OPERATOR’S MANUAL VOLVO PENTA IPS 350/400/450/500/600
This operator’s manual is available in English. Denne instruktionsbog kan bestilles på dansk. Complete the form at the end of the operator’s manual to order a copy. Bestillingskupon findes i slutningen af instruktionsbogen. Diese Betriebsanleitung ist auch auf Deutsch erhältlich. Tämän ohjekirjan voi tilata myös suomenkielisenä. Ein Bestellcoupon ist am Ende der Betriebsanleitung zu finden. Tilauskuponki on ohjekirjan lopussa. Ce manuel d’instructions peut être commandé en français.
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 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.
Contents Safety Information .............................................. 3-7 General.................................................................... 3 Boat travel............................................................... 4 Maintenance and service........................................ 6 Stopping the engine ....................................... 59-60 Stopping ............................................................... 59 Laying up ...........................................................
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 contact your Volvo Penta dealer.
Safety Information 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 correctly. If this is your first boat, or is a boat type with which you are not familiar, we recommend that you practice controlling the boat in peace and quiet.
Safety Information Carbon monoxide poisoning When a boat is moving forward, it will cause a certain 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 monoxide 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.
Safety Information Safety precautions for maintenance and service operations Preparations Knowledge The operator’s manual contains instructions on how to carry out general maintenance and service operations safely and correctly. Read the instructions carefully before starting work. Service literature covering more complicated operations is available from your Volvo Penta dealer.
Safety Information Hot surfaces and fluids There is always a risk of burns when working with a hot engine. Beware of hot surfaces. For example: the exhaust pipe, 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.
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.
Introduction Certified engines It is important to be aware of the following information if you own or run an engine that is exhaust emission certified: Certification means that an engine type is inspected and approved by the authorities. The engine manufacturer guarantees that all engines manufactured of that type correspond to the certified engine. This places special requirements for maintenance and service as follows: ● The maintenance and service intervals recommended by Volvo Penta must be observed.
Declaration of Conformity for Recreational Craft Propulsion Engines with the sound and exhaust emission requirements of Directive 94/25/EC as amended by 2003/44/EC VOLVO PENTA IPS Body for sound and exhaust emission assessment International Marine Certification Institute Rue Abbé Cuypres 3 B-1040 Bruxells Belgium ID Number: 0609 Engine manufacturer AB Volvo Penta Gropegårdsgatan 405 08 Göteborg Sweden Module used for sound emission assessment . ....
Introduction Identification numbers Always provide the engine and transmission identification numbers when ordering service or replacement components. The identification numbers are on an information decal located on the front edge of the engine. Note the information below. Make a copy of the page. Store the information so that it is available in event of the boat being stolen.
Presentation Volvo Penta IPS – Inboard Performance System Volvo Penta IPS overvieiw Volvo Penta IPS is setting a new standard: Maneuvering and handling – The reasons for the amazing maneuverability are: Much improved efficiency, higher top speed, reduced fuel consumption/extended range and great acceleration – Low-speed maneuvering is easier than ever before, and high speed handling is a dream – Onboard comfort is greatly enhanced thanks to much lower levels of sound and vibrations – Installation
Presentation Comfort Environmental care Volvo Penta IPS new technology leads to major improvements for all comfort enhancing factors. The Volvo Penta IPS has been developed as a complete system with excellent environmental performance as one of the main design targets. The very high efficiency of the Volvo Penta IPS system gives greatly reduced overall emissions. – The propulsion forces and vibrations are absorbed by the combined rubber suspension and sealing.
Presentation Engine technical description Volvo Penta’s D6 is developed from the latest design in modern diesel technology. The engine has common rail fuel injection system, double overhead camshafts, 4 valves per cylinder, turbocharger, compressor, and aftercooler. The interaction of these, the large swept volume, and the EVC system results in exceptional diesel performance combined with low emissions.
Presentation Engine monitoring and the EVCEC system Helm station Control Unit (HCU) Steering unit Servo Unit Steering (SUS) Helm station Control Unit (SHCU) CAN bus Power train Control Unit (PCU) Engine Control Unit (ECU) Engine monitoring system The engines are equipped with common rail system and electronically controlled injectors. The injectors contain an electro-magnetic valve which sets the amount of fuel injected and the correct timing.
Presentation The EVCEC system The Electronic Vessel Control (EVC) system is a so called distributed system. The principle of a distributed system is to have "small" electronic units, called nodes, located at suitable places in the boat. Engine speed and gear shift Speed and gear shift contol is handled electronically with dual function electronic controls. The EVC nodes are the Powertrain Control Unit (PCU) and the Steering Helm station Control Unit (SHCU).
Presentation Fuel level Fuel level can be displayed on the EVC system tachometer if a (0-180 ohm or 240-30 ohm) fuel level sender is installed in the fuel tank. The sender is connected to the PCU–engine cable harness. If a fuel level gauge is used it must be connected to the instrument serial communication bus. Fresh water level Fresh water level can be displayed on the EVC system tachometer if a (0-180 ohm) fuel level sender is installed in the water tank.
Presentation Orientation 10 11 2 3 9 6 8 4 5 1 18 7 (D4)/D6-IPS, starboard 1. Oil filter, drive-unit 2. Water shut off valve, drive-unit (only D6) 3. Turbocharger 4. Crankcase ventilation filter 5. Air filter 6. Aux stop 7. Compressor 8. Engine control unit 9. Generator 10. Oil filler cap 11.
Presentation 24 D4-IPS, port 12. Sea water filter 13. Sea water pump 14. Fuel filter 15. Oil dipstick, engine 16. Oil bypass filter 17. Oil filter 18. Charge air cooler 19. Cooling water intake 20. Oil dipstick, drive-unit 21. Water shut off valve, drive-unit 22. Oil filler cap, drive-unit 23. Automatic fuse 24. Expansion tank 23 22 20 19 12 14 15 16 17 18 13 21 24 D6-IPS, port 12.Sea water filter 13. Sea water pump 14. Fuel filter 15. Oil dipstick, engine 16. Oil bypass filter 17. Oil filter 18.
Instruments This chapter describes the instrument and control panels sold by Volvo Penta for your engine. If you want to supplement the instrumentation, or if your boat is equipped with instruments not described here, or you are not sure about their function, please contact your Volvo Penta dealer. Instruments 1. 2. 3. 4. 5. 1. EVC system tachometer (with display) 2. Voltmeter 3. Oil pressure gauge 4. Temperature gauge 5.
Instruments Start/stop panel The start/stop panel is used to start or stop the engine. The starter key on the main helm station must be in position “I” (driving position) for the engine to start. The engine can only be stopped if the control panel is activated. IMPORTANT! Read the starting instructions in the “Engine starting” chapter.
Instruments Alarm display (extra optional) The following warning lamps should never light up during operation. On the other hand, the warning lamps light up when the starter key is first turned to the drive position. Check that all lamps function. When the engine has started, all lamps should have gone out. The lamps flash if the diagnostic function has registered malfunction. When the fault has been acknowledged, the lamp gives continuous light. Warning lamps (should never light up during operation).
Instruments Battery. (orange indication) The battery lamp lights up if the alternator is not charging. Stop the engine if this lamp lights up during operation. If the lamp lights up, this can be due to a fault in the electrical system or because the alternator drive belt is slack. Check the alternator drive belts. Please refer to “Maintenance: Engine, general”. Also check that there is no poor contact/broken wires. WARNING! Do not continue operation if there is any problem with the alternator drive belts.
Instruments Coolant level (orange indication) The coolant lamp lights up when the coolant level is too low. Check coolant level. Please refer to “Maintenance: Fresh water system”. Red warning indication, serious fault If the red warning indication is shown during operation, a serious fault has occured. Please refer to the “In case of emergency” chapter, and you will find detailed information about recommended action in the “Diagnostic function” section.
Instruments EVC control panel The control panel is used in combination with the EVC system tachometer. The tachometer display shows operating information and menus that can be navigated from the control panel. Activation button Used to activate and lock the control panel and helmstation. Tachometer display selection (twin installation, port or starboard tachometer) Off: Control panel not activated. Is used to select which of the engines menu systems should be navigable from the control panel.
Instruments Docking Station Panel 1 2 The docking station panel allow stopping and restarting of the engines and handling of faults when operating the boat from a docking station. The docking function (maneuvering with the joystick) is enabled when the docking station is activated. Please refer to the chapter “Operation” section “Docking (Joystick)” for more information on docking. 1 2 NOTE! Docking station can only be activated when the engines are running.
Instruments EVC System Tachometer Introduction Volvo Penta EVC System Tachometer presents relevant boat and engine information to the helmsman. Information is presented on a display in the tachometer. Information is depending on engine model, number of sensors and type of accessories. Using the instrument Start-up screen This is the start-up screen for the EVC System Tachometer. After a few seconds the first item in MAIN MENU will appear.
Instruments Trip menu (extra optional) In the TRIP MENU the user gets trip information from the EVC System and the user is allowed to select which view that should be presented in the EVC System Tachometers MAIN MENU as trip information.
Instruments Gauges menu In GAUGES MENU the user gets information from analogue senders, placed on the engine. If the data is not available the parameter will not be displayed. When in GAUGES MENU, select view by turning NAVIGATION WHEEL. To select view as favorite, push NAVIGATION WHEEL. System returns to MAIN MENU. Push BACK BUTTON to return to MAIN MENU without setting a new favorite.
Instruments Settings menu In the SETTINGS MENU the user is allowed to set various options for the EVC system and to calibrate various parameters. IMPORTANT! For all settings and calibration procedures: Activate helm station by pushing the ACTIVATION BUTTON. NOTE! For twin installations always perform the settings on the port side system. Port side is the master side. When in SETTINGS MENU, select view by turning NAVIGATION WHEEL. Views with a POINTING HAND-symbol indicates a SUB-MENU.
Instruments Depth alarm (extra optional) All depth alarm functions are accessed through this menu. A multisensor needs to be installed. DEPTH ALARM, ON/OFF Depth alarm can be switched ON/OFF. SET DEPTH Adjust the depth alarm value by turning the NAVIGATION WHEEL. The value can be adjusted at a resolution of 0.1 m or 1 ft. Once adjustment value is reached, the data is stored by pushing NAVIGATION WHEEL.
Instruments Select units and language Choose which units and languages to display. NOTE! Language and unit settings must be performed in all EVC system tachometers. US or METRIC 1. Activate helm station by pushing the ACTIVATION BUTTON. 2. Select SETTINGS from MAIN MENU by turning NAVIGATION WHEEL. Push NAVIGATION WHEEL to enter SETTINGS MENU. 3. Select UNITS and push NAVIGATION WHEEL. 4. Select US OR METRIC and push NAVIGATION WHEEL. 5.
Instruments Fuel tank calibration There are two possible calibration methods for the fuel tank. One approximative, FULL TANK CALIBRATION, and one more precise, FUEL MULTIPOINT CALIBRATION. A fuel level sender need to be installed. NOTE! If FUEL TANK CALIBRATION is not shown in SETTINGS MENU, please contact your Volvo Penta dealer.
Instruments FUEL FULL TANK CALIBRATION When FUEL FULL TANK CALIBRATION is selected, the fuel level sender is calibrated in one step. This only gives an approximated value of the fuel level. Therefore all trip data concerning and based on, remaining fuel volume should be recognized as approximated values only. 1. Activate helm station by pushing the ACTIVATION BUTTON. 2. Select SETTINGS from MAIN MENU by turning NAVIGATION WHEEL. Push NAVIGATION WHEEL to enter SETTINGS MENU. 3.
Instruments Speed factor The speed factor for the boat´s paddle wheel speed sensor can be adjusted at a resolution of 1% and is used by the EVC to apply a correction to the output from the speed sensor. Set speed factor Set speed factor while driving the boat. Compare displayed speed with speed data from GPS (or other boat) and adjust the speed factor until they correspond. Adjust the speed factor by turning the NAVIGATION WHEEL.
Instruments EVC System Display (extra optional) Introduction Volvo Penta EVC system display is an instrument which displays operating information about the engine and allows you to communicate with the engine’s electrical system. Operation information is shown on an LCD display. The driver can select the display mode operative on the display with the aid of the five buttons on the front of the instrument.
Instruments Start image This is the starting image that is shown on the display for a brief period after starting. If the unit gives a constant audible warning after starting, the self-test has failed. The unit will still work, but may behave in an unexpected manner.
Instruments Set display contrast Press button 5 (furthest right) to set display contrast. Then press the appropriate buttons to adapt the levels, then save the settings by pressing EXIT. The display unit has 5 contrast settings. Configuration menu (button 5) (depressed for longer than 3 s) The configuration menu is used to: - access the display mode SYSTEM INFORMATION. - do various settings for the display. - reach information and functions for servicing the display.
Instruments Display mode System Information SYSTEM INFORMATION is a display mode that functions in the same way as the display in the tachometer (EVC System Tachometer). You navigate round these functions, using the buttons on the free-standing control panel.
Instruments - ment intervals of the speedometers and tachometers. Rpm engine: [2500 rpm: 9000 r/min] in stages of 500 rpm - Speed: Change speed display (on/off) - Speed: [10 KNOT: 100 KNOT] in states of 10 (in the appropriate speed intervals) - Graph interval: 2 MIN,10 MIN, 30 MIN, 60 MIN, 2 H, 4 H, 8 H Units: (This menu is only displayed if LOCAL has been selected in menu SETTINGS). This is where you select the measurement units to be used to display operating information.
Instruments Display mode Engine (Button 1) This display mode shows the engine speed and boat speed in the form of standard instruments, together with a trip computer and fuel level gauge. The fuel level gauge are displayed if there is a tank sender installed.
Instruments Display mode Multi (button 2) This display mode shows operating information in four different windows (see below). The user can choose the operating information to be displayed in each window. Example of display in several windows for single engine installation The information can be displayed as figures or as standard instruments. Display indication shifts between the two modes when you press button 2 repeatedly.
Instruments Display mode Trip (button 3) This display mode shows: - Fuel used after last zeroing - Instantaneous fuel consumption (amount of fuel used per hour) (If speed information is available, instantaneous fuel consumption can also be calculated in relation to distance.
Controls This chapter describes the controls sold by Volvo Penta for your engine. Electronic lever control Operation Both the shift function and engine speed control are controlled using the lever control. N = Neutral position (Drive-unit is disengaged and the engine runs at idle speed). F = Drive-unit engaged for movement ahead. R = Drive-unit engaged for movement astern. T = Adjustment of engine speed. NOTE! The engine can only be started if the Control lever is in the neutral position.
Friction brake The control has a friction brake which can be adjusted as necessary to provide lighter or heavier lever action. Adjusting the friction brake: 1. Stop the engine. 2. Mover the control lever forwards so that the groove in the hub of the control lever is accessible. 3. Position a screwdriver in the groove and remove the plug. 4. Adjust the friction brake (8 mm wrench): Clockwise = heavier lever action Counter clockwise = lighter lever action. 5. Reinstall the plug.
Starting the engine Make it a habit to give the engine and engine bay a visual check before starting. This will help you to discover quickly if anything abnormal has happened, or is about to happen. Also check that instruments and warning displays show normal values after you have started the engine. To minimize starting smoke in cold starting, we recommend that a heater should be installed to warm the engine bay at temperatures below +5°C.
Starting the engine Starting method Turn the ignition on Turn the starter key to position I to switch the ignition on. Check LEDs Each time the ignition is turned on, all LEDs are illuminated on the main control panel. Check that all LEDs function. If the boat has more than one control panel, the LEDs on the other panel(s) are not checked until the control panel(s) is(are) activated. Check the tachometer display If a fault is registered it will be shown in the tachometer display.
Starting the engine Start the engine Start using the ignition switch Turn the key to position III. Release the key and let it key spring back to position I as soon as the engine has started. Stop cranking if the engine does not start with in 20 sek. Starting with the starter button Press the starter button. Release the button as soon as the engine has started. Please note that if you start from an alternative control station, the starter key at the main control station must be in position I.
Operation Learn to handle the engine, controls and other equipment in a safe and correct manner before you cast off on your maiden voyage. Remember to avoid sudden or surprising rudder movements and gear shifting. There is a risk that passengers could fall over, or overboard. WARNING! A rotating propeller can cause severe injury. Check that there is nobody in the water before you engage forward / aft drive.
Operation Acknowledging alarms and messages There are several types of alarms and messages that can appear as a pop-up in the tachometer/display. NOTE! Some alarms for fault are also accompanied by a buzzer. First silence the buzzer by pushing the NAVIGATION WHEEL on the control panel. 1. Read the alarm/message pop-up. 2. Acknowledge the pop-up by pushing the NAVIGATION WHEEL on the control panel (sometimes repeatedly). The pop-up will disappear. 3. Take the indicated actions.
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. 1.
Operation Operation 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 drive-unit, 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 1500 rpm. 1 Always do a forward/reverse operation as follows: 1.
Operation Steering with control levers NOTE! Engine speed is limited to 1500 rpm . Rotate the boat Put one control lever in the position for forward and put the other control lever in the position for reverse. Use a suitable engine speed for manoeuvring. The direction of rotation is determined by the lever which is put in the position for reverse. If the boat is to move to starboard, the starbord control lever should be put in the position for reverse. Steering the boat Put the control levers in forward.
Operation Docking (Joystick) The Volvo Penta IPS docking function (joystick) makes it possible to rotate the boat and maneuver it in any direction – sideways, diagonally, forward and backward – with one hand. IMPORTANT! The the docking function (joystick) should only be used for docking (slow speed maneuvering). B A NOTE! Learn to use the docking function (joystick) and its functions in a safe and correct manner, before starting to use the function in a crowded marina.
Operation Enabling boost mode In situations where normal thrust is insufficient, for example when it is windy or there is a strong current, the boost mode can be enabled. When the boost mode is enabled, the operator has more thrust available than in the normal docking mode. NOTE! The boost mode should not be used more than necessary. 1. Enable the docking function. B 2. Enable the boost mode by pushing the boost button (B) on the joystick. 3. A beep indicates that the boost mode is enabled.
Operation Maneuvering with the joystick WARNING! A rotating propeller can cause serious injury. Ensure that there is no one in the water before you enable docking mode. Never go near people who are bathing or where there is a risk that there are people in the water. WARNING! Remember that the side thrust is considerably greater than with a conventional bow propeller. The boat will continue to move in the selected direction even after the joystick has been released.
Operation Diagonally Rotate Turn 57
Operation Calibrating joystick function This calibration only needs to be performed if the boat movement does not corresponds to the movement of the joystick. Calibrate the joystick function as follows: 1 A IMPORTANT! When calibrating the joystick function the boat must be operated in open water and under safe conditions. Avoid performing the calibration in strong winds or sea-current as such conditions may affect the outcome of the calibration.
Stopping the engine The engine should be run for a few minutes at idle (in neutral) before turning it off. This will avoid boiling and even out the temperature. This is especially important if the engine has been operated at high engine speeds and loads. Stopping Turn the key to stop position “S”. Keep the key turned until the engine stops. The key will automatically return to the “0” position when it is released and can then be removed.
Stopping the engine Cold weather precautions To prevent freezing damage, the seawater system must be drained and the freshwater system coolant must have sufficient antifreeze protection. Refer to the cooling system section in chapter “Maintenance”. IMPORTANT! A poorly charged battery may burst as a result of freezing.
Maintenance schedule General information Your Volvo Penta engine and its equipment are designed for high reliability and long life. They are built to withstand a marine environment, but also to have the smallest possible environmental impact. If given preventive maintenance, according to the maintenance schedule, and if Volvo Penta original spares are used, these qualities are retained and unnecessary malfunctions can be avoided.
Maintenance schedule Every 200 hours / at least once a year, included in extended protection: Crankcase ventilation filter. Change............................................................... page 64 Air filter Change.............................................................................................. page 64 Drive belts. Check belt tension....................................................................... page 65 Compressor Check oil level....................................................
Maintenance This chapter describes how to carry out the above maintenance. Read the instructions carefully before starting work. Maintenance intervals are contained in the chapter above: Maintenance schedule WARNING! Read the safety precautions for maintenance and service in the chapter: Safety Information, before starting work. WARNING! Unless otherwise specified all maintenance and service must be carried out with the engine stopped. Stop the engine before opening or removing engine hatches.
Maintenance: Engine general Changing air filter Remove the air filter cover. Remove the old air filter. Clean the air filter cover/housing if necessary. Take care not to allow impurities to enter the engine. Fit the new air filter and the air filter cover. Changing crankcase ventilation filter Unscrew the lid and remove the old filter. Clean the filter cover/housing if necessary. Take care not to allow impurities to enter the engine. Fit the new filter.
Maintenance. Engine general Checking drive belts WARNING! Stop the engine before commencing maintenance work. General Check belt tension and condition regularly. If the belt is too taut it can damage bearings and if it is too loose it may slip. Therefore, check the belt tension regularly. Check and adjust after operation when the belt is warm. IMPORTANT ! Always change a belt that appears worn or is cracked (belts working in pairs must be replaced together). Adjusting/changing drive belts.
Maintenance: Engine general Compressor. Checking oil Checking and topping up Unscrew and remove the dipstick. Wipe off oil. Screw the dipstick down fully and then remove it again. Check that the level oil is between the markings. If the dipstick is not screwed down fully the oil level will be slightly above the MIN marking if the oil level is correct. Ensure therefore that the dipstick is fully screwed in to read off the oil level correctly. Top up the oil as required (use the dip stick tube to fill).
Lubrication system, Engine IMPORTANT! With a new or reconditioned engine, the oil and oil filters must be changed after 20–50 hours of operation. Use only the recommended grades of oil. Please refer to the “Technical Data” chapter. Oil change intervals can vary from 100 to 200 hours, depending on oil grade and sulphur content of the fuel. Please refer to the “Technical Data” chapter. Note that oil change intervals must never exceed a period of 12 months.
Maintenance. Lubrication system Changing engine oil Always observe the recommended oil change interval. IMPORTANT! Only use a recommended grade of oil. Please refer to the “Technical Data” chapter. IMPORTANT! The oil level should always be between the MAX and MIN marks on the dipstick. Higher or lower oil level than permitted could lead to engine damage. 1. Start the engine (this makes it easier to suck the oil up from the sump).
Maintenance. Lubrication system Changing oil filter and bypass filter. Change the oil filter and bypass filter during each oil change. Remember to hand the old filters in to a re-cycling station. WARNING! Hot oil and hot surfaces can cause burns. 1. Put a suitable vessel underneath the filters to avoid oil spillage. 2. Clean the filter bracket. 3. Unscrew the bypass filter (1) and the oil filters (2) with a suitable extractor. 4.
Freshwater system The fresh water system is the engines’ internal cooling system, which ensures that the engine operates at the correct temperature. It is a closed circuit system and must always be filled with a mixture of at least 40 % concentrated coolant and 60 % water to protect against internal corrosion, cavitation and damage caused by freezing.
Maintenance. Freshwater system Coolant. Mixture WARNING! All glycol is hazardous and harmful to the environment. Do not consume! Glycol is flammable. IMPORTANT! Ethylene glycol must not be mixed with other types of glycol. Mix: 40 % “Volvo Penta Coolant” (conc. coolant) 60 % water This mixture protects the engine against internal corrosion, cavitation and frost damage down to -28 °C (-18°F). (Using 60 % glycol lowers the freezing point to -54 °C (-65°F)).
Maintenance. Freshwater system Checking coolant level WARNING! Do not open the engine coolant system filler cap when the engine is still hot except in an emergency. Steam or hot coolant may spray out. Turn the filler cap slowly counter clockwise and let any pressure escape from the system before removing the cap. Top up coolant if necessary. The coolant level should be between the MAX and MIN marking on the expansion tank. Reinstall the filler cap.
Seawater system The seawater system is the boat’s external cooling system. On engines with drives, the seawater pump draws in water via the drive-unit, through the control system oil cooler to the seawater pump, after which the water passes the seawater filter before being pumped through the fuel cooler, intercooler, engine oil cooler and heat exchanger. Finally, the water is pumped into the exhaust pipe elbow, where it is mixed with the exhaust gases.
Maintenance. Seawater system Cleaning seawater filter 1 WARNING! Risk for water penetration. 2 3 Screw off cover (1) and remove seal plate (2). Lift out and clean the insert (3). IMPORTANT! If the boat is used in water that has a lot of contaminants, seaweed etc. the filter must be checked more frequently than indicated in the maintenance schedule. Otherwise there is a risk the filter will clog and the engine will overheat. Draining seawater system Use a suitable receptacle while draining.
Maintenance. Seawater system Checking/Changing sacrificial anodes WARNING! Risk of water entering. Close the seawater cock before starting work on the seawater system. 1. Close the seawater cock. 2. Drain the seawater as described in ”Draining the seawater system”. 3. Remove the sacrificial anodes in the heat exchanger and the intercooler. 4. Check the sacrificial anodes and replace them if they are less than 50% of their original size.
Maintenance. Seawater system Seawater system. Cleaning and inhibiting To prevent the build up of deposits and salt crystals in the seawater system it must be flushed with freshwater. When the boat is laid up it must also be inhibited. WARNING! Risk of water penetration. Cleaning and inhibiting the seawater system should be carried out with the boat on land. 1. Open the seawater cock on drive-unit. 2.
Fuel system The engine fuel system is a so-called common rail-system. The advantage of the common rail-system is that the engine control unit controls the timing and fuel amount, this mean better emission control and a smooth running engine. All work on the engine common rail-system must be carried out at an authorized workshop. Use only the recommended grade of fuel: See the chapter “Technical Data”. WARNING! Fire risk. When carrying out work on the fuel system makes sure the engine is cold.
Maintenance. Fuel system Bleeding the fuel system The fuel system must be bled e.g. after changing fuel filter, if the fuel tank has been run dry and after long stops. 2 1 WARNING! Never detach the pressure pipes. 1. Attach a transparent hose to the air vent valve (1). Lead the hose to a suitable receptacle to avoid spillage. 2. Open the air vent valve and pump fuel using the hand pump (2) until the fuel running out is free from air bubbles. Close and tighten the air vent valve. 3.
Maintenance. Fuel system 1 Fuel pre-filter. Changing filter insert Close fuel cock at the fuel tank. Position a container under the fuel filter. Remove the cover by slackening off screw (1). Replace insert and reinstall cover. Open fuel cock. Vent fuel system. Deposit the old filter insert at a properly designated disposal site. Start the engine and check for leaks. WARNING! Approaching a running engine is dangerous. Watch out for rotating components and hot surfaces.
Electrical system The engine is equipped with a two-pole system electrical system which means that the voltage (minus) is returned directly from the starter motor minus terminal with the battery negative lead. Individual components on the system return voltage to the starter motor minus terminal via separate cables. WARNING! Always stop the engine and break the current using the main switches before working on the electrical system.
Maintenance: Electrical system Electrical connections Also check that all electrical connections are dry and free of oxidation and that there are no loose connections. If necessary, spray these connections with a water-repellent spray (Volvo Penta Universal oil). Battery. Maintenance WARNING! Risk of fire and explosion. Never allow an open flame or electric sparks near the battery or batteries. WARNING! Never mix up battery positive and negative terminals. This may cause sparks and an explosion.
Maintenance: Electrical system Battery. Charging WARNING! Danger of explosion! The batteries give off hydrogen gas during charging which when mixed with air can form an explosive gas – oxyhydrogen. A short-circuit, naked flame or spark can cause a large explosion. Ensure that the ventilation is good. WARNING! The battery electrolyte contains extremely corrosive sulfuric acid. Protect your skin and clothes when charging or handling batteries. Always use protective goggles and gloves.
Maintenance: Electrical system Electrical installations Leakage current from the electrical system can be caused by incorrect installation of electrical equipment. Leakage current can knock out the galvanic protection of components such as the drive, propeller, propeller shaft, rudder stock and keel and cause damage by electrolytic corrosion. IMPORTANT! Work on the boat’s low tension circuit should only be carried out by qualified or experienced persons.
Maintenance: Electrical system 4. There must be a main switch connected to the starter battery positive (+) terminal. The main switch should cut off power to all power consuming equipment and should be switched off when the boat is not in use. 5. If an auxiliary battery is in use, a main switch should be connected between its (+) terminal and the fuse block, and the (–) terminal and the terminal block for the boat’s electrical equipment.
Volvo Penta IPS drive-unit The drive-unit is hydraulic, which means that forward/reverse engagement and disengagement is hydraulically activated. The drive-unit lubrication system has an oil filter and oil cooler. The drive-unit is equipped with solenoid valves for electronically controlled shifting. The drive-unit is protected against galvanic corrosion. This protection consists of sacrificial anodes and ground braids.
Maintenance: Drive-unit Checking corrosion protection between the housing and the clamping ring Check that the space between the drive-unit housing and the clamping ring are entirely coated with corrosion protection, Volvo Penta P/N 9510227. If the coating needs to be renewed, follow the instructions below: 1. Clean and dry off the space between the housing and the clamping ring. 2. Spray a liberal coating of corrosion protection in the space between the housing and the clamping ring.
Propellers For best performance and fuel economy the engine speed should be within the maximum RPM range: See chapter “Operation”. If the engine speed at maximum RPM falls outside the max. RPM range then the propeller should be changed. WARNING! Make it impossible to start the engine when working on the propellers. Take the starter key out of the starter switch. IMPORTANT! Damaged propellers should be replaced immediately.
Maintenance: Propellers Assembly 1. Apply water-resistant grease, part no. 828250 to the splines and thread on both propeller shaft. 2. Install the aft propeller. Then install the aft nut (C) and tighten it by hand until it bottoms. Install locking ring (5). Tighten the locking ring with the accompanying special tool and four socket cap screws (4). Torque 24-28 Nm (17.7-20.65 lbf ft). B 4 5 D 3 A 3. Install the forward propeller on the propeller shaft.
Laying up/Launching Before taking the boat out of the water for winter/out-of-season storage have an authorized Volvo Penta workshop inspect the engine and other equipment. Have any necessary repairs or service work carried out so that your boat is in top condition for the new season. Inhibition should be carried out to ensure that the engine and transmission are not damaged while out of commission during the winter/off-season. It is important this is done properly and than nothing is forgotten.
Laying up/Launching Bringing out of storage ● Check oil level in the engine and the drive-unit. Top up if necessary. If there is inhibiting oil in the system drain and fill with new oil, change oil filter. For correct oil grade: See the chapter “Technical Data”. ● Drain the antifreeze from the seawater system. ● Install the impeller in the seawater pump. Replace if the old one looks worn. Please refer to the Sea Water System chapter. ● Close/tighten drain cocks/plugs.
Laying up/Launching Repairing the drive-unit antifouling coating The propulsion unit and propellers have an antifouling coating applied from delivery. Inspect the coating annually and scrape off any loose coating and apply a fresh coating. Volvo Penta recommends the coating “Prop speed ® “. For instructions on how to apply the coating, please refer to the instructions that come with the “Prop speed ® “.
In case of emergency Despite regular maintenance according to the maintenance schedule and perfect operation, faults may occur which must be attended to before the boat can travel further. This chapter contains tips for rectifying some of the possible faults. There are safety functions which are activated when certain faults occur, to protect the engine. The following can occur: ● Engine can not be started ● Gear in neutral and engine speed is limited to 1500 rpm, no steering.
In case of emergency Emergency shifting If a fault occurs which prevents the drive-unit from being operated (shifted) with the control lever it is possible to shift manually using the description below. WARNING! In emergency shifting, the unit is locked in forwards operation. Please note that the gear can not then be disengaged with the control lever. Forward motion can only be cut off by stopping the engine with the ignition key or stop button.
In case of emergency Alignment of drive-unit If a fault occurs which prevents the drive-unit from being operated with the steering wheel it is possible to align the drive-unit to straight forward manually using the description below. The tools needed during this operation are delivered in a special tool box together with the boat. WARNING! The following procedure must be carried out with the engines stopped. 1. 2. 1. Remove the plug (1).
In case of emergency 4. Turn the crank tool back 75 turns. The drive-unit is now aligned straight forward. 5. Remove crank tool. Disconnect the switch by pressing down the lock (2) and at the same time unplugg the switch by slowly wiggle it (please refer to procedure in step 1) Fit the plug. 6. Reconnect the cable you disconnected in step 1.
In case of emergency 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. WARNING! Read through the safety advice for care and maintenance work in the “Safety information” chapter before starting work.
In case of emergency Diagnostic function The diagnostic function monitors and checks that the engine, drive-unit and EVC system function normally. The diagnostic function has the following tasks: ● Discover and localize malfunctions ● Notify that malfunctions have been discovered ● Give advice in fault finding ● Protect the engine and ensure continued operation when serious malfunctions are discovered. The diagnostic function affects the engine in the following ways when: 1.
In case of emergency Malfunction messages Steering system Tachometer display Pop-ups Steering System If the diagnostic function discovers a malfunction in steering system a steering specific pop-up will appear in the tachometer display.The pop-up is shown in the tachometer display and the ordinary boat information is not visible at all. The audible warning will sound and the relevant warning lamp on the alarm panel will start to flash. The pop-ups that are shown are related to the steering function only.
In case of emergency Limited steering If there is steering function on only one driveline side, this pop-up is shown. At least one of the sides is able to shift gear and run the engine to be able to move the boat. The engine speed is limited. The shifting status is unchanged. Acknowlege the alarm and take the recommended measures. Please refer to the “Fault register” chapter. No steering wheel response If there is no ability to steer the boat with the steering wheel, this pop-up is shown.
In case of emergency No gear/throttle and steering If there are multiple errors unabling the system to control both steering and propulsion this pop-up is shown . Steering malfunction on both sides. There are also a combination of errors unabling propulsion or control of propulsion through control levers on both sides. It is adviced to shut down the engines on both sides and try to restart them again. If the errors remain after restart, tow the boat to service provider.
In case of emergency Malfunction message engine and EVCsystem If the diagnostic function discovers a malfunction, it warns the driver by showing pop-ups in the tachometer display and the buzzer will sound. Pop-ups will alternate between "cause of fault" and "measures to take". To acknowledge the alarm, press NAVIGATION WHEEL. When the fault has been acknowledged, the buzzer will become silent. Press NAVIGATION WHEEL. The pop-up will disappear and normal display window will be shown.
In case of emergency Faults list A faults list can be viewed from the MAIN MENU in the tachometer, if a fault is registered. When in MAIN MENU, select FAULTS by pushing NAVIGATION WHEEL. Number after FAULTS indicates number of faults stored in faults list. Show faults in faults list by turning NAVIGATION WHEEL. Faults are stored and malfunctions have been registered Shown fault pop-ups will alternate between "cause of fault" and "measures to take".
Fault register WARNING! Read the safety precautions for maintenance and service in the ”Safety information” chapter before starting work. Explanation Faults are presented with information about reason and proposed measures to be taken. 2. 1. Description 3. R 4. Explanation: Reaction: Action: 1. Description of current fault and measures to take. 2. Current warning lamp which flashes during an alarm. O/R means that an orange or red lamp flashes. 3. Audible warning 4.
Fault register Air temperature R Explanation: Charge air temperature too high. Reaction: Engine power is reduced. Action: • Please contact a Volvo Penta workshop. Coolant level R Explanation: Coolant level too low. Reaction: Engine power is reduced. Action: • Check coolant level. Please refer to "Maintenance: Freshwater system". • Check that no leakage occurs in auxiliary equipment connected to the engine cooling system.
Fault register Fuel pressure R Explanation: Fuel pressure too low. Reaction: Engine power is reduced. Action: • Check the fuel level. • Open the fuel taps and check that no leakage occurs. • Check that the fuel filters are not blocked. Please refer to “Maintenance: Fuel system” • Please contact a Volvo Penta workshop if the fault remains. Fuel temperature R Explanation: Fuel temperature too high. Reaction: Engine power is reduced. Action: • Check the fuel level.
Fault register Engine oil temperature R Explanation: Engine oil temperature too high. Reaction: Engine power is reduced. Action: • Check the oil level. Please refer to "Maintenance: Lubrication system". • Check that the oil filters are not blocked. Please refer to "Maintenance: Lubrication system". • Check that no leakage occurs. • Please contact a Volvo Penta workshop if the fault remains. Engine oil filter R Explanation: Oil pressure differential too big.
Fault register Battery voltage O Explanation: Battery voltage too low. Reaction: Action: • Check battery fluid level. • Check belt tension. • Please contact a Volvo Penta workshop if the fault remains. Auxiliary stop R Explanation: External stop signal. Reaction: Engine stops or can not be started Action: • Check emergency stop button. Reset if necessary. Please refer to "Stopping the engine: Emergency stop" • Please contact a Volvo Penta workshop if the fault remains.
Fault register EMS supply fuse R R O/R Explanation: Fuse is broken. Reaction: Action: • Please contact a Volvo Penta workshop. Extra supply fuse Explanation: Fuse is broken. Reaction: Action: • Please contact a Volvo Penta workshop. Check control lever Explanation: Fault in control lever. Reaction: Engine in emergency mode. Gear to neutral. Action: • Restart engine(s).
Fault register System failure R Explanation: Miscellaneous fault. Reaction: Action: • Restart engine(s). • Please contact a Volvo Penta workshop if the fault remains. Check joystick O/R Explanation: Fault in joystick. Reaction: Engine power is reduced. Action: • Restart engine(s). • If the engine can not be operated from the chosen control panel, use an alternative control panel. • Please contact a Volvo Penta workshop if the fault remains.
Fault register No steering wheel response R Explanation: Fault in steering wheel unit. Reaction: Engine power is reduced on both sides. No steering. Action: • Restart both engines. • Please contact a Volvo Penta workshop if the fault remains. No gear/throttle and steering R Explanation: Fault in steering system. Reaction: No steering. No propulsion. Action: • Restart both engines. • Please contact a Volvo Penta workshop if the fault remains.
Technical Data Engine General information Volvo Penta IPS system designation........................ Engine model/after market designation.................... Crankshaft power kW (hp)*...................................... Propellershaft power kW (hp)*.................................. Idling speed.............................................................. Swept volume........................................................... Injection sequence....................................................
Technical Data Recommended types of engine oil Important! Use of improper or inferior oil can cause excessive wear of bearings and moving parts, thus shortening the engine life. It can also result in sticking of piston rings and seizing of pistons in the cylinders, thus causing major damage.
Notes 113
Notes 114
✂ Yes please, I would like an operator’s manual in English at no charge. Orders can also be placed via the Internet: http://www.volvopenta.com/ manual/coupon Publication number: 774 7996 42200/615001/155099900192 Post or fax this coupon to: Document & Distribution Center Order Department ARU 2, Dept. 64620 SE-405 08 Göteborg Sweden Fax: +46 31 545 772 Name Address Country NB! This offer is valid for a period of 12 months from delivery of the boat.
✂ Sí gracias, deseo recibir gratuitamente un libro de instrucciones en español. El pedido puede hacerse también por internet: http://www.volvopenta.com/ manual/coupon Número de publicación: 774 8005 42200/615001/155099900192 Franquear o enviar fax a: Document & Distribution Center Order Department ARU 2, Dept.
✂ Ja graag, Ik wil kosteloos een instructieboek in het Nederlands ontvangen. U kunt ook bestellen via internet: http://www.volvopenta.com/ manual/coupon Publicatienummer: 774 8008 42200/615001/155099900192 Stuur of fax de coupon naar: Document & Distribution Center Order Department ARU 2, Dept. 64620 SE-405 08 Göteborg Zweden Fax: +46 31 545 772 Naam Adres Land Denk eraan dat het aanbod geldt gedurende 12 maanden na de datum waarop de boot werd afgeleverd, daarna alleen indien nog verkrijgbaar.
✂ Sim, obrigado(a)! Gostaria de receber gratuitamente um manual de instruções em português. A encomenda também pode ser feita através da Internet: http://www.volvopenta.com/ manual/coupon Número de publicação: 774 8014 42200/615001/155099900192 Envie o talão pelo correio ou um fax para: Document & Distribution Center Order Department ARU 2, Dept.
✂ Evet lütfen, Dokument & Distribution center Ordermottagningen ARU 2, Avd. 64620 SE-405 08 Göteborg Ýsveç ücretsiz Türkçe kullanım el kitabı istiyorum Yayın numarası: 7748017 Ýsim Adres Faks: +46 31 545 772 Sipariþler Ýnternet üzerinden de verilebilir: http://www.volvopenta.com/ manual/coupon Ülke NB! Bu teklif, teknenin teslim edilmesinden itibaren 12 aylýk bir süre için geçerlidir. Bu süre sonunda ürün daðýtýmý stoklarla sýnýrlýdýr.
7747996 English 06-2007
