVC system If this is the case new fault codes are set This means that 1 Fault codes for malfunctions which have been at tended to or have disappeared are automatically erased 2 Fault codes for malfunctions which have not been attended to must be acknowledged every time the system voltage is switched on If the dia...

Page 109: ... 3 Audible warning 1 1 Explanation No fault codes are stored and no malfunctions have been registered 1 2 1 O Explanation Water in water trap in fuel ﬁlters Reaction None Action Empty the water trap underneath the fuel ﬁlters please refer to the In case of emergency chapter Water in fuel Contact a Volvo Penta workshop if the fault remains 1 2 4 O Explanation Fault in engine speed sensor on ﬂywheel...

Page 110: ...ontact a Volvo Penta workshop 1 4 9 O R Explanation Sensor fault in engine Reaction Engine power can be reduced Action Please contact a Volvo Penta workshop 1 6 1 R Explanation Excessive coolant temperature Reaction Engine power is reduced Action Check coolant level Please refer to Maintenance Fresh water system Check that the sea water ﬁlter is not blocked Please refer to Maintenance Sea water sy...

Page 111: ...uel taps and check that no leakage occurs Check that the fuel ﬁlters are not blocked Please refer to Maintenance Fuel system Contact a Volvo Penta workshop if the fault remains 1 7 1 1 7 6 O Explanation Injector system failure injector 1 6 Reaction Engine power is reduced Action Please contact a Volvo Penta workshop 1 7 7 R Explanation Serious fault in the fuel system Fault in the supply e g leaka...

Page 112: ... a Volvo Penta workshop if the fault remains 1 9 9 R Explanation Internal system fault in engine Reaction Action If the engine can not be operated from the chosen control panel use an alternative control panel Please contact a Volvo Penta workshop 2 1 2 R Explanation Incompatible engine type Reaction System does not work Action Check the driveline installation Please contact a Volvo Penta workshop...

Page 113: ...ns 2 4 7 R Explanation Faulty solenoid secundary Reaction Cannot engage gears Engine in emergency mode Action Emergency shifting see chapter In case of emergeny Please contact a Volvo Penta workshop if the fault remains 2 7 3 O R Explanation Fault in PowerTrim system Reaction Can not change trim position Action Emergency Trimming see chapter In case of emergeny Please contact a Volvo Penta worksho...

Page 114: ...re Check that the control levers are approved by Volvo Penta Please contact a Volvo Penta workshop if the fault remains 3 1 4 Y Explanation Incorrect lever calibration procedure Reaction It is not possible to calibrate the control levers Action Switch the ignition off and repeat the calibration procedure Check that the control levers are approved by Volvo Penta Please contact a Volvo Penta worksho...

Page 115: ... controlled Action If the engine can not be operated from the chosen control panel use an alternative control panel Switch the ignition off and repeat the calibration procedure Check that the control levers are approved by Volvo Penta and correctly installed Please contact a Volvo Penta workshop 3 9 9 O R Explanation Internal fault in the EVC system Reaction Engine power is reduced Action If the e...

Page 116: ...See table below See table below Propellershaft power kW hp See table below See table below Idling speed 700 rpm 600 rpm Swept volume 3 7 liter 1 0 US gals 5 5 liter 1 5 US gals Injection sequence 1 3 4 2 1 5 3 6 2 4 Direction of rotation seen from front Clockwise Clockwise Max forwards inclination 10 10 Max rearwards inclination in operation 20 20 Max sideways inclination in operation 30 30 Oil pr...

Page 117: ...ced ACEA E5 but if available ACEA E5 can be used 3 If sulphur content is 1 0 by weight use oil with TBN 15 SAE5W 30 30 20 10 0 10 20 30 40 22 4 14 32 50 68 86 104 15o C SAE15W 40 25o C SAE10W 30 10o C SAE20W 30 0o C SAE30 SAE40 10o C o C o F 1 1 1 1 1 Viscosity Select the viscosity from the table below Note The temperature values refer to stable ambient temperatures Refers to synthetic or semi syn...

Page 118: ...tional hours in warm waters above 25 C 77 F VP 1141666 API GL SAE 75W 140 Synthetic oil should be used Reverse gear excluding oil cooler HS45AE Oil volume 2 5 liter 0 7 US qals Oil grade ATF Dexron II III HS63AE Oil volume 4 0 liter 1 US qals Oil grade ATF Dexron II III HS63VE Oil volume 4 4 liter 1 2 US qals Oil grade ATF Dexron II III HS80 85AE Oil volume 5 5 liter 1 5 US qals Oil grade ATF Dexr...

Page 119: ...117 Notes ...

Page 120: ...r als Fax an Document Distribution Center Order Department ARU2 Dept 64620 SE 405 08 Göteborg Schweden Fax 46 31 545 772 Die Bestellung kann auch über das Internet erfolgen http www volvopenta com manual coupon Ja ich will kostenlos eine Betriebsanleitung in deutscher Sprache erhalten Publikationsnummer 7745006 Name Anschrift Land 42200 615001 155099900192 Notez que l offre est valable pendant 12 ...

Page 121: ...cación y posteriormente solamente mientras duren las existencias Franquear o enviar fax a Document Distribution Center Order Department ARU2 Dept 64620 SE 405 08 Göteborg Suecia Fax 46 31 545 772 El pedido puede hacerse tam bién por internet http www volvopenta com manual coupon Sí gracias deseo recibir gratuitamente un libro de instrucciones en español Número de publicación 7745008 Nombre Direcci...

Page 122: ...ller fax til Document Distribution Center Order Department ARU2 Dept 64620 SE 405 08 Göteborg Sverige Fax 46 31 545 772 Bestillingen kan også ske på internet http www volvopenta com manual coupon Ja tak jeg vil gerne gratis have en instruktionsbog på dansk Publikationsnummer 7745019 Navn Adresse Land 42200 615001 155099900192 Huomaa että tarjous on voimassa 12 kuukautta veneen toimituspäivä määräs...

Page 123: ...e publicação 7745028 Nome Endereço País 42200 615001 155099900192 ÐÑÏÓÏ Ç ÁõôÞ ç ðñïóöïñÜ éó ýåé ãéá ñïíéêÞ ðåñßïäï 12 ìçíþí áðü ôçí ðáñÜäïóç ôïõ óêÜöïõò ÌåôÜ ôï ðÝñáò ôçò åí ëüãù ñïíéêÞò ðåñéüäïõ ç äéáèåóéìüôçôá ôùí áíôéôýðùí èá åîáñôÜôáé áðü ôçí ðïóüôçôá ôùí áðïèåìÜôùí Ôá õäñïìÞóôå áõôü ôï êïõðüíé óôçí ðáñáêÜôù äéåýèõíóç Þ óôåßëôå ôï ìå öáî óôïí ðáñáêÜôù áñéèìü öáî Document Distribution Center O...

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Page 126: ...7745861 English 04 2006 ...

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