Volvo Penta IPS 600 Betreibershandbuch

OPERATOR’S MANUALVolvo Penta IPS

IntroductionThis Operator's Manual has been prepared to give you the greatest possible benefit from your Volvo Penta marineengine. It contains th

StorageShort Term StorageIf 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

Long Term StorageIf the boat is not going to be used for a longer periodthan two months, either left in the water or layed up onland, a long-term pres

•Clean the outside of the engine. Touch up any dam-aged areas of paintwork with Volvo Penta originalpaint.IMPORTANT!Never use a high-pressure washer w

Bringing Out of StorageThe following should be carried out on eachpropulsion unit with the boat out of the water:•Paint the hull.•Check the sacrificia

Calibration and SettingsSettnings menuSettings are entered and certain calibrations are car-ried out in the Settings menu.Navigate through the menus b

4 Turn to Set Level. Press the wheel to accessadjustment of depth level alarm.Turn the wheel to set the alarm depth, i.e. the depthwhen the alarm shou

P0005853 P0005854 Depth alarm popup windowWhen the depth is less than the alarm level, the popupwindow will display intermittently, followed by the a

My ViewIn 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 de

ACPSetting the ACP protection position.1 Turn until ACP is shown in the settings menu. Pressto reach the submenu.2 Turn to the desired position Normal

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 sele

Service and spare partsVolvo Penta marine engines are designed for highreliability and long life. They are built to withstand amarine environment, but

Fuel TankThere are two alternative methods for calibrating thelevel sensor in the fuel tank. Full Fuel Tank Calibra-tion is an approximate method, whi

Full Fuel Tank CalibrationFor this method the tank must be full and calibration ofthe fuel level sensor takes place in one step. Thismeans that the fu

JoystickJoystick calibration need only be carried out if boatmovements do not correspond to joystick movements.When calibrating the joystick the boat

4 Simultaneously press both buttons on the joystickfor 5 sec. to reach calibration mode.5 Calibration mode is confirmed by an audible signaland by bot

8 An audible signal and both lamps on the joystickand the neutral button lamps on the control panelwill light up to confirm that calibration is comple

4 Calibration mode is confirmed by an audible signaland by both lamps on the joystick and the neutralbutton lamps on the control panel flashing.5 Pres

Technical DataEnginesEngine, GeneralVolvo Penta IPS system designation D4 — See table below D6 — See table belowEngine model/after market designation

Lubrication SystemEngine: D4 D6Oil volume, (incl. oil filter)for all allowed installation inclinations 12.5 liters (3.3 US gals) 20 liters (5.3 US gal

ViscositySelect the viscosity according to the table.The temperature values refer to stable ambient tem-peratures.* SAE 5W/30 refers to synthetic or s

Electrical SystemSystem voltage 12V 24VAlternator, rated power, maxvoltage/max. amperage 14V/115A 28V/80Aoutput, approx. 1610W 2240WBattery capacity 2

PresentationVolvo Penta IPS - InboardPerformance Systemp0006599Volvo Penta IPS overviewVolvo Penta IPS is setting a new standard:- Much improved effic

Identification NumbersThere are type plates on the engine and transmission, marked with identification numbers. This information mustalways be used as

Body for sound and exhaust emission assessment International Marine Certification Institute Rue Abbé Cuypres 3 B-1040 Bruxells Belgium ID Number: 0609

ACP... 28, 106Air Filter, Change... 6

Dansk Suomi Português Ελληνικά Русско Türkçe English Svenska Deutsch Français Español Italiano NederlandsPublication Reference: 7748921Name: A

7748921  English  04-2008

ComfortVolvo Penta IPS new technology leads to majorimprovements for all comfort enhancing factors.- The propulsion forces and vibrations are absor-be

Instruments and ControlsThis chapter describes the instruments, panels and controls Volvo Penta sells for your engine.If you would like to complement

GaugesTachometerThe tachometer displays engine speed; multiply thevalue shown on the dial by 1,000 to get the number ofengine revolutions per minute.B

Control PanelThe control panel is used for station handling, disen-gaging the drive and to navigate the EVC systemmenu.Always push the buttons firmly

Multifunction ButtonWith the multifunction button the instruments and pan-els backlighting is adjusted.Push the button for over a second to turn the

Alarm acknowledge buttonPush this button to acknowledge an alarm of a fault. Afault is always indicated with a flashing lamp above thebutton and a mo

malfunction. The display will work but may act in anunexpected way.NOTICE! Only installed functions will be shown in thedisplay.Display modesPress but

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 or

Multi, button 2In the multi mode the information can be shown in sev-eral windows, analogue or digital. The display canshow windows with different inf

Configuration menuPress button 5 for five seconds to enter the Configu-ration menu. Navigate with the up and down arrows,select with the right arrow.N

EVC Menu The EVC menu can be shown in both the EVC systemdisplay and the tachometer display. The main menushows operating information, the settings me

SettingsTurn the control panel wheel until the start screen forthe settings menu is displayed. Press the wheel toreach the sub menus.Turn to move betw

ControlsSingle Lever ControlManeuveringA single-lever control operates both gearshift andthrottle functions with the same lever.The engine can only be

Adjusting the friction brakeThe lever is fitted with a friction brake to allow adjust-ment for easier or stiffer movement as required. Thefriction bra

1 Activate the docking function by pressing the dock-ing button (A) on the joystick.2 A sound signal confirms that the docking function isactive and t

Maneuvering with joystickTo maneuver the boat move the joystick forwards, back-wards, sideways or by turning the top of the joystick, seefigure.IMPORT

OptionalSport Fishing ModeVolvo Penta's sport fish function has been developedby deep-sea fishermen. When the function is activated,the IPS units

Activating single-lever function1 In order to activate the single-lever function, thecontrol levers must be roughly the same position,max 10% differen

ContentForeword ... 2Safety Information ...

ACPVolvo Penta ACP (Active Corrosion Protection) pro-tects against galvanic corrosion by controlling an elec-tric current that can be monitored by the

•No Protection; risk of corrosion, system gives warn-ing alarm. The display switches between the twoscreens.Seek service for system checks.•If the ACP

•Inactive; this mode should only be used when theboat is taken out of the water on to dry land.To avoid fault codes, select inactive mode beforeliftin

StartingMake a habit of visually checking the engine, engine bay and transmission before start. This will help you todiscover quickly if anything abno

Starting the EngineShifting, adjusting speed and performing EVC settingsand calibrations is only possible at an active station.On a boat with one stat

Check lampsEach time the ignition is turned on, all lamps in thealarm instrument are illuminated. Check that all lampslight up and go out. If a lamp f

OperationLearn to handle the engine, controls and other equipment in a safe and proper manner before casting off on yourmaiden voyage. Remember to avo

ManeuveringShifting between forward and reverse should be doneat idling. Shifting at higher engine speeds can beuncomfortable for passengers and cause

Helm StationsChanging stations1 Put the gear in neutral.The lamp above the neutral button (1) is lit when thegear is in neutral.2 Unlock, if locked, t

Cruising SpeedFor best fuel economy operations at full must beavoided. We recommend a cruising speed that is atleast 10% below the maximum engine revo

ForewordVolvo Penta marine engines are used all over the world. They are used in all possible operating conditions forprofessional as well as leisure

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

Auxiliary stopIf the engine cannot be stopped in a normal procedure,it is possible to stop the engine via auxiliary stopmounted on the side of the eng

Operation break with the boat in waterIf the boat is not used, but left in the water, the enginemust be warmed up at least once every fortnight. Thisp

Fault HandlingDespite regular maintenance according to the maintenance schedule and perfect operation conditions faults mayoccur which must be attende

Acknowledging alarm1 Push the knob on the control panel to ackowledgethe alarm. The buzzer becomes silent.2 Read the alarm or message in the pop-up.3

Faults listIs a fault registered the display shows Faults in theEVC menu along with the number of faults.Push the knob on the control panel to open th

Fault TracingA number of symptoms and possible causes of engine malfunctions are described in the table below. Alwayscontact your Volvo Penta dealer i

Fault Code Register CAUTION!Read the safety precautions for maintenance and service in the Safety Information chapter before starting work.When a malf

Engine SpeedExplanation:Fault in engine speed sensor.P0005008DANGER! Engine Speed See Opera-tor's ManualStop engineSymptom:Engine power is reduce

Coolant LevelExplanation:Coolant level too low.RP0005012WARNING! Coolant Level See Opera-tor's ManualSymptom:None.Action:• Check coolant level. P

Safety InformationRead this chapter very carefully. It has to do with your safety. This describes how safety information is presentedin the instructio

Engine Oil LevelExplanation:Oil level too low.P0005017WARNING! Engine Oil Level See Oper-ator's ManualNOTICE! In rough following seas or head sea

Transmission Oil PressureExplanation:Reverse gear oil pressure too low.P0005023WARNING! Transmission Oil PressureSee Operator's ManualSymptom:Non

Primary BatteryExplanation:Poor batteries or charging.P0005026WARNING! Primary Battery See Oper-ator's ManualSymptom:None.Action:• Check the batt

Check Control LeverExplanation:Fault in control lever.P0005031WARNING!Check Control LeverSee Operator's ManualSymptom:Engine in emergency mode. G

Check EVC SystemExplanation:Internal fault in EVC system.P0005034WARNING!Check EVC SystemSeeOperator's ManualSymptom:Engine power is reduced.Acti

Check JoystickExplanation:Faulty joystick.P0005037WARNING!Check JoystickSee Opera-tor's ManualSymptom:Engine power is reduced.Action:• Restart en

Limited Engine RPMExplanation:Fault in steering system.P0005040CAUTION! Limited Engine RPM SeeOperator's ManualSymptom:Engine power is reduced.Ac

No Gear/Throttle, No SteeringExplanation:Fault in steering system.P0005043DANGER! No Gear/Throttle, No Steer-ingRestart Engines See Operator's Ma

Key FailureExplanation:Key or start panel out of order.P0001199CAUTION! Key FailureSee Operator'sManualSymptom:None.Action:Please contact a Volvo

In Case of EmergencyIn Case of EmergencyDespite regular maintenance according to the mainte-nance schedule and perfect operation, faults mayoccur whic

Your new boatRead the instruction books and other informationcarefully, which came with your new boat. Learn tohandle the engine, controls and other e

Starting Using AuxiliaryBatteries WARNING!Explosion hazard. Batteries contain and give off anexplosive gas which is highly flammable and explosive.A s

Emergency ShiftingIf a fault occurs which prevents gear shifting with thecontrol levers, it is possible to shift manually using thedescription below.N

Manual engagement – forward gear:1 Undo the two connectors, marked “Secondary” and“Primary”, from the solenoid valves.2 Remove the cap nut from the lo

Emergency Alignment, PropulsionUnitIf a fault occurs which prevents one or several propul-sion units from being operated with the steering wheelit is

2 Connect the switch and fit the red crank tool.3 Press the switch button down and keep it pressedwhile turning the crank tool carefully to an end pos

5 Remove the crank tool. Disconnect the switch bypressing down the lock and at the same timeunplugg the switch by slowly wiggling it (pleaserefer to p

Steering the boatPut the control levers in forward. Use a suitable enginespeed for maneuvring.The direction of the steering is determined by the useof

Maintenance ScheduleCRALI=====CleanReplaceAdjustLubricateInspect (Clean, Adjust, Lubricate or Replace if nec-essary)FSI, S2 = First time Service Inspe

BEvery 200 hours / at least once a year, included in extended protectionCrankcase ventilation filter RAir filter insert RFuel pre-filter and fuel fine

MaintenanceThis chapter contains general technical information and instructions on how the prescribed maintenance itemsmust be carried out. Read throu

Carbon monoxide poisoningWhen a boat moves forwards, an area of low pressureair forms behind the boat. In adverse conditions, thislow pressure can be

Engine, GeneralGeneral inspectionMake a habit of visually checking the engine andengine bay before starting, and after operations whenyou have stopped

Crankcase Ventilation, FilterChange1 Unscrew the cover and remove the old filter.2 Clean the filter cover/housing as necessary. Becareful to prevent c

Drive Belt, Check and Change WARNING!Stop the engine before doing any maintenance work.GeneralCheck belt tensions and condition regularly. A belt that

Compressor, checking oilChecking and filling1 Unscrew and lift up the oil dipstick. Dry the oil off.Screw the oil dipstick down as far as it will go a

Lubrication SystemOil change intervals can vary depending on oil gradeand sulphur content of the fuel, please refer to Tech-nical Data page 115.Oil ch

WARNING!Hot oil and hot surfaces can cause burns.1 Run the engine until warm so that the oil is easierto pump. Then stop the engine and wait 10 minut

Fuel SystemOnly use the grades of fuel recommended in the fuelspecification, see Technical Data page 116. Alwaysobserve the greatest cleanliness duri

Fuel system, bleedingThe fuel system must be bled after a filter change, ifthe fuel tank has been run dry and after a long-termstoppage.IMPORTANT!Neve

Water in FuelIf the EVC system warns for too much water in the fuelpre-filter, the water separator needs emptying.IMPORTANT!Do not continue operating

Freshwater SystemThe freshwater system is the engine's internal coolingsystem that ensures that the engine operates at thecorrect temperature. It

PreparationsKnowledgeThe operator’s manual contains instructions on howto carry out general maintenance and service opera-tions safely and correctly.

Coolant, Mixing WARNING!All coolant is hazardous and harmful to the environ-ment. Do not consume. Coolant is flammable.IMPORTANT!Volvo VCS coolant (ye

Coolant Level, Checking andTopping Up WARNING!Do not open the coolant filler cap when the engine iswarm, except in emergencies, this could cause serio

Seawater SystemThe raw water system is the engine's external coolingsystem. On IPS engines, the raw water pump sucks inwater via the IPS cooling

Zinc Anodes, Check and Change WARNING!Risk of water entry. Close the seawater cocks beforedoing any work on the seawater system.1 Close the sea cock(s

Seawater System, Cleaning andInhibitingTo prevent the build up of deposits and salt crystals inthe seawater system it must be flushed with freshwa-ter

7 The antifreeze mixture should be left in the systemwhile the boat is not used. Before starting to use theboat again drain the mixture and clean the

Electrical SystemThe engine is equipped with a 2-pole electrical systemand an alternator. System voltage is 12V or 24V. WARNING!Always stop the engine

24–volt system (engine)The engine is fitted with two automatic circuit breakers(1). The circuit breakers cut the power if the system isoverloaded.If i

Battery, Maintenance WARNING!Risk of fire and explosion. Never allow an open flameor electric sparks near the battery or batteries. WARNING!Never conf

FillingThe electrolyte level should be 5–10 mm (0.2– 0.4”)above the cell plates in the battery. Top up with distilledwater as required.After filling,

Hot surfaces and fluidsThere is always a risk of burns when working with ahot engine. Beware of hot surfaces. For example: theexhaust pipe, turbo unit

•Charge batteries if they have become discharged.During charging, unscrew the cell plugs but leavethem in the plug holes. Ventilate well, especially i

Always consider the following:1 If shore power is connected it must always beground protected ashore, never in the boat. Fur-thermore, the shore power

DriveThe propulsion unit has an electronically controlledhydraulic clutch. Two soleniod valves, primary (for-ward gear) and secondary (reverse gear),

Changing oil and filter1 Open the oil filling (1) cap slowly so that any over-pressure is released. Unscrew the draining plug(3) and allow the oil to

Inspection/replacing corrosion protection– Sacrificial anodesCheck the sacrificial anodes regularly. There are twoanodes per stern drive; one is fixed

Inspect the drive unit paintVolvo Penta recommends ”Prop speed ®” coating.Instructions regarding the application of ”Prop speed®” coating are included

Propeller WARNING!Make sure the engine can not start during work onpropeller(s); remove ignition key(s) and shift driveinto forward or reverse.NOTICE!

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). Removethe f

Assemble propellers1 Apply water-resistant grease, P/N 828250 to thesplines and threads on both propeller shafts.2 Install the aft propeller. Then ins

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 accompan