Volvo Penta D4 User manual

OPERATOR’S MANUAL
D4, D6

CALIFORNIA
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Welcome aboard
Volvo Penta marine engines are used all over the world. They are used in all possible operating
conditions for professional as well as leisure purposes. That’s not surprising.
After 100 years as an engine manufacturer the Volvo Penta name has become a symbol of reli-
ability, technical innovation, 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
operation and maintenance before your maiden voyage so that you will be ensured of fulfilling
your expectations. Please pay attention to the safety instructions contained in the manual.
As owner of a Volvo Penta marine engine, we would also like to welcome you to a worldwide
network of dealers and service workshops to assist you with technical advice, service require-
ments and replacement parts. Please contact your nearest authorized Volvo Penta dealer for
assistance.
We also invite you to visit our home page on the Internet at www.volvopenta.com
With warm regards
AB VOLVO PENTA

Safety Information ............................................ 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 information ............................................. 9
Identification numbers .......................................... 12
Presentation ................................................... 13–20
Technical 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
Power trim ........................................................... 54
Power trim Assistant............................................ 58
Volvo Penta Lowspeed ....................................... 59
Running aground.................................................. 60
Stopping the engine ...................................... 61-62
Stopping .............................................................. 61
Laying up ............................................................. 61
Cold weather precautions .................................... 62
Maintenance schedule ................................... 63-65
Maintenance ................................................... 66–96
Engine, general .................................................... 66
Lubrication system ............................................... 70
Freshwater system ............................................... 73
Seawater system .................................................. 76
Fuel system ......................................................... 80
Electrical system .................................................. 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 underwater 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
Power Trim.......................................................... 116
Steering .............................................................. 116
© 2007 AB VOLVO PENTA
All rights to changes or modifications reserved.
Printed on environmentally friendly paper.
(Cover: Department of transport (shipping), license 9809095)
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 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 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
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.
Refueling
When refueling there is always a danger of fire and
explosion. Smoking is forbidden and the engine must
be switched off.
Never overfill 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
4

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 stern. 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, however, 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. Try changing speed, trim or load
distribution instead. Try 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 Life jackets 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 over the planned route. Calculate distance and fuel consumption. Lis-
ten to the weather reports
●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.
●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.
Safety Information
5

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 correctly. 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 Volvo
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.
To 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 risk. Loose clothing, hair, fingers or
a dropped tool can be caught in the rotating parts of
the engine and cause serious personal injury. Volvo
Penta recommend that all servicing with the engine
running be undertaken by an authorized Volvo Penta
workshop.
Lifting the engine
When lifting the engine use the lifting eyes installed
on the engine (reverse gear where installed). Always
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. Check that no
tools or other items have been left on the engine.
Never start a turbocharged engine without installing
the air cleaner (ACL). The rotating compressor in the
Turbocharger unit can cause serious personal injury.
Foreign objects can also be sucked in and cause me-
chanical damage to the unit.
Fire and explosion
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 Volvo 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
6

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, Turbo 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. To 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. 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.
Fuel system
Always use protective gloves when tracing leaks.
Liquids ejected under pressure can penetrate body
tissue and cause serious injury. There is a danger of
blood poisoning.
Always cover 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. Always 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
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
We would all like to live in a clean and healthy envi-
ronment. Somewhere where we can breathe clean
air, see healthy trees, have clean water in our lakes
and oceans, and are able to enjoy the sunshine wit-
hout being worried about our health. Unfortunately,
this cannot be taken for granted nowadays but is so-
mething we must work together to achieve.
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
has been made in reducing exhaust emissions, fuel
consumption, engine noise, etc.
We hope you will take care in preserving these qua-
lities. Always follow any advice given in the instruc-
tion manual concerning fuel grades, operation and
maintenance and you will avoid causing unecessary
interference to the environment. Get in touch with your
Volvo Penta dealer if you notice any changes such as
increased fuel consumption exhaust smoke.
Adapt speed and distance to avoid wash and noise
disturbing or injuring animal life, moored boats, jetties,
etc. Leave islands and harbours in the same condition
as you want to find them. Remember to always leave
hazardous waste such as waste oil, coolant, paint and
wash residue, flat batteries, etc., for disposal at a de-
struction plant.
Our joint efforts will make a valuable contribution
to our environment.
Running-in
The engine must be run in for its first 10 operating
hours as follows: Operate the engine normally. Do not
operate it at full load except for short periods. Never
run the 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.
Fuel and oils
Only use the fuel and oils recommended in the chap-
ter Technical Data. Other grades of fuel and oil can
cause operating problems, increased fuel consump-
tion and, in the long-term, a shorter engine service
life.
Always change oil, oil filters and fuel filters at the re-
commended intervals.
Service and replacement parts
Volvo Penta marine engines are designed for high
operational reliability and long service life. They are
constructed to withstand the marine environment
while also affecting it as little as possible. Through
regular service and the use of Volvo Penta original
spare parts, these qualities will be retained.
The Volvo Penta worldwide network of authorized
dealers are at your service. They are specialists in
Volvo Penta products and have accessories and
the original replacement parts, test equipment and
special tools necessary for high quality service and
repair work.
Always follow the maintenance intervals contained
in the operator’s manual. Remember to state the en-
gine/transmission identification number when order-
ing service and replacement parts.
8