OPERATOR’S MANUAL D11
An English version of this Operator’s Manual may be ordered free of charge up to 12 months after delivery, via internet, mail or fax. Refer to the order form in the back of the book. En dansk version af denne instruktionsbog kan bestilles gratis, op til 12 måneder efter levering, via internet, post eller telefax. Se bestillingsformular i slutningen af bogen. All information is stored internally at AB Volvo Penta and will not be passed on to third parties.
Content Foreword ...................................................................................................... 2 Safety Information ...................................................................................... 3 Introduction ................................................................................................. 8 Instruments and Controls ........................................................................ 11 Optional ...........................................................
Foreword 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. This is not a coincidence. After 100 years as an engine manufacturer the Volvo Penta name has become a symbol of reliability, 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.
Safety Information Read this chapter very carefully. It has to do with your safety. This describes how safety information is presented in the instruction book and on the product. It also gives you an introduction to the basic safety rules for using and looking after the engine. Check that you heave received the correct instruction book before you read on. If not, please contact your Volvo Penta dealer.
Safety Information Your new boat Fuel filling Read the instruction books and other information carefully, which came with your new boat. Learn to handle the engine, controls and other equipment in a safe and correct manner. If this is your first boat, or a type of boat you are not experienced in using, we recommend that you practice operating the boat in peace and quiet.
Safety Information Carbon monoxide poisoning When a boat moves forwards, an area of low pressure air forms behind the boat. In adverse conditions, this low pressure can be so strong that the boat’s own exhaust fumes are sucked into the cockpit or cabin, which entails a risk of carbon monoxide poisoning for all aboard. The problem of low-pressure suction is worst in high, wide boats with a square transom.
Safety Information Preparations Before starting the engine Knowledge The operator’s manual contains instructions on how to carry out general maintenance and service operations safely and correctly. Read the instructions carefully before starting work. 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.
Safety Information Hot surfaces and fluids Fuel system 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. 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.
Introduction This Operator's Manual has been prepared to give you the greatest possible benefit from your Volvo Penta marine engine. It contains the information you need to be able to operate and maintain the engine safely and correctly. Please read the Operator's Manual carefully and learn to handle the engine, controls and other equipment in a safe manner before you cast off on your maiden voyage. Always have the Operator's Manual available.
Introduction Warranty Running in Your new Volvo Penta marine engine is covered by a limited warranty, under the conditions and instructions compiled in the Warranty and Service book. Please note that AB Volvo Penta’s liability is limited to the specification in the Warranty and Service book. Read it carefully, as soon as possible after delivery. It includes important information about warranty cards, service, maintenance, which it is the responsibility of the owner to know, check and carry out.
Introduction Certified engines If you own or operate an emission certified engine it is important to be aware of the following: Certification means that an engine type has been checked and approved by the relevant authority. The engine manufacturer guarantees that all engines made of the same type are equivalent to the certified engine.
Instruments and Controls This chapter describes the instruments, panels and controls Volvo Penta sells for your engine. If you would like to complement your instrumentation, or if your boat is equipped with instruments not described here, we ask that you contact your Volvo Penta dealer. Ignition Lock The start keys are supplied with a plate bearing the start code to be used when ordering spare keys. Keep the code beyond the reach of unauthorized people. S 0 I II III = = = = = Stop position.
Instruments and Controls Gauges Tachometer The tachometer displays engine speed; multiply the value shown on the dial by 1,000 to get the number of engine revolutions per minute. Boat and engine information is displayed in the tachometer window. Information displayed depends on engine type, the number of sensors and which accessories are installed. Optional instruments These instruments are sold as engine options by Volvo Penta.
Instruments and Controls Control Panel The control panel is used for station handling, disengaging the gear/drive and to navigate the EVC system menu. There is one control panel for single installations and one for twin installations. Always push the buttons firmly and for at least one second. Activation button The control panel and station are activated by pushing the activation button once. Push twice to lock the station. On boats with only one station, this is always active.
Instruments and Controls above the button shows which engine is chosen, green lamp for starboard engine and red lamp for port engine. Lamp off: Menu inactivated. Lamp lit: Menu activated. Multifunction Button With the multifunction button the instruments and panels backlighting is adjusted. Push the button for over a second to turn the backlighting on or off. The backlighting can be adjusted in five stages by repeatedly pushing the multifunction button quickly (less than 1 second).
Instruments and Controls Display modes Press button 1–4 to view the function menu for the buttons, apperaring in the lower part of the display. Press button 1–4 to choose the desired display mode. 1 Engine 2 Multi 3 Trip 4 Graph To leave the menu, wait a few seconds or press button 5 (EXIT). Contrast In the display modes Engine, Trip and Graph, it is possible to adjust the contrast. Press button 5 when outside the menu and then + (button 4) and – (button 3).
Instruments and Controls Multi, button 2 In the multi mode the information can be shown in several windows, analogue or digital. The display can show windows with different information or be divided to show windows and system information. To handle the system information, see section Instruments and Controls page 19. To go between the different display modes, press button 2 repeatedly. By pressing button 5 (the right arrow) you can choose which information to be shown in the different windows.
Instruments and Controls In a twin installation the port engine is shown as a black line and the starboard engine as a grey line. Twin installation Configuration menu Press button 5 for five seconds to enter the Configuration menu. Navigate with the up and down arrows, select with the right arrow. NOTICE! The port engine, or both engines, must have the ignition on when display settings are made. System information System information shows the EVC-menyn and is handled by the knob on the control panel.
Instruments and Controls - Display: Setting of intervals (unit settings are made in the EVC menu, see Instruments and Controls page 19): Rpm interval, 2500–9000 rpm, in steps of 500 rpm Speed, on/off Speed interval, 10–100 knots, in steps of 10 knots Graph interval, 2 min, 10 min, 30 min, 60 min, 2 h, 4 h or 8 h 18 7748887 04-2008
Instruments and Controls EVC menu The EVC menu can be shown in both the EVC system display and the tachometer display. The main menu shows operating information, the settings menu and the fault menu (only shown when a fault in the system is detected). Only installed functions are shown in the menu. Turn the knob to navigate through the menus. Press the knob to access sub menus and to confirm selections in the settings menu. It is always possible to return to the previous menu by .
Instruments and Controls Settings P0001015 Turn the control panel wheel until the start screen for the settings menu is displayed. Press the wheel to reach the sub menus. Turn to move between the available setting functions. For further information, refer to section Settnings menu page 88. Fault The fault window is only shown in the main menu if a fault has been detected. For further information, refer to section Fault Handling page 39.
Instruments and Controls Controls This section describes the controls Volvo Penta sells for your engine. Contact your dealer if your boat is equipped with controls other than those described here, and you feel uncertain about their function. Single Lever Control Maneuvering A single-lever control operates both gearshift and throttle functions with the same lever. The engine can only be started with the control lever in the neutral position. N = Neutral position.
Instruments and Controls Adjusting the friction brake The control lever is fitted with a friction brake that can be adjusted to apply more or less resistance to lever movement. The friction brake only affects movement of the throttle control lever. 1 Stop the engine. 2 Move the control lever forward so that the groove in the lever hub is accessible. 3 Remove the plug with the aid of a screwdriver.
Instruments and Controls Adjusting the friction brake The control lever is fitted with a friction brake that can be adjusted to apply more or less resistance to lever movement. Adjust the friction brake by turning the screw (control A), or by twisting the lever (control B). Turn clockwise (+) for stiffer lever movement, and counterclockwise (-) for easier movement.
Optional Trolling The Volvo Penta trolling function is available for engines with some versions of hydralic reverse gear. Trolling requires two control levers, one for throttle/ gear, and the other to control the slip function. Trolling makes it possible to use higher engine power without increasing boat speed. WARNING! If engine speed exceeds the maximum permissible engine speed for trolling (approx.
Optional Low speed The Lowspeed function is available for engines with some hydralic reverse gear. Boats with powerful engines can have high speed even at idle. The Lowspeed function reduces the boat speed. N = Neutral. Reverse gear is disengaged and engine runs at idle speed. F = Forward idling. Reverse gear engaged for movement ahead and engine runs at idle speed. Maximum slip in reverse gear. R = Reverse idling Reverse gear engaged for movement astern and engine runs at idle speed.
Optional Engaging Lowspeed 1 Move the lever to neutral position. 2 RPMX100 0 3 4 2 Press the neutral button (N) to activate Lowspeed. If the message “Lowspeed initierate” (A) followd by the snail symbol (B) in the display the lowspeed function is not ready. Normal gear shifting until Lowspeed is activated. When Lowspeed is engaged “Lowspeed activated” (C) shows on the display. 3 Active Lowspeed is indicated by the snail symbol on the display. Delay in gear shifting may occur when Lowspeed is active.
Optional In cases where the propeller shaft may rotate faster than in normal operations, e.g. boat under sail, a temperature gauge should be installed for monitoring the oil temperature. Max. permissible temperature for ZF reverse gears is 95°C (203°F). When the above-mentioned regulations cannot be met, or when the shaft needs to be stopped or reasons of comfort, a shaft brake must be fitted. On isolated occasions the propeller shaft flange may be locked in a suitable manner instead.
Starting Make a habit of visually checking the engine, engine bay and transmission before start. This will help you to discover quickly if anything abnormal has happened, or is about to happen. Also check that instruments and warning displays show normal values when you have started the engine. To minimize cold start smoke we recommend the installation of an engine heater or engine bay heater if temperatures below +5° C are encountered. WARNING! Never use start spray or similar products as starting aid.
Starting Starting the Engine Shifting, adjusting speed and performing EVC settings and calibrations is only possible at an active station. On a boat with one station the station is always active. On a boat with two or more stations the main station automatically becomes active when the EVC system is started up with the ignition key(s). If the engine(s) is/ are started from another station this station automatically becomes active instead.
Starting Check lamps - ! Each time the ignition is turned on, all lamps in the alarm instrument are illuminated. Check that all lamps light up and go out. If a lamp flashes a fault has been registred, please refer to section Fault Handling page 39 for further information and recomended actions. If the boat has more than one station, it has to be activated before the lamps can vbe checked.
Starting Check the oil level in the reverse gear Check the oil level when the reverse gear has reached operating temperature, please refer to the section “Maintenance, Reverse Gear”.
Operation Learn to handle the engine, controls and other equipment in a safe and proper manner before casting off on your maiden voyage. Remember to avoid sudden and extreme rudder maneuvers and gear shifts. There is a risk for passengers and crew falling over or falling overboard. 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.
Operation Maneuvering 1 Shifting between forward and reverse should be done at idling. Shifting at higher engine speeds can be uncomfortable for passengers and cause unnecessary stress on the stern drive/reverse gear, or cause the engine to stop. If you attempt to shift gear at an excessive engine speed, a safety function cuts in automatically, and delays shifting until engine speed has fallen to 1000 rpm.
Operation Helm Stations Changing and activating stations Changing stations 3 1 Put the gear in neutral. The lamp above the neutral button (1) is lit when the gear is in neutral. 2 1 P0006366 2 Unlock, if locked, the station you leave by pushing the activation button (2). 3 Activate the station you change to by pressing the activation button (2). The lamp above the activation button lights when the station is active. An active station is indicated by the lit lamp above the activation button.
Operation Synchronizing Engine Speed When driving with twin engines, both the operating economy and comfort will be increased when the engines are operating at the same engine speed (rpm). When the synchronization function is activated, the engine speed (rpm) of the starboard engine is automatically adjusted to that of the port engine. The synchronization function is activated automatically if the following conditions are met.
Engine Shutdown Allow the engine to run at low idle, in neutral, for a few minutes after operations are completed. In this way afterboiling is avoided at the same time as temperature equalization takes place. This is especially important when the engine has been run at high rpm or under heavy load. Stop the Engine If a station is active and locked the engine(s) can only be started and stopped from that station. IMPORTANT! Never disconnect the current with the main switches when the engine is running.
Engine Shutdown 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. 1 OP ST 10 10 P0004514 After Engine Shutdown • Check the engine and engine bay for leakages. • Close the fuel tap. • Close the sea cock where fitted. • Take an hour meter reading and carry out preventive maintenance according to the maintenance schedule. • Turn off the main switch before any long stoppage.
Engine Shutdown If you expect the boat to be unused for two months or more, it must be laid up, please refer to Short Term Storage. IMPORTANT! Use emery paper. Do not use a wire brush or other steel tools when cleaning, as these may damage the galvanic protection.
Fault Handling Despite regular maintenance according to the maintenance schedule and perfect operation conditions faults may occur which must be attended to before the boat can travel further. This chapter describes alarms and fault handling. Alarm handling Fault information from engine and EVC system - ! P0006368 ! + If a malfunction is discovered the driver is warned by a buzzer sounding and a pop-up showing in the display. The pop-ups will toggles between cause of fault and tasks to perform.
Fault Handling Acknowledging alarm 1 Push the knob on the control panel to ackowledge the alarm. The buzzer becomes silent. 2 Read the alarm or message in the pop-up. 3 Push the knob on the control panel again and the pop-up disappears. NOTICE! The alarm has to be acknowledged before the engine can be started. Popup windows There are three levels of fault messages showing in the pop-up: danger, warnign and caution. Danger If the Danger pop-up is shown during operation, a serious fault has occured.
Fault Handling Faults list Is a fault registered the display shows Faults in the EVC menu along with the number of faults. Push the knob on the control panel to open the menue. Turn the knob to see all faults registred. The popup toggles between cause of fault and tasks to perform. Erasing faults in faults list Acknowledged faults that has been stored automatically erased every time the starter key is turned to the stop position (S).
Fault Handling Fault Tracing A number of symptoms and possible causes of engine malfunctions are described in the table below. Always contact your Volvo Penta dealer if problems occur which you can not solve by yourself. NOTICE! Read through the safety advice for care and maintenance work in the Safety Information page 6 chapter before starting work.
Fault Handling 19. Insufficient air supply to engine: - blocked air filter - air leakage between turbocharger and engine inlet manifold - fouled compressor section in turbocharger - faulty turbocharger - poor engine bay ventilation 20. Excessive coolant temperature 21. Too low coolant temperature 22. Too low oil level 23. Faulty / wrong propeller 24. Faulty engine mounting 25. Coolant level too low 26. Air in the freshwater system 27. Drive belt broken/slips 28. Faulty circulation pump 29.
Fault Code Register CAUTION! Read the safety precautions for maintenance and service in the Safety Information chapter before starting work. When a malfunction i discovered the driver is warned by a sound alarm and at the same time a pop-up window is shown in the display. The fault message gives information about what has caused the fault and what actions to take. This chapter gives a more detailed description of cause and actions.
Fault Code Register Engine Speed Explanation: Fault in engine speed sensor. Symptom: Engine power is reduced. Action: Please contact a Volvo Penta workshop. P0005008 DANGER! Engine Speed See Operator's Manual Stop engine Water in Fuel Explanation: Water in water trap in fuel filters. Symptom: None. Action: • Empty the water trap underneath the fuel filters. Se Maintenance page 66. • Please contact a Volvo Penta workshop if the fault remains.
Fault Code Register Coolant Level Explanation: Coolant level too low. Symptom: None. Action: • Check coolant level. Se Coolant Level, Checking and Topping Up page 71. • Check that no coolant leakage occurs in auxiliary equipment connected to the engine cooling system. • Please contact a Volvo Penta workshop if the fault remains. R P0005012 WARNING! Coolant Level See Operator's Manual Coolant Temperature Explanation: Coolant temperature too high. Symptom: Engine power is reduced.
Fault Code Register Fuel Temperature Explanation: Fuel temperature too high. Symptom: None. Action: • Check fuel level. • Check that no leakage occurs. • Please contact a Volvo Penta workshop if the fault remains.
Fault Code Register Engine Oil Level Explanation: Oil level too low. NOTICE! In rough following seas or head seas, the system can incorrectly sense that the engine oil level is too low. If this happens, acknowledge the fault, and check the points below for safety reasons. Symptom: None. Action: • Check the oil level in the engine. Se Oil level, checking and topping up page 63. • Check that no leakage occurs. • Please contact a Volvo Penta workshop if the fault remains.
Fault Code Register Transmission Oil Pressure Explanation: Reverse gear oil pressure too low. Symptom: None. Action: • Check the oil level. Se Oil level, checking and topping up page 84. • Check that the oil strainer is not blocked. • Check that no leakage occurs. • Please contact a Volvo Penta workshop if the fault remains. P0005023 WARNING! Transmission Oil Pressure See Operator's Manual Crankcase Pressure Explanation: Crankcase pressure too high. Symptom: Engine power is reduced.
Fault Code Register Emergency Stop Switch Explanation: External stop signal. Symptom: Engine stops or can not be started. Action: • Check emergency stop button if any. Reset if necessary. Se Engine Shutdown page 36. • Please contact a Volvo Penta workshop if the fault remains. P0005025 WARNING! Emergency Stop Switch See Operator's Manual Primary Battery Explanation: Poor batteries or charging. Symptom: None. Action: • Check the batteries fluid level. Se Battery, Maintenance page 80.
Fault Code Register Extra Supply Fuse Explanation: The fuse has blown. Symptom: None. Action: Please contact a Volvo Penta workshop. P0005030 WARNING! Extra Supply Fuse See Operator's Manual Start Relay Explanation: Faulty relay. Symptom: None.If engine is off, engine will not start. Action: • Check fuses at engine. • Please contact a Volvo Penta workshop if the fault remains.
Fault Code Register Check control lever Explanation: Fault in control lever. Symptom: Engine in emergency mode. Gear to neutral. Action: • Restart engine(s). • If the engine can not be operated from the chosen station, use an alternative station. • Please contact a Volvo Penta workshop if the fault remains. P0005031 WARNING!Check control lever See Operator's Manual P0005032 CAUTION!Check control leverSee Operator's Manual Lever Calibration Explanation: Incorrect lever calibration.
Fault Code Register Check EVC system Explanation: Internal fault in EVC system. Symptom: Engine power is reduced. Action: • Restart engine(s). • If the engine can not be operated from the chosen station, use an alternative station. • Please contact a Volvo Penta workshop if the fault remains. P0005034 WARNING!Check EVC systemSee Operator's Manual P0005035 CAUTION!Check EVC systemSee Operator's Manual Check Engine Explanation: Miscellaneous system faults. Symptom: None.
Fault Code Register Helm Restarted Explanation: Lost active helm during crank. Symptom: None. Action: Restart engine(s). P0001206 CAUTION! Helm Restarted See Operator's Manual Key Failure Explanation: Key or start panel out of order. Symptom: None. Action: Please contact a Volvo Penta workshop. P0001199 CAUTION! Key FailureSee Operator's Manual Check Multilink Explanation: Fault in multilink communication. Symptom: Possible loss of engine synchronization or loss of display(s).
In Case of Emergency Despite regular service in accordance with the planned maintenance schedule and perfect operating conditions, faults may occur that must be remedied before the boat can continue its trip. This chapter provides advice on how to remedy a number of conceivable faults. When certain faults occur safety functions engage to protect the engine. The following may occur: • Engine cannot be started. • The gear is in neutral and engine rpm is limited. • The engine stops.
In Case of Emergency WARNING! Working with, or going close to a running engine is a safety risk. Watch out for rotating components and hot sufaces. WARNING! Do not touch the connections during the start attempt: Risk of arcing. Do not bend over any of the batteries either. 5 Turn off the engine. Remove the start cables in the exact opposite order to their connection. Emergency Shifting The descriptions refer to electrically shifted revers gear.
Maintenance Schedule Your Volvo Penta engine and its equipment are designed for high reliability and long life. The engines are built to withstand the marine environment, but also to have the smallest possible environmental impact. If the engine and transmission are serviced regularly according to the schedule, these qualities will be retained and unnecessary malfunctions will be avoided.
Maintenance Schedule Every 50–500 Hours / at Least Every 12th Month Engine Oil and Oil Filters / By-pass filter2), 3) R 1) Or within 180 days of the date of delivery, or the end of the first season, whichever comes first. 2) Oil change intervals vary, depending on engine type, oil grade and sulfur content of the fuel., see Technical Data page 97. Change the filters during each oil change.
Maintenance Schedule A Every 500 Hours / at Least Every 12th Month Drive Belts I Zink anodes I Seawater pump impeller I Seawater filter I Inspection with VODIA (Diagnostic Tool) I Reverse gear, oil and filter (ZF) R Reverse gear, oil strainer (ZF) C Batteries, electrolyte level I B Every 1000 Hours / at Least Every 12 Months Fuel fine filter R Fuel pre-filter, filter insert R Air filter insert R Engine and revers gear, inspection for leakage I Engine and reverse gear, inspect hoses
Maintenance This chapter contains general technical information and instructions on how the prescribed maintenance items must be carried out. Read through the instructions carefully before starting work. The times when maintenance items must be carried are indicated in the Maintenance Schedule page 57. Read through the safety precautions for maintenance and service in the Safety Information page 4 chapter before work on the engine is begun.
Maintenance Engine, General General inspection Make a habit of visually checking the engine and engine bay before starting, and after operations when you have stopped the engine. This will help you to discover abnormalities quickly, or if something is about to happen. Look especially carefully for oil, fuel and coolant leakages, loose bolts, worn or poorly-tensioned drive belts, loose cable connections, damaged electrical cables and hoses.
Maintenance Drive Belt, Check and Change WARNING! Stop the engine before doing any maintenance work. Check belt tension and condition regularly. The drive belt has an automatic tensioner and need not be adjusted. Check that the belt tensioner does not bottom. A belt which is to tense can damage the bearings and a belt which is too loose can slip. IMPORTANT! Always change a belt which looks worn or cracked. Changing the alternator belt 1 Remove the protective cover over the drive belt.
Maintenance Lubrication System Oil change intervals can vary depending on oil grade and sulphur content of the fuel, please refer to Technical Data page 97. NOTICE! Oil change intervals must never exceed a period of 12 months. If you want longer oil change intervals than given in the table Technical Data page 97, the condition of the oil must be checked by the oil manufacturers through regular oil testing.
Maintenance Engine Oil, Change Always follow the recommended oil change interval. Use an oil drain pump - an electrical oil drain pump is available as an accessory - to pump the oil out of the oil pan. 1 Run the engine until warm so that the oil is easier to pump. Then stop the engine. WARNING! Hot oil and hot surfaces can cause burns. 2 Connect the suction pipe on the oil drain pump to the drain pipe (1). Pump out the oil. 3 Replace the oil filter and by-pass filter at every oil change.
Maintenance Oil Filter/By-pass Filter, Change The oil filter and bypass filter must be replaced at every oil change. Remember to hand the old filters in to a re-cycling station. WARNING! Hot oil and hot surfaces can cause burns. 1 Place a collection vessel underneath the filter drip tray to avoid oil spillage. 2 Clean the filter bracket. 3 Unscrew the bypass filter (1) and the oil filters (2) with a suitable puller.
Maintenance Fuel System Only use the grades of fuel recommended in the fuel specification, see Technical Data page 98. Always observe the greatest cleanliness during re-fuelling and work on the fuel system. All work on the unit injectors of the engine must be carried out by an authorized workshop. WARNING! Fire hazard. When carrying out work on the fuel system make sure the engine is cold. A fuel spill onto a hot surface or an electrical component can cause a fire.
Maintenance 7 Screw on the new filter by hand until the gasket just bottoms on the sealing surface. Then tighten a further 1/2 turn. Install the water separator and connect the union. Close the drain tap. 8 Open the main fuel tap. 9 Open the purging nipple and pump fuel with the hand pump (5) until the fuel is free from bubbles. Close the purging nipple while fuel is flowing out. 10 Remove the hose and replace the protective cover on the purging nipple. 11 Start the engine and check that there are no leaks.
Maintenance Primary fuel filter Volvo Penta fuel pre-filters are supplied in single and double models. Checks The double filter is fitted with a pressure gauge (1) that indicates when it is time to replace the filter cartridges. The filter cartridges must be replaced according to maintenance schedule recommendations, or earlier if the pressure gauge shows a pressure drop of 6–10 (in. Hg) at idle or 16–20 (in. Hg) at full rpm/engine load.
Maintenance Replacing filter cartridges Double filter cartridges can be replaced while the engine is running, by shutting off the fuel flow to one filter holder at a time. Fuel flow is controlled by moving the lever (1) to the following positions: A Normal operating position (both filters connected). B Left filter cartridge can be replaced. C Right filter cartridge can be replaced. D Both filters shut off.
Maintenance Freshwater System The freshwater system is the engine's internal cooling system that ensures that the engine operates at the correct temperature. It is a closed system that must always be filled with a mixture of concentrated coolant and water in order to protect the engine against internal corrosion, cavitation and frost bursting. We recommend “Volvo Penta Coolant, Ready Mixed”, or “Volvo Penta Coolant” (concentrated) mixed with pure water according to specifications.
Maintenance Coolant, Mixing WARNING! All coolant is hazardous and harmful to the environment. Do not consume. Coolant is flammable. IMPORTANT! Volvo VCS coolant (yellow in color) must not be used in Volvo Penta engines. Different kinds of coolant must not be mixed with each other! Mix: 40 % “Volvo Penta Coolant” (conc. coolant) and 60 % water This mixture protects against internal corrosion, cavitation and frost bursting down to –28 °C (–18 °F).
Maintenance Filling coolant WARNING! Burn hazard. Steam and hot fluid may spray out. Stop the engine and allow it to cool before opening the filler cap. IMPORTANT! Top up with the same type of coolant as already used in the system. Different types of coolant must not be mixed. Topping up Top up coolant to the correct level through the filler opening on the expansion tank. Top up slowly, to allow air that is displaced to flow out through the filler opening.
Maintenance Coolant, Draining WARNING! Stop the engine and let it cool before starting work on the cooling system. Hot fluids and hot surfaces can cause burns. WARNING! All coolant is hazardous and harmful to the environment. Do not consume. Coolant is flammable. Drain the coolant via taps (F). 1 Remove the filling cap (1) from the expansion tank. 2 Connect a hose to each drain tap. Open the taps and allow all the coolant to drain off into a suitable vessel. Check that all coolant really does drain out.
Maintenance Freshwater system, Flushing The cooling system should be flushed when the coolant is changed, to avoid loss of cooling performance due to deposits in the cooling system. 1 Drain the coolant, please refer to section Coolant, Draining page 73. 2 Put a hose into the filling hole in the heat exchanger and flush with fresh water. 3 Flush until the water which runs out of the drain points is clean. 4 Close all drain points when all coolant has run out.
Maintenance Seawater System The seawater system is the engine’s external cooling system. The seawater system sucks in water through the seawater inlet and pumps it through the heat exchanger and the reverse gear oil cooler. The system is protected from galvanic corrosion by means of zinc anodes located in the heat exchanger and the reverse gear oil cooler. WARNING! Risk of water entry. Water will flow into the boat if any hose, plug etc.
Maintenance Draining: 1 Close the sea cock. 2 Connect a hose to each drain tap before opening the tap (one at a time). 3 Open the drain taps/remove the drain plugs (S) and allow the water to run out. Drain points: - tap at rear of heat exchanger - tap at rear of charge air cooler - Open the drain taps/remove the drain plugs (S) and allow the water to run out. Check that all water really does drain out. Deposits may need to be cleared away, inside the drain plug/tap.
Maintenance 1 Close the sea cock. 2 Open the drain tap (1) on the heat exchanger and the tap (2) on the charge air cooler, and drain off the seawater. 3 Remove the zinc anodes (Z) in the heat exchanger and in the reverse gear oil cooler. 4 Check the zinc anodes and replace them if more than 1/3 of their original size has been used up. If not, clean the zinc anodes with emery cloth to remove the oxide layer before re-installing them. IMPORTANT! Use an emery cloth for cleaning.
Maintenance Seawater Filter, Check and Cleaning The seawater filter is optional equipment. If the water where the boat is operated contains a lot of contamination, weed etc., check the filter more frequently than specified in the maintenance schedule. There is otherwise a risk that the filter would be blocked, which would make the engine overheat. WARNING! Risk of water entry. Close the seawater cocks before doing any work on the seawater system. 1 Close the sea cock.
Maintenance Electrical System 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 switches must never be switched off before the engine has stopped. If the circuit between the alternator and the battery is disconnected when the engine is running, the alternator and electronics can be damaged.
Maintenance Electrical Connections Check that electrical connections are dry, free from oxide, and that they are securely tightened. Spray the connections as necessary with 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. P0002107 WARNING! Never confuse the positive and negative poles on the batteries. Risk of arcing and explosion.
Maintenance Cleaning Keep the batteries clean and dry. Contamination and oxide on the batteries and battery poles can cause stray currents, voltage drop and discharge, especially in wet weather. Remove oxidation from the battery poles and terminals, using a brass brush. Tighten the terminals securely and grease them with terminal grease or petroleum jelly. Filling The electrolyte level should be 5–10 mm above the cell plates in the battery. Top up with distilled water as required.
Maintenance IMPORTANT! Observe the instruction manual for the battery charger carefully. To avoid the risk of electrochemical corrosion when an external charger is connected, the battery cables should be removed from the batteries before the charger is connected. Always switch off the charging current before the charging clips are removed. • Charge batteries if they have become discharged. During charging, unscrew the cell plugs but leave them min the plug holes.
Maintenance Always consider the following: 1 If shore power is connected it must always be ground protected ashore, never in the boat. Furthermore, the shore power installation should be equipped with a ground fault interrupter. The shore power installation (transformer, inverter, battery charger etc.) must be designed for marine use where the high-tension side is galvanically separated from the low-tension side.
Maintenance Reverse Gear Oil level, checking and topping up Checking 1 Remove the dipstick (1), wipe it off and put it back into the reverse gear. 2 Remove the dipstick again and check the oil level. The correct oil level is between the MAX and MIN marks. 3 Start the engine and let it run on idle a few minutes with control lever in neutral. Stop the engine and check the oil again. WARNING! Working with, or going close to a running engine is a safety risk. Watch out for rotating components and hot sufaces.
Maintenance Oil filter, Change WARNING! Working with, or going close to a running engine is a safety risk. Watch out for rotating components and hot sufaces. 1 Put a suitable vessel beneath the filter, to avoid oil spillage. 2 Unscrew the oil filter with a suitable extractor. 3 Clean the filter mating surface on the filter bracket. 4 Lubricate the seal on the new filter with engine oil. 5 Screw the filter on by hand until the rubber seal just touches the mating surface on the filter bracket.
Storage The boat must be laid up to prevent damage to the engine and other equipment if the boat is not used for two months or more. It is important that this is done in the correct manner, and nothing is forgotten. For this reason, we have compiled a check list of the most important points. Before the boat is taken out of service for a long period of time, an authorised Volvo Penta workshop should over the engine and other equipment.
Storage • Clean the outside of the engine. Do not use a high pressure washer for engine cleaning. Touch up paint damage with Volvo Penta original paint. • Check and rust-proof any control cables. • Put a note on the engine with the date, type of conservation and the conservation oil used. • Cover over the engine air inlet, exhaust opening and engine if necessary. Bringing out of storage • Remove any covers from the engine, air inlet and exhaust pipe.
Calibration and Settings Settnings menu Settings are entered and certain calibrations are carried out in the Settings menu. Navigate through the menus by turning and depressing the control panel wheel. It is always possible to return to the menu above by pressing . Repeated presses or holding the button down for >3 seconds will return to the main menu. NOTICE! Only installed functions are shown in the settings menu. p0005184 1 Turn clockwise until Settings is shown on the display.
Calibration and Settings 4 Turn to Set Level. Press the wheel to access adjustment of depth level alarm. Turn the wheel to set the alarm depth, i.e. the depth when the alarm should begin sounding. Press the wheel to confirm the set depth. The depth alarm is dependent on depth compensation (offset depth). P0001033 5 Turn to Set offset. Press the wheel to access offset depth adjustment. Adjust it to correspond to the boat's deepest point or the boat's waterline, depending on the depth to be displayed.
Calibration and Settings Depth alarm popup window When the depth is less than the alarm level, the popup window will display intermittently, followed by the alarm signal. The pop-up window will be displayed every 30 seconds until the depth is greater than the alarm level. Confirm the selection by depressing the navigation wheel. P0005853 P0005854 Lost depth alarm signal If the signal from the depth alarm disappears, e.g. if the depth alarm sensor is defective, the popup window is displayed to the left.
Calibration and Settings 2 Turn to navigate through the menu with available operating information. 3 Press the wheel to check and uncheck the information to be displayed in the main menu. P0001014 Neutral Beep Sound indication, controls in neutral position. The sound may be set on or off. The sound level is set under Information beep. The setting must be entered at each station. If the station has several displays, the setting need only be made at one display.
Calibration and Settings 2 Features shows what accessories are installed. Press the wheel to access the submenu. 3 Components shows what hardware components are installed. Press the wheel to access the submenu. 4 Software shows what software is installed. Press the wheel to access the submenu. Units Setting operating information and trip data units. 1 Activate the station. 2 Turn until Units is shown in the settings menu. Press to reach the units menu.
Calibration and Settings Information Beep Adjusting the volume of the integral tachometer alarm. 1 Turn until Info Beep is shown in the settings menu. Press to access adjustment. 2 Turn to the desired volume. Press to confirm the selection; the setting will be confirmed by a beep at the set volume. The display will return to the settings menu. P0001039 Fuel Tank There are two alternative methods for calibrating the level sensor in the fuel tank.
Calibration and Settings 4 Fill the tank with the quantity shown in the display, POS 1. P0001010 5 Fill the tank up to the level shown in the display, POS 2. Press the wheel to confirm that the tank has been filled to the indicated level. 6 Repeat the procedure for POS 3 , POS 4 and POS 5. Confirm by pressing the wheel at each position. Full Fuel Tank Calibration For this method the tank must be full and calibration of the fuel level sensor takes place in one step.
Calibration and Settings 2 Turn to Log cal. factor in the settings menu and press to reach adjustment, 3 Turn the wheel to set the level. Press to confirm the selection.
Technical Data Engines Engine model D11-670 Crankshaft power* @ 2300 rpm 493 kW (670 hp) Max. torque @ 1500 rpm 2527 Nm (1864 lbf.ft) After market designation D11A-B No. of cylinders and configuration in-line 6 Bore 123 mm (4.84”) Stroke 152 mm (5.98”) Displacement 10.8 dm3 (659 in3) Dry weight bobtail 1130 kg (2491 lb) Compression ratio 16.5:1 Low idle speed** 600 (±25) rpm. * According to ISO 8665. ** At delivery, the idling speed is adjusted to 600 rpm.
Technical Data Lubrication System Oil capacity including oil filters, approx., no engine inclination 38 liters (10.0 US gals) volume difference MIN – MAX 4 liters (1.0 US gals) engine inclination 7° 30 liters (7.9 US gals) volume difference MIN – MAX 4 liters (1.0 US gals) Oil pressure, hot engine, at normal running rpm (1100 rpm or higher) 350–500 kPa (50.8–72.5 PSI) at idling rpm min. 250 kPa (36.3 PSI) Sulphur content in fuel, by weight Oil grade 1) up to 0.5% 0.5 – 1.0% more than 1.
Technical Data Viscosity Select the viscosity according to the table. The temperature values refer to stable ambient temperatures. * SAE 5W/30 refers to synthetic or semi-synthetic oils. Fuel System Fuel specification The fuel must comply with national and international standards for commercially supplied fuels, such as: EN 590 (with national environment and cold requirements) ASTM D 975 No 1-D and 2-D JIS KK 2204 Sulfur content: Complying with legal requirements in each country.
Technical Data Electrical System System voltage 24V AC generator, voltage/max. amperage 28V/80A output, approx. 2240W Alternative generator equipment (accessory): voltage/max. amperage 14V/115A output, approx. 1610W Battery capacity 2 connected in series 12V, max. 152Ah Battery electrolyte density at +25°C (77°F): fully charged battery 1.28 g/cm3 = 0.0462 lb/in3 (1.24 g/cm3 = 0.0448 lb/in3)* battery recharged at 1.24 g/cm3 = 0.0448 lb/in3 (1.20 g/cm3 = 0.
Technical Data Reverse Gear ZF Type designation 305-2AE Gear ratios 1.51:1; 1.73:1; 2.04:1 Angle (output shaft) 7° Oil capacity, approx. 5–6 liters (5.3–6.3 US quarts) Oil grade (in accordance with API-system) CD, CE, CF, CF-4, CG-4, CH-4, CI-4, SF, SG, SH, SJ, SL, ACEA category A,B,E Viscosity at oil temperature 66–85°C (151– SAE30* 185°F) Oil pressure during** neutral 2.3–2.4 MPa (334–348 PSI) Oil pressure during*** operation 2.3–2.4 MPa (334–348 PSI) Weight, approx.
Technical Data Identification Numbers There are type plates on the engine and transmission, marked with identification numbers. This information must always be used as reference when service and spare parts are ordered. You will probably find similar plates on your boat and its equipment. Note this information below, make a copy of the page and store it in a safe place, so that you can have the information available if the boat is stolen. The appearance and location of the type plates is shown below.
Declaration of Conformity for Recreational Craft Propulsion Engines with the exhaust emission requirements of Directive 94/25/EC as amended by 2003/44/EC D11 Engine manufacturer: Body for exhaust emission assessment: AB Volvo Penta Gropegårdsgatan 405 08 Göteborg Sweden Germanisher Lloyd Vorsetzen 32/35 20459 Hamburg Germany ID Number: 0098 Module used for exhaust emission assessment ........... B + ”EC Type examination” according to annex ...............................................................
Alphabetical index Air Filter, Check and Change............................... 61 Alarm handling........................................................ 39 Alarms..................................................................... 32 Battery, Charging.................................................. 81 Battery, Maintenance.............................................. 80 Control Panel......................................................... Coolant Level, Checking and Topping Up...............
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7748887 English 04-2008
