Volvo Penta D4 User manual

OPOP
ERER
AA
TT
OR’S MAOR’S MA
NN
UU
ALAL
D4, D6D4, D6

CALIFORNIACALIFORNIA
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Welcome aboardWelcome aboard
VV
olvo Penta marine engines are used olvo Penta marine engines are used
all over the world. They are used in all possible operatingall over the world. They are used in all possible operating
conditions for professional as well as leisure conditions for professional as well as leisure
purposes. purposes.
That’s not surprising.That’s not surprising.
After 100 years as After 100 years as
an engine manufacturer the Van engine manufacturer the V
olvo Penta name has become a symbol olvo Penta name has become a symbol
of reli-of reli-
abilityability
, technical innovation, top , technical innovation, top
of the of the
range performance and range performance and
long service long service
life. life.
We also believeWe also believe
that this that this
is what you is what you
demand and demand and
expect of your Vexpect of your V
olvo Penta engine.olvo Penta engine.
We would like you to read this We would like you to read this
operator’s manual thoroughly and consider the advice operator’s manual thoroughly and consider the advice
we give onwe give on
operation and maintenance before your maiden operation and maintenance before your maiden
voyvoy
age so that age so that
you will be ensured of you will be ensured of
fulfillingfulfilling
your expectations. your expectations.
Please pay attention to the Please pay attention to the
safety instructions contained in the safety instructions contained in the
manual.manual.
As owner of a VolvAs owner of a Volv
o Penta marine engine, we would also o Penta marine engine, we would also
like to welcome you to a like to welcome you to a
worldwideworldwide
network of dealers and service workshops to assist you with technical advice, service require-network of dealers and service workshops to assist you with technical advice, service require-
ments and ments and
replacement parreplacement par
ts. Please contact your nearest ts. Please contact your nearest
authorized Vauthorized V
olvo Penta dealer forolvo Penta dealer for
assistance.assistance.
We also invite you to visit our We also invite you to visit our
home page on home page on
the Internet the Internet
at www.vat www.v
olvopenta.comolvopenta.com
With warm regardsWith warm regards
AB VOLVAB VOLV
O O
PENPEN
TT
AA

Safety
Informatio
n
 ............................................ 3–7
General
...................................................................
3
Boat
travel...............................................................
4
Maintenance and
service .......................................
6
Introduction
...................................................
8–12
Running-in
.............................................................
8
Fuel and oil types
..................................................
8
Certificated engines
...............................................
9
Warranty inf
ormation .............................................
9
Identification numbers
..........................................
12
Presentation
...................................................
13–20
T
echnical Description............................................
13
Engine
monitoring and
EVC ................................
14
Orientation
...........................................................
17
Instrumentation
 ..............................................21-44
Ignition lock
...........................................................
21
Start/stop panel
....................................................
21
Instruments
...........................................................
22
Alarm display
........................................................
23
EVC
control
panel.................................................
26
EVC system tachometer
.......................................
27
EVC system
display
..............................................
37
Controls
.......................................................... 45-47
Starting the engine
........................................48-50
Before starting
......................................................
48
General about starting
..........................................
48
Starting method
....................................................
50
Operation
 .........................................................51-57
Reading
instruments ...........................................
51
Acknowleging
alarms and
messages
.................
51
Cruising
speed
.....................................................
52
Synchronising
engine
speed
..............................
52
Changing helm
station ........................................
53
Operation ............................................................ 54
Pow
er trim ...........................................................
54
Pow
er trim Assistant
............................................
58
V
olvo
Penta
Lowspeed
.......................................
59
Running aground
..................................................
60
Stopping the engine
...................................... 61-62
Stopping
..............................................................
61
Laying
up .............................................................
61
Cold w
eather precautions ....................................
62
Maintenance schedule
 ...................................63-65
Maintenance
...................................................
66–96
Engine,
general
....................................................
66
Lubrication sy
stem
...............................................
70
Freshwater
system
...............................................
73
Seawater system
..................................................
76
Fuel
system
.........................................................
80
Electrical s
ystem
..................................................
83
Reverse gear
........................................................
88
Drive
.....................................................................
90
Steering
................................................................
93
Propellers
.............................................................
96
Laying up/Launching
 .....................................97-99
Inhibiting
...............................................................
97
Bringing out of winter storage
...............................
98
Painting the drive and underw
ater hull .................
99
In case of emergency
..................................
100-106
Starting using auxiliary batteries
........................
100
Emergency shifting
.............................................
101
Emergency
trimming
..........................................
102
Engine stop after
crash-stop
...............................
102
Fault-tracing
........................................................
103
Diagnostic function
.............................................
104
Malfunction message engine and
EVC-system
..
105
Faults
list ............................................................
106
Erasing
faults .....................................................
106
Fault register
 ...............................................107-113
Technical Data
 ............................................114-116
Engine
................................................................
114
Fuel
specification ...............................................
115
Drive
..................................................................
116
Reverse gear
......................................................
116
Pow
er
T
rim ..........................................................
116
Steering
..............................................................
116
Contents

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.
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 Volv
o 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.

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

Carbon monoxide poisoning
When a boat is moving forward, it will cause a cer-
tain vacuum to form behind the boat. In unfortunate
circumstances, the suction from this vacuum can be
so great that the exhaust gases from the boat are
drawn into the cockpit or cabin and cause carbon mo-
noxide poisoning.
This problem is most prevalent on high, wide boats
with abrupt ster
n. In certain conditions, however
, this
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.
Most modern boats,
howev
er, are designed in such
a way that this problem is
very rare. If suction should
arise anyway
, do not
open hatches or
portholes at
the fore of the
boat. Surprisingly
, this will otherwise
increase the suction. T
ry changing
speed, trim or
load
distribution instead. T
ry
taking down/opening or
in any
other way changing the setup
of the cover as well.
Get in touch with your boat dealer for help in obtain-
ing the best solution for your boat.
Checklist
●
Safety equipment Li
fe jack
ets for all
passengers, communication
equipment, emergency rockets
,
approved fire extinguisher
, first-aid equipment,
life belt, anchor, paddle, torch etc.
●
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.
●
Get out your charts and go o
ver the planned route
.
Calculate distance and fuel
consumption.
Lis-
ten to the weather reports
●
Make sure that relations
or contact persons are inf
ormed when planning a longer v
oyage.
Re-
member to inform them if your plans have changed or been delayed.
●
T
ell your passengers and crew where the saf
ety 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.
Safety Information

Safety precautions for maintenance and service operations
Preparations
Knowledge
The operator’s manual contains instructions on
how
to carry out general maintenance and service opera-
tions safely and corr
ectly
. Read the instructions
care-
fully before starting work.
Service literature covering more complicated opera-
tions is available from your Volvo Penta dealer.
Never carry out any work on the engine if you are
unsure of how it
should be done, contact
your V
olvo
Penta dealer who will be glad
to offer assistance.
Stop the engine
Stop the engine before opening or removing engine
hatches. Unless otherwise specified all maintenance
and service must be carried out with the engine
stopped.
T
o prevent accidental start
of the boat
engine remove
the ignition key
, turn
off the power supply to
the en-
gine at the main switches and lock them in the OFF
position before starting work. Put up a warning sign
in the control position that work on the engine is be-
ing carried out.
Approaching or working on an engine that is run-
ning is a safety r
isk. Loose clothing, hair, fingers or
a dropped tool can be caught in the rotating parts of
the engine
and cause
serious personal
injury
. V
olvo
Penta recommend that all servicing with the engine
running be
undertaken by
an authorized Volv
o Penta
workshop.
Lifting the engine
When lifting the engine use the lifting eyes installed
on the
engine (reverse gear where
installed). Alwa
ys
check that lifting equipment is in good condition and
has sufficient load capacity to lift the engine (engine
weight including reverse gear and any extra equip-
ment installed). For safety’s sake lift the engine
us-
ing an adjustable lifting beam. All chains and
cables
should run parallel to each other and as perpendicu-
lar as possible in relation to the top of the engine.
Bear in mind that extra equipment installed on the
engine may alter
its center
of gravity
. Special lifting
equipment may then be required in order to maintain
the correct balance and make the engine safe to han-
dle. Never carry out work on an engine suspended on
a hoist.
Before starting the engine
Reinstall all protective parts removed during service
operations before starting the
engine. Chec
k that no
tools or other items have been left on the engine.
Never start a turbocharged engine without installing
the air cleaner
(ACL).
The rotating compressor
in the
T
urbocharger unit
can cause
serious personal
injury
.
Foreign objects can also be sucked in and cause me-
chanical damage to the unit.
Fire and explos
ion
Fuel and lubrication oil
All fuel, most lubricants and many chemicals are
inflammable.
Read and follow the instructions on
the
packaging.
When carrying out work on the fuel system make
sure the engine is cold. A fuel spill onto a hot surface
or electrical components can cause a fire.
Store fuel soaked rags and other flammable material
so that there is no danger of them catching fire. Fuel-
soaked rags can self-ignite under certain conditions.
Do not smoke when filling fuel, oil or in proximity of a
filling station or in the engine room.
Non-original components
Components used in the fuel and ignition system
(gasoline engines) and
electrical systems on Volvo
Penta products are designed and constructed to
minimize the risk of fire and explosion.
Using non-original V
olvo Penta parts can result
in fire
or explosion on board.
Batteries
The batteries contain
and give off oxyhydrogen gas,
especially during charging. This gas is easily ignited
and highly volatile.
Do not under any circumstances smoke or use naked
flame or allow sparks in the vicinity of the batteries or
battery compartment.
Incorrectly connection a battery terminal cable or
jump-start cable can cause a spark which in its turn
can be sufficient to cause an explosion.
Start spray
Never use start spray or similar agents to start an en-
gine equipped with air pre-heating (glow plugs/starter
element).
This may cause an explosion in
the inlet
manifold. Danger of personal
injury
.
Safety Information

Hot surfaces and
fluids
There is always a risk of burns when working with
a hot engine. Beware of hot surfaces. For example:
the exhaust pipe, T
urbo unit, oil
pan, charge air
pipe,
starter element, hot coolant and hot oil in oil lines and
hoses.
Carbon monoxide poisoning
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
gases and crankcase ventilation emissions from the
working area.
Chemicals
Most chemicals such as anti-freeze, rustproofing
agent, inhibiting oil, degreasing agent etc. are haz-
ardous to health. Read and follow the instructions
on
the packaging.
Some chemicals such as inhibiting oil are inflam-
mable and dangerous if
breathed in as
well. Ensure
good ventilation and use a protective mask when
spraying.
Read and follow the instructions
on the
packaging.
Store chemicals and other hazardous materials out
of the
reach of
children.
T
o protect
the environment
please dispose of used or leftover chemicals at a
properly designated disposal site for destruction.
Cooling system
There is a risk of flooding when working on the sea-
water system.
T
urn 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 syste
m
Hot oil can cause
burns. A
void skin contact with hot
oil. Ensure that the lubrication system is not under
pressure before commencing work on
it. Nev
er star
t
or operate the engine with the oil filler cap removed,
oil can spray out.
Fuel system
Always use protective gloves when
tracing leaks.
Liquids ejected under pressure can penetrate body
tissue and cause ser
ious injury.
There is a
danger of
blood poisoning.
Always cov
er the generator
if it is located
under the
fuel filter.
The generator can be
damaged by spilled
fuel.
Electrical system
Cutting off power
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.
Batteries
The batteries contain an extremely corrosive elec-
trolyte. Protect your skin and clothes when charging
or handling
batteries. Alwa
ys use protective
goggles
and gloves.
If battery electrolyte comes into contact with unpro-
tected skin wash off immediately using plenty of wa-
ter and soap. If battery acid comes into contact with
the eyes, flush immediately with plenty of water and
obtain medical
assistance without
delay
.
Safety Information

The EVC system
The Electronic V
essel Control (EVC) system is
a so
called distributed system. The principle of a distrib-
uted system is to
have many small electonic units,
called nodes, located on suitable places in the boat.
The EVC nodes are the Powertrain Control Unit
(PCU) and the Helm
station Control Unit (HCU).
Nodes are located close to the components they
control. A helm node is located
close to the helm. A
powertrain node is mounted in the engine room.
Each node controls a number of adjacent compo-
nents, for example sensors, controls, instruments and
actuators.
Each PCU and HCU is programmed for a specific
engine individual. On the PCU and HCU there is a
sticker with chassis
no.
The chassis
no. shall corre-
spond to the sticker on the engine.
A data bus, a CAN bus, connects the nodes to each
other. Together they form a network and exchange
information and take advantage of
each others’ serv-
ices.
The principle of
forming a network of
nodes to
which all components are connected reduces wiring
radically.
CAN stands for Controller Area Network, an industry
standard for communication between nodes in distr
ib-
uted systems.
A distributed system supports a growing multiplicity
of system configurations
and optional
features. N
ew
nodes can be connnected to the network with mini-
mal wiring
redesign. New effectiv
e functionality can
be created by letting the nodes interact and combine
their capabilities, creating a more useful and safe
product.
Functionalities
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
synchron
ization
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
The instruments use
a serial communication bus. The
serial communication bus in combination with EVC
radically reduces wiring and
simplifies installation.
EVC system tachometer
The EVC system tachometer is mandatory for boats
with EVC, unless the optional EVC system
display
is installed. The tachometer display shows operation
information, information massages and
alarms.
The
user selects what operation information to display
with the control
panel.
NOTE!
Only one operation in-
formation can be
displayed at one and the same
time.
The EVC system tachometer and control panel is
also used when calibrating
EVC functions.
Power Trim
The function is
considerably improved compared
to non EVC governed
Po
wer trim systems. EVC in-
troduces a new trim panel with the same design as
other EVC control panels. If you have a twin engine
installation the stern drives can be both individually
and simultaneously controlled.
Trimming in and out can be calibrated to suit the spe-
cific installation. T
o protect
the drive it
cannot be
tilted
when engine is running above a certain rpm.
The Power trim control panel shall be connected to
the
multilink bus
and the gauge
to the instrument
cable harness from
the HCU.
The cable harness for
stern drives has connectors for the power trim angle
sensor and the power trim pump.
Extra optional equipment
EVC system display
The EVC system display is a complement or replace-
ment for EVC system tachometer and optional in-
struments. The display shows operation information,
information massages and alar
ms.
The user selects
what operation information to display with the buttons
on the display. The EVC system display can display
more than one operation information at one and the
same time.
The display also has access
to the same
display mode and calibration functions as
for the EVC
system tachometer display.
Trim indicator
A trim indicator sender is included in all aquamatic
drives.
The trim angle
can be displayed on the EVC
system tachometer. It is also advised to install a
trim
instrument. The instrument shows trim angle and trim
range. If a trim instrument is used it must be connect-
ed to the
instrument serial
communication bus.
Fuel level
Fuel level can be displayed on the EVC system
ta-
chometer if a (3-180 ohm or 240-30 ohm) fuel level
sender is installed in the fuel tan
k.
The sender
is
connected to the
PCU–engine cable harness. If a
fuel level gauge is used it must be connected to the
instrument serial
communication bus.
Presentation