Volvo Penta D6 User manual
operator’s manual
d4/D6
WARNING!
Operating, servicing and maintaining a marine vessel can expose you to chemicals including
engine exhaust, carbon monoxide, phthalates, and lead which are known to the State of
California to cause cancer and birth defects or other reproductive harm.
Breathing diesel engine exhaust exposes you to chemicals known to the State of California
to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid
breathing exhaust when operating, servicing and maintaining the engine.
• Always start and operate the engine in a well-ventilated area.
• If in an enclosed area, vent the exhaust to the outside.
• Wear gloves or wash your hands frequently when servicing the vessel.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information
www.P65warnings.ca.gov/marine
www.p65warnings.ca.gov/products/diesel
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.Volvo Penta
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Table of Content
Foreword ...................................................................................................... 5
Safety Information ...................................................................................... 6
Maneuvering .......................................................................................... 14
Introduction ............................................................................................... 16
About this Manual ................................................................................... 16
Warranty .................................................................................................. 17
Your New Boat ........................................................................................ 17
Running in the engine ............................................................................. 18
Fuel, oils and coolant .............................................................................. 18
Maintenance and replacement parts ....................................................... 18
Excessive strain on a product and components ...................................... 19
Volvo Penta EVC system, integrity and modification .............................. 19
Installation and use of Volvo Penta External Helm ................................. 19
Recording engine data ............................................................................ 20
Certified Engines ..................................................................................... 21
Volvo Penta Dealer Network ................................................................... 22
Volvo Penta Action Service ..................................................................... 22
Instruments and Controls ........................................................................ 23
Ignition Lock .......................................................................................... 23
e-Key Panel ......................................................................................... 23
e-Key Remote ...................................................................................... 24
Ignition switch ...................................................................................... 24
Control Panels ....................................................................................... 25
Start/Stop Panel ................................................................................... 25
Station Panel ........................................................................................ 25
Cruise control panel ............................................................................. 26
Docking Panel ...................................................................................... 26
Powertrim panel ................................................................................... 28
Gauges ................................................................................................ 29
Displays ................................................................................................. 30
Information Display .............................................................................. 30
4" Display ............................................................................................. 31
7" Display ............................................................................................. 38
Alarm handling display ......................................................................... 45
Glass Cockpit Display .......................................................................... 46
Powertrim ............................................................................................... 49
Trim Ranges ......................................................................................... 49
Trim Controls ........................................................................................ 50
Powertrim Assistant ............................................................................. 51
Maneuvering ........................................................................................ 52
Controls ................................................................................................. 54
Top mounted control ............................................................................ 54
Side mounted control ........................................................................... 56
Disengaging the Shift Function ............................................................ 57
Adjusting the friction brake ................................................................... 58
Joystick ................................................................................................ 59
Features ..................................................................................................... 60
Lowspeed ................................................................................................ 60
Autopilot .................................................................................................. 62
Cruise Control ......................................................................................... 63
47712786 11-2022 © AB VOLVO PENTA 1
Joystick for docking ................................................................................. 64
Joystick Driving ....................................................................................... 68
Thruster Mode ......................................................................................... 71
Optional ..................................................................................................... 73
Optional ................................................................................................... 73
Dynamic Positioning System ............................................................... 73
DPS Repositioning ............................................................................... 76
Battery Management System ............................................................... 78
Local Control ........................................................................................ 78
Battery Management display ............................................................... 79
Active Corrosion Protection ................................................................ 82
Power Take-off ....................................................................................... 84
Volvo Penta Interceptor System .......................................................... 85
Operation ............................................................................................. 86
Swim platform Interface ....................................................................... 88
Alternator Voltage Reducer .................................................................. 89
Volvo Penta Easy Connect ................................................................... 90
Starting ...................................................................................................... 91
Before Starting ...................................................................................... 91
Starting the Engine ............................................................................... 92
Helm stations ....................................................................................... 92
Starting the Engine .............................................................................. 92
Read the instruments and warm the engine up ................................... 93
Operation ................................................................................................... 94
Reading the Instruments ...................................................................... 94
Alarms .................................................................................................... 94
Maneuvering .......................................................................................... 95
Helm station priority ............................................................................. 96
Transfer under way .............................................................................. 97
Cruising Speed .................................................................................... 97
Engine synchronization disable ........................................................... 98
Engine Shutdown ...................................................................................... 99
Stop the Engine ..................................................................................... 99
Ignition Auto Off ................................................................................. 100
Auxiliary stop ...................................................................................... 100
After Engine Shutdown ...................................................................... 101
Operation Break ................................................................................. 101
Laying Up and Launching .................................................................. 102
Trailering Your Boat ............................................................................ 102
Cold Weather Precautions ................................................................. 102
Fault handling ......................................................................................... 103
Alarm Handling ...................................................................................... 103
Acknowledge message ......................................................................... 103
Alarm List .............................................................................................. 104
Fault Tracing ........................................................................................ 105
Fault Code Register ................................................................................ 106
In Case of Emergency ............................................................................. 113
Running Aground ................................................................................ 113
Towing the Boat ................................................................................... 114
Starting Using Auxiliary Batteries ..................................................... 114
Emergency Shifting ............................................................................. 115
Emergency shifting, DPH ................................................................... 115
2 47712786 11-2022 © AB VOLVO PENTA
Emergency Steering ............................................................................ 116
Engine limp home ............................................................................... 116
Emergency Steering DPI .................................................................... 116
Emergency steering with twin control levers ...................................... 119
Emergency Alignment, Electrical Rudder Actuator ............................ 119
Emergency Trimming .......................................................................... 122
Emergency Start .................................................................................. 123
Start after crash-stop ......................................................................... 123
Start/Crank override ........................................................................... 123
Maintenance Schedule ........................................................................... 124
Maintenance ............................................................................................ 125
Engine, General ................................................................................... 126
Lubrication System ............................................................................. 127
Engine oil level, checking ................................................................... 127
Fuel System ......................................................................................... 127
Fuel system, bleeding ........................................................................ 128
Water in Fuel ...................................................................................... 128
Freshwater System ............................................................................. 129
Coolant level, checking ...................................................................... 130
Seawater System ................................................................................. 131
Seawater Filter, Check and Cleaning ................................................. 132
Electrical System ................................................................................ 133
Electrical Connections ....................................................................... 133
Battery ................................................................................................ 134
Reversing gear .................................................................................... 135
Oil level, checking .............................................................................. 136
Drive ..................................................................................................... 137
Transmission lubricant, checking ....................................................... 137
Storage ..................................................................................................... 138
Calibration and Settings ......................................................................... 139
Settings Menu ....................................................................................... 139
My View ................................................................................................. 139
Neutral beep .......................................................................................... 139
Information beep ................................................................................... 140
Trip Reset .............................................................................................. 140
Depth Alarm .......................................................................................... 140
Display Contrast .................................................................................... 142
Side Selection ....................................................................................... 142
Units ...................................................................................................... 142
Language .............................................................................................. 143
EVC Info ................................................................................................ 143
PTA Calibration ..................................................................................... 144
Fuel Tank ............................................................................................... 145
Speed Factor ......................................................................................... 146
Key Management .................................................................................. 146
Ignition Auto Off .................................................................................... 147
Joystick calibration ................................................................................ 148
Joystick calibration, DPI/DPH ............................................................... 149
Joystick Inboard calibration ................................................................... 150
Drive Straight calibration ....................................................................... 152
Technical Data ......................................................................................... 153
Viscosity ................................................................................................ 154
47712786 11-2022 © AB VOLVO PENTA 3
Coolant, Mixing ..................................................................................... 158
Identification Numbers ....................................................................... 161
Declaration of Conformity .................................................................. 163
Declaration of Conformity .................................................................. 163
Index ......................................................................................................... 165
4 47712786 11-2022 © AB VOLVO PENTA
Foreword
Welcome!
Congratulations on your new boat equipped with a Volvo Penta marine engine.
Volvo Penta engines are designed to fulfill Volvo’s core values; quality, safety and
environmental care. After more than 100 years as an engine manufacturer, the
Volvo Penta brand has also become a symbol of reliability, technical innovation, top-of-
the-range performance and long service life. Volvo Penta marine engines are used all over
the world, in all possible operating conditions for professional as well as leisure purposes.
Make sure to thoroughly read through this Operator’s Manual and take necessary actions
regarding running and maintenance before your maiden voyage. It contains the
information you need to be able to operate and maintain the engine safely and correctly.
Pay careful attention to the safety instructions included in the manual.
As the owner of a Volvo Penta marine engine, you become part of a worldwide network of
dealers and service workshops that assist you with technical advice, service requirements
and replacement parts. Contact your nearest authorized Volvo Penta dealer for
assistance.
It is possible to buy additional literature about your Volvo Penta engine, e.g. the Service &
Maintenance manual. More information on how to do this can be found at
www.volvopenta.com.
Information about your closest Volvo Penta dealer and other useful news and
information can be found at www.volvopenta.com and by following Volvo Penta on
Facebook.
www.volvopenta.com
www.facebook.com/volvopenta
47712786 11-2022 © AB VOLVO PENTA 5
Safety Information
This chapter describes how safety precautions are
presented in the manual and on the product. Read the
chapter through very carefully before you start the
engine or do any maintenance or service. It has to do
with your safety; an incorrect operation can lead to
personal injury and damage to products or property. It
also gives you an introduction to the basic safety rules
for using and looking after the engine.
If anything remains unclear or if you are unsure of
something, contact your Volvo Penta dealer for
assistance.
IMPORTANT:
Always follow local safety instructions and
regulations.
Safety texts have the following order of priority:
DANGER!
Indicates a hazardous situation, which, if not avoided, result in death or serious injury.
WARNING!
Indicates a hazardous situation, which, if not avoided, could result in death or serious
personal injury.
CAUTION!
Indicates a hazardous situation, which, if not avoided, could result in minor or moderate
personal injury.
IMPORTANT:
Indicates a situation, which, if not avoided, could result in property damage.
NOTICE! Used to draw attention to important information that facilitates work or
operations.
!
This symbol is may be used on the product to call your attention to the fact that this is
safety information. Always read such information very carefully.
Make sure that warning and information symbols on the engine are clearly visible and
legible. Replace symbols that have been damaged or have been painted over.
In some cases, this symbol is used on our products and refers to important information
in the Operator’s Manual.
6 47712786 11-2022 © AB VOLVO PENTA
Most chemicals such as engine and transmission oils,
glycol, petrol and diesel oil and chemicals used in
workshops such as degreasing agents, paint and
solvents are harmful to health.
Carefully read the instructions on the product
packaging! Always follow the safety regulations, such
as the use of protective masks, goggles, gloves, etc.
Make sure that other personnel are not exposed to
substances that are hazardous to health. Ensure good
ventilation.
Manage used and leftover chemicals in the prescribed
manner.
Daily Checks
WARNING!
Do not start the engine if there is reason to suspect fuel
leaks or if there is explosive material nearby.
Make it a habit to give the engine and engine
compartment a visual check before the engine is
started and after operations, once the engine has
stopped. This helps you to quickly discover fuel,
coolant or oil leakages or any other abnormality that
has occurred, or is about to occur.
Personal safety equipment
CAUTION!
Always use appropriate safety equipment. Personal
protective equipment does not eliminate the risk of
injury but it will reduce the degree of injury if an
accident does happen.
Some examples are ear protection, eye and face
protection, protective footwear, personal protective
equipment, head protection, protective clothing,
gloves and respirators.
WARNING!
Ensure that all machine guards and safety devices are
in place and are functional.
CAUTION!
Never use tools or products that show signs of
damage.
Protect your eyes
CAUTION!
Wear safety glasses.
Always wear safety glasses if there is a risk of
splintering, sparks and spray from the electrolyte (so-
called battery acid), or other chemicals. Your eyes are
very delicate and damage can result in loss of sight!
P0024482
Safety Information
47712786 11-2022 © AB VOLVO PENTA 7
Protect your skin
CAUTION!
Risk of skin damage.
Avoid getting oil on your skin! Prolonged or repeated
exposure to oil can dry out the skin. Thereafter,
irritation, dryness and eczema and other skin problems
may occur.
Use protective gloves and avoid oil-soaked clothes
and rags. Wash regularly, especially before eating.
Wear suitable protective creams to prevent skin from
drying out and to facilitate cleaning.
Fire safety
WARNING!
Fire and Explosion Risk!
Accidental spark could ignite fuel vapors.
All fuels – as well as many lubricants and chemicals –
are flammable. Do not allow open flames or sparks
near them. Smoking forbidden! Hydrogen from the
batteries is also very flammable and explosive in
certain mixture with air.
Ensure that the workplace is well ventilated and take
the necessary precautions before welding or grinding
begins. Always ensure that there is a fire extinguisher
close at hand in the work area.
Spare parts — safety
WARNING!
Always use spare parts with the same quality as
genuine Volvo Penta parts to minimize the risk of an
explosion or fire.
Components in fuel systems and electrical systems on
Volvo Penta engines are designed and manufactured
to minimize the risk of explosions and fire, in
accordance with applicable legal requirements.
Used oils, filters and chemicals etc.
WARNING!
Risk of fire.
Store fuel soaked rags and other flammable material
so that there is no danger of them catching fire.
Oil-soaked rags can spontaneously ignite under
certain circumstances.
IMPORTANT:
Used fuel and oil filters are environmentally hazardous
waste and must be taken to an approved waste
management facility for correct handling, as must any
used lubricating oil, contaminated fuel, paint residue,
solvents, degreasers and wash residue.
P0024470
Safety Information
8 47712786 11-2022 © AB VOLVO PENTA
Prevent start of the engine
WARNING!
Immobilize the engine by turning off the power supply
with the main switch(es) and lock it (them) in the off
position before starting work. Place a warning notice at
the main switch.
If the engine is equipped with BMS (Battery
Management System), always disconnect both battery
cables from the battery terminals.
Ventilation when running the engine
WARNING!
Only start the engine in a well-ventilated area. If
operating the engine in a closed area ensure that there
is exhaust ventilation leading out of the work area to
remove exhaust gases and crankcase ventilation
emissions.
The engine must not be operated in areas where there
are explosive materials or stored gas.
Rotating parts and hot surfaces
DANGER!
Working with or approaching a running engine is a
safety risk. Watch out for rotating components and hot
surfaces.
If the engine is in operation and operates another
device, you must not, under any circumstances,
staying close to the engine.
Work on running engines is strictly prohibited. There
are however adjustments that require the engine to be
run. Approaching a running engine is a safety risk.
Loose clothing and long hair can get caught in the
rotating parts; careless movements or a dropped tool
can lead to serious personal injury.
Be careful to avoid hot surfaces (exhaust pipes,
turbochargers, charge air manifolds, start elements
etc.) and hot fluids in pipes and hoses on engines that
are running or have just stopped. Re-install all
protective covers that were removed during
maintenance work before starting the engine.
Information on the engine
IMPORTANT:
Make sure that all warning and information decals on
the product are always visible. Replace decals which
have been damaged or painted over.
P0024481
P0024808
Safety Information
47712786 11-2022 © AB VOLVO PENTA 9
Prohibition on use of start spray
WARNING!
Never use start spray or similar agents to start an
engine. This may cause an explosion in the inlet
manifold. Risk of personal injury.
Before start of engine
WARNING!
Never start the engine if there is reason to suspect fuel
and/or gas leaks, or if there is explosive material
nearby.
IMPORTANT:
Only start the engine with the air filter and protective
caps fitted. Foreign objects in the inlet line could cause
machine damage. Also make sure that no tools or other
parts have been left next to the engine.
WARNING!
Never start the engine with the valve cover removed.
There is a risk of personal injury.
For engines with turbochargers, the rotating
compressor turbine can in addition cause serious
personal injuries.
Before any work on the electrical system
WARNING!
Always stop the engine first. Then disconnect the
current at the main switches and any external power
supply before working on the electrical system – to
minimize the risk of electrical hazards.
IMPORTANT:
Never disconnect the current using the main switches
when the engine is running or by disconnecting the
battery cables.
The alternator and electronics could be damaged.
Avoid damage to the engine control
module and other electronics
IMPORTANT:
Switch off the main switch before connecting or
disconnecting a connector.
Before welding work
IMPORTANT:
Before any work with electric weld can begin, the
connection to all control units must be disconnected.
After finished welding, re-connect the connection to all
control units before connecting any battery cable.
P0024483
P0024688
Safety Information
10 47712786 11-2022 © AB VOLVO PENTA
Before any work on the cooling system
WARNING!
Stop the engine and let it cool before starting work on
the cooling system. Hot fluids and hot surfaces can
cause burns.
Risk of water penetration/sinking
WARNING!
If a launched boat is equipped with sea water tap and
safety valve, ensure that these are closed before any
work is allowed to begin on the cooling system.
Remember to open the tap and valve before starting
the engine!
Hot coolant under pressure
CAUTION!
Hot coolant can cause burns. Avoid opening the filler
cap for the coolant when the engine is still hot. Steam
or hot coolant can spray out and system pressure is
lost.
Open the filler cap slowly and release the pressure in
the cooling system if the filler cap or valve must be
opened – or if a plug or a coolant hose must be
removed from a hot engine.
Hot oil under pressure
CAUTION!
Hot oil can cause burns. Avoid getting hot oil on the
skin. Ensure that the lubrication system is not
pressurized before starting any work. Never start or
operate the engine without the oil filler cap is on. There
is a risk that hot oil can spray out.
Refueling
WARNING!
There is always a risk of fire and explosion during
refueling. Smoking is forbidden and the engine must be
stopped.
P0024484
Safety Information
47712786 11-2022 © AB VOLVO PENTA 11
Proper fuel quality
IMPORTANT:
Always use the fuel recommended by Volvo Penta.
See Technical Data in Operator’s Manual. Other fuel
can damage the engine.
Wrong fuel quality can also lead to higher service
costs.
WARNING!
Risk of personal injury.
Wrong fuel quality in a diesel engine can cause the fuel
control mechanism to bind which can cause the engine
to overspeed!
Legal requirements to use proper fuel
IMPORTANT:
To meet regulatory requirements for certified emission
levels must always recommended fuel according to
Technical Data in the Operator’s Manual be used.
At any leak detection on the fuel system
WARNING!
Wear safety goggles!
Be extremely careful when searching for leaks in the
fuel system high-pressure circuits. There is very high
pressure in the jet from pipes and injectors. The fuel
may penetrate the tissue and cause serious risk of
blood infection (septicemia).
Handling of fuel pipes
IMPORTANT:
High pressure pipes for fuel must not be bent or
straightened under any circumstances. Cracks may
occur. Damaged pipes must be replaced.
Safe handling of batteries
WARNING!
Risk of fire and explosion. Never allow an open flame
or electric sparks near the batteries.
A spark caused by an incorrectly connected battery
can be enough for the battery to explode with serious
injuries.
Do not touch the connections during start attempts.
Sparking hazard! Do not lean over batteries.
P0024477
P0024488
Safety Information
12 47712786 11-2022 © AB VOLVO PENTA
Correct polarity of the batteries
IMPORTANT:
Make sure that the positive (+) and negative (–) battery
cables are correctly connected to the corresponding
battery terminals. Wrong connection may cause
severe damage to electrical equipment.
Risks of electrolyte in batteries
WARNING!
Always wear protective goggles when charging or
handling batteries.
Battery electrolyte is highly corrosive.
Rinse immediately with copious amounts of water if the
electrolyte gets in your eyes. Search directly after the
rinsing help by medical staff.
If it comes electrolyte to unprotected skin, wash
immediately with soap and water.
Layout of the battery compartment
IMPORTANT:
Make sure the battery compartment is designed
according to current safety standards.
Cleaning the engine and components
IMPORTANT:
Never use a high pressure washer for cleaning of
engine or engine components.
Cleanliness for sensitive components
IMPORTANT:
Observe meticulous cleanliness when handling
system components.
Even minimal amounts of dirt could cause a
breakdown.
Adjustment of the clutch
CAUTION!
Clutch adjustments must be carried out with the engine
stopped.
P0024468
P0024486
Safety Information
47712786 11-2022 © AB VOLVO PENTA 13
Maneuvering
WARNING!
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.
To avoid passengers falling overboard, refrain from
extreme and sudden rudder movements and ahead/
astern movements.
Lanyard switch
We recommend installing and using a lanyard switch
(optional), especially if the boat is capable of high
speeds. The lanyard switch stops the engine if the
driver looses control of the boat.
Accidents at sea
Maritime rescue statistics show that a large number of
boat accidents are caused by inadequate engine and
boat maintenance and the lack of safety equipment.
Make sure that the boat engine is properly maintained
by making sure that the recommended service is
performed, and that necessary safety equipment is
available and functional.
Stern turbulence
WARNING!
Carbon Monoxide Poisoning. When the boat moves
forward, an area of lower pressure air is formed behind
the boat — so-called turbulence. In certain conditions,
this turbulence can be powerful enough to draw the
exhaust fumes into the cockpit or cabin, creating a risk
of carbon monoxide poisoning to people on board.
The turbulence problem is most pronounced on tall,
broad-beamed boats with a transom stern. But even for
other boat types, low-pressure suction can be a
problem in certain conditions, such as driving with
cockpit awnings rigged. Other factors that can increase
the effect of turbulence are wind conditions, load
distribution, swell, trim, open hatches and ventilators
etc.
Most modern boats are, however, designed so that the
problem of low-pressure suction is very rare. Should
turbulence nevertheless occur, hatches or ventilators
must not be opened since this might exacerbate the
problem. Instead, try to change the speed, trim or load
distribution. If possible, take down or open the cockpit
awning. Contact your boat dealer for the best solution
for your boat.
Safety Information
14 47712786 11-2022 © AB VOLVO PENTA
To remember before the boat trip
The lists below includes some tips on what to
remember to bring on any boat trip. The list can be
extended since the need for safety equipment varies
with the boat type and where or how it is used etc. We
recommend you ask a regional boat or sea safety
organization for more detailed maritime safety
information.
•Take your chart out and study your planned route.
Calculate distance and fuel consumption. Listen to
weather reports.
•Tell your friends/relatives about route plans if you
undertake a long journey. Remember to notify
changed plans or delays.
•Inform everybody aboard about where the safety
equipment is located, and how it works. Make sure
that there is more than one person aboard who can
start and operate the boat safely.
Safety Equipment:
•life jackets
•communication equipment
•emergency rockets
•approved fire extinguisher
•first aid kit
•life buoy
•anchor
•paddle
•flashlights
•Emergency steering kit (DPI, single)
Spare Parts and Tools:
•impeller
•fuel filters
•fuses
•tape
•hose clamps
•engine oil
•other tools that may be required
Safety Information
47712786 11-2022 © AB VOLVO PENTA 15
Introduction
Check that you heave received the correct
operator’s manual before continuing reading. If
not, please contact your Volvo Penta dealer. Read
the Operator’s Manual carefully and learn to handle the
engine, controls and other equipment in a safe manner
before you start the engine.
For engine designations, refer to Technical
Data, page 153. The designation is stated on the
engine plate, refer to Technical Data, page 161.
The illustrations in this book may cover several product
types, which means that there may be slight
differences between the illustrations and the
purchased product. This does, however, not affect the
validity of the information and/or instructions in the
manual. Volvo Penta reserves the right to make
alterations to specifications, design features, and
illustrations without prior notice.
At service, software can be updated that affects the
functionality described in this manual.
About this Manual
This Operator's Manual has been prepared to give you
the greatest possible benefit from your Volvo Penta
marine engine. It contains necessary information
regarding safe and correct engine operation and
maintenance.
Always have the Operator's Manual available. Store it
safely and do not forget to hand it over to the next
owner if you sell your boat.
16 47712786 11-2022 © AB VOLVO PENTA
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