Volvo Penta IPS Operator's Manual
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Volvo Penta IPS Operator's Manual

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OPERATOR'S MANUAL
Volvo Penta IPS

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Summary of Contents for Volvo Penta IPS

  • Page 1 OPERATOR’S MANUAL Volvo Penta IPS...

  • Page 2: Proposition 65 Warning

    Se bestillingsformular i slutningen af bo- the book. gen. All information is stored internally at AB Volvo Penta and will Alle oplysninger gemmes internt hos AB Volvo Penta og not be passed on to third parties. overgives ikke til tredje part.

  • Page 3: Table Of Contents

    Content Foreword ...................... 2 Safety Information ..................3 Introduction ....................8 Presentation ....................10 Instruments and Controls ................ 12 Optional ..................... 26 Starting ...................... 31 Operation ....................34 Engine Shutdown ..................38 Fault Handling ................... 41 Fault Code Register .................. 45 In Case of Emergency ................

  • Page 4: Foreword

    As owner of a Volvo Penta marine engine, we would also like to welcome you to a worldwide network of dealers and service workshops to assist you with technical advice, service requirements and replacement parts. Please contact your nearest authorized Volvo Penta dealer for assistance.

  • Page 5: Safety Information

    Check that you heave received the correct instruction book before you read on. If not, please contact your Volvo Penta dealer. This symbol is used in the instruction book and on the product, to call your attention to the fact that this is safety information.

  • Page 6: Daily Checks

    Safety Information Your new boat Fuel filling Read the instruction books and other information There is always a risk of fire and explosion during fuel carefully, which came with your new boat. Learn to filling. Smoking is not permissible, and the engine handle the engine, controls and other equipment in a should be stopped.
  • Page 7 Safety Information Carbon monoxide poisoning When a boat moves forwards, an area of low pressure Most modern boats are designed so that the problem air forms behind the boat. In adverse conditions, this of low-pressure suction is very rare, however. If low- low pressure can be so strong that the boat’s own pressure suction does occur anyway, do not open exhaust fumes are sucked into the cockpit or cabin,...

  • Page 8: Fire And Explosion

    Volvo Penta workshop. Using non-original Volvo Penta parts can result in fire or explosion on board. Lifting the engine When lifting the engine, use the lifting eyes installed Batteries on the engine.

  • Page 9: Fuel System

    Safety Information Hot surfaces and fluids Fuel system There is always a risk of burns when working with a Always use protective gloves when tracing leaks. Liq- hot engine. Beware of hot surfaces. For example: the uids ejected under pressure can penetrate body tis- exhaust pipe, turbo unit, oil pan, charge air pipe, sue and cause serious injury.

  • Page 10: Introduction

    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.

  • Page 11: Service And Spare Parts

    Certification means that an engine type has been possible environmental impact. Through regular serv- checked and approved by the relevant authority. The ice and use of by Volvo Penta approved spare parts, engine manufacturer guarantees that all engines these qualities are retained.

  • Page 12: Presentation

    Performance System p0006599 Volvo Penta IPS overview Maneuvering and handling Volvo Penta IPS is setting a new standard: The reasons for the amazing maneuverability are: Much improved efficiency, higher top speed, The Volvo Penta IPS drive-units are steerable, reduced fuel consumption/extended range and turning and pointing the entire thrust in the great acceleration.
  • Page 13 Comfort Environmental care Volvo Penta IPS new technology leads to major The Volvo Penta IPS has been developed as a com- improvements for all comfort enhancing factors. plete system with excellent environmental perform- ance as one of the main design targets. The very high...

  • Page 14: Instruments And Controls

    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.
  • Page 15 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 tach- ometer window. Information displayed depends on engine type, the number of sensors and which acces- sories are installed.

  • Page 16: Control Panel

    Instruments and Controls Control Panel The control panel is used for station handling, disen- gaging 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.

  • Page 17: Docking Station Panel

    Instruments and Controls Multifunction Button With the multifunction button the instruments and pan- els backlighting is adjusted. Push the button for over a second to turn the back- lighting on or off. The backlighting can be adjusted in five stages by repeatedly pushing the multifunction button quickly (less than 1 second).

  • Page 18: Evc System Display

    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.
  • Page 19 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.
  • Page 20 Instruments and Controls Multi, button 2 In the multi mode the information can be shown in sev- eral windows, analogue or digital. The display can show windows with different information or be divid- edto show windows and system information. To handle the system information, see chapter Instruments and Controls page 20.
  • Page 21 Instruments and Controls Configuration menu Press button 5 for five seconds to enter the Configu- ration 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 han- dled by the knob on the control panel.

  • Page 22: Evc Menu

    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).
  • Page 23 Instruments and Controls Settings 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 P0001015 menu page 102.

  • Page 24: Single Lever Control

    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.

  • Page 25: Adjusting The Friction Brake

    (–) for easier movement. 5 Reinstall the plug. Joystick Volvo Penta IPS Joystick is a control used for docking and maneuvering in low speed. The joystick makes it possible to rotate the boat and maneuver the boat in different directions –...
  • Page 26 Instruments and Controls 1 Activate the docking function by pressing the dock- ing 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.
  • Page 27 Instruments and Controls Maneuvering with joystick To maneuver the boat move the joystick forwards, back- wards, 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.

  • Page 28: Optional

    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.
  • Page 29 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.
  • Page 30 12 V/24 V system. If the batteries begin to discharge, the ACP switches from primary to secondary protection. The IPS is then protected by the consumption of a sacrificial zinc anode installed in the ACP unit on the transom.
  • Page 31 Optional • No Protection; risk of corrosion, system gives warn- ing 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- tify ACP status and three lines will be shown on the display.
  • Page 32 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. P0003049 The system is re-started when the ignition is P0003049 switched on;...

  • Page 33: Starting

    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 temper- atures below +5°C (41°F) are encountered.

  • Page 34: Starting The Engine

    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).
  • Page 35 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 Han- dling page 41 for further information and reco- mended actions.

  • Page 36: Operation

    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.
  • Page 37 Operation Maneuvering 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.

  • Page 38: Helm Stations

    Operation Helm Stations Changing stations 1 Put the gear in neutral. The lamp above the neutral button (1) is lit when the gear is in neutral. 2 Unlock, if locked, the station you leave by pushing the activation button (2). 3 Activate the station you change to by pressing the activation button (2).

  • Page 39: Cruising Speed

    “Fault tracing” chapter. Select a propeller with greater pitch if actual engine revolutions exceed the full throttle range. Contact your Volvo Penta dealer for advice. 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).

  • Page 40: Engine Shutdown

    Engine Shutdown Allow the engine to run at low idle, in neutral, for a few minutes after operations are completed. In this way after- boiling 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.

  • Page 41: After Engine Shutdown

    Engine Shutdown Auxiliary stop If the engine cannot be stopped in a normal procedure, it is possible to stop the engine via auxiliary stop mounted on the side of the engine. P0003709 After Engine Shutdown • Check the engine and engine bay for leakages. •...

  • Page 42: Cold Weather Precautions

    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. If you expect the boat to be unused for two months or more, it must be laid up, please refer to Stor- age page 98 Operation break with the boat out of water...

  • Page 43: Fault Handling

    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 If a malfunction is discovered the driver is warned by a buzzer sounding and a pop-up showing in the display.
  • Page 44 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.

  • Page 45: Faults List

    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.

  • Page 46: 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.

  • Page 47: Fault Code Register

    Check the batteries fluid level • Check belt tension. • Please contact a Volvo Penta workshop if the fault remains. P0005024 1 Is the orange “water in fuel” lamp lit there is to much water in the water separator on the fuel pre-filter.

  • Page 48: Engine Speed

    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. P0001200 CAUTION! Water in Fuel See Operator's Manual Air Temperature Explanation: Charge air temperature too high.

  • Page 49: Coolant Level

    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. P0005012 WARNING! Coolant Level See Opera- tor's Manual Coolant Temperature Explanation: Coolant temperature too high.

  • Page 50: Engine Oil Level

    72. P0005017 • Check that no leakage occurs. WARNING! Engine Oil Level See Oper- • Please contact a Volvo Penta workshop if the fault remains. ator's Manual Engine Oil Pressure Explanation: Oil pressure too low. Symptom: Engine power is reduced.

  • Page 51: Battery Voltage

    Check that the oil strainer is not blocked. • Check that no leakage occurs. P0005023 • Please contact a Volvo Penta workshop if the fault remains. WARNING! Transmission Oil Pressure See Operator's Manual Battery Voltage Explanation: Battery voltage too low.
  • Page 52 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 Oper- ator's Manual SUS, Battery Voltage Low Explanation: Low supply voltage to SUS unit.
  • Page 53 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...
  • Page 54 • 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...
  • Page 55 • 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 Opera- tor's Manual P0005038 CAUTION!Check JoystickSee Opera-...
  • Page 56 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.
  • Page 57 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 Steer- Restart Engines See Operator's Man- Helm Restarted Explanation: Lost active helm during crank.
  • Page 58 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).

  • Page 59: In Case Of Emergency

    In Case of Emergency In Case of Emergency Despite regular maintenance according to the mainte- nance 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.

  • Page 60: Starting Using Auxiliary Batteries

    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 vio- lent explosion. Ventilate well. WARNING! Never confuse the positive and negative poles on the batteries.

  • Page 61: Emergency Shifting

    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...
  • Page 62 In Case of Emergency Manual engagement – forward gear: 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-clock- wise.

  • Page 63: Emergency Alignment, Propulsion Unit

    In Case of Emergency Emergency Alignment, Propulsion Unit If a fault occurs which prevents one or several propul- sion 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.
  • Page 64 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 posi- tion. When the end position is reached, stop turn- ing.

  • Page 65: Emergency Steering With Control Levers

    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.
  • Page 66 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.

  • Page 67: Maintenance Schedule

    Coolant level and antifreeze mixture Drive belt (tension) Seawater filter Drive-unit, oil level Corrosion protection (space between IPS-housing and clamping ring) Instrument panel function Start and warm up engine Inspection with VODIA (Diagnostic Tool) Engine and transmission, oil / fuel / water leakage...
  • Page 68 Seawater pump impeller Sacrificial anodes (charge air cooler and heat exchanger) Corrosion protection (space between IPS-housing and clamping ring) Engine and propulsion unit. Clean and touch up paintwork as required All hoses and pipes – Check the condition and re-tighten the hose clamps...

  • Page 69: Maintenance

    Make it impossible to start the engine by removing the start key and cutting the system voltage with the main switches. Orientation Volvo Penta IPS, starboard 1 Volvo Penta IPS, Servo Unit 2 Turbocharger 3 Crankcase ventilation filter 4 Air filter...

  • Page 70: General Inspection

    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 dis- cover abnormalities quickly, or if something is about to happen.

  • Page 71: Crankcase Ventilation, Filter Change

    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.

  • Page 72: Drive Belt, Check And Change

    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.

  • Page 73: Compressor, Checking Oil

    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.

  • Page 74: Engine Oil, Change

    Maintenance Lubrication System Oil change intervals can vary depending on oil grade and sulphur content of the fuel, please refer to Tech- nical 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.

  • Page 75: Oil Filter/By-Pass Filter, Change

    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.

  • Page 76: Engine Fuel Filter Replacement

    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.

  • Page 77: Fuel System, Bleeding

    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).
  • Page 78 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.

  • Page 79: Freshwater System

    Water Quality page 116. Only coolant of this grade is suitable for, and approved by, Volvo Penta. The use of anti-corrosion agents alone is not permitted in Volvo Penta engines. Never use water alone as the coolant. IMPORTANT! Coolant of a suitable chemical composition must be used all year round.
  • Page 80 The coolant must be mixed with distilled, deionized water. The water must fulfill the requirements specified by Volvo Penta; refer to Water Quality page 116. It is extremely important that the system is filled with the correct coolant concentration. Mix in a separate clean vessel before filling the cooling system.

  • Page 81: Freshwater System, Draining

    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.

  • Page 82: Seawater System

    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...

  • Page 83: Zinc Anodes, Check And Change

    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 Sys- tem, Draining page 80. 3 Remove the zinc anodes from the heat exchanger (1) and intercooler (2).
  • Page 84 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 freshwa- ter. The system must also be preserved when the boat is going to be layed up on land for longer periods than two month.
  • Page 85 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.

  • Page 86: Main Switch

    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, bat- tery charger or accessories mounted on the engine.

  • Page 87: Electrical Connections

    Volvo Penta workshop. Electrical Connections Check that electrical connections are dry, free from oxide, and that they are securely tightened. Spray the connections as necessary with water-repellent spray (Volvo Penta universal oil). 7748921 04-2008...

  • Page 88: Battery, Maintenance

    Maintenance Battery, Maintenance WARNING! Risk of fire and explosion. Never allow an open flame or electric sparks near the battery or batteries. WARNING! P0002107 Never confuse the positive and negative poles on the batteries. Risk of arcing and explosion. WARNING! The battery electrolyte contains extremely corrosive sulfuric acid.

  • Page 89: Battery, Charging

    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.

  • Page 90: Electrical Installations

    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 manu- facturer’s recommendations).
  • Page 91 Maintenance Always consider the following: 1 If shore power is connected it must always be ground protected ashore, never in the boat. Fur- thermore, 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.
  • Page 92 While checking the oil level, ensure there are no signs of water dilution. The oil should have a golden brown hue. If the oil is thin and greyish it is probable water diluted. If so, always let the propulsion unit be checked by a Volvo Penta workshop. 7748921 04-2008...

  • Page 93: Changing Oil And Filter

    Check that the space between the drive housing and the lock plate is completely covered by corrosion pro- tection, Volvo Penta part # 9510227. Follow the instructions below if the protection needs renewing: 1 Clean and dry the surface between the housing and the lock plate.

  • Page 94: Sacrificial Anodes

    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.
  • Page 95 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.
  • Page 96 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.
  • Page 97 Maintenance 3 Undo the locking ring with the accompanying spe- cial 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).
  • Page 98 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 accompa- nying special tool and four socket cap screws (4).
  • Page 99 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.

  • Page 100: Storage

    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 tem- perature at least once every 14 days. This prevents corrosion in the engines. WARNING! If the engines must be run up to normal operating tem- perature with the boat kept up on land, make sure to...

  • Page 101: Long Term Storage

    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 pro- pulsion unit should be carried out. This ensures that the engine and propulsion unit are kept in good condi- tion and that no damage arises.
  • Page 102 Storage • Clean the outside of the engine. Touch up any dam- aged 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 compo- nents, as this could cause serious damage.

  • Page 103: Bringing Out Of Storage

    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.

  • Page 104: Calibration And Settings

    2 Press the wheel to access the settings menu. 3 Navigate by turning the wheel. P0001015 Depth Alarm Setting the depth alarm for the Volvo Penta echo soun- der. The setting need only be entered at one display, at one station.
  • Page 105 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 compen- sation (offset depth).

  • Page 106: Trip Reset

    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.

  • Page 107: My View

    Calibration and Settings My View In My view it is possible to select the operating infor- mation 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.

  • Page 108: Evc Info

    Calibration and Settings 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...

  • Page 109: Information Beep

    Calibration and Settings 1 Activate the station. 2 Turn until Units is shown in the settings menu. Press to reach the units menu. 3 Turn to US or Metric; press the wheel and select US or Metric. P0001036 Press the wheel to confirm the selection. 4 Turn to Distance;...

  • Page 110: Fuel Tank

    Calibration and Settings Fuel Tank There are two alternative methods for calibrating the level sensor in the fuel tank. Full Fuel Tank Calibra- tion 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.

  • Page 111: Speed Factor

    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.
  • Page 112 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.
  • Page 113 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.
  • Page 114 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;...
  • Page 115 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 sys- tem is now in docking mode.

  • Page 116: Technical Data

    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...
  • Page 117 SAE 15W/40 (See table) Compressor, oil Oil volume 0.1 liters (0.2 US pint) Oil grade Volvo Penta, part no. 1141641 Sulphur content in fuel, by weight Oil grade < 0.5 – 1.0% more than 1.0% Oil change interval: Reached first in operation:...

  • Page 118: Fuel Specification

    Technical Data Viscosity Select the viscosity according to the table. The temperature values refer to stable ambient tem- peratures. * 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...
  • Page 119 = 0.0434 lb/in g/cm = 0.0434 lb/in NOTICE! * Applies to batteries with tropical acid. Sterndrive Volvo Penta IPS system designation IPS 350/400 IPS 400/450/500 IPS 600 Oil volume, approx. 14 liters (3.7 US gals) 14 liters (3.7 US gals) 14 liters (3.7 US gals) Oil volume difference MIN –...

  • Page 120: Identification Numbers

    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.
  • Page 121 ................with integral exhaust Engine(s) models covered by this declaration EC Type certificate number Volvo Penta IPS 350 (D4-260) Volvo Penta IPS 400 (D4-300) ........SDVOLV005 (noise) EXVOLV001 (exhaust) Volvo Penta IPS 400 (D6-310) Volvo Penta IPS 450 (D6-330) Volvo Penta IPS 500 (D6-370) Volvo Penta IPS 600 (D6-435) ........SDVOLV004 (noise)

  • Page 122: Alphabetical Index

    Units..............106 Display Contrast............ 105 Water Quality............116 Docking Station Panel..........15 Drive................ 90 Volvo Penta IPS - Inboard Performance Sys- Drive Belt, Check and Change........ 70 tem................10 Electrical Connections.......... 85 Zinc Anodes, Check and Change......81 Electrical Installations..........88 Electrical System..........
  • Page 123 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 Dansk Svenska Suomi Deutsch Português Français Ελληνικά Español Русско...

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