OPERATOR’S MANUAL

D4, D6
 This operator’s manual is also available in the following languages:

Diese Betriebsanleitung ist auch auf Dit instructieboek kan worden besteld
Deutsch erhältlich. in het Nederlands.
Ein Bestellcoupon ist am Ende der Betriebs- De bestelcoupon vindt u achter in het instruc-
anleitung zu finden. tieboek.

Ce manuel d’instructions peut être Denne instruktionsbog kan bestilles på

commandé en français. dansk.
Vous trouverez un bon de commande à la fin Bestillingskupon findes i slutningen af in-
du manuel d’instructions. struktionsbogen.

Este libro de instrucciones puede soli- Tämän ohjekirjan voi tilata myös suo-
citarse en español. menkielisenä.
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El cupón de pedido se encuentra al final del Tilauskuponki on ohjekirjan lopussa.

libro.

Den här instruktionsboken kan bestäl- Este manual de instruções pode ser
las på svenska. encomendado em português.
Beställningskupong finns i slutet av instrukti- O talão de requerimento encontra-se no fim
onsboken. do manual.

Questo manuale d’istruzioni può esse- Áõôü ôï åã÷åéñßäéï ÷ñÞóçò

re ordinato in lingua italiana. äéáôßèåôáé óôçí áããëéêÞ ãëþóóá.
Il tagliando per l’ordinazione è riportato alla Ãéá íá ðáñáããåßëåôå Ýíá áíôßôõðï,
fine del manuale. óõìðëçñþóôå ôç öüñìá ðïõ âñßóêåôáé óôï
ôÝëïò áõôïý ôïõ åã÷åéñéäßïõ ÷ñÞóçò.

CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
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Welcome aboard
Volvo Penta marine engines are used all over the world today. They are used in all pos-
sible operating conditions for professional as well as leisure purposes. That’s not sur-
prising.
After more than 90 years as an engine manufacturer and after delivering over 500,000
marine engines, the Volvo Penta name has become a symbol of reliability, technical in-
novation, top of the range performance and long 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 descriptions of controls or

operation for boats with waterjet. If your boat is equipped with Volvo Penta
waterjet, this information can be found in the operator’s manual that came
with the waterjet.

1
7745861 English 04-2006
 Content

Safety Information ............................................ 3–7 Maintenance schedule ................................... 60-62

General................................................................... 3
Maintenance ................................................... 63–93
Boat travel............................................................... 4
Engine, general .................................................... 63
Maintenance and service ....................................... 6
Lubrication system ............................................... 67
Introduction ................................................... 8–12 Freshwater system ............................................... 70
Running-in ............................................................. 8 Seawater system .................................................. 73
Fuel and oil types .................................................. 8 Fuel system ......................................................... 77
Certificated engines............................................... 9 Electrical system .................................................. 80
Warranty information ............................................. 9 Reverse gear ........................................................ 85
Identification numbers .......................................... 12 Drive ..................................................................... 87
Steering ................................................................ 90
Presentation ................................................... 13–19
Propellers ............................................................. 93
Technical Description............................................ 13
Engine monitoring and EVC ................................ 14 Laying up/Launching ..................................... 94-96
Orientation ........................................................... 16 Inhibiting ............................................................... 94
Bringing out of winter storage............................... 95
Instrumentation .............................................. 20-41
Painting the drive and underwater hull ................. 96
Instruments........................................................... 20
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Start/stop panel .................................................... 20 In case of emergency .................................... 97-104

Alarm display ........................................................ 22 Starting using auxiliary batteries .......................... 97
EVC control panels............................................... 25 Emergency shifting ............................................... 98
EVC-display.......................................................... 26 Emergency trimming ............................................ 99
Engine stop after crash-stop................................. 99
Controls .......................................................... 42-44
Water in fuel ....................................................... 100
Power Trim ..................................................... 45-47 Fault-tracing........................................................ 101
Starting the engine ........................................ 48-49 Diagnostic function ............................................. 102
Before starting ...................................................... 48 Malfunction message engine and EVC-system.. 103
General about starting.......................................... 48 Alarm list............................................................. 104
Starting method .................................................... 49 Fault codes ......................................................... 105
Erasing fault codes ............................................. 106
Operation ......................................................... 51-57
Reading instruments ........................................... 51 Fault code register ..................................... 107-113
Alarm .................................................................. 51 Technical Data ............................................ 114-116
Cruising speed ..................................................... 52 Engine ................................................................ 114
Synchronising engine speed .............................. 52 Fuel specification ............................................... 115
Changing helm station ........................................ 53 Drive .................................................................. 116
Operation ............................................................ 54 Reverse gear ...................................................... 116
Power Trim while running..................................... 54 Power Trim .......................................................... 116
Running aground .................................................. 57 Steering .............................................................. 116
Stopping the engine ...................................... 58-59
Stopping .............................................................. 58
Laying up ............................................................. 58
Cold weather precautions .................................... 59

© 2005 AB VOLVO PENTA

All rights to changes or modifications reserved.
Printed on environmentally friendly paper.
2 (Cover: Department of transport (shipping), license 9809095)
 Safety Information
Read this chapter carefully. It concerns your safety. This section describes how safety information is presented in
the operator’s manual and on the engine. It also gives a general account of basic safety precautions to be taken
when operating the boat and maintaining the engine.
Check that you have the correct operator’s manual before you read on. If this is not the case please con-
tact your Volvo Penta dealer.
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If operations are performed incorrectly it could result in personal injury, or damage to property
or the engine. Read the operator’s manual carefully before operating or servicing the engine. If
anything is unclear please contact your Volvo Penta 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 to draw your attention to something that can cause damage, product
malfunction or damage to property.
NOTE! Used to draw your attention to important information that will facilitate work or opera-
tions.

This symbol is used in certain cases on our products and refers to important information in
the operator’s manual. Ensure that warning and information symbols on the engine and trans-
mission are always visible and legible. Replace symbols that have been damaged or painted
over.

3
 Safety Information

Safety precautions to be taken when operating the boat

Your new boat Refueling

Read operator’s manuals and other information When refueling there is always a danger of fire and
supplied with your new boat. Learn to operate the explosion. Smoking is forbidden and the engine must
engine, controls and other equipment safely and cor- be switched off.
rectly.
Never overfill the tank. Close the fuel tank filler cap
If this is your first boat, or is a boat type with which properly.
you are not familiar, we recommend that you prac-
tice controlling the boat in peace and quiet. Learn Only use the fuel recommended in the operator’s
how the boat behaves at different speeds, weather manual. The wrong grade of fuel can cause operat-
conditions and loads before casting off for your “real” ing problems or cause the engine to stop. On a diesel
maiden voyage. engine poor quality fuel can cause the control rod to
seize and the engine to overrev with a resultant risk
Remember that the person driving a boat is legally of damage to the engine and personal injury.
required to know and follow the current rules regard-
ing traffic and safety at sea. Make sure you know the Do not start the engine
rules that apply to you and the waters you are sailing Do not start or run the engine with a suspected fuel
in by contacting the relevant authorities or organiza- or LPG leak in the boat, nor when you are close to or
tion. in a discharge of explosive media, etc. There is risk
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A good piece of advice is to take a course in sea- for fire and/or explosion in explosive surroundings.
manship. We recommend that you contact your local
boating organization to find a suitable course.
Safety breaker
We recommend that you install and use a safety
Accidents breaker (accessory), especially if you boat can travel
Statistics show that poor maintenance of boats and at high speeds. The safety breaker stops the engine if
engines and a lack of safety equipment are often the the driver falls down and loses control over the boat.
cause of accidents at sea.
Ensure that your boat is maintained in accordance
with the relevant Instruction Manual and that the nec-
essary safety equipment is on-board and is service-
able.

Daily checklist
Make a habit of checking the engine and engine
compartment visually before operating the boat (be-
fore the engine is started) and after operating 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 nobody is in the water before engaging ahead or
astern. Never drive near bathers or in areas where
people could be in the water.
Avoid trimming an outboard drive too much, as steer-
ing will be severely reduced.

4
 Safety Information

Carbon monoxide poisoning

When a boat is moving forward, it will cause a certain Most modern boats, however, are designed in such
vacuum to form behind the boat. In unfortunate cir- a way that this problem is very rare. If suction should
cumstances, the suction from this vacuum can be so arise anyway, do not open hatches or portholes at
great that the exhaust gases from the boat are drawn the fore of the boat. Surprisingly, this will otherwise
into the cockpit or cabin and cause carbon monoxide increase the suction. Try changing speed, trim or load
poisoning. distribution instead. Try taking down/opening or in any
other way changing the setup of the cover as well.
This problem is most prevalent on high, wide boats
Get in touch with your boat dealer for help in obtain-
with abrupt stern. In certain conditions, however, this
ing the best solution for your boat.
suction can be a problem on other boats, e.g. when
running with the cover up. Other factors that can in-
crease the effect of the suction are wind conditions,
load distribution, swells, trim, open hatches and port-
holes, etc.
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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 repairs that might have to be carried out.
L Get out your charts and go over the planned route. Calculate distance and fuel consumption. Lis-
ten to the weather reports
L Make sure that relations or contact persons are informed when planning a longer voyage. Re-
member to inform them if your plans have changed or been delayed.
L Tell your passengers and crew where the safety equipment is stored and how to operate it. Make
sure you are not the only person on board who knows how to start the boat and operate it safely.

This list can be added to because safety equipment and other requirements vary depending on the
type of boat and how it is used. We recommend that you contact your local boating organization for
more detailed information on safety afloat.

5
 Safety Information

Safety precautions for maintenance and service operations

Preparations Never start a turbocharged engine without installing

the air cleaner (ACL). The rotating compressor in the
Knowledge
Turbocharger unit can cause serious personal injury.
The operator’s manual contains instructions on how
Foreign objects can also be sucked in and cause me-
to carry out general maintenance and service opera-
chanical damage to the unit.
tions safely and correctly. Read the instructions care-
fully before starting work.
Service literature covering more complicated opera- Fire and explosion
tions is available from your Volvo Penta dealer. Fuel and lubrication oil
Never carry out any work on the engine if you are All fuel, most lubricants and many chemicals are
unsure of how it should be done, contact your Volvo inflammable. Read and follow the instructions on the
Penta dealer who will be glad to offer assistance. packaging.
When carrying out work on the fuel system make
Stop the engine sure the engine is cold. A fuel spill onto a hot surface
Stop the engine before opening or removing engine or electrical components can cause a fire.
hatches. Unless otherwise specified all maintenance
and service must be carried out with the engine Store fuel soaked rags and other flammable material
stopped. so that there is no danger of them catching fire. Fuel-
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soaked rags can self-ignite under certain conditions.

To prevent accidental start of the boat engine remove
the ignition key, turn off the power supply to the en- Do not smoke when filling fuel, oil or in proximity of a
gine at the main switches and lock them in the OFF filling station or in the engine room.
position before starting work. Put up a warning sign
in the control position that work on the engine is be- Non-original components
ing carried out. Components used in the fuel and ignition system
(gasoline engines) and electrical systems on Volvo
Approaching or working on an engine that is run- Penta products are designed and constructed to
ning is a safety risk. Loose clothing, hair, fingers or minimize the risk of fire and explosion.
a dropped tool can be caught in the rotating parts of
the engine and cause serious personal injury. Volvo Using non-original Volvo Penta parts can result in fire
Penta recommend that all servicing with the engine or explosion on board.
running be undertaken by an authorized Volvo Penta
workshop. Batteries
The batteries contain and give off oxyhydrogen gas,
Lifting the engine especially during charging. This gas is easily ignited
When lifting the engine use the lifting eyes installed and highly volatile.
on the engine (reverse gear where installed). Always Do not under any circumstances smoke or use naked
check that lifting equipment is in good condition and flame or allow sparks in the vicinity of the batteries or
has sufficient load capacity to lift the engine (engine battery compartment.
weight including reverse gear and any extra equip-
ment installed). For safety’s sake lift the engine us- Incorrectly connection a battery terminal cable or
ing an adjustable lifting beam. All chains and cables jump-start cable can cause a spark which in its turn
should run parallel to each other and as perpendicu- can be sufficient to cause an explosion.
lar as possible in relation to the top of the engine.
Bear in mind that extra equipment installed on the Start spray
engine may alter its center of gravity. Special lifting Never use start spray or similar agents to start an en-
equipment may then be required in order to maintain gine equipped with air pre-heating (glow plugs/starter
the correct balance and make the engine safe to han- element). This may cause an explosion in the inlet
dle. Never carry out work on an engine suspended on manifold. Danger of personal injury.
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.

6
 Safety Information

Hot surfaces and fluids Fuel system

There is always a risk of burns when working with Always use protective gloves when tracing leaks.
a hot engine. Beware of hot surfaces. For example: Liquids ejected under pressure can penetrate body
the exhaust pipe, Turbo unit, oil pan, charge air pipe, tissue and cause serious injury. There is a danger of
starter element, hot coolant and hot oil in oil lines and blood poisoning.
hoses.
Always cover the generator if it is located under the
fuel filter. The generator can be damaged by spilled
Carbon monoxide poisoning fuel.
Only start the engine in a well-ventilated area. If op-
erating the engine in an enclosed space, ensure that
there is proper ventilation in order to remove exhaust
Electrical system
gases and crankcase ventilation emissions from the Cutting off power
working area. Always stop the engine and break the current using
the main switches before working on the electrical
system. Isolate shore current to the engine block
Chemicals heater, battery charger, or accessories mounted on
Most chemicals such as anti-freeze, rustproofing the engine.
agent, inhibiting oil, degreasing agent etc. are haz-
ardous to health. Read and follow the instructions on Batteries
the packaging. The batteries contain an extremely corrosive elec-
Some chemicals such as inhibiting oil are inflam- trolyte. Protect your skin and clothes when charging
or handling batteries. Always use protective goggles
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mable and dangerous if breathed in as well. Ensure

good ventilation and use a protective mask when and gloves.
spraying. Read and follow the instructions on the If battery electrolyte comes into contact with unpro-
packaging. tected skin wash off immediately using plenty of wa-
Store chemicals and other hazardous materials out ter and soap. If battery acid comes into contact with
of the reach of children. To protect the environment the eyes, flush immediately with plenty of water and
please dispose of used or leftover chemicals at a obtain medical assistance without delay.
properly designated disposal site for destruction.

Cooling system
There is a risk of flooding when working on the sea-
water system. Turn off the engine and close the sea
cock (where installed) before starting work on the
system.
Avoid opening the coolant filler cap when the engine
is hot. Steam or hot coolant can spray out and 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 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.

7
 Introduction
This operator’s manual has been compiled to help you get the most from your Volvo Penta engine. It contains
all the information you need in order to operate and maintain your engine safely and correctly. Please read the
operator’s manual carefully and learn how to operate the engine, controls and other equipment safely.
Always have the operator’s manual available. Keep it in a safe place and do not forget to give it to the new owner
if you sell your boat.

Care of the environment Fuel and oils

We would all like to live in a clean and healthy envi- Only use the fuel and oils recommended in the chap-
ronment. Somewhere where we can breathe clean air, ter Technical Data. Other grades of fuel and oil can
see healthy trees, have clean water in our lakes and cause operating problems, increased fuel consump-
oceans, and are able to enjoy the sunshine without tion and, in the long-term, a shorter engine service
being worried about our health. Unfortunately, this life.
cannot be taken for granted nowadays but is somet-
Always change oil, oil filters and fuel filters at the re-
hing we must work together to achieve.
commended intervals.
As a manufacturer of marine engines, Volvo Penta has
a special responsibility, why care of the environment is
a core value in our product development. Today, Volvo
Penta has a broad range of engines where progress Service and replacement parts
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has been made in reducing exhaust emissions, fuel Volvo Penta marine engines are designed for high
consumption, engine noise, etc. operational reliability and long service life. They are
We hope you will take care in preserving these qua- constructed to withstand the marine environment
lities. Always follow any advice given in the instruc- while also affecting it as little as possible. Through
tion manual concerning fuel grades, operation and regular service and the use of Volvo Penta original
maintenance and you will avoid causing unecessary spare parts, these qualities will be retained.
interference to the environment. Get in touch with your
Volvo Penta dealer if you notice any changes such as The Volvo Penta worldwide network of authorized
increased fuel consumption exhaust smoke. dealers are at your service. They are specialists in
Volvo Penta products and have accessories and
Adapt speed and distance to avoid wash and noise the original replacement parts, test equipment and
disturbing or injuring animal life, moored boats, jetties, special tools necessary for high quality service and
etc. Leave islands and harbours in the same condition repair work.
as you want to find them. Remember to always leave
hazardous waste such as waste oil, coolant, paint and Always follow the maintenance intervals contained
wash residue, flat batteries, etc., for disposal at a de- in the operator’s manual. Remember to state the en-
struction plant. gine/transmission identification number when order-
ing service and replacement parts.
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 engine at a constant engine speed for long pe-
riods during the running-in period.
The engine can be expected to use more engine oil
during the running-in period than would otherwise be
normal. Check the oil level more often than is normally
recommended.
A First Service Inspection must be carried out after
20–50 running hours. For further information: See the
Warranty and Service Book.

8
 Introduction

Certified engines L The engine must not be modified in any way

It is important to be aware of the following information except with accessories and service kits approved
if you own or run an engine that is exhaust emission by Volvo Penta.
certified: L No modifications to the exhaust pipes and air sup-
Certification means that an engine type is inspected ply ducts for the engine may be undertaken.
and approved by the authorities. The engine manu- L Seals may only be broken by authorized person-
facturer guarantees that all engines manufactured of nel.
that type correspond to the certified engine.
Otherwise the general instructions contained in the
This places special requirements for maintenance
Operator's Manual concerning operation, service and
and service as follows:
maintenance must be followed.
L The maintenance and service intervals recom-
mended by Volvo Penta must be observed. IMPORTANT! Late or inadequate maintenance/
L Only genuine Volvo Penta replacement parts may service or the use of spare parts other than
be used. Volvo Penta original spare parts will invalidate
AB Volvo Penta’s responsibility for the engine
L The service of injection pumps and injectors or specification being in accordance with the cer-
pump settings must always be carried out by an tificated variant.
authorized Volvo Penta workshop.
Volvo Penta accepts no responsibility or liabil-
ity for any damage or costs arising due to the
above.
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Warranty
Your new Volvo Penta marine engine is covered by a limited warranty according to the conditions and
instructions contained in the Warranty and Service book.
Note that AB Volvo Penta’s liability is limited to that contained in the Warranty and Service Book. Read
this book as soon as you take delivery of the engine. It contains important information about warranty
cards, service and maintenance which you, the owner, must be aware of, check and carry out. Liability
covered in the warranty may otherwise be refused by AB Volvo Penta.
Contact your Volvo Penta dealer if you have not received a Warranty and Service Book and a
customer copy of the warranty card.

9
 Declaration of Conformity for Recreational Craft Propulsion Engines with the
exhaust emission requirements of Directive 94/25/EC as amended by 2003/44/EC

D4, D6
Engine manufacturer: Body for exhaust emission assessment
AB Volvo Penta International Marine Certification Institute
Gropegårdsgatan Rue Abbé Cuypres 3
405 08 Göteborg B-1040 Bruxells
Sweden Belgium
ID Number:0609

Module used for exhauust emission assessment .......B+C

Other Community Directives applied ...........................EMC 89/336/EEC

Description of engine(s) and essential requirements

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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

Other normative
Essential requirements Standards Used
document used

Annex I.B – Exhaust Emissions

Engine identification Volvo Penta std Annex 1.B.1

Exhaust emission requirements EN ISO 8178-1:1996 Annex 1.B.2

Durability Volvo Penta std Annex 1.B.3

Operator’s manual ISO 10240:2004 Annex 1.B.4

EN 61000-3-2,
EMC Directive EN 61000-3-3,
CISPR 25

This declaration of conformity is issued under the sole responsibility of the manufacturer. I declare on behalf of the engine manufac-
turer that the engine(s) mentioned above complie(s) with all applicable essential requirements in the way specified and is in confor-
mity with the type for which above mentioned EC type examination certificate(s) has been issued.

Name and function: Sam Behrmann, Product Liability Signature and title:
(identification of the person empowered to sign on behalf of the (or an equivalent marking)
engine manufacturer or his authorised representative)

Date and place of issue: (yr/month/day) 2006/04/21 Göteborg PL-83/06

10
 Declaration of Conformity for Recreational Craft Propulsion Engines with the
sound emission requirements of Directive 94/25/EC as amended by 2003/44/EC

D4, D6
Engine manufacturer: Body for sound emission assessment
AB Volvo Penta International Marine Certification Institute
Gropegårdsgatan Rue Abbé Cuypres 3
405 08 Göteborg B-1040 Bruxells
Sweden Belgium
ID Number:0609

Module used for sound emission assessment ...... Aa

International production control
Test according to Annex VI

Other Community Directives applied ......................EMC 89/336/EEC

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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

D4-210 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

Essential requirements Standards Used Other normative

document used
Annex I.C – Noise Emis-
sions
EN ISO 14509:2000/ Annex 1.C.1
Sound emission levels prA1:2004

Operator’s manual ISO 10240:2004 Annex 1.C.2

EN 61000-3-2,
EMC Directive
EN 61000-3-3,
CISPR 25

This declaration of conformity is issued under the sole responsibility of the manufacturer. I declare on behalf of the engine manufac-
turer that the engine(s) mentioned above complie(s) with all applicable essential requirements in the way specified and is in confor-
mity with the type for which above mentioned EC type examination certificate(s) has been issued.

Name and function: Sam Behrmann, Product Liability Signature and title:
(identification of the person empowered to sign on behalf of the (or an equivalent marking)
engine manufacturer or his authorised representative)

Date and place of issue: (yr/month/day) 2005/12/07 Göteborg PL-78/05

11
 Introduction

Identification numbers
Always provide the engine and transmission identification numbers when ordering service or replacement com-
ponents.
The identification numbers are on an information decal located on the front edge of the engine. Note the infor-
mation below. Make a copy of the page. Store the information so that it is available in event of the boat being
stolen.

Engine
Product designation (1*)
Serial number (2*)
Product number (3*)

Drive/Reverse gear Warranty decal

(Engine/Transom shield/Drive/Reverse gear )
Product designation (4*)
Gear ratio (5*)
Serial number (6*)
Product number (7*) Engine plate

Shield (Drive)
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Product designation (8*)

Serial number (9*)
Product number (10*)
Drive plate Transom shield plate
* The numbers refer to the position of the
identification numbers on the information decal

Reverse gear plate

Location of information decal and identification plates:

Warranty decal, IMO decal and EPA decal

Transom shield plate

Drive plate

Reverse gear plate

Engine plate

12
 Presentation
Volvo Penta’s D4 and D6 is developed from the latest design in modern diesel technology. The engine has com-
mon rail fuel injection system, double overhead camshafts, 4 valves per cylinder, turbocharger, compressor, and
aftercooler. The interaction of these, the large swept volume, and the EVC system results in exceptional diesel
performance combined with low emissions.

Technical description:
Engine block and head Instruments/control
— Cylinder block and cylinder head made of cast- — Complete instrumentation including key switch
iron and interlocked alarm
— Combined ladder frame and balance shafts (D4) — Digital Power Trim instrument with analog or digi-
— Ladder frame fitted to engine block (D6) tal reading
— Double overhead camshafts — EVC monitoring panels for single or twin installa-
tions
— Oil-cooled pistons with two compression rings and
one oil scraper ring — Electronic remote control for throttle and shift
— Integrated cylinder liners — Plug-in connections
— Replaceable valve seats Drive
— Seven-bearing crankshaft — Complete with transom shield, and installation
components
— Rear-end transmission
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— Max tilt angle 50° (adjustable)

Engine mounting
— Protective zinc anodes to prevent corrosion
— Flexible engine mounting
— Built-in kick-up function to reduce possible da-
Lubrication system
mage, in the event the drive strikes an underwater
— Easily replaceable separate full-flow and by-pass object
oil filter
— Electrical shifting performed by electronic actuator
— Seawater-cooled tubular oil cooler
— Power Trim with one-button operation in twin in-
Fuel system stallation
— Common rail fuel injection system — Fully integrated water inlet and exhaust system
— Control unit for processing the injection — Fully hydraulic power-assisted steering system
— Fine filter with water separator — Isolated propellers to prevent corrosion
— Emergency stop device Reverse gear
Air inlet and exhaust system — Reverse gear with matched drop center and 8°
— Belt-driven compressor with silencer of absorption down angel for compact installation and minimum
type on both inlet and output port propeller shaft angel. V-drive available
— Air filter with replaceable insert — Bevel gears which resualts in smooth running at
— Crankcase gases vented into the air inlet all speeds
— Exhaust elbow or exhaust riser — Hydraulically operated clutch for smooth shifting
— Freshwater-cooled turbocharger — Electrical shifting performed by elctromagnetic
valves.
Cooling system
— When under sail propeller shaft can rotate 24
— Thermostatically regulated freshwater cooling
hours without engine start.
— Tubular heat exchanger with separate large vo-
— Seawater-cooled oilcooler
lume expansion tank
Accessories
— Coolant system prepared for hot water outlet
— An extensive range of accessories are available.
— Seawater strainer and easily accessible impeller
For detailed information, please see Accessory
pump
catalogs.
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

13
 Presentation

Engine Management and EVC system

Helm station Con-

trol Unit
(HCU))
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Helm station Con-

trol Unit
(HCU)

CAN bus

Power train
Control Unit
(PCU)

Engine Management
System
(EMS)

Engine Management System

The engines are equipped with common rail system To protect the engine at too high coolant or charge air
and electronically controlled injectors with an elec- temperatures and boost pressure as well as oil pres-
tronic control module. sure the monitoring system reduces the amount of
fuel (reduced engine output) until the current values
The injectors contain an electro-magnetic valve which
normalises.
sets the amount of fuel injected and the correct tim-
ing. The monitoring system measures the charge air The engine monitoring system also has a diagnostic
pressure and temperature, and calculates the avail- system, which assists users and service technicians
able air mass. This determines the maximum amount to quickly determine the cause of any malfunctions in
of fuel that can be injected (smoke limiter function). the system using the diagnostic lamp or a diagnostic
tool.
The system also limits the maximum torque available
at the engine speed registered to protect the engine Any fault is shown as a series of flashes on the diag-
from overload. nostic lamp.

14
 Presentation

Power Trim
The EVC system
The function is considerably improved compared
The Electronic Vessel Control (EVC) system is a so
to non EVC governed PowerTrim systems. EVC in-
called distributed system. The principle of a distrib-
troduces a new trim panel with the same design as
uted system is to have many small electonic units,
other EVC control panels. If you have a twin engine
called nodes, located on suitable places in the boat.
installation the stern drives can be both individually
The EVC nodes are the Powertrain Control Unit and simultaneously controlled.
(PCU) and the Helm station Control Unit (HCU).
Trimming in and out can be calibrated to suit the spe-
Nodes are located close to the components they
cific installation. To protect the drive it cannot be tilted
control. A helm node is located close to the helm. A
when engine is running above a certain rpm.
powertrain node is mounted in the engine room.
The PowerTrim control panel shall be connected to
Each node controls a number of adjacent compo-
the multilink bus and the gauge to the instrument
nents, for example sensors, controls, instruments and
cable harness from the HCU. The cable harness for
actuators.
stern drives has connectors for the power trim angle
Each PCU and HCU is programmed for a specific sensor and the power trim pump.
engine individual. On the PCU and HCU there is a
sticker with chassis no. The chassis no. shall corre- Extra optional equipment
spond to the sticker on the engine. Display
A data bus, a CAN bus, connects the nodes to each The EVC display is a complement or replacement for
other. Together they form a network and exchange the instruments. The functionality of the EVC display
information and take advantage of each others’ serv- reminds of the functionality of the EDC display but
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ices. The principle of forming a network of nodes to the information has been extended.
which all components are connected reduces wiring
radically. The EVC display must be connected to the HCU.

CAN stands for Controller Area Network, an industry Fuel level

standard for communication between nodes in distrib- EVC enables easy installation of the fuel level indica-
uted systems. tion. All you need is a fuel level sensor in the fuel tank
A distributed system supports a growing multiplicity and a fuel level gauge or a display at the helm. If a
of system configurations and optional features. New fuel level gauge is used it shall be connected to the
nodes can be connnected to the network with mini- instrument serial communication bus. The PCU–en-
mal wiring redesign. New effective functionality can gine cable harness has an input for the fuel level
be created by letting the nodes interact and combine sender.
their capabilities, creating a more useful and safe Boat speed
product.
Boat speed can be shown in a display and in a
Functionalities speedometer, if you have a NMEA 0183 compatible
GPS.
Engine speed and gear shift
Speed and gear shift contol is handled electronically.
The reverse gear or stern drive has high speed shift-
ing protection. Dual function electronic controls works
in the EVC system as well as mechanical controls
with control adapters.
Engine synchronization
Engine synchronization 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
serial comminication bus in combination with EVC
radically reduces wiring and simplifies installation.
The gauges are available with white or black dial face
and chromed or black bezel.
15
 Presentation

11
Orientation

9 10
5 7
3 6 8
4
D4 with drive, starboard
2 1. Zinc anode
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2. Cooling water intake

3. Zinc anode
4. Turbocharger
5. Crankcase ventilation filter
6. Aux Stop
7. Air filter
8. Compressor
19 9. EDC control module
10. Generator
11. Oil filler cap

11 13 15 16 18
12 14 17

D4 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
19. Expansion tank

16
 Presentation

D4 with reverse gear, starboard

1. Turbocharger
1 3
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5 2. Crankcase ventilation filter

2 4 6 3. Aux Stop
4. Air filter
5. EDC control module
6. Generator
7. Oil filler cap

16

D4 with reverse gear, port

8. Sea water pump
9. Fuel filter
10. Oil dipstick (engine)
11. Oil bypass filter 14 15
9 11
12. Oil filter 10 12
8 13
13. Starter
14. Charge air cooler
15. Oil dipstick (reverse gear)
16. Expansion tank

17
 Presentation

11

9
6 8 10
3 5
4 7
2
D6 with drive, starboard
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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
19 10. Generator
11. Oil filler cap

11 15 16
13 18
12 17
D6 with drive, port
11. Sea water filter 14
12. Sea water pump
13. Fuel filter
14. Oil dipstick
15. Oil bypass filter
16. Oil filter
17. Starter
18. Charge air cooler

18
 Presentation

6
2 3 4 5 D6 with reverse gear, starboard
1
1. Turbocharger
2. Crankcase ventilation filter
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3. Air filter
4. Aux Stop
5. EDC control module
6. Generator
7. Oil filler cap

16

D6 with reverse gear, port

8. Sea water pump
9 11
9. Fuel filter 12 13 14 15
8 10
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

19
 Instruments
This chapter describes the instrument and control panels sold by Volvo Penta for your engine.
If you want to supplement the instrumentation, 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.

Instruments
1. Tachometer
1. 2. 3. 4.

2. Voltmeter
5. 3. Oil pressure gauge
4. Temperature gauge
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5. Hours counter

Extra optional instruments

6. 7. 6. Rudder indicator
7. Fuel level gauge
8. Water level gauge

8.

20
 Instruments

Ignition lock
A tab with the key code accompanies the ignition
keys, and is used to order extra ignition keys. Do not
store the code where it is accessible to unauthorized
persons.
S = Stop position.
0 = Key can be inserted and removed.
I = System 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
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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 starting instructions in

the “Engine starting” chapter.

21
 Instruments

Alarm display
The following warning lamps should never light up during operation. On the other hand, the warning lamps light
up when the starter key is first turned to the drive position. Check that all lamps function. When the engine has
started, all lamps should have gone out. The lamps flash if the diagnostic function has registered malfunction.
When the fault has been acknowledged, the lamp gives continuous light.

Warning lamps (should never light up

during operation).

Oil pressure (red indication)

If the oil pressure lamp lights up during 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”
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Please refer to the “In case of emergency” chapter,

and you will find detailed information about recommen-
ded action in the “Diagnostic function” section.

WARNING! Continued operation when the oil

pressure is too low can cause serious engine da-
mage.

Water in fuel filter (orange indication)

If the lamp lights up, there is too much water in the wa-
ter trap in the fuel filters.
Empty the water trap underneath the fuel filter on
the engine and pre filters. Please refer to “In case
of emergency”.

22
 Instruments

Battery. (orange indication)

The battery lamp lights up if the alternator is not
charging. Stop the engine if this lamp lights up during
operation. If the lamp lights up, this can be due to a
fault in the electrical system or because the alternator
drive belt is slack.
Check the alternator drive belts. Please refer to
“Maintenance: Engine, general”.
Also check that there is no poor contact/broken wires.

WARNING! Do not continue operation if there is

any problem with the alternator drive belts. This
could cause serious engine damage.
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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 pump.
Please refer to “Maintenance: Sea water system”.
Please refer to the “In case of emergency” chapter, and
you will find detailed information about recommended
action in the “Diagnostic function” section.

WARNING! Do not open the coolant filler cap

when the engine is warm, except in emergencies.
Steam or hot fluid could spray out.

23
 Instruments

Coolant level (orange indication)

The coolant lamp lights up when the coolant level is
too low.
Check coolant level. Please refer to “Maintenan-
ce: Fresh water system”.

Red warning indication, serious fault

If the red warning indication is shown 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.
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Please refer to the “In case of emergency” chapter,

and you will find detailed information about recom-
mended action in the “Diagnostic function” section.

24
 Instruments

EVC control panel

There are two versions of the EVC control panel, one for single engine installations and another for twin installa-
tions.
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Activation button Synchronization indication

Used to activate the control panel, so that the engine The synchronization function automatically adjusts
can be started and stopped. the engines to the same speed (rpm).
Indication (red): Indication (blue):
No light: Helm station is not activated. No light: The synchronization function is not acti-
vated.
Light on: Helm station is activated.
Light on: The synchronization function is activated
Flashing: The helm station cannot be activated be-
cause the control lever is not in the neutral position Diagnostic button
or the system has been locked from another control Used if the diagnostic function has registered mal-
panel. function.

Padlock: Indication (yellow):

The padlock-symbol lights up if the helm station is No light: Normal operation.

locked manually by pressing the -button, or if gear Light on: Fault codes can be read.
is engaged during "Changing helm station while crui- Flashing: Diagnostic function has registered a mal-
sing". function.
Light on: The system is locked and the engine can Dimmer function
only be controlled from an activated control panel.
Used to light up and extinguish background lighting in
Neutral button the instruments and panels.
Used to activate de-activate the reversing gear / stern Press the button for at least 1 second to light or ext-
drive, so that the engine can be revved up. inguish background lighting. Background lighting can
Indicator (green): be adjusted in five stages, by pressing the dimmer
button.
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.

25
 Instruments

EVC-Display
Introduction
The Volvo Penta EVC-display is an instrument for indi-
cation of engine operating values. The display consists
of a computerised unit for fixed installation in a control
panel.
Indications are presented on a LCD-screen. The ope-
rator selects presentation mode using five white keys
on the front of the instrument. The four leftmost keys
allows the user to display data parameters in diffrent
ways. The right-most key allows the user to adjust the
contast/lighting or enter the configuration menu.
There is a 12-pin connector on the rear of the instru-
ment. The cable between the EVC display and the
Key 1 Key 2 Key 3 Key 4 Key 5
helm control unit (HCU) is connected here.
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EVC display top level menu structure

Key 1 Key 2 Key 3 Key 4 Key 5

Engine Multi Trip Graph Contrast/

(3 diffrent fuel (3 diffrent (Reset trip) (16 diffrent Lighting or
data) data views) Graph data) Configuration

Key 1 Key 2 Key 3 Key 4 Key 5 Key 5

pressed pressed pressed pressed pressed pressed 5 sek

Fuel rate Digital data Trip data Graph Configuration

view Contrast/
data 1 menu
lighting
-units
Press and -settings
hold key 3 -alarm status
for 3 sec -service
-system

Fuel con- Gauge data

view 1 Graph
sumption
data 2

Reset
Trip data

Trip fuel Gauge data

Graph
view 2
data 3...

26
 Instruments

EVC data parameter names and icons

Engine RPM Inlet manifold temperature

Coolant temperature Exhauste temperature

Voltage
Engine oil temperature
Fuel pressure Transmission oil pressure

Engine oil pressure Transmission oil temperature

Fuel level
Coolant pressure
Navigation based vehicle speed
Engine oil filter differential pressure
Fuel rate

Turbo pressure (actual)

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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 initialisation page will be invoked on the
display. It allows the user to choose whether to use
imperial or metric units.

27
 Instruments

Engine page
This page is always displayed after the start-up
screen. It shows the engine rpm value and boat speed
as standard gauges, a fuel computer and the fuel tank
level. The fuel tank level will only be displayed if the
relevant data is received.
Scale values for max engine rpm and max boat speed
can be set in the configuration menu, which will be de-
scribed on the following pages.
Single engine screen 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 selected in configuration menu.
The engine page will be described in detail later in this
chapter.
Twin engine screen
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Data communications failure

If the unit does not detect EVC engine data transmis-
sions the data communications failure pop-up window
will flash. Once data transmissions have been detec-
ted/restored the pop-up window will dis-appear and
normal data display will continue.

Contrast and lighting control

Press key 5 (the rightmost button) to access the ligh-
ting and contrast menu. Then press relevant keys to
adjust levels and press exit to store these settings.
The display unit has 5 lighting levels.

28
 Instruments

Configuration menu, key 5 (the rightmost

key), held for > 3s
The configuration menu allows the user to;
- adjust various functions/settings
- calibrate various parameters
- get various kind of information from the EVC system
Note! The port engine or both engines have to have
ignition on when settings are made or when resetting
data.

Configuration menu structure

Unit Speed KTS MPH KM/H

Pressure kPa/PSI
Volume L GAL IGAL
Temperature ºF/ºC

Settings Language 8 available

Bleep On, off
Engine PORT, STBD, TWIN,
SINGLE
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Display 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 HRS, 4 HRS, 8 HRS
Calibration Depth Depth alarm
Alarm depth
Alarm status Depth offset
Alarm status page
Fuel Fuel alarm
Service Adjust and reset service Fuel level
Speed Speed calib. page
System Demo
Restore defaults Imp/Met units
Com viewer
Prog tx
About
EVC About

Units
The units page allows the user to choose which
units to display.
- Speed: KTS, MPH, KM/H
- Distance is adjusted according to speed unit:
NM, MILE, KM
- Pressure: kPa, PSI
- Volume: LITRE, GAL, Imperial GAL
- Fuel rate: is adjusted according to volume unit:
L/H, GAL/H, IGAL/H
- Temperature: ºC (CELSIUS), ºF (Fahrenheit)

29
 Instruments

Settings
The settings page allows the user to set various op-
tions for the functional operation of the unit and to
calibrate various parameters.
- Language: 8 different languages are available
- Bleep: Keys are bleeping when pressed (on/off)
- Engine: Defines the engine source (Port, Stbd or
Twin)*
- Display: Set the range of boat speed and engine
rpm gauges. Rpm engine: [2500 rpm: 9000 rpm]
step 500 rpm
- Engine: Defines the engine source (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
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later on in this chapter.)

-Depth: Depth alarm, alarm depth, depth offset.
-Fuel: Fuel alarm, fuel level
-Speed: Speed calibration

Alarm status
The alarm status page views the current active
alarms list screen. The same screen that is active
when an alarm is first received. Please refer to chap-
ter "In case of emergency" section "Diagonstic func-
tion".

Service
The service page allows a time period to be set be-
fore the next service is required. Ensure that all units
have the same service interval indicator.
When a service interval is reached, a pop-up window
will be displayed. This service indicator will only ap-
pear when the unit is first switched on and will remain
for approximately 10 seconds.
When the service has been completed, return to the
service menu and press hold reset button to reset
the service hours.

30
 Instruments

System - Prog. tx: Transfers the contents of the application

The system configuration page allows to set various program on flash memory to other CANtrak units
options for the operation of the unit: on the same CANbus link
- Demo: Switches the demo mode on/off. The unit is - About: Displays the following information
in the normal operation mode when demo is off ID no: Serial number of the display
- Restore defaults: Eeprom: Number of write on Eeprom
Allows the resetting of all information in the confi- Vers: Software version number
guration settings to a set of default values (imperial Chk: Flash memory checksum
or metric). Sends the request to change settings
Part no: Volvo software part number
message with a set of valid pre-determined values
for the configuration. Source: Display the source of received data
- Com viewer: Displays latest messages received Label: Allocated Label on the bus. Each unit on
on communication ports the same bus should have a different label
- EVC About: Shows information about the EVC-
system and the VIN (Vehicle Identification Number)

The system menu below showing access to “EVC About” screens.

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Port configuration screens

31
 Instruments

Engine page, key 1

This page is always displayed after the start-up
screen. It shows the engine rpm value and boat speed
as standard gauges, a fuel computer and the fuel tank
level. The fuel tank level will only be displayed if the
relevant data is received.
Scale values for max engine rpm and max boat speed
can be set in the configuration menu.
The lower display window provides access to fuel
Single engine screen 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 selected in configuration menu.
If boat speed is not available the display will show
coolant temperature rather than “no data”.

Double engine screen

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Note! This screen is the default screen

Menu fuel consumption

Key 1
pressed

Fuel rate (L/hr)

Fuel Consumption (L/N.M.) – If boat speed is available > 2kts

Trip Fuel (L)

Note! If the data is not available the parameter will not be selectable

32
 Instruments

Multi page, key 2

The page shows data parameters displayed in four
data windows. 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.
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33
 Instruments

Adjusting display parameters

This page has an adjust mode which provides for any
available parameter to be displayed in any of the four
data windows.
The adjust mode is entered by pressing key 5 (the
rightmost key) when the pop-up menu is visible.
Note! If the data is not available the parameter will
not be selectable.
Note!

Single engine screen On the graphic display:

Press key 5 to enter the adjust mode
The 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.
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Twin engine screen

Single engine screen

Keys 1 to 4 will adjust the corresponding window
(as highlighted in black)

Twin engine screen

34
 Instruments

Trip page, key 3

The page displays:
- Trip fuel used since last reset
- Instantaneous fuel rate (volume of fuel used per
hours)
Or instantaneous fuel rate (volume of fuel used per
distance, if speed available)
- Trip engine hours since last reset
Single engine screen - Total engine 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 beco-
mes too large to fit.
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Twin engine screen

35
 Instruments

Graph page, key 4

By repeatedly pressing key 4, the data parameters will
be displayed with a historic graph:
If a data parameter is not available, that particular
screen will not be selectable.
If the data is lost, whilst in the screen, then the graph
line will just stop drawing but continue to scroll across
the screen.
Port or single engine data will be drawn as a black
Single engine graph screen
(showing engine speed)
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.
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Twin engine graph screen

(showing engine speed)

36
 Instruments

Depth alarm functions

All deph alarm functions are accessed through the
CONFIGœSETTINGSœCALIBRATION menu as des-
cribed below.
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.
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37
 Instruments

Depth alarm unacknowledged pop-up

The depth alarm un-acknowledged pop-up will appear
and flash if the depth alarm is enabled and enabled
active state is transmitted from the EVC-unit. The
display buzzer will also sound as for standard EVC
alarms. All standard EVC-system alarms will have
priority over the depth alarm. Pressing any key will in-
stigate a depth alarm acknowledge.

Detph alarm unacknowledged pop-up screen showing depth

When acknowledged
by pressing any button

Depth alarm 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.
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Depth alarm acknowledged pop-up screen showing depth

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 a slow rate.

Depth alarm signal loss pop-up screen

38
 Instruments

Fuel level/ alarm functions

All fuel alarm functions are accessed through the
CONFIGœSETTINGSœCALIBRATION menu as
described below.
Note! The port engine or both engines have to
have ignition on when settings are made or when
resetting data.

Fuel alarm
The Fuel Alarm can be switched ON/OFF.

Fuel level
The fuel level system is calibrated as follow.
Position the fuel level sensor in appropriate ”empty”
position and press ”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
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buzzer sounds.
If the display is configured for a twin engine instal-
lation then the ”PORT/STBD” key is displayed to
allow the tank on either side to be calibrated.

The extra key 3 appears if the display is configured

as either a port, starboard or twin engined display.
The ‘FUEL’ title is modified to show the current
engine selected for the fuel alarm ‘ON/OFF’ function.

39
 Instruments

Fuel alarm un-acknowledged Pop up

The fuel level alarm un-acknowledged pop-up will ap-
pear and flash if the fuel level alarm is enabled and
enabled active state is transmitted from the EVC-
unit. The display buzzer will also sound as for stan-
dard EVC alarms. All standard EVC-system alarms
as well as depth alarm will have priority over the fuel
level alarm. Pressing any key will instigate a fuel level
alarm acknowledge.
The display shows the actual fuel 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 alarm acknowledged Pop up

The fuel level alarm acknowledged pop-up will appear
constantly if the fuel level alarm is enabled. This will
show the percentage of fuel remaining value until the
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enabled inactive message is received from the EVC-

unit.

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 flash at a slow rate.

40
 Instruments

Speed Calibration
Speed Calibration function are accessed via the CO
NFIGœSETTINGSœCALIBRATION menu described
below.
Note! The port engine or both engines have to have
ignition on when settings are made or when resetting
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.
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Once adjustment value is reached, the data is stored

by pressing “BACK” key.

41
 Controls
This chapter describes the instrument panels sold by Volvo Penta for your engine. If your boat is equipped with
controls which are not described here and you feel uncertain about the function, please contact the dealer you
purchased the boat from.

Single lever control. Electronic

Operation
Both the shift function and engine speed control are con-
trolled using the single lever control.
N = Neutral position (reverse/stern drive is disengaged and
the engine runs at idle speed).
F = Reversing gear/stern drive engaged for movement
ahead.
R = Reversing gear/stern drive engaged for movement
astern.
T = Adjustment of engine speed.
NOTE! The engine can only be started if the Control lever
is in the neutral position.
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Disengaging the shift function

The shift function can be disengaged so that the control
lever only affects the engine speed.
1. Move the lever to the neutral position (N)
2. Press the neutral button (N) in and hold it down while
moving the control lever forward to the shift position
(F).
3. Release the neutral button. The green indicator begins
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.

42
 Controls

Friction brake
The control has a friction brake which can be adjusted as
necessary to provide lighter or heavier lever action.
Adjusting the friction brake:
1. Stop the engine.
2. Mover the control lever forwards so that the groove in
the hub of the control lever is accessible.
3. Position a screwdriver in the groove and remove the
plug.
4. Adjust the friction brake (8 mm wrench):
Clockwise = heavier lever action
Counter clockwise = lighter lever action.
5. Reinstall the plug.
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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 drive engaged for movement astern.
T = Adjustment of engine speed.
NOTE! The engine can only be started if the Control le-
ver is in the neutral position.

43
 Controls

Two lever control. Mechanical

Operation
The two lever control has separate levers for shifting (1) and
A speed control (2).
The control has a neutral position switch that only allows the
engine to be started with the reversing gear in 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):

B Engine speed control.
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A 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-
clockwise (–) for lighter lever movement.

44
 Power Trim
Your Volvo Penta drive is equipped with a hydraulic trim system, Power Trim, with which you can change the
angle of the drive in relation to the transom. This will affect the running position of the boat and make it possible
to optimize boat handling in various conditions.
Power Trim is operated from the control position using the panels, controls and instruments described in this
chapter. The ”Running” chapter will provide more information on running with Power Trim.

WARNING! Avoid extreme trimming of the drive as it may have a negative effect on steering ability.

Power Trim Control Panel

This control panel is used for both single and twin
engine installations. The current position of the drive is
shown on the trim instrument, refer to the ”Trim instru-
ment” chapter.
For twin engine installations, the control panel can be
1 used to make individual or simultaneous adjustments
2 3 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-
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rizontal axis and trimming in the drive will “lower” the

5 6 bow of the boat.
4
Trimming out the drive
Press in button 1 on the control panel to raise the bow
of the boat (drive trimmed out).
In twin engine installations, both drives can be opera-
ted simultaneously by pressing button 1.
The drives can be operated separately by pressing
1
button 2 on the control panel for the port drive and
button 3 for the starboard drive.
4
Trimming in the drive
Press in button 4 on the control panel to lower the
bow of the boat (drive trimmed in).
In twin engine installations, both drives can be opera-
ted simultaneously by pressing button 4.
The drives can be operated separately by pressing
button 5 on the control panel for the port drive and
button 6 for the starboard drive.

45
 Power Trim

Trim ranges
In order to utilize the information gained from the
trim instrument, it is essential to know about the dif-
ferent trim ranges and their uses. There are three trim
ranges:

Trim range
The trim range is used to obtain the best comfort at all
running speeds (from start to maximum speed).

Beach range
The beach range is used for running at reduced
speed in shallow water or where water depth is un-
certain.

WARNING! Max. permitted engine speed when

running in beach range is 1500 rpm. Make sure
the drive’s coolant inlet is never trimmed out of
the water.

Lift range
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Lift range is used to lift the drive to maximum height,

but not when running. 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 drive
2 angle* is between +6° and +30° (Beach range). LED
1 (1) lights orange.
While the drive angle* is over +30° (tilt range), the
LED (2) will light red. No text in display window.
*The number corresponds to the drive angle in relation to the ho-
rizontal (stationary boat). The lowest value shows that the drive is
at max trim in and the highest value that the drive is raised to max.
Observe that the lowest value can vary from boat to boat depending
on the angle of the transom.

46
 Power Trim

3 Analogue trim instrument

This instrument shows the current position of the
2 drive. Beach range is marked with an orange zone and
lift range with a red zone.
1. Trim range.
2. Beach range (orange).
1 3. Lift range (red).
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47
 Starting the engine
Make it a habit to give the engine and engine bay a visual check before starting. This will help you to discover
quickly if anything abnormal has happened, or is about to happen. Also check that instruments and warning dis-
plays show normal values after you have started the engine.
To minimize starting smoke in cold starting, we recommend that a heater should be installed to warm the engine
bay at temperatures below +5°C.

WARNING! Never use start spray or similar products as a starting aid. Explosion risk!

Before starting
L Open the fuel tap
L Open the sea cock (reverse gear)
L Do the tasks under the “Daily before first start”
heading in the maintenance schedule.
L Turn the main switches on.
IMPORTANT! Never disconnect the current
with the main switches when the engine is
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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. The engine management system en-
sures that the engine receives the correct amount of
fuel - even when the engine is cold.
The engine is pre-heated by the engine control unit,
which allows the engine to crank several revolutions
with the starter motor before fuel is injected. The
colder the engine is, the more revolutions the engine
makes. This raises the temperature in the combustion
chambers, which ensures reliable starting and redu-
ces starting smoke.
The idling speed is also governed by engine tempe-
rature, and is somewhat raised after a cold start.

48
 Starting the engine

Starting method
Put the reverse gear/stern drive in neutral
Put the reverse gear in neutral by moving the control
lever(s) to neutral at all control positions.
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. Stop cranking if the engine does not start with in
20 sek.
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Check the warning lamps and LEDs

Each time 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 activated control board. Press the
activation button for a second to lock the system. The
padlock sign lights up in confirmation.
Unlock the system by pressing the activation button
for one second. This can only be done from an acti-
vated control panel.

49
 Starting the engine

Start the engine

Start using the ignition switch
Turn the key to position III. Release the key and let it
key spring back to position I as soon as the engine
has started.

Starting with the starter button

Press the starter button. Release the button as soon
as the engine has started. Please note that if you start
from an alternative control station, the starter key at
the main control station must be in position I.

Overheating protection
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

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engine up
Allow the engine to idle for the first ten seconds, and
check that instruments and warning displays show
normal values. Check that no warning lamps flash on
the alarm display.
Then warm the engine up at low speed and low load,
so that reaches normal operating temperature before
full power is used.

IMPORTANT! Never race the engine when it is

cold.

50
 Operation
Learn to handle the engine, controls and other equipment in a safe and correct manner before you cast off on
your maiden voyage. Remember to avoid sudden or surprising rudder movements and gear shifting. There is a
risk that passengers could fall over, or overboard.

WARNING! A rotating propeller can cause severe injury. Check that there is nobody in the water before
you engage forward / aft drive. Never drive close to bathers or in areas where you could reasonably expect
that people could be in the water.
Reading the instruments
Read all instruments and alarm displays directly after star-
ting, and then regularly during your voyage.

Oil pressure
The oil pressure gauge should normally indicate between
3-5 bar. It will indicate a somewhat lower value when id-
ling.
If the oil pressure is too low, the audible warning will sound
automatically at the same time as the lamp in the warning
display will flash.

Coolant temperature
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The temperature gauge should normally indicate between

75– 95°C (167-203°F) 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 panel will start to flash.
The diagnostic button LED will flash rapidly and the dis-
play will show a pop-up screen with a warning icon.
1. Reduce engine speed to idling.
2. If a EVC-display is mounted, press any key to enter
the alarm list and then press acknowledge button on
the display.
3. The alarm can also be acknowledged by pressing the
Diagnos button on the control panel once.

When the fault has been acknowledged, the lamp con-

cerned gives constant light and the audible warning will
become silent.
Please refer to the “In case of emergency” chapter, and
you will find detailed information about recommended ac-
tion in the “Diagnostic function” section.
The fault will also be stored in the form of a fault code for
as long as the malfunction remains. It is possible to read
the fault code during a subsequent service.

51
 Operation

Cruising speed
Avoid operation at full throttle, for best fuel economy. We
recommend a cruising speed which is at least 10% below
the maximum engine speed at full speed (full throttle). The
maximum engine speed will vary due to propeller choice,
load and sea conditions, but it should be in the full throttle
range.
Full throttle range:
D4 ...................................................... 3400–3600 rpm
D6 ...................................................... 3400–3600 rpm

If the engine does not reach the full throttle range, this
could be caused by a number of factors which are noted
in the “Fault tracing” chapter. If the engine speed exceeds
the full throttle range, select a coarser pitch propeller. Ask
your Volvo Penta dealer for advice.
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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 starboard engine is automatically adjus-
ted to that of the port engine. The synchronization function
is activated automatically if the following conditions are met.
1. The engine speed levers for both engines are in (approx-
1
imately) the same position.
2. The engine speed on both engines must exceed 800
rpm.
NOTE! The synchronizer is disengaged as soon as the
conditions are no longer met.

52
 Operation

Changing the helm station

The first time you change control panel after starting the
EVC system, a bulb check is done automatically. All LEDs
and bulbs light up for 2 seconds.
1 1. Check that the control lever(s) is (are) in neutral on
both the control panel you leave and on the new con-
trol panel.
2. Check that the EVC system is not locked.
3. Press the activation button (1) for at least one second.
When the button is released, the indication lights up to
confirm that the control position is activated.
4. Press the activation button (1) for a further second to
lock the EVC system. The padlock sign lights up in
confirmation. Unlock the system by pressing the ac-
tivation button for one second. This can only be done
from an activated control panel.
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Changing helm station while cruising

(optional extra)
This function must be enabled to permit the control panel
to be changed during operation. The function can only
be enabled by authorized Volvo Penta personnel. Please
contact your Volvo Penta dealer.
1. Press the activation button (1) to unlock the system.
The padlock sign goes out on all control panels to in-
dicate that it is possible to change control panel.
2. The control lever on the alternative control panel must
be in neutral before it is possible to change control pa-
nel.
3. Press the activation button (1) on the alternative con-
trol panel. The activation button indication flashes on
the alternative control panel, and on the main control
panel it gives constant light.
4. The alternative control panel becomes active when
the correct gear and approved engine speed is de-
manded. The activation 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.

53
 Operation

Operation
Shifting between forward and reverse should be done at
idling. Shifting at higher engine speeds can be uncom-
fortable for passengers and cause unnecessary stress
on the stern drive/reversing gear, or cause the engine to
stop.
If you attempt to shift gear at an excessive engine speed,
1 a safety function cuts in automatically, and delays shifting
until engine speed has fallen to 1500 rpm.
Always do a forwards/reverse operation as follows:
1. Reduce engine speed to idle and let the boat more or
less lose way.
WARNING! Never shift to reverse when the boat
is planing.
2 2. Move the control lever to neutral with a rapid, distinct
movement. Make a brief pause.
NOTE! A beep will sound to indicate that the control
lever is in neutral.
3. Then move the control lever to reverse with a rapid,
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distinct movement and increase engine speed.

IMPORTANT! If the boat has twin engines, it is
important that both should be running during
3 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 different speeds, with varying loads, and in a
range of wind and sea conditions.
Power Trim settings and adjustment are controlled
from the helm position using the controls and instru-
ments described in the Power Trim section.

WARNING! Avoid over-trimming the drive sys-

tem as this can adversely effect the steering of
the boat severely.
The engine must not be run with the drive in the
“Lift” range.

IMPORTANT! Avoid running with the drive fully

trimmed for long periods (when planing). Apart
from excessive fuel consumption this can cause
cavity damage to the propeller(s).

54
 Operation

Operating with the drive in the Trim range

The Trim range is used to achieve maximum comfort
under normal operation at all speeds from start to
maximum speed.
Since every boat has its own unique characteristics
and will be effected in different ways by the factors in-
volved, only general advice is given here on how to get
the best trimming angle for your boat. It can generally
be said that when the boat feels well-balanced, easy
to steer and pleasant to operate, then that is the opti-
mal trim angle for the boat.
To familiarize yourself with the Power trim, make test
runs at slower speeds and at various trim positions to
see the effect ot trimming. Note the time it takes for the
boat plane. Watch the tachometer and speedometer
readings and the ride action of the boat.

When starting
Trim the drive in. The bow will be pressed down and
the boat accelerates faster. This gives improved run-
ning and steering characteristics at speeds below the
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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’s bow will tend to go deeper into
the water. If the boat is operated at high speed and/or
against high waves, the bow of the boat will plow into
the water. The boat may tend to bow steer or spin
about rapidly and possibly eject occupants.

IMPORTANT! The boat trim should be adjusted

to provide balanced steering as soon as possible
each time you get underway. Some boat, engine,
and propeller combinations may encounter boat
instability and/or high steering torque when ope-
rated at or near the limits of the “bow-up” or “bow-
down” positions. Boat stability and steering torque
can also vary due to changing water conditions.
If you experience boat instability and/or high ste-
ering torque, see your Volvo Penta dealer to cor-
rect these conditions.

55
 Operation

At planing speed
Trim the drive out to the operating position which pro-
vides the most stable and comfortable running.
If the boat has twin motors the drives can be trimmed
with different angles to compensate for side winds
and to a certain extent compensate for uneven load-
ing on one side of the boat or the other.

Operating in “Bow-up” Position

The “bow-up” position is normally used for cruising,
running with a choppy wave condition, or running at
full speed. In a full “bow-up” position the boat may
tend to self-steer. You may have to compensate with
the steering wheel to keep the boat in a straight-
ahead path. In this position the boat’s bow will tend to
raise clear of the water. Excessive “bow-up” trim will
cause propeller ventilation resulting in propeller slipp-
age. Engine RPM will also increase, but boat speed
will not increase and may even drop.

IMPORTANT! Use caution when operating in

rough water or crossing another boat’s wake.
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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 increase in the position that gives the
highest engine speed. The throttle opening can then
be slightly reduced to retain the original speed.

In choppy seas or running against a heavy sea

Trim drive so the bows drop. This will provide more
comfortable running. See section "Operating in Bow-
down Position"

Operating with the drive in the Beach

range
The beach range is used for operation at reduced
speed in shallow water or where water depth is un-
certain.

IMPORTANT! Max. permitted engine speed

(rpm) when running in the “Beach range” is 1
500 rpm. Check that drive is never trimmed so
that the cooling water intake is out of the water.

56
 Operation

Running aground
The automatic Kick-up function releases the drive if it
grounds or hits an object in the water. If the function
has been tripped and the drive released it must be
trimmed back to the original position using the control
buttons.

IMPORTANT! The Kick-up function only protects

the drive when running ahead (forwards). There
is no protection for the drive while running astern
(backward).

Check after running aground that the drive or propel-

ler are not damaged or if there are vibrations from
the drive. If this is the case then the boat (if possible)
should be run to harbor at reduced speed and taken
out of the water.
Take the boat out of the water. Check the oil level in
the drive. If 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
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and test drive. If there are still vibrations it must be in-

spected by an authorized Volvo Penta workshop.

IMPORTANT! To prevent galvanic corrosion any

damage to the paintwork on the drive and propel-
ler must be repaired before launching the boat:
See section “Laying up/Launching”.

Control of parallel strut

WARNING! If the parallel strut shows signs of
damage, run at reduced speed to harbor. The
parallel strut is a vital safety component, damage
may affect steering characteristics. 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.

57
 Stopping the engine
The engine should be run for a few minutes at idle (in neutral) before turning it off. This will avoid boiling and
even out the temperature. This is especially important if the engine has been operated at high engine speeds
and loads.

Stopping
Turn the key to stop position “S”. Keep the key turned until
the engine stops. The key will automatically return to the
“0” position when it is released and can then be removed.

Auxiliary stop
If the engine cannot be stopped in a normal procedure, it
is possible to stop the engine via auxiliary stop mounted
on the side of the engine.

After stopping the engine

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L Close the fuel cock and sea cock (reverse gear) for the
cooling water intake.
IMPORTANT! 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 switches if the boat is not to be
used for some time.
IMPORTANT! Never break the circuit with the
main switches while the engine is running. This
could damage the generator.

Laying up
If the boat is not going to be used for some time but is be-
ing left in the water, the engine must be run to operating
temperature at least once every 14 days. This prevents
the corrosion in the engine. If the boat will not be used for
more than two months then inhibiting should be carried
out: Refer to section “Laying up/Launching”.

58
 Stopping the engine

Cold weather precautions

To prevent freezing damage, the seawater system must
be drained and the freshwater system coolant must have
sufficient antifreeze protection. Refer to the cooling system
section in chapter “Maintenance”.

IMPORTANT! A poorly charged 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 differences be-
tween different countries’ trailer laws.
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It is possible to trim the drive without starting the engine.

IMPORTANT! The engine must not be run with the

drive in the “Lift” range. Before transporting the boat
by trailer always secure the drive in the lift position
with a Trailer Kit (accessory) or similar, so that it can-
not drop down.
Boats with reverse gear: Drain water out the exhaust
pipes to prevent water entering the engine when trans-
porting the boat by trailer.

Laying up on land
Where boats are kept laid up on land when not in use, for
example, trailer boats, there is a lower level of galvanic
corrosion protection due to oxidation on the sacrificial an-
odes. Before launching the boat the sacrificial anodes on
the drive and shield must be cleaned with emery paper to
remove any oxidation.

IMPORTANT! Do not use a wire brush or other steel

tools when cleaning, as these may damage the gal-
vanic protection.

59
 Maintenance schedule
General information
Your Volvo Penta engine and its equipment are designed for high reliability and long life. They are built to
withstand a marine environment, but also to have the smallest possible environmental impact. If given preventive
maintenance, according to the maintenance schedule, and if Volvo Penta original spares are used, these quali-
ties are retained and unnecessary malfunctions can be avoided.

Warranty inspection
During the first period of operation, the specified warranty inspection “First service inspection” must be done by
an authorised Volvo Penta workshop. Instructions about when and where this should be done are found in the
Warranty and service book.

Extended Protection
Volvo Penta offers an Extended Protection for your marine diesel engine, including transmission, if used for
pleasure use only. To be valid a Extended Protection service has to be performed at the owners cost and ex-
pense by an authorized Volvo Penta distributor, dealer or workshop before the expiry of the 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.
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IMPORTANT! Maintenance points marked must be done by an authorised Volvo

Penta workshop.

Daily, before first start:

L Engine and engine room. General inspection................................................ page 63
L Engine oil. Check level................................................................................... page 68
L Coolant. Check level ...................................................................................... page 72
L General inspection of drive, propeller, shield, steering.
Leakage and function check......................................................................not shown

Every 14 days:
L Drive belts. Check for wear. Change as required........................................... page 65
L Sea water filter. Clean.................................................................................... page 74
L Battery. Check electrolyte level...................................................................... page 81
L Reverse gear. Check oil level......................................................................... page 85
L Outboard drive. Check corrosion protection .................................................. page 87
L Outboard drive. Check oil level ...................................................................... page 88
L Outboard drive. Power Trim pump. Check oil level......................................... page 89
L Outboard drive. Servo pump. Check oil level ................................................. page 91
Do a visual check of the alignment between the stern drives....................not shown

Every 50-200 hours / at least once a year, included in extended protection:

L Engine oil. Change1) ..................................................................................... page 68
L Oil filter. Change 2) ........................................................................................ page 69
L Outboard drive. Check/Adjust drive alignment .............................................. page 92

60
 Maintenance schedule

Every 200 hours / at least once a year, included in extended protection:

L Crankcase ventilation filter. Change .............................................................. page 64
L Air filter. Change ............................................................................................ page 64
L Exhaust pipe. Check...................................................................................... page 65
L Drive belts. Check belt tension ...................................................................... page 65
L Compressor. Check oil level .......................................................................... page 66
L Sea water pump. Check impeller ................................................................... page 73
L Sacrificial anodes. Charge air cooler, heat exchanger. Check....................... page 75
L Fuel filter/ fuel pre-filter. Change ................................................................... page 77
L Reverse gear. Change oil and filter ............................................................... page 85
L Outboard drive. Change oil 3) ........................................................................ page 88
L Outboard drive. Check exhaust bellows ........................................................ page 89
L Clean and touch up the paintwork as required...........................................not shown
Inspection of exhaust hose and cooling water hoses. ..............................not shown
– Check hoses/pipes, unions and hose clamps
Check the condition of all rubber hoses, and re-tighten hose clamps ........not shown
Outboard drive. Change universal joint bellows..........................................not shown
Thoroughly inspect all hydraulic hoses and fittings for signs of leaks,
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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 leakage ..........not shown
Outboard drive. Check for function and wear ............................................not shown
– Bushes/shaft stubs in shield and suspension fork
– Propellershaft seal
– Propellershaft (check straightness)
– Gear change mechanism and control cable
– Steering

1)
Oil change intervals vary, depending on engine type oil grade and sulfur content of the fuel. Please refer
to page 67.
2)
Change the filters during each oil change.

3)
IMPORTANT! In operation situations where the number of forward-reverse operations averages
more than 20 per hour, the oil should be changed every 100 hours.

61
 Maintenance schedule

Every 1200 hours / at least every 5 years:

L Drive belts. Change ....................................................................................... page 65
Drive belt, compressor. Change .................................................................not shown
L Compressor. Change oil ................................................................................ page 66
Heat exchanger. Inspect/Clean...................................................................not shown
Intercooler. Inspect/Clean...........................................................................not shown
Control cables and seals. Change..............................................................not shown
Inspect exhaust hose and cooling water hoses. .......................................not shown
– Check hoses/pipes, unions and hose clamps
Safety and function check ..........................................................................not shown
– In a safety and function check, the outboard drive is disassembled to check for 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.
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Change as required....................................................................................not shown

Outboard drive. Perform pressure check ...................................................not shown

1)
Oil change intervals vary, depending on engine type oil grade and sulfur content of the fuel. Please refer
to page 67.
2)
Change the filters during each oil change.

3)
IMPORTANT! In operation situations where the number of forward-reverse operations averages
more than 20 per hour, the oil should be changed every 100 hours.

62
 Maintenance
This chapter describes how to carry out the above maintenance. Read the instructions carefully before starting
work. Maintenance intervals are contained in the chapter above: Maintenance schedule

WARNING! Read the safety precautions for maintenance and service in the chapter: Safety Information,
before starting work.

WARNING! Unless otherwise specified all maintenance and service must be carried out with the engine
stopped. Stop the engine before opening or removing engine hatches. Immobilize the engine by removing
the ignition key, turning off the power supply with the main switch.

Engine, general
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General inspection
Make a habit of “visually” inspecting the engine and
engine 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 operating disturbances and costly
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.

IMPORTANT! If an oil, fuel or coolant leak is de-

tected, the cause must be investigated and the
fault rectified before the engine is started.

IMPORTANT! Never point high-pressure water

jets directly at seals, rubber hoses or electrical
components. Never use the high-pressure func-
tion when washing the engine.

63
 Maintenance: Engine general

Changing air filter

Remove the air filter cover. Remove the old air filter.
Clean the air filter cover/housing if necessary. Take
care not to allow impurities to enter the engine. Fit the
new air filter and the air filter cover.
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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.

64
 Maintenance. Engine general

Checking exhaust line

The exhaust line of drive installations must be in-
spected every year with respect to corrosion between
the hose (1) and the pipe (2).

WARNING! Risk of water entering. The exhaust

3. line must be inspected while the boat is on land.
5.
1. In case of serious corrosion damage, the pipe
must be repaired or replaced with a new one.

To check: Undo the clamps (3) and (4) holding the

hose (1). Detach the hose. Check the contact surface
(5). In case of serious corrosion damage, the pipe
must be repaired or replaced with a new one.
4.

2.
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Checking drive belts

WARNING! Stop the engine before commen-
cing maintenance work.

General
Check belt 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 driven
by a poly-V belt for optimum function and service life.
Change/tension the belt as follows:
1. Undo the bolts (1) on the tensioning roller brack-
et. Remove and change the belt if necessary.
2. Tension the belt to apply a torque of 70 Nm on
the tensioning roller square fitting (2). Secure the
tensioning roller with the bolts (1). The bolts must
be torque tightened to 50 Nm.
3. Undo the bolts (1) when warm and repeat the belt
tensioning procedure.

65
 Maintenance: Engine general

Compressor. Checking oil

Checking and topping up
Unscrew and remove the dipstick. Wipe off oil. Screw
the dipstick down fully and then remove it again.
Check that the level oil is between the markings. If the
dipstick is not screwed down fully the oil level will be
slightly above the MIN marking 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 oil dipstick. Remove the plug (1) and let the oil run
out. Reinstall the plug and fill with oil to correct level
as above.
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66
 Lubrication system
IMPORTANT! With a new or reconditioned engine, the oil and oil filters must be changed after 20–50
hours of operation. Use only the recommended grades of oil.

Oil change intervals can vary from 50 to 200 hours, depending on engine type, oil grade and sulphur con-
tent of the fuel. Note that oil change intervals must never exceed a period of 12 months. If you want
longer oil change intervals than given in the table below, the condition of the oil must be checked by the oil
manufacturers through regular oil testing.

Sulfur content in fuel, by weight

< 0,5 – 1,0 % > 1,0 %3)

Oilgrade1) Oil change interval, reached first in operation

All engines: 200 h / 12 months 100 h / 12 months

VDS-2 and ACEA E7 2)
or VDS-2 and Global DHD-1
or VDS-2 and API CH-4
or VDS-2 and API CI-4
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1)
When oil quality specifications are joined by “or” (Type 1, 2 and 3), either engine oil specification can be
used.
When oil quality specifications are joined by “and” (Type 2 and 3), the engine oil must fulfill both require-
ments.
2)
ACEA E7 has replaced ACEA E5, but if available ACEA E5 can be used.
3)
If sulphur content is > 1.0 % by weight, use oil with TBN >15.

NOTE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the quality
requirements above.
VDS =Volvo Drain Specification
ACEA = Association des Constructeurs Européenne d’Automobiles
API = American Petroleum Institute
Global DHD = Global Diesel Heavy Duty
TBN = Total Base Number

30 20 10 ±0 +10 20 30 40
Viscosity
o
C Select the viscosity from the table below.
15oC SAE 15W/40 Note. The temperature values refer to stable ambient
temperatures.
25oC SAE 10W/30
1 * Refers to synthetic or semi-synthetic oils.
SAE 5W/30
10oC SAE 20W/30
±0oC SAE 30 Oil change volume
+10oC SAE 40 Please refer to the “Technical Data” chapter.

o
22 4 14 32 50 68 86 104 F

67
 Maintenance. Lubrication system

Checking and topping up oil level

The oil level should be within the marked area on the dip-
stick (1) and should be checked every day before the first
time the engine is started.
Topping up is done on the top of the engine. Top up oil
slowly. Wait a few minutes before checking the oil level
again to give the oil time to run down to the oil pan. Then
check the level again. Use only the recommended grades
of oil: See the chapter “Technical Data”.

IMPORTANT! Do not fill the oil above the MAX level.

NOTE! Between MAX and MIN there are apporx. 1,5 liter
(0,4 US gals) for D4 and 3,5 liter ( 0,9 US gals) for D6.

Changing engine oil

Always observe the recommended oil change interval.
1. Start the engine (this makes it easier to suck the oil
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up from the sump). Let the engine run till operation

temperature is reached (temperature gauge indicate
a value between 75– 95°C (167-203°F)). Then stop
the engine. Wait ten minutes 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 volume).
IMPORTANT! Only use a recommended grade of
oil (please refer to previous page).
5. Start the engine. Check that the low oil pressure
warning lamp goes out and that no leakage occurs by
the filters.
Let the engine run till operation temperature is
reached (temperature gauge indicate a value be-
tween 75– 95°C (167-203°F)).
IMPORTANT! The oil level check must be done
on a warm engine. If the oil is cold it will take very
long time for the oil to flow back into the oil sump.

WARNING! Working with, or going close to a run-

ning engine is a safety risk.Watch out for rotating
components and hot surfaces.
6. Stop the engine. Wait ten minutes before checking the
oil level. Top up if necessary.

NOTE! Hand the old oil in to a re-cycling station.

68
 Maintenance. Lubrication system

Changing oil filter and bypass filter.

Change the oil filter and bypass filter during each oil
change.
Remember to hand the old filters in to a re-cycling station.

WARNING! Hot oil and hot surfaces can cause

burns.

1. Put a suitable vessel underneath the filters to

avoid oil spillage.
2. Clean 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 turn.
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7. Start the engine (low idle) and check that no leak-

age occurs. Check the oil level once the engine
has stopped.

69
 Freshwater system
The fresh water system is the engines’ internal cooling system, which ensures that the engine operates at the
correct temperature. It is a closed circuit system and must always be filled with a mixture of at least 40 % con-
centrated coolant and 60 % water to protect against internal corrosion, cavitation and damage caused by freez-
ing.
We recommend that you use “Volvo Penta Coolant, Ready Mixed”, alternatively “Volvo Penta Coolant”
(concentrated) mixed with pure water according to spec, see “Coolant. Mixture”. Only coolant of this quality is
suited too and approved by Volvo Penta.
The coolant should contain ethylene glycol of a good quality with a suitable chemical consistency for an ade-
quate protection of the engine. Using anti-corrosion aditive exclusively is not permitted in Volvo Penta’s engines.
Never use water by itself as coolant.

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 less effective after a time, which means that the coolant must be re-
placed, see “Service schematic”. The cooling system should be flushed out at the same time as the coolant is
replaced, see “Cooling system. Flushing”.
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“Volvo Penta Coolant” is a concentrated coolant that

is to be mixed with water. It has been developed to
function optimally with Volvo Penta’s engines and pro-
vides excellent protection against corrosion, cavitation
and frost damage.

“Volvo Penta Coolant, Ready Mixed” is a ready-

mixed coolant, 40% “Volvo Penta Coolant” and 60%
water. This concentration protects the engine against
corrosion, cavitation damage and freezing conditions
down to -28 °C (18°F).

70
 Maintenance. Freshwater system

Coolant. Mixture
WARNING! All glycol is hazardous and harmful
to the environment. Do not consume!
Glycol is flammable.

IMPORTANT! Ethylene glycol must not be

mixed with other types of glycol.

Mix:
40 % “Volvo Penta Coolant” (conc. coolant)
60 % water
This mixture protects the engine against internal cor-
rosion, cavitation and frost damage down to -28 °C
(18°F). (Using 60 % glycol lowers the freezing point
to -54 °C (65°F)). Never mix more than 60 % concen-
trate (Volvo Penta Coolant) in the cooling liquid, this
will give reduced cooling effect and 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
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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 system. Ensure that the
liquids mix properly.

Water quality

ASTM D4985:
Total solid particles ........................................ < 340 ppm
Total hardness:............................................... < 9.5° dH
Chloride ......................................................... < 40 ppm
Sulfate............................................................ < 100 ppm
pH value......................................................... 5,5–9
Silica (acc. ASTM D859)................................ < 20 mg SiO2/l
Iron (acc. ASTM D1068) ................................ < 0.10 ppm
Manganese (acc. ASTM D858)...................... < 0.05 ppm
Conductivity (acc. ASTM D1125)................... < 500 μS/cm
Organic content, CODMn (acc. ISO8467) ....... < 15 mg KMnO4/l

71
 Maintenance. Freshwater system

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 and let

any pressure escape from the system before remov-
ing the cap. Top up coolant if necessary. The coolant
level should be between the MAX and MIN marking
on the expansion tank. Reinstall the filler cap.

Draining fresh water system

Remove the filler cap on the expansion tank (to allow
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the coolant to run out faster). Use a suitable receptacle

while draining.
There is a hose mounted on the intercooler. Move the
hose and connect it to the drain nipple (1). Open the
drain nipple 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 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

72
 Seawater system
The seawater system is the boat’s external cooling system. On engines with drives, the seawater pump draws in
water via the drive, through the control system oil cooler to the seawater pump, after which the water 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 intercooler, heat exchanger, engine oil cooler
and reverse gear oil cooler. Finally, the water is pumped into the exhaust pipe elbow, where it is mixed with the
exhaust gases.

WARNING! There is a risk that water will enter while working on the seawater system (if the boat is in the
water). Water may flow into the boat if a hose, plug or similar object located below the waterline is removed.
So always close the seawater cock. If the boat does not have a seawater cock, the flow of water must be
stopped in a safe manner. The boat must be brought up on land if this is not possible.

Checking/Changing impeller.
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WARNING! Risk for water penetration.

Remove the cover from the seawater pump and re-

move the impeller (1).
If there are cracks or other defects the impeller must
be replaced. (If the pump shaft can be turned by
hand the flange must be replaced). Lubricate the
pump housing and the inside of the cover with a little
waterproof grease for rubber.

Reinstall the impeller using a rotating movement. In-

stall the seal washers on the shaft
center. Install the cover together with a new o-ring.
Reverse gear: Open the sea cock.

73
 Maintenance. Seawater system

Cleaning seawater filter.

1 WARNING! Risk for water penetration.
2 Screw off cover (1) and remove seal plate (2). Lift out
3 and clean the insert (3).

IMPORTANT! If the boat is used in water that

has a lot of contaminants, seaweed etc. the filter
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.
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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 continue to drain the coolant
from the drain nipple (2) and (3).

74
 Maintenance. Seawater system

Checking/Changing sacrificial anodes

WARNING! Risk of water entering. Close the se-
awater cock before starting work on the seawater
system.

1. Close the seawater cock.

2. Drain the seawater as described in ”Draining the
seawater system”.
3. Remove the sacrificial anodes in the heat exchan-
ger and 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 goods.
6. Close the drain nipples.
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7. Open the seawater cock before starting the engi-

ne.
8. Make sure there are no leaks.

75
 Maintenance. Seawater system

Seawater system. Cleaning and inhibiting

To prevent the build up of deposits and salt crystals in
the seawater system it must be flushed with freshwa-
ter. When the boat is laid up it must also be inhibited.

WARNING! Risk of water penetration. Cleaning

and inhibiting the seawater system should be
carried out with the boat on land.

1. Open the seawater cock (reverse gear).

2. Detach hose from the seawater pump and connect
a hose (1) which reaches to a bucket filled with
fresh water. Take care of filling.
1 3. Check that there is nothing that will get splashed
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.
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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 mixture
(50/50 freshwater and antifreeze). Secure a con-
tainer by the exhaust outlet. Repeat step 4.
6. Connect seawater hose.
7. The system is now inhibited. The antifreeze mix-
ture should be left in the system while the boat is
laid up. Drain the mixture just before the boat is
launched. Reuse the antifreeze mixture next sea-
son or deposit it at a properly designated disposal
site.

76
 Fuel system
The engine fuel system is a so-called common rail-system. The advantage of the common rail-system is that the
engine control unit controls the timing and fuel amount, this mean better emission control and a smooth running
engine.
All work on the engine common rail-system must be carried out at an authorized workshop. Use only the recom-
mended grade of fuel: See the chapter “Technical Data”.

WARNING! Fire risk. When carrying out work on the fuel system makes sure the engine is cold. A fuel spill
onto a hot surface or an electrical component can cause a fire. Store fuel soaked rags so that they cannot
cause a fire.

Changing fuel filter

1. Close 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..
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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 inside the threaded hole in the
center of the filter.
NOTE! Do not fill the new filter with fuel before as-
sembly. Contaminations may get into the system
and cause damage and malfunction.
6. Screw the new filter on by hand until the seal just
touches the mating surface. Then tighten a further
1/2 turn. Reinstall the water trap cables.
7. Open the fuel valve.
8. Bleed the fuel system. See Chapter ”Bleeding the
fuel system”.
9. Start the engine and check for leakages.

77
 Maintenance. Fuel system

Bleeding the fuel system

The fuel system must be bled e.g. after changing fuel
filter, if the fuel tank has been run dry and after long
stops.

2 WARNING! Never detach the pressure pipes.

1
1. Attach a transparent hose to the air vent valve (1).
Lead the hose to a suitable receptacle to 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 on or approaching a run-

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ning engine is a safety hazard. Beware of rotating

parts and hot surfaces.

78
 Maintenance. Fuel system

1 Fuel pre-filter. Changing filter insert

Close fuel cock at the fuel tank. Position a container
under the 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.
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79
 Electrical system
The engine is equipped with a two-pole system electrical system which means that the voltage (minus) is re-
turned directly from the starter motor minus terminal with the battery negative lead. Individual components on
the system return voltage to the starter motor minus terminal via separate cables.

WARNING! Always stop the engine and break the current using the main switches before working on the
electrical system. Isolate shore current to the engine block heater, battery charger, or accessories mounted
on the engine.

Main switch
The main switch must never be turned off before the en-
gine has stopped. If the circuit between the generator and
the battery is cut off when the engine is running the gen-
erator can be seriously damaged. For the same reason
charging circuits must never be switched over while the
engine is running.

IMPORTANT! Never break the circuit with the main

switches while the engine is running.
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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 fault persists, read out the
flash codes and take the necessary measures.

IMPORTANT ! Always investigate the cause of the

overload!

24-volt system
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 the circuit breaker.
If the fault persists, read out the flash codes and take the
necessary measures.

IMPORTANT ! Always investigate the cause of the

overload!

EVC system
The EVC system is protected through the engine circuit
breakers.

IMPORTANT ! Always investigate the cause of the

overload!

80
 Maintenance: Electrical system

Electrical connections
Also check that all electrical connections are dry and
free of oxidation and that there are no loose connec-
tions. If necessary, spray these connections with a
water-repellent spray (Volvo Penta Universal oil).

Battery. Maintenance
WARNING! Risk of fire and explosion. Never
allow an open flame or electric sparks near the
battery or batteries.

WARNING! Never mix up battery positive and

negative terminals. This may cause sparks and
an explosion.

WARNING! The battery electrolyte contains ex-

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tremely corrosive sulfuric acid. Protect your skin

and clothes when charging or handling batter-
ies. Always use protective goggles and gloves.
If battery electrolyte comes into contact with
unprotected skin wash off immediately using
plenty of water and soap. If battery acid comes
into contact with the eyes, flush immediately
with plenty of water and obtain medical assis-
tance without delay.

Connecting and disconnecting

First connect the red battery lead + to the battery +
terminal. Then connect the 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 terminals well and grease them with terminal
grease or petroleum jelly.

Topping up
The electrolyte should be 5–10 mm over the plates in
the battery. Top up using distilled water if necessary.
Charge the battery after topping up for at least 30
minutes by running the engine at fast idle.
NOTE! Certain maintenance-free batteries have spe-
cial instructions which must be followed.

81
 Maintenance: Electrical system

Battery. Charging
WARNING! Danger of explosion! The batteries
give off hydrogen gas during charging which
when mixed with air can form an explosive gas
– oxyhydrogen A short-circuit, naked flame or
spark can cause a large explosion. Ensure that
the ventilation is good.
WARNING! The battery electrolyte contains ex-
tremely corrosive sulfuric acid. Protect your skin
and clothes when charging or handling batter-
ies. Always use protective goggles and gloves.
If battery electrolyte comes into contact with
unprotected skin wash off immediately using
plenty of water and soap. If battery acid comes
into contact with the eyes, flush immediately
with plenty of water and obtain medical assis-
tance without delay.

If the 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
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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 disconnect the battery leads
before connecting the charger.

When charging, unscrew filler plugs but leave them

in their holes. Ventilation should be good, particularly
if the batteries are being charged in an enclosed
area.

WARNING! Always switch off the charging

circuit before removing the battery charger
connectors. Never mix up battery positive and
negative terminals. This may cause sparks and
an explosion.

Special instructions apply when boost charging the

batteries. Avoid boost charging the batteries as it will
shorten their service life.

82
 Maintenance: Electrical system

Electrical installations
Leakage current from the electrical system can be
caused by incorrect installation of electrical equip-
ment. Leakage current can knock out the galvanic
protection of components such as the drive, propel-
ler, propeller shaft, rudder stock and keel and cause
damage by electrolytic corrosion.

IMPORTANT! Work on the boat’s low tension

circuit should only be carried out by qualified or
experienced persons. Installation or work on the
shore power equipment must only be carried
out by electricians authorized to work with high-
voltage installations.

The following should always be observed:

1. If shore power is 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-
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cally separated from the low tension circuit.

2. Route and clamp electric cables so that they will
not be exposed to rubbing, damp or bilge water in
the keelson.
3. Engine or drive/reverse gear must never be used
as a ground point.
IMPORTANT! The engine or drive/reverse
gear must never be used as a ground or be
electrically connected to other equipment
such as the radio, navigational equipment,
the rudder, bathing steps etc.
Protective grounds for the radio, navigational
equipment, rudder, bathing steps or other equip-
ment with separate ground leads must be con-
nected to a common ground terminal.

83
 Maintenance: Electrical system

4. There must be a main switch connected to the

starter battery positive (+) terminal. The main
switch should cut off power to all power consum-
ing equipment and should be switched off when
the boat is not in use.
5. If an auxiliary battery is in use, a main switch
should 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 independent battery
circuits, fit a Volvo Penta charge distributor (ac-
cessory) to the regular generator.
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84
 Reverse gear
The HS45AE/HS63AE/HS63VE/HS80/85AE/HS80/85reverse gear is hydraulic, which means that ahead/astern
engagement and disengagement is hydraulically activated. The reverse gear lubrication system has an oil filter
and oil cooler. The reverse gears is equipped with solenoid valves for electronically controlled shifting.

IMPORTANT! Volvo Penta recommends the installation of a seawater filter to guarantee the proper cool-
ant water flow to the engine and reverse gear. Contaminants in the seawater will otherwise foul the reverse
gear radiator and other cooling system components.

Cheking oil level

Start the engine and let it run a couple of minutes.
Stopp the engine and remove the dipstick by turning
it anti clockwise. Dry off the dipstick and reinstall it
in the reverse gear, without screwing it into place.
Remove the oil dipstick again and check the oil level.
The correct oil level is inside the marked area.
If necessary, top the oil up through the dipstick hole.
Please refer to the “Technical Data” chapter for oil
grades and volume.
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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 in the lid.
3. Remove the filter (3).

1 4. Suck up the oil with an oil drain pump, via the oil
filter housing. Connect hose to the suction pipe (4)
at the bottom of the housing.
2 NOTE! Maximum outside diameter of suction
hose is 5/8 inch (16 mm).
5. Measure up the correct quantity of oil and fill the
reverse gear with the oil via the oil filter housing.
3 Please refer to the “Technical Data” chapter for oil
grades and volume.

IMPORTANT! Never over-fill the reverse

gear.
6. Install the new filter (3) in the filter housing.
7. Install the lid. Tightening torque 5–8 Nm.
8. Put the control lever in neutral. Start and run the
engine at 1500 rpm for a few minutes to ensure
that the reverse gear oil cooler is filled with oil.
9. Stop the engine and check the oil level. Top up as
4 necessary.

85
 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.
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86
 Drive
Your drive is protected against galvanic corrosion. This protection consists of two-three layers of paint, sacrificial
anodes and ground braids. The ground braids maintain a connection between the different components of the
drive. A broken connection can result in the rapid corrosion of an individual component even though the protec-
tion is otherwise effective. Check ground braids every year. Faulty electrical installation can also cause the break
down of the galvanic protection. Damage due to electrolytic corrosion occurs rapidly and is often extensive. For
further information see the chapter: “Electrical system”.

IMPORTANT! Always repair damage to paintwork immediately. Improperly applied paint or the wrong type
of paint on the keel can put the corrosion protection system out of action. For further information on paint-
ing see the chapter: Laying up and launching

The drive is equipped with a cone clutch for shifting using a control cable with either mechanical operation 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
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there is a lower level of galvanic corrosion protection

due to the oxidation on the sacrificial anodes. Even
a new anode can be oxidized on the surface. Before
launching the sacrificial anodes must be cleaned/
ground using an emery cloth.

IMPORTANT ! Clean with sandpaper. Use no

steel tools (e.g. wire brush) as this will impair
electrical protection.

Your drive is equipped with sacrificial anodes of

zinc as standard, intended for use with salt water.
On drives used mainly in freshwater the sacrificial
anodes should be of magnesium.

IMPORTANT ! Use protective anodes as follows:

Zinc for use in salt water

Magnesium for use in fresh water
Aluminium if the boat is used primarily in salt water
and occasionally in fresh water.

Changing corrosion protection

All anodes are secured with screws. Undo the screws
holding the anode. Clean the contact surface and fit
the new anode.

87
 Maintenance: Drive

Checking oil level

Trim up the drive to 35°. Remove the cover (1) and
the plug (2).

IMPORTANT! Always trim up the drive to 35°

when checking the oil level.

The oillevel must always be at the top of the oil filler

cap (3). If not, top up with oil until the oil filler cap is
completely filled. Refer to ”Technical Data” concerning
3 grade and capacity.
Check that the plug is tight and fit the cover.

1
2 Changing oil
Trim up the drive to 35°. Remove the cover (1) and the
plug (2).

IMPORTANT! Always trim up the drive to 35°

when changing the oil.

Dismantle the propeller and remove the oil drain plug

(4) together with its gasket from the gear housing and
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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 oillevel must always be at the top of the oil filler
4 cap (3). Refer to ”Technical Data” concerning grade
and capacity.
Lower the sterndrive and tilt the sterndrive to 35° posi-
tion again to eliminate possible air pockets.
Remove the oil fill plug and check oil level. Top up with
oil if the oil filler cap is not completely filled.
Check that the plug is tight and fit the cover.
NB! Leave the old oil to a destruction plant.

88
 Maintenance. Drive

Checking oil level, power trim

Trim the drive in as far as possible. Check the oil level
is between the MAX and MIN markings on the oil con-
tainer. Top up if necessary using ATF oil. Cleanliness
is extremely important, no dirt must get into the drive
when topping up with oil.
If the system has been drained, fill with new oil and
trim the drive in and out 6–10 times to vent the system.
Check the oil level and top up if necessary.

Changing universal joint bellows

Check the condition of the joint bellows once a year.
It must be changed if there are any visible cracks or
other defects.
The joint bellows should be renewed every 200 ope-
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
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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 hydraulics without first securing the drive in
raised position in such a way that it cannot fall
down. The drive can cause severe personal injury
if it falls down.

Special tool no.885800, applied correctly, will prevent

the drive from falling down. Fit the tool as follows: Trim
out the drive to max and apply the special tool.
Then inspect the bellows thoroughly for damage and
change if necessary.

WARNING! Do not overload the tool by standing

on the raised drive.

89
 Steering
The DPH/R drive is equipped with a fully hydraulic steering system with additional power assistance to allow
steering without the engine running.

Checking oil level, steering system

IMPORTANT! Follow the directions below to
ensure problem free and safe steering:

Check the steering system oil level every two weeks

so that any changes in level are discovered. Check
oil level at the helm pump. Min level is 12 mm below
lower edge of the fill hole. If the boat has a flybridge,
12 mm
(1/2") do NOT open lower helm pump. Only check the oil
level at the upper helm station. Normally, the oil level
will not change, ”oil consumption” in one year is neg-
ligible.
A drop in level is a 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.
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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 or if there are any visible contaminants,
it must be changed. The fluid must also be purged
from air if the steering system has been opened for
service.

WARNING! Use only Volvo Penta recommen-

ded fluid and grade. Never top up the steering
system with fluid of unknown grade. Never use
brake fluid or hydraulic oil. Any non-appproved
fluid may cause irreparable damage, loss of
steering and cancellation of warranty. The
incorrect fluid can also result in damage to the

90
 Maintenance. Steering

components used in the steering system.

Checking oil level, servo pump

The oil recovery tank is a see-through reservoir, check
oil level without opening the reservoir. Oil should be
right below the neck of the recovery tank.
If oil needs to be added, first disconnect quick connect
coupling, before opening the cap.

Hydraulic hoses. Checking

Carefully check the steering system’s hydraulic hoses
for 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-
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portant, no dirt must get into the hydraulic sys-

tem. Before removing, clean and check carefully
how hoses are routed and connected. Faulty
routing or dirt in the hydraulic system can
negatively affect steering, and at worst steer-
ing can be lost altogether. Please contact your
nearest authorized Volvo Penta workshop for as-
sistance.

91
 Maintenance: Steering

Parallel strut. Checking

The parallel strut (twin and triple installation) is a vi-
tal safety component. Inspect it carefully if the drive
kick-up function has been triggered by the boat going
aground or hitting an object in the water.

WARNING! If the parallel strut shows signs of

damage, run at reduced speed to harbor. The
parallel strut is a vital safety component, damage
may affect steering characteristics. 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.

A Hydraulic tie-bar. Adjusting

The tie-bar can be adjusted both with the boat in the
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30 Nm 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
B out fully to one side.
3. Tighten adjustment screw (B), torque 30 Nm) se-
30 Nm
curely. Install protective cap screw (A).
This procedure will line up the stern drives parallel
to each other (straight ahead).

With the boat on land:

1. Remove protective cap screw (A). Loosen adjust-
ment screw (B) 1-2 turns.
2. Set stern drives to desired alignment (straight
ahead recommended).
3. Tighten adjustment screw (B), torque 30 Nm) se-
curely. Install protective cap screw (A).

92
 Propellers
For best performance and fuel economy the engine speed should be within the maximum RPM range: See
chapter “Operation”. If the engine speed at maximum RPM falls outside the max. RPM range then the propeller
should be changed.

WARNING! Make it impossible to start the engine when working on the propellers. Take the starter key
out of the starter switch.
IMPORTANT! Damaged propellers should be replaced immediately. Operating the boat with a damaged
propeller should be undertaken with extreme care and only at reduced engine speeds.

1
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Propellers. DPR/DPH drive Assembly

NB! A tool for removing and fitting the propellers is 1. Lubricate both propeller hubs. Use Volvo Penta
supplied together with the Transom shield kit (see grease 828250.
figure). 2. Turn on the power and move the control lever to
forward. Take the starter key out of the starter
Dismantling switch.
1. Turn on the power and move the control lever to
reverse. Take the starter key out of the starter 3. Push the front propeller onto the shaft.
switch. 4. Screw on the large lock nut (2) and torque tighten
2. Undo the lock nut (1) and remove the rear propel- to 50-70 Nm.
ler. 5. Turn on the power and move the control lever to
3. Turn on the power and move the control lever to reverse. Take the starter key out of the starter
forward. Take the starter key out of the starter switch.
switch. 6. Push the rear propeller onto the shaft and secure
4. Undo the large lock nut (2) using the special tool it with the lock nut (1). Torque tighten to 70-80
supplied. Remove the front propeller. Nm..

5. Wipe the propeller shafts clean.

93
 Laying up/Launching
Before taking the boat out of the water for winter/out-of-season storage have an authorized Volvo Penta work-
shop inspect the engine and other equipment. Have any necessary repairs or service work carried out so that
your boat is in top condition for the new season.
Inhibition should be carried out to ensure that the engine and transmission are not damaged while out of com-
mission during the winter/off-season. It is important this is done properly and than nothing is forgotten. We have
therefore provided a checklist covering the most important points.

WARNING! Read the chapter on Maintenance carefully before starting work. It contains instructions on
how to carry out the most common maintenance and service operations safely and correctly.

Inhibiting
The following are best carried out with the boat in L Change oil in the drive.
the water:
L Change engine oil and replace oil filter. L Clean the seawater filter.

L Change oil in the reverse gear. L Clean and inhibit the seawater system.

L Replace fuel filter. Replace fuel pre-filter if in- L Remove the impeller from the seawater pump.
stalled. Store the impeller in a sealed plastic bag in a cool
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place.
L Run engine to normal operating temperature. L Check the condition of the engine coolant anti-
freeze. Top up if required.
L Take the boat out of the water:
IMPORTANT! An anti-corrosion mixture
The following should be carried out with the boat in the engine coolant system provides no
protection against freezing. If there is any
out of the water:
possibility the engine will be subjected to
L Clean the hull and drive directly after taking up the freezing temperatures then the system must
boat (before it dries). be drained.

L Drain any water and contaminants from the fuel

tank. Fill the tank completely with fuel to avoid
condensation.

L Clean the outside of the engine. Do not use a high

pressure spray to clean the engine. Touch up any
damaged areas of paintwork with Volvo Penta
original paint.

L Check all control cables and treat with rust inhib-

itor.

L Repair any damaged areas of paintwork with

Volvo Penta original paint. NOTE! Read the spe-
cial instructions on painting the drive under the
heading: “Painting the drive and underwater hull”.

L Disconnect battery leads. Clean and charge the

batteries. NOTE! A poorly charged battery may
burst as a result of freezing.

IMPORTANT! Be careful when cleaning with a L Spray electrical system components with moisture
high pressure water spray. The spray must not repellent spray.
be pointed toward the exhaust and drive union
bellows, the trim/steering cylinder seals, the pro- L Remove propeller for winter storage. Grease the
peller shaft seal, hoses etc. propeller shaft using water repellent grease VPnr.
828250.

94
 Laying up/Launching

Bringing out of storage

L Check oil level in the engine and drive/reverse L Paint the drive and hull: See next page.
gear. Top up if necessary. If there is inhibiting oil
in the system drain and fill with new oil, change oil L Check the sacrificial anode on the drive. If there is
filter. For correct oil grade: See the chapter “Tech- less than 2/3 of the anode left it must be replaced.
nical Data”. Clean with emery cloth just before the boat is
launched.
L Drain the antifreeze from the seawater system.
IMPORTANT! Do not use a wire brush or other
L Install the impeller in the seawater pump. Replace
steel tools when cleaning, as these may dam-
if the old one looks worn. Please refer to the Sea
age the galvanic protection.
Water System chapter.

L Close/tighten drain cocks/plugs. L Install propellers.

L Check the tension and condition of the drive belts. L Launch the boat. Check for leaks.

L Check the condition of rubber hoses and tighten L Vent and lubricate the propeller shaft seal (reverse
hose clamps. gear).

L Check engine coolant level and antifreeze protec- L Start the engine. Check that there are no fuel,
tion. Top up if necessary. engine coolant or exhaust gas leaks and that all
control functions are operating.
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L Connect the fully charged batteries.

95
 Laying up/Launching

Painting the drive and underwater

hull
Drive
Before treating the drive with anti-fouling agent any
damaged paintwork must be repaired. Sand down
metal surfaces lightly using a 120 grade paper and a
finer grade for painted surfaces. Wash off using thin-
ners or similar. Any pores in the surface should be
filled and sanded down. Paint using Volvo Penta ori-
ginal primer and topcoat. Let the paint dry. A further
two coats of Volvo Penta anti-fouling primer should
then be applied. Let them dry. A further two coats of
Volvo Penta anti-fouling should then be applied.

IMPORTANT! The sacrificial anodes on the

drive must not be painted or treated with Teflon.
This also applies to stainless or bronze propel-
lers.

Use of anti-fouling agents is not permitted in all coun-

tries. Please make sure that it is permitted where
your boat is to be used. If anti-fouling agents are not
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permitted we recommend that a pure Teflon®* agent

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 regulations.
In many cases it is completely forbidden to use them
on pleasure boats, for example in freshwater. For
boats that are relatively easy to get out of the water
we recommend only Teflon treatment combined with
mechanical cleaning several times per season.
For larger craft this is not practicable. If the boat is
in an area where the water quickly produces fouling
then anti-fouling paints must probably be used. If this
is the case use a copper-based paint containing cop-
per cyanide and not copper oxide.

IMPORTANT! Leave an area of 10 mm around

the drive unpainted.

Tin-based agents (TBT) must not be used. Check

the legislation that applies where the boat is to
be used. Wait for the paint to dry before launching
the boat.

96
 In case of emergency
Despite regular maintenance according to the maintenance schedule and perfect operation, it may occur that a
fault occurs which must be attended to before the boat can travel further. This chapter contains tips for rectifying
some of the possible faults.
There are safety functions which are activated when certain faults occur, to protect the engine. The following can
occur:
L Engine can not be started
L Reverse gear in neutral and engine speed is limited to 1000-1200 rpm, depending on engine.
L The engine stops
Flash out any fault codes and take the recommended measures. Please refer to the “Diagnostic function” and
“Fault codes” chapters.

Starting with auxiliary batteries

WARNING! Ventilate well. Batteries contain and
give off an explosive gas which is highly flam-
mable and explosive. A short circuit, open flame
or spark could cause a violent explosion.
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WARNING! Never confuse the positive and ne-

gative poles on the batteries. Risk of arcing and
explosion.
1. Check that the rated voltage of the help start bat-
tery is the same as the system voltage of the
engine.
2. Connect the red jumper cable to the positive pole
(+) of the flat battery, and then to the positive pole
of the help start battery.
3. Connect the black jumper 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 are no extra accessories connected to
the electrical system.

WARNING! Working with, or going close to a

running engine is a safety risk. Watch out for ro-
tating components and hot surfaces.

WARNING! Do not touch the connections

during the start attempt: Risk of arcing. Do not
stand bending over any of the batteries either.

5. Stop the engine. Remove the jumper cables in the

exact reverse order from installation.

97
 In case of emergency

Emergency shifting
If a fault occurs which prevents the drive or the revers
gear from being operated (shifted) with the control
lever, it is possible to shift manually, using the des-
cription below.

WARNING! In emergency shifting, the unit is

locked in forwards operation. Please note that
the drive can not then be disengaged with the
control lever. Forward motion can only be cut
off by stopping the engine with the ignition key
or stop button.

2
1
Drives
The drives gears are changed electronically using
a gear lever carrier mounted in the engine compart-
ment
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Manual drive engagement

2
Gear forward 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)
Gear backward 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 refer to electrically shifted re-
A vers gear.
Manual engagement of the reverse gear:

B 1. Stop the engine and remove the ignition key from

the ignition lock.
2
2. Undo the screw (1) on the side where the cable
harness marked A is connected.
1
3. Remove washer (2) and tighten the screw.
4. Undo cables A and B from the solenoid valves.

98
 In case of emergency

Emergency trimming
If a fault occurs which prevents the drive from being
timmed with the trim panel, it is possible to trim manu-
ally, using the description below.
WARNING! In emergency triming, the automa-
tic stop will not work. The drive can be trimmed
outside the trim ranges, this can damage boat
or drive.

Manual trim
1. Press N-button on the control panel and hold.
2. Trim the drive using the trim panel.

1
2 3

5 6
4
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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
engine.
4. Acknowledge the alarm and start the engine.
5. Stop the engine. Wait until the system is shutdown
proberly, all lamps has gone out. Then start the
engine.

99
 In case of emergency

Water in fuel
Draining the fuel filter

If the light on the lamp panel comes on, there is

toomuch water in the water separator on the fuel filter.
Proceed as follows to rectify this:
1. Stop the engine and take the starter key out of the
starter switch.
2. Remove the cable from the water separator (1).
3. Place a suitable receptacle under the fuel filter and
carefully 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).
1
Draining of fuel pre-filter.
2
The fuel pre-filter is an accessory.
Position a container under the fuel filter. On the fuel
1 filter first open the venting screw (1) approximately
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4 turns. Drain off water and contaminants using the

cock/plug at the bottom of the filter. Vent fuel system.

IMPORTANT! Wait a few hours after the engine

has been turned off before draining the filter.

100
 In case of emergency

Fault-tracing
A number of symptoms and possible causes for engine disturbances are described in the table below. If faults or
hitches arise that you cannot solve alone, you must always get in touch with your Volvo Penta dealer.

WARNING! Read the safety directions for maintenance and service in the chapter “Safety information” be-
fore starting work.

Symptom and possible cause

The diagnostic button indicator flashes See the “Diagnostic function” chapter
Starter motor not turning (or slow) 1, 2, 3, 24
Engine does not start 4, 5, 6, 7, 24
Engine starts but stops again 6, 7, 24
Engine difficult to start 4, 5, 6, 7
Engine does not reach correct speed at wide open throttle (WOT) 5, 6, 7, 8, 9, 10, 11, 15, 18, 19, 20, 21, 24
Engine knocks 4, 5, 6, 7
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Engine runs unevenly 4, 5, 6, 7, 10, 11

Engine vibrates 15, 16
High fuel consumption 8, 9, 10, 12, 15
Black exhaust smoke 10
Blue or white exhaust smoke 12, 22
Low oil pressure 13, 14
Engine coolant temperature too high 17, 18, 19, 20, 21
None or poor charging 2, 23

1. Discharged battery 10. Insufficient air supply 18. Blocked seawater intake/pipe/filter
2. Loose connection/open-circuit 11. Engine coolant temperature too 19. Circulation pump drive belt slipping
high
3. Fuse tripped 20. Defective impeller
12. Engine coolant temperature is too
4. Lack of fuel 21. Defective/incorrect thermostat
low
5. Fouled fuel filter. 22. Lubricating oil level too high
13. Lubricating oil level too low.
6. Air in the fuel injection system 23. Generator drive belt slipping
14. Blocked oil filter
7. Water/contaminants in the fuel 24. Stored diagnostic trouble codes
15. Defective/incorrect propeller
(DTCs)*
8. Boat abnormally loaded
16. Defective engine mounting
9. Fouling on underwater hull/drive/
17. Too little coolant
propeller

*See the “Diagnostic function” chapter for additional information.

101
 In case of emergency

Diagnostic function
The diagnostic function monitors and checks that the engine, stern drive/reversing gear and EVC system func-
tion normally.

The diagnostic function has the following tasks:

L Discover and localize malfunctions

L Notify that malfunctions have been discovered
L Give advice in fault finding
L Protect the engine and ensure continued operation when serious malfunctions are discovered.

Malfunction message
If the diagnostic function discovers a malfunction,
it warns the driver by starting to flash the indicator
on the diagnostic button. To acknowledge the alarm,
press button D on the control panel. When the fault
has been acknowledged, the lamp concerned gives
constant light.
NOTE! To enable engine start the alarm must be ack-
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nowledged.

The diagnostic function affects the engine in the

following ways when:

1. The diagnostic function has discovered 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-
mage.
Reaction: Engine power is reduced.
4. The diagnostic function has discovered a serious
malfunction which makes it impossible to control
the engine.
Reaction: The reversing gear/drive is disengaged
and engine speed is cut to 1000 rpm.
It is possible to do an emergency shift: Please re-
fer to the “Emergency shifting” section.
5. The diagnostic function has discovered a serious
malfunction on the sterndrive shift mechanism or
in the engine fuel injection system.
Reaction: Engine is stopped
It is possible to do an emergency shift: Please re-
fer to the ”Emergency shifting” section. In serious
emergency it is also possible to start the engine
with gear engaged after acknowledging the alarm.

102
 In case of emergency

Malfunction message engine and EVC-

system
If the diagnostic function discovers a malfunction, it
warns the driver by starting to flash the indicator on
the diagnostic button, a pop-up window will appear in
the display and the buzzer will not sound.
To acknowledge the alarm, press any key on the dis-
play . When the fault has been acknowledged, the
lamp concerned gives constant light. Press any key on
the display to go to the alarm list screen.
NOTE! To enable engine start the alarm must be ack-
nowledged.

STOP pop-up
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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 the Waring pop up is shown during operation, a fault
has occured.
Acknowledge the alarm.
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".

103
 In case of emergency

Alarm list
The alarm list screen contain all previously acknow-
ledged alarms (black text on grey background) and
new unacknowledged alarms (grey text on black back-
ground) as shown.
- Alarm index number (in order of receipt).
- Which engine the alarm is from (Port, Stbd).
- Source node of the unit with fault.
The 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 cleared from the list
until the system is powered down.
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The alarm list can be viewed, at any time, from the

configuration menu.

104
 In case of emergency

Fault codes
Before the fault codes can be read out enter Service
mode by pressing button D for about 5 sec.
The D indication gives a steady light and indicator on
alarm panel flashes with a orange/red light.
The codes are flashed out on the D button indication.
The fault code consists of three groups of flashes,
separated by a pause of two seconds. A fault code is
obtained by counting the number of flashes in each
group:
Example:
pause pause = 2.4.2
The fault code is stored and can be read as long as
the malfunction remains.
A fault code list, containing information about cause
and effect, is found in the “Fault code list” chapter.
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Reading fault codes

1. Reduce engine speed to idling if fault codes are
read when the engine is running. 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 that is flashed out.
4. Repeat the points above. A new fault code is
flashed out if more are stored. Repeat until fault
code 1.1 is flashed.
NOTE! When the fault code 1.1 is flashed, all fault
codes have been read out.
5. Look up the fault code in the fault code list and
take the necessary measures.
Alternatively: If the controls, warning display and
other instrumentation indicate normal function, the
operator can continue the journey and remedy the
malfunction at a later time.
6. To leave Service mode press D button for at least
5 sec. or turn the ignition off.

105
 In case of emergency

Erasing fault codes

Any fault codes in the diagnostic function are auto-
matically erased every time the starter key is turned
to the stop position (S).
NOTE! Stop the engine and check that the ignition
key(s) is(are) in position 0 in all control positions.
When system voltage is switched 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 diagnostic button is pressed after all stored fault
codes have been erased, code 1.1 (“No fault”) will be
flashed out.
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106
 Fault code register
WARNING! Read the safety precautions for maintenance and service in the ”Safety information” chapter
before starting work.

Explanation
Fault codes are presented in numerical order, with information about reason and proposed measures to be taken.

1. 2. 3.

1.6.1 R

1. Current fault code which is flashed out on the diagnostic button display.
2. Current warning lamp which flashes during an alarm. O/R means that an orange or red lamp flashes.
3. Audible warning
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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.
Reaction: Engine power is reduced. Engine is difficult to start.
Action:
• Please contact a Volvo Penta workshop.

1.2.5 O
Explanation: Fault in engine speed sensor on camshaft.
Reaction: Engine is difficult to start.
Action:
• Please contact a Volvo Penta workshop.

107
 Fault code register

1.2.9 R
Explanation: Fault in engine speed sensor.
Reaction: Engine power is reduced.
Action:
• Please contact a Volvo Penta workshop.

1.3.9 O
Explanation: Fault in compressor.
Reaction: Engine power is reduced.
Action:
• Please contact a Volvo Penta workshop.

1.4.6 O
Explanation: Fault in engine starter motor
Reaction: Engine can not be started.
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Action:
• Please contact 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 system”.
• Check the impeller in the sea water pump. Please refer to “Maintenance: Sea water system”.
• Check that no leakage occurs.
• Contact a Volvo Penta workshop if the fault remains.

108
 Fault code register

1.6.6 R
Explanation: Incorrect oil pressure.
Reaction: Engine power is reduced.
Action:
• Check the oil level in the engine. Please refer to “Maintenance: Lubrication” to check and top the oil up.
• Check that the oil filters are not blocked.
• Check that no leakage occurs.
• Contact a Volvo Penta workshop if the fault remains.

1.6.7 R
Explanation: Incorrect fuel pressure.
Reaction: Engine power is reduced.
Action:
• Check the fuel level.
• Open the fuel taps and check that no leakage occurs.
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• 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. leakage in pipes and connections.
Reaction: Engine power is reduced or engine stops.
Action:
• Please contact a Volvo Penta workshop.

1.7.8 R
Explanation: Fault in fuel pump monitoring.
Reaction: Engine power is reduced.
Action:
• Please contact a Volvo Penta workshop.

109
 Fault code register

1.7.9 R
Explanation: Incorrect fuel pressure. Relief valve in the fuel system has released or is broken.
Reaction: Engine power is reduced.
Action:
• Please contact a Volvo Penta workshop.

1.9.7 R
Explanation: Fuel temperature too high.
Reaction: Engine power is reduced.
Action:
• Check the fuel level.
• Check fuel cooler.
• Check that no leakage occurs.
• Please contact a Volvo Penta workshop if the fault remains.
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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.

2.1.8 Y
Explanation: External unit is not correctly configured.
Reaction: EVC system does not work.
Action:
• Check the driveline installation.
• Please contact a Volvo Penta workshop.

110
 Fault code register

2.3.5 R
Explanation: Fault in shift actuator.
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.

2.4.5 R
Explanation: Faulty solenoid, primary.
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.

2.4.7 R
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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 workshop if the fault remains.

2.9.9 O/R
Explanation: Internal fault in the EVC system.
Reaction: Engine power is reduced.
Action:
• If the engine can not be operated from the chosen control panel, use an alternative control panel.
• Please contact a Volvo Penta workshop

111
 Fault code register

3.1.2 Y
Explanation: Faulty control lever detection.
Reaction: It is not possible to calibrate the control lever.
Action:
• Check that the control lever is connected.
• Check that the lever combination is approved by Volvo Penta.
• Please contact a Volvo Penta workshop if the fault remains.

3.1.3 Y
Explanation: Too short lever movement between calibration points.
Reaction: It is not possible to calibrate the control lever.
Action:
• Check that there is enough room, so that the control lever can reach the end points.
• Check the mechanical connection to the potentiometer.
• Switch the ignition off, and repeat the calibration procedure.
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• 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 workshop if the fault remains.

3.1.6 Y
Explanation: Control lever is not calibrated.
Reaction: It is not possible to activate a control panel.
Action:
• 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 if the fault remains.
• Check that the control levers are approved by Volvo Penta.
• Please contact a Volvo Penta workshop.

112
 Fault code register

3.2.5 O
Explanation: Fault in EVC control panel.
Reaction: EVC control panel is out of order.
Action:
• If the engine can not be operated from the chosen control panel, use an alternative control panel.
• Please contact a Volvo Penta workshop.

3.3.1 R
Explanation: Fault in control lever.
Reaction: Engine can not be 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.
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3.9.9 O/R
Explanation: Internal fault in the EVC system.
Reaction: Engine power is reduced.
Action:
• If the engine can not be operated from the chosen control panel, use an alternative control panel.
• Please contact a Volvo Penta workshop.

113
 Technical Data
Engine
General information
After market designation ............................................. D4 -See table below D6 - See table below
Engine model........................................................... See table below See table below
Crankshaft power kW (hp)* ..................................... See table below See table below
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 pressure, hot engine ..........................................
Idling ................................................................... 1.25 bar (18.1 psi) 1.25 bar (18.1 psi)
Full speed ........................................................... 4.5 bars (65 psi) 4.5 bars (65 psi)
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Compressor
Oil volume................................................................ 0.1 liter (0.2 US pint) 0.1 liter (0.2 US pint)
Oil grade. ................................................................. Volvo Penta, part no. 1141641-9

Cooling system
Thermostats open/fully open ................................... 82°C/92°C 82°C/92°C
Fresh water system volume, app. ............................ 13 liter (3.4 US gals) 16.5 liter (4.4 US gals)

Electrical system
System voltage ........................................................ 12/24V
Alternator, rated power, max.................................... 14V/115A 28V/80A
Starter motor, rated power....................................... 12V/3.6 kW 24V/5 kW

* According to ISO 8665

After market Engine model Crankshaft power Propellershaft power

designation kW (hp) kW (hp)
D4-180 I-B D4-180 I 132 (180) 128 (174)
D4-225 I-B D4-225 I 165 (225) 160 (218)
D4-225 A-B D4-225 A 165 (225) 158 (215)
D4-260 I-B D4-260 I 191 (260) 186 (253)
D4-260 A-B D4-260 A 191 (260) 184 (250)
D6-280 I-B D6-280 I 206 (280) 201 (274)
D6-280 A-B D6-280 A 206 (280) 198 (269)
D6-310 I-B D6-310 I 228 (310) 223 (303)
D6-310 A-B D6-310 A 228 (310) 219 (298)
D6-350 A-B D6-350 A 257 (350) 248 (337)
D6-370 I-B D6-370 I 272 (370) 267 (363)
D6-435 I-A D6-435 I 320 (435) 310 (422)

114
 Technical Data

Lubrication system
Oil volume, (incl. oil filter)......................................... 12.5 liter (3.3 US gals) 20 liter (5.28 US gals)
Oil volume, oil filter .................................................. 1.6 liter (0.4 US gals) 1.6 liter (0.4 US gals)
Oil volume between min. and max. markings .......... 1.5 liter (0.4 US gals) 3.5 liter (0.9 US gals)
Oil grade .................................................................. See table below
Viscosity .................................................................. SAE 15W/40 (See table below)

Sulfur content in fuel, by weight

< 0,5 – 1,0 % > 1,0 %3)

Oilgrade1) Oil change interval, reached first in operation

All engines: 200 h / 12 months 100 h / 12 months

VDS-2 and ACEA E7 2)
or VDS-2 and Global DHD-1
or VDS-2 and API CH-4
or VDS-2 and API CI-4

1)
When oil quality specifications are joined by “or” (Type 1, 2 and 3), either engine oil specification can be used.
When oil quality specifications are joined by “and” (Type 2 and 3), the engine oil must fulfill both requirements.
7745861 - Downloaded from www.volvopenta.com 16/02/2009 14:42:32

2)
ACEA E7 has replaced ACEA E5, but if available ACEA E5 can be used.
3)
If sulphur content is > 1.0 % by weight, use oil with TBN >15.

Note! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the quality
requirements above.
VDS =Volvo Drain Specification
ACEA = Association des Constructeurs Européenne d’Automobiles
API = American Petroleum Institute
Global DHD = Global Diesel Heavy Duty
TBN = Total Base Number

Viscosity
Select the viscosity from the table below. Note! The temperature values refer to stable ambient temperatures.
* Refers to synthetic or semi-synthetic oils.

30 20 10 ±0 +10 20 30 40 o
C
15oC SAE 15W/40
o
25 C SAE 10W/30
1 SAE 5W/30
10oC SAE 20W/30
±0oC SAE 30
+10oC SAE 40
o
22 4 14 32 50 68 86 104 F

Fuel specification
The fuel must comply with national and international standards for commercially supplied fuels, such as:
EN 590 (with nationally adapted environmental and cold requirements)
ASTM D 975 No. 1-D and 2-D
JIS KK 2204
Sulfur content: Complying with legal requirements in each country.

115
 Technical Data

Drive
DPH
Oil volume............................................................ 5.4 liters (1.4 US gals)
Oil volume between min. and
max. markings ..................................................... 0.2 liter (0.4 US pint)
Oil grade and viscosity ........................................ VP 1141634 (API GL5 SAE 75W /90) Synthetic*
DPR
Oil volume............................................................ 4.2 liter (1.1 US qals)
Oil volume between min. and max. markings ...... 0.2 liter (0.4 US pint)
Oil grade and viscosity:........................................ VP 1141634 (API GL5 SAE 75W /90) Synthetic*
* NOTE. At long operational 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
7745861 - Downloaded from www.volvopenta.com 16/02/2009 14:42:32

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 (Dexron II, III)

HS80/85VE
Oil volume...................................................... 7.0 liter (1.8 US qals)
Oil grade ........................................................ ATF (Dexron II, III)

Power Trim
Oil grade ........................................................ ATF (Dexron II, III)

Steering
Power steering
Oil grade ........................................................ ATF (Dexron II, III)

116
 7745861 - Downloaded from www.volvopenta.com 16/02/2009 14:42:32

Notes

117
 
Yes please,
I would like an operator’s manual in English at no charge.
Post or fax this coupon to: Publication number: 7745861

42200/615001/155099900192
Document & Distribution Center Name
Order Department
ARU 2, Dept. 64620
SE-405 08 Göteborg Address
Sweden
Fax: +46 31 545 772
Orders can also be placed via
the Internet:
http://www.volvopenta.com/
manual/coupon Country

NB! This offer is valid for a period of 12 months from delivery of the boat.
Availability after this period will be as far as supplies admit.


Ja,
7745861 - Downloaded from www.volvopenta.com 16/02/2009 14:42:32

ich will kostenlos eine Betriebsanleitung in deutscher Sprache erhalten.

Schicken Sie den Coupon Publikationsnummer: 7745006

42200/615001/155099900192
per Post oder als Fax an: Name
Document & Distribution Center
Order Department
ARU 2, Dept. 64620 Anschrift
SE-405 08 Göteborg
Schweden
Fax: +46 31 545 772
Die Bestellung kann auch über
das Internet erfolgen:
http://www.volvopenta.com/ Land
manual/coupon

Bitte beachten Sie, dass dieses Angebot für die Dauer von 12 Monaten ab dem
Lieferdatum des Bootes gilt, danach bis zum Aufbrauchen des Lagerbestandes.


Oui merci,
Je souhaite recevoir un manuel d’instructions gratuit en français.
Numéro de publication: 7745007
Envoyez ou faxez le bon de
42200/615001/155099900192

commande à: Nom
Document & Distribution Center
Order Department
ARU 2, Dept. 64620 Adresse
SE-405 08 Göteborg
Suède
Fax: +46 31 545 772
Vous pouvez également pas-
ser la commande par Internet:
http://www.volvopenta.com/ Pays
manual/coupon

Notez que l’offre est valable pendant 12 mois à partir de la date de livrai-
son du bateau, ensuite seulement en fonction des stocks disponibles.

118
 
Sí gracias,
deseo recibir gratuitamente un libro de instrucciones en español.
Franquear o enviar fax a: Número de publicación: 7745008

42200/615001/155099900192
Document & Distribution Center Nombre
Order Department
ARU 2, Dept. 64620
SE-405 08 Göteborg Dirección
Suecia
Fax: +46 31 545 772
El pedido puede hacerse tam-
bién por internet:
http://www.volvopenta.com/
manual/coupon País

Nótese que el ofrecimiento vale durante 12 meses después de la fecha de entrega

de la embarcación, y posteriormente solamente mientras duren las existencias.


Sì, grazie,
7745861 - Downloaded from www.volvopenta.com 16/02/2009 14:42:32

desidero ricevere gratuitamente un manuale d’istruzioni in lingua italiana.

Spedire il tagliando per posta Public. No.: 7745009

42200/615001/155099900192
o per fax a: Nome e Cognome
Document & Distribution Center
Order Department
ARU 2, Dept. 64620 Indirizzo
SE-405 08 Göteborg
Svezia
Fax: +46 31 545 772
L’ordinazione può essere fatta
anche su Internet:
http://www.volvopenta.com/ Paese
manual/coupon

Si ricorda che l’offerta è valida per 12 mesi dalla data di consegna dell’imbarcazio-
ne; dopo il suddetto periodo l’offerta resta valida solo in base alla disposizione della
pubblicazione in oggetto.


Ja tack,
jag vill kostnadsfritt ha en instruktionsbok på svenska.
Posta eller faxa kupongen till: Publikationsnummer: 7745017
42200/615001/155099900192

Dokument & Distribution center Namn

Ordermottagningen
ARU 2, Avd. 64620
SE-405 08 Göteborg Adress
Sverige
Fax: +46 31 545 772
Beställningen kan även göras
via internet:
http://www.volvopenta.com/
manual/coupon Land

Observera att erbjudandet gäller i 12 månader från båtens leveransdatum,

därefter endast i mån av tillgång.

119
 
Ja graag,
Ik wil kosteloos een instructieboek in het Nederlands ontvangen.
Stuur of fax de coupon naar: Publicatienummer: 7745018

42200/615001/155099900192
Document & Distribution Center Naam
Order Department
ARU 2, Dept. 64620
SE-405 08 Göteborg Adres
Zweden
Fax: +46 31 545 772
U kunt ook bestellen via
internet:
http://www.volvopenta.com/
manual/coupon Land

Denk eraan dat het aanbod geldt gedurende 12 maanden na de datum

waarop de boot werd afgeleverd, daarna alleen indien nog verkrijgbaar.


Ja tak,
7745861 - Downloaded from www.volvopenta.com 16/02/2009 14:42:32

jeg vil gerne gratis have en instruktionsbog på dansk

Send kuponen med post eller Publikationsnummer: 7745019

42200/615001/155099900192
fax til: Navn
Document & Distribution Center
Order Department
ARU 2, Dept. 64620 Adresse
SE-405 08 Göteborg
Sverige
Fax: +46 31 545 772
Bestillingen kan også ske på
internet:
http://www.volvopenta.com/ Land
manual/coupon

Bemærk at tilbudet gælder i 12 måneder fra bådens leveringsdato, Deref-

ter kun så længe lager haves.


Kyllä kiitos,
haluan suomenkielisen ohjekirjan veloituksetta.
Postita tai faksaa kuponki Julkaisunumero: 7745027
42200/615001/155099900192

osoitteella: Nimi
Document & Distribution Center
Order Department
ARU 2, Dept. 64620 Osoite
SE-405 08 Göteborg
Ruotsi
Fax: +46 31 545 772
Tilauksen voi tehdä myös
Internetissä:
http://www.volvopenta.com/ Maa
manual/coupon

Huomaa, että tarjous on voimassa 12 kuukautta veneen toimituspäivä-

määrästä lukien ja sen jälkeen vain niin kauan kuin kirjoja riittää.

120
 
Sim, obrigado(a)!
Gostaria de receber gratuitamente um manual de instruções em português.
Envie o talão pelo correio ou Número de publicação: 7745028

42200/615001/155099900192
um fax para: Nome
Document & Distribution Center
Order Department
ARU 2, Dept. 64620 Endereço
SE-405 08 Göteborg
Sweden
Fax: +46 31 545 772
A encomenda também pode
ser feita através da Internet:
http://www.volvopenta.com/ País
manual/coupon

Observar que esta oferta é válida durante um período de 12 meses a contar da

data de entrega do barco. Após este período, a oferta está dependente do número
de exemplares disponíveis.


Íáé,
7745861 - Downloaded from www.volvopenta.com 16/02/2009 14:42:32

Èá Þèåëá Ýíá áíôßôõðï ôïõ åã÷åéñéäßïõ ÷ñÞóçò óôçí áããëéêÞ ãëþóóá ÷ùñßò êáìéÜ
÷ñÝùóç.
Ôá÷õäñïìÞóôå áõôü ôï êïõðüíé

42200/615001/155099900192
óôçí ðáñáêÜôù äéåýèõíóç ¼íïìá
Þ óôåßëôå ôï ìå öáî óôïí
ðáñáêÜôù áñéèìü öáî:
Document & Distribution Center Äéåýèõíóç
Order Department
ARU 2, Dept. 64620
SE-405 08 Göteborg
Sweden
Fax: +46 31 545 772
Ìðïñåßôå åðßóçò íá äþóåôå ôçí ×þñá
ðáñáããåëßá óáò ìÝóù ôïõ Inter-
net, óôç äéåýèõíóç:
http://www.volvopenta.com/ ÐÑÏÓÏ×Ç: ÁõôÞ ç ðñïóöïñÜ éó÷ýåé ãéá ÷ñïíéêÞ ðåñßïäï 12 ìçíþí
manual/coupon áðü ôçí ðáñÜäïóç ôïõ óêÜöïõò. ÌåôÜ ôï ðÝñáò ôçò åí ëüãù ÷ñïíéêÞò
ðåñéüäïõ ç äéáèåóéìüôçôá ôùí áíôéôýðùí èá åîáñôÜôáé áðü ôçí
ðïóüôçôá ôùí áðïèåìÜôùí.

121
 7745861 - Downloaded from www.volvopenta.com 16/02/2009 14:42:32

122
7745861 - Downloaded from www.volvopenta.com 16/02/2009 14:42:32
 04-2006
English
7745861

AB Volvo Penta
SE-405 08 Göteborg, Sweden
www.volvopenta.com