OPERATOR’S MANUAL Volvo Penta IPS
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 Presentation .............................................................................................. 10 Instruments and Controls .................................
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 Service and spare parts Certified engines Volvo Penta marine engines 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. Through regular service and use of by Volvo Penta approved spare parts, these qualities are retained. Volvo Penta’s world-wide network of authorised dealers is at your service.
Presentation Volvo Penta IPS - Inboard Performance System p0006599 Volvo Penta IPS overview Volvo Penta IPS is setting a new standard: - 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 is greatly simplified.
Presentation Comfort Volvo Penta IPS new technology leads to major improvements for all comfort enhancing factors. - The propulsion forces and vibrations are absorbed by the combined rubber suspension and sealing. - A U-joint in the drive shaft makes it possible to have the engine soft suspended, which efficiently reduces engine vibrations. - The propellers are working in undisturbed water with no cavitation, and have good clearance from the hull.
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 key 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 drive and to navigate the EVC system menu. 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. The lamp above the activation button shows the status of the station. Red lamp: Active station.
Instruments and Controls 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). If the button is pressed on an inactive station, operating information is shown on the display(s) and the menu structure is activated.
Instruments and Controls Alarm acknowledge button Push this button to acknowledge an alarm of a fault. A fault is always indicated with a flashing lamp above the button and a more serious faults is also indicated with a buzzer. When the fault is acknowledged the lamp will light continuously and the buzzer will silence. The fault pop-up must be read and acknowledged on a station that is equipped with displays. Please refer to the “Operation” chapter, section “Acknowleging alarms and messages”.
Instruments and Controls malfunction. The display will work but may act in an unexpected way. NOTICE! Only installed functions will be shown in the display. 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 G 1 3 2 H 4 Graph 4 To leave the menu, wait a few seconds or press button 5 (EXIT).
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 dividedto show windows and system information. To handle the system information, see chapter Instruments and Controls page 20. To go between the different display modes press button 2 repeatedly. By pressing button 5, the right arrow, you choose what information to be shown in the different windows.
Instruments and Controls 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. For more information, see chapter Instruments and Controls page 20.
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 102. 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 41.
Instruments and Controls Controls 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. Reverse gear/drive disengaged and engine at idle. F = Reverse gear/drive engaged for forward motion. R = Reverse gear/drive engaged for rearward motion. T = Engine rpm control (throttle).
Instruments and Controls Adjusting the friction brake The lever is fitted with a friction brake to allow adjustment for easier or stiffer movement as required. 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 1 Activate the docking function by pressing the docking button (A) on the joystick. 2 A sound signal confirms that the docking function is active and the lamp by the docking button is lit. 3 To inactivate the function press the docking button. To confirm that the function is inactivated the signal sounds twice and the lamp goes out. P0006292 4 The docking function is also deactivated if the controls is moved out of neutral.
Instruments and Controls Maneuvering with joystick To maneuver the boat move the joystick forwards, backwards, sideways or by turning the top of the joystick, see figure. IMPORTANT! The boat keeps moving even after the joystick is released, compensate this by moving the joystick in opposite direction.
Optional Sport Fishing Mode Volvo Penta's sport fish function has been developed by deep-sea fishermen. When the function is activated, the IPS units are angled outwards and the helmsman can quickly rotate and maneuver forward/backwards to follow the movement of the fish. When activated, the wheel is disconnected and the boat is maneuvered solely via the control lever. When the function is disengaged, both the IPS units are set to straight forward.
Optional Activating single-lever function 1 In order to activate the single-lever function, the control levers must be roughly the same position, max 10% difference. 2 Press the single lever button. The activation of the function is acknowledged by an acoustic signal and the lamp next to the button lighting. An image stating that the function is active is shown on the display for 5 seconds.
Optional ACP Volvo Penta ACP (Active Corrosion Protection) protects against galvanic corrosion by controlling an electric current that can be monitored by the engine electrical system. It is preferable to connect the boat to shore supply, if such is available. If shore power is unavailable, ACP utilizes the batteries, as it is connected to the boat's 12 V/24 V system. If the batteries begin to discharge, the ACP switches from primary to secondary protection.
Optional • No Protection; risk of corrosion, system gives warning alarm. The display switches between the two screens. Seek service for system checks. P0001218 • If the ACP is set to inactive, the system cannot iden- P0001203 P0001203 tify ACP status and three lines will be shown on the display. If this should occur when the system is not set to inactive, seek service for checks.
Optional • Inactive; this mode should only be used when the P0003049 P0003049 30 boat is taken out of the water on to dry land. To avoid fault codes, select inactive mode before lifting the boat out of the water. In this mode the ACP no longer monitors the corrosion condition, but the IPS is protected by the zinc anode. The system is re-started when the ignition is switched on; inactive mode switches to normal mode.
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 (41°F) are encountered.
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 41 for further information and recomended actions. If the boat has more than one station, it has to be activated before the lamps can be checked.
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 transmission 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.
Operation Helm 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 2 Unlock, if locked, the station you leave by pushing the activation button (2). 1 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. P0006366 An active station is indicated by the lit lamp above the activation button.
Operation Cruising Speed For best fuel economy operations at full must be avoided. We recommend a cruising speed that is at least 10% below the maximum engine revolutions at top speed (full throttle). Depending on hull type, the choice of propeller, the load and sea state etc., the maximum revolutions at top speed may vary, but they should be within the full throttle range; refer to the “Technical data” chapter.
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 engines 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 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. X S TO P AU Auxiliary stop P0003709 After Engine Shutdown • Check the engine and engine bay for leakages. • Close the fuel taps. • Close the two sea cocks at each propulsion unit. Position A open. Position B closed. • Take an hour meter reading and carry out preventive maintenance according to the maintenance schedule.
Engine Shutdown Operation break with the boat in water If the boat is not used, but left in the water, the engine must be warmed up at least once every fortnight. This prevents corrosion damage in the engine.
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. P0004375 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 chapter Safety Information page 6 before starting work.
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. Please refer to Maintenance page 74. • 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. Please refer to Coolant Level, Checking and Topping Up page 79. • 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 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. Please refer to Oil level, checking and topping up page 72. • 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. Please refer to Oil level, checking and topping up. • 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 Battery Voltage Explanation: Battery voltage too low. Symptom: None.
Fault Code Register Primary Battery Explanation: Poor batteries or charging. Symptom: None. Action: • Check the batteries fluid level Please refer to Battery, Maintenance page 86. • Check belt tension. Please refer to Drive Belt, Check and Change page 70. • Please contact a Volvo Penta workshop if the fault remains. P0005026 WARNING! Primary Battery See Operator's Manual SUS, Battery Voltage Low Explanation: Low supply voltage to SUS unit. Symptom: Engine power is reduced.
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 Check Joystick Explanation: Faulty joystick. 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. P0005037 WARNING!Check JoystickSee Operator's Manual P0005038 CAUTION!Check JoystickSee Operator's Manual Check Steering Wheel Explanation: Faulty steering wheel unit. Symptom: Engine power is reduced.
Fault Code Register Limited Engine RPM Explanation: Fault in steering system. Symptom: Engine power is reduced. Action: • Restart engine(s). • Please contact a Volvo Penta workshop if the fault remains. P0005040 CAUTION! Limited Engine RPM See Operator's Manual Limited steering Explanation: Fault in steering system. Symptom: Engine power is reduced. Limited steering. Action: • Restart engine(s). • Please contact a Volvo Penta workshop if the fault remains.
Fault Code Register No Gear/Throttle, No Steering Explanation: Fault in steering system. Symptom: No steering. No drifting. Action: • Restart engine(s). • Please contact a Volvo Penta workshop if the fault remains. P0005043 DANGER! No Gear/Throttle, No Steering Restart Engines See Operator's Manual Helm Restarted Explanation: Lost active helm during crank. Symptom: None. Action: Restart engine(s).
Fault Code Register 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). Action: Please contact a Volvo Penta workshop.
In Case of Emergency 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 Starting Using Auxiliary Batteries WARNING! Explosion hazard. Batteries contain and give off an explosive gas which is highly flammable and explosive. A short circuit, open flame or spark could cause a violent explosion. Ventilate well. WARNING! Never confuse the positive and negative poles on the batteries. Risk of arcing and explosion. P0002107 1 Check that the auxiliary battery has the same voltage as the engine system voltage.
In Case of Emergency Emergency Shifting If a fault occurs which prevents gear shifting with the control levers, it is possible to shift manually using the description below. NOTICE! The following procedure can be performed with the engine(s) shut down or running. WARNING! In emergency shifting, the unit is locked in forwards operation and the revers gear can not 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 Manual engagement – forward gear: 1 1 Undo the two connectors, marked “Secondary” and “Primary”, from the solenoid valves. 2 Remove the cap nut from the lower solenoid valve marked “P” (forward gear). 3 Release the spring loaded button by pushing and at the same time turning it 1/2 turn counter-clockwise. The gear is now engaged for forward motion and cannot be disengaged by the control lever.
In Case of Emergency Emergency Alignment, Propulsion Unit If a fault occurs which prevents one or several propulsion units from being operated with the steering wheel it is possible to align the propulsion unit(s) for straight forward operation manually using the description below. If one or several propulsion units can be operated by the steering wheel, this emergency operation is not necessary.
In Case of Emergency 2 Connect the switch and fit the red crank tool. 3 Press the switch button down and keep it pressed while turning the crank tool carefully to an end position. When the end position is reached, stop turning. The end position feels like a compression spring. IMPORTANT! Do not force the crank tool beyond the end position, it could damage the propulsion unit. 4 Turn the crank tool back 75 turns. The propulsion unit is now aligned for straight forward motion.
In Case of Emergency 5 Remove the crank tool. Disconnect the switch by pressing down the lock and at the same time unplugg the switch by slowly wiggling it (please refer to procedure in step 1). Screw back the plug. 6 Reconnect the cable you disconnected in step 1. Emergency steering with control levers If a fault occurs which prevents all propulsion units from being operated with the steering wheel, align all the propulsion units and use the steering method described below to reach nearest habor.
In Case of Emergency Steering the boat Put the control levers in forward. Use a suitable engine speed for maneuvring. The direction of the steering is determined by the use of the control levers. If the boat is to turn to starboard, reduce speed on starboard engine. The greater the difference in speed between the control levers the more the boat turns. To make a sharp turn, move one of the control lever to reverse for a moment.
Maintenance Schedule C R A L I = = = = = Clean Replace Adjust Lubricate Inspect (Clean, Adjust, Lubricate or Replace if necessary) FSI, S2 = First time Service Inspection A, B, C, D, E = Type of service (regular service) FSI First service inspection, after 20–50 running hours1) Coolant level and antifreeze mixture I Drive belt (tension) I Seawater filter IC Drive-unit, oil level I Corrosion protection (space between IPS-housing and clamping ring) I Instrument panel function I Start and warm
Maintenance Schedule B Every 200 hours / at least once a year, included in extended protection Crankcase ventilation filter R Air filter insert R Fuel pre-filter and fuel fine filter R Drive belt (tension) I Compressor, oil level I Seawater pump impeller I Sacrificial anodes (charge air cooler and heat exchanger) I Corrosion protection (space between IPS-housing and clamping ring) I Engine and propulsion unit.
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 65. 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 Crankcase Ventilation, Filter Change 1 Unscrew the cover and remove the old filter. 2 Clean the filter cover/housing as necessary. Be careful to prevent contamination from entering the engine. 3 Install the new filter. 4 Screw the cover back in place. IMPORTANT! Scrap the old filter. They may not be cleaned. p0003704 Air Filter, Change 1 Unscrew the air filter cover and remove the old filter. 2 Clean the air filter cover/housing as necessary.
Maintenance Drive Belt, Check and Change WARNING! Stop the engine before doing any maintenance work. General Check belt tensions and condition regularly. A belt that is tensioned too tightly may damage bearings, while a belt too-loosely tensioned may slip. Check and adjust the belt after operation, while the belt is still warm. IMPORTANT! Always replace a belt that appears worn or has cracks (belts that work in pairs shall always be changed together).
Maintenance Compressor, checking oil Checking and filling 1 Unscrew and lift up the oil dipstick. Dry the oil off. Screw the oil dipstick down as far as it will go and then unscrew and lift up. 2 Check that the oil level is between the MAX and MIN marks. Check that the dip stick is screwed fully home so that the reading is correct. If the dipstick is not screwed fully home, the oil level will be above the MIN mark even if the oil level is correct. 3 Fill with oil as required, use the dipstick hole.
Maintenance Lubrication System Oil change intervals can vary depending on oil grade and sulphur content of the fuel, please refer to Technical Data page 115. 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 115, the condition of the oil must be checked by the oil manufacturers through regular oil testing.
Maintenance WARNING! Hot oil and hot surfaces can cause burns. 1 Run the engine until warm so that the oil is easier to pump. Then stop the engine and wait 10 minutes. 2 Connect the oil suction pump to the draining pipe. Pump out the oil. 3 Replace the oil filter and by-pass filter at every oil change, see sectionOil Filter/By-pass Filter, Change page 73. 4 Fill with oil to the correct level through the filling hole on the top of the engine. Oil quantity, see section Technical Data page 115.
Maintenance Fuel System Only use the grades of fuel recommended in the fuel specification, see Technical Data page 116. 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 Fuel system, bleeding The fuel system must be bled after a filter change, if the fuel tank has been run dry and after a long-term stoppage. IMPORTANT! Never disconnect the pressure pipe. 1 Connect a transparent hose to the bleed nipple (1). Feed the hose to a container to avoid spillage. 2 Open the bleeding nipple and pump fuel with the hand pump (2) until the fuel is free from bubbles. Close and tighten the bleed nipple. 3 Pump a further 10 times on the hand pump.
Maintenance Water in Fuel If the EVC system warns for too much water in the fuel pre-filter, the water separator needs emptying. IMPORTANT! Do not continue operating if there is water in the water separator, it can damage the engine. Draining the fuel filter 1 Stop the engine and remove the ignition key from the ignition lock. 2 Remove the connector piece from the water separator (1).
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 Coolant Level, Checking and Topping Up WARNING! Do not open the coolant filler cap when the engine is warm, except in emergencies, this could cause serious personal injury. Steam or hot fluid could spray out. 1 Turn the filler cover slowly counter-clockwise and release any pressure from the system before removing the cover completely. 2 Top the coolant up as necessary. The coolant level shall be between the MAX and MIN marks on the expansion tank. 3 Screw the filler cover on.
Maintenance Seawater System The raw water system is the engine's external cooling system. On IPS engines, the raw water pump sucks in water via the IPS cooling water inlet, through the IPS unit oil cooler to the raw water pump. The water then passes through the raw water filter before being pumped through the fuel cooler, intercooler, engine oil cooler and heat exchanger. Finally the water is fed out through the exhaust elbow, where it is mixed with the exhaust gases.
Maintenance Zinc Anodes, Check and Change WARNING! Risk of water entry. Close the seawater cocks before doing any work on the seawater system. 1 Close the sea cock(s). 2 Drain the raw water as described in Seawater System, Draining page 80. 3 Remove the zinc anodes from the heat exchanger (1) and intercooler (2). 2 1 4 Check the zinc anodes and replace if consumed to more than 1/3rd of original size. If not, clean the zinc anodes with Emery cloth to remove the oxide layer before re-installing them.
Maintenance 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. The system must also be preserved when the boat is going to be layed up on land for longer periods than two month. This procedure can be performed with the boat either in or out of the water. WARNING! Working with or going close to a running engine is a safety risk. Watch out for rotating components and hot surfaces.
Maintenance 7 The antifreeze mixture should be left in the system while the boat is not used. Before starting to use the boat again drain the mixture and clean the system using the same procedure as above. 8 Deposit antifreeze mixture at a properly designated waste site. 9 Check that the system is intact and that there are no leaks. Seawater Filter, Check and Cleaning WARNING! Risk of water entry. Close the seawater cocks before doing any work on the seawater system.
Maintenance Electrical System The engine is equipped with a 2-pole electrical system and an alternator. System voltage is 12V or 24V. 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 IMPORTANT! Never disconnect the current with the main switches when the engine is running, the alternator and electronics could be damaged.
Maintenance 24–volt system (engine) The engine is fitted with two automatic circuit breakers (1). The circuit breakers cut the power if the system is overloaded. If it is not possible to start the engine or if the instrument stops working while running, the circuit breaker may have been activated. Reset by pressing in the circuit breakers (1) (red button). IMPORTANT! Always investigate the cause of the overload. If the fuse trips frequently, contact an authorized Volvo Penta workshop.
Maintenance 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. 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 Filling The electrolyte level should be 5–10 mm (0.2– 0.4”) above the cell plates in the battery. Top up with distilled water as required. After filling, the battery should be charged for at least 30 minutes by running the engine at idle. Some maintenance-free batteries have special instructions, which must be followed. P0002110 Battery, Charging WARNING! Risk of fire and explosion. Never allow an open flame or electric sparks near the battery or batteries.
Maintenance • Charge batteries if they have become discharged. During charging, unscrew the cell plugs but leave them in the plug holes. Ventilate well, especially if the batteries are charged in an enclosed space. • If the engine is not used for a longer period of time, the batteries should be fully charged, then possibly trickle charged (please refer to the battery manufacturer’s recommendations). Batteries are damaged by being left discharged, and can also freeze and burst easier in cold weather.
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 Drive The propulsion unit has an electronically controlled hydraulic clutch. Two soleniod valves, primary (forward gear) and secondary (reverse gear), is controlled by electrical signals from the operator’s control levers. The propulsion unit's lubrication system is equipped with an oil filter and an oil cooler. The propulsion unit is protected against galvanic corrosion. This protection consists of sacrificial anodes. An active corrosion protection, ACP, is optional.
Maintenance Changing oil and filter 1 Open the oil filling (1) cap slowly so that any overpressure is released. Unscrew the draining plug (3) and allow the oil to run out. 2 Change the filter. 3 Refit the drain plug with a new gasket. NOTICE! Always replace the gasket when the drain plug has been removed. 4 Measure up the correct quantity of oil and fill the propulsion unit with the oil via the oil filling hole. For oil grades and volume, please refer to Technical Data page 115.
Maintenance Inspection/replacing corrosion protection – Sacrificial anodes Check the sacrificial anodes regularly. There are two anodes per stern drive; one is fixed to the drive and the other to the transom. Refer to the illustrations. Replace an anode when approximately 1/3 of it has corroded away. When the boat is stored ashore, corrosion protection deteriorates due to sacrificial anode oxidization. Even new anodes oxidize on the surface. The anodes must be cleaned before the boat is launched.
Maintenance Inspect the drive unit paint Volvo Penta recommends ”Prop speed ®” coating. Instructions regarding the application of ”Prop speed ®” coating are included with the product. Inspect the coating every year and scrape away any loose coating and apply new. Do not apply coating in the groove (A) between the drive unit and the hull or to the exhaust cushion (B). Allow the coating to dry before launching the boat.
Maintenance Propeller WARNING! Make sure the engine can not start during work on propeller(s); remove ignition key(s) and shift drive into forward or reverse. NOTICE! Damaged propellers should be replaced immediately otherwise there is high risk of serious damage to the propulsion unit. Operating the boat with a damaged propeller should be undertaken with extreme care and only at reduced engine speeds.
Maintenance 3 Undo the locking ring with the accompanying special tool by unscrew the four socket cap screws (2). Remove nut (B) and locking ring (3). Remove the forward propeller from the propeller shaft. 4 Undo the locking ring for the aft propeller with the accompanying special tool by unscrew the four socket cap screws (4). Remove nut (C) and locking ring (5). Remove the aft propeller from the propeller shaft. 5 Wipe the propeller shafts clean.
Maintenance Assemble propellers 1 Apply water-resistant grease, P/N 828250 to the splines and threads on both propeller shafts. 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 (17.7-20.7 ft. lb.).
Maintenance 3 Install the forward propeller on the propeller shaft. Tighten nut (A) by hand and install locking ring (3). Tighten the locking ring with the accompanying special tool and four socket cap screws (2). Torque 24-28 Nm (17.7-20.7 ft. lb.). 4 IMPORTANT! Tighten the screw (D) until it bottoms. Otherwise it will not be possible to change the propeller without damaging the spinner. 5 Push the spinner into place by hand.
Storage Short Term Storage If the boat is not going to be used for a shorter period, the engines must be run up to normal operating temperature at least once every 14 days. This prevents corrosion in the engines. WARNING! If the engines must be run up to normal operating temperature with the boat kept up on land, make sure to provide the seawater system with water during the operation. If the seawater pump is run dry the impeller could be damaged. Always check the impeller after dry runs.
Storage Long Term Storage If the boat is not going to be used for a longer period than two months, either left in the water or layed up on land, a long-term preservation of the engine and propulsion unit should be carried out. This ensures that the engine and propulsion unit are kept in good condition and that no damage arises. It is important that this is done properly and that nothing is forgotten. We have provided a checklist covering the most important points.
Storage • Clean the outside of the engine. Touch up any damaged areas of paintwork with Volvo Penta original paint. IMPORTANT! Never use a high-pressure washer when washing the engine and never point highpressure water jets directly at seals, rubber hoses or electrical components, as this could cause serious damage. • Disconnect the battery leads. Clean and charge the batteries. A poorly charged battery may burst as a result of freezing.
Storage Bringing Out of Storage The following should be carried out on each propulsion unit with the boat out of the water: • Paint the hull. • Check the sacrificial anode on the propulsion unit If there is less than 2/3 of the anode left, it must be replaced. Clean just before the boat is launched. IMPORTANT! Use emery paper. Do not use a wire brush or other steel tools when cleaning, as these may damage the galvanic protection. • Check the oil level in the propulsion unit. Top up if necessary.
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 . Repeated presses or holding the button pressing 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 P0001024 5 Turn to Set offset. Press the wheel to access offset depth adjustment.
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 My View In My view it is possible to select the operating information to be displayed in the main menu. The type of information that may be selected depends on the functions installed. P0001016 1 Turn to My View in the settings menu. Press to reach the submenu. 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.
Calibration and Settings ACP Setting the ACP protection position. 1 Turn until ACP is shown in the settings menu. Press to reach the submenu. P0001022 2 Turn to the desired position Normal, Chlorine Gas Free or Inactive. Press the wheel to confirm the selection. P0001021 EVC Info Information regarding accessories, components and software installed in the boat is displayed here. P0001020 1 Turn to EVC About in the settings menu and press the wheel to reach the submenu.
Calibration and Settings 1 Activate the station. 2 Turn until Units is shown in the settings menu. Press to reach the units menu. P0001036 3 Turn to US or Metric; press the wheel and select US or Metric. Press the wheel to confirm the selection. 4 Turn to Distance; press the wheel and select km, Nm (nautical miles) or Miles. Press the wheel to confirm the selection. Language It is possible to select between 10 languages.
Calibration and Settings Fuel Tank There are two alternative methods for calibrating the level sensor in the fuel tank. Full Fuel Tank Calibration is an approximate method, while Fuel Multipoint Calibration provides more precise results. Multi-point calibration is a prerequisite if the trip computer is to show fully accurate information. Fuel Multipoint Calibration In order for multi-point calibration to be carried out, the fuel tank may not be filled to more than 20% of its total capacity.
Calibration and Settings Full Fuel Tank Calibration For this method the tank must be full and calibration of the fuel level sensor takes place in one step. This means that the fuel level value will be approximate, and therefore all trip data based on remaining fuel must be seen as approximate values. 1 Turn to Fuel Tank and press the wheel to reach the submenu. P0001012 2 Turn to Full Tank Calibr. and press the wheel. P0001009 3 Fill the fuel tank.
Calibration and Settings Joystick Joystick calibration need only be carried out if boat movements do not correspond to joystick movements. When calibrating the joystick the boat must be driven on open waters in safe conditions. Avoid calibrating in high winds or currents that can influence the result of the calibration. Allow the boat to run for a fairly long distance during the calibration. Hold the joystick firmly in position.
4 Simultaneously press both buttons on the joystick for 5 sec. to reach calibration mode. 5 Calibration mode is confirmed by an audible signal and by both lamps on the joystick and the neutral button lamps on the control panel flashing. 6 Move the joystick sideways as far as it will go in one direction. Correct boat movements by moving the joystick up and down, and by turning it. 7 When the boat is moving straight abeam, depress the docking button.
Calibration and Settings 8 An audible signal and both lamps on the joystick and the neutral button lamps on the control panel will light up to confirm that calibration is complete and stored. The system is now in docking mode. 9 When the joystick is returned to the central position the lamps stop flashing; the lamps by the docking button and the neutral button shine continuously instead. Resetting the calibration 1 Activate docking mode by depressing the docking button.
Calibration and Settings 4 Calibration mode is confirmed by an audible signal and by both lamps on the joystick and the neutral button lamps on the control panel flashing. 5 Press the docking button. Calibration is now reset, which is confirmed by an audible signal. The system is now in docking mode.
Technical Data Engines Engine, General Volvo Penta IPS system designation D4 — See table below D6 — See table below Engine model/after market designation See table below See table below Crankshaft power kW (hp)* See table below See table below Propellershaft power kW (hp)* See table below See table below Idling speed 700 rpm 600 rpm Displacement 3.7 dm3 (225.8 in3) 5.5 dm3 (335.
Technical Data Lubrication System Engine: D4 D6 for all allowed installation inclinations 12.5 liters (3.3 US gals) 20 liters (5.3 US gals) volume difference MIN – MAX 1.5 liters (0.4 US gals) 3.5 liters (0.9 US gals) idling 125 kPa (18.1 PSI) 125 kPa (18.1 PSI) at full speed 450 kPa (65.3 PSI) 450 kPa (65.3 PSI) SAE 15W/40 (See table) SAE 15W/40 (See table) Oil volume, (incl. oil filter) Oil pressure, hot engine, Oil, viscosity: Compressor, oil Oil volume 0.1 liters (0.
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 12V 24V voltage/max. amperage 14V/115A 28V/80A output, approx. 1610W 2240W Alternator, rated power, max Battery capacity 2 connected parallelly 12V, max. 2 connected in series 12V, max. 88Ah 88Ah Battery electrolyte density at +25°C (77°F): fully charged battery 1.28 g/cm3 = 0.0462 lb/in3 (1.24 1.28 g/cm3 = 0.0462 lb/in3 (1.24 g/cm3 = 0.0448 lb/in3)* g/cm3 = 0.0448 lb/in3)* battery recharged at 1.24 g/cm3 = 0.0448 lb/in3 (1.20 1.24 g/cm3 = 0.
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 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 . ....
Alphabetical index ACP................................................................. 28, 106 Air Filter, Change.................................................... 69 Alarm handling........................................................ 41 Alarms..................................................................... 34 Orientation............................................................... 67 Battery, Charging.................................................. 87 Battery, Maintenance..................
NOTICE: The free-of-charge Operator’s Manual offer is valid for 12 months after delivery. Fill in your name, postal address, email address and desired language. Publication Reference: 7748921 Name: Address: Country: E-mail: English Svenska Deutsch Français Español Italiano Nederlands Dansk Suomi Português Ελληνικά Русско Türkçe http://vppneuapps.volvo.com/manual/coupon/ Document & Distribution Center Order Department ARU2, Dept.
7748921 English 04-2008
