Volvo Penta D4-260 Operator'S Manual Download Page 77

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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

(

). Feed the hose to a container to avoid spillage.

2 Open the bleeding nipple and pump fuel with the

hand pump (

) until the fuel is free from bubbles.

Close and tighten the bleed nipple.

3 Pump a further 10 times on the hand pump. Resist-

ance in the hand pump can feel heavy, but this is
completely normal and necessary to bleed the sys-
tem.

4 Remove the hose and fit the protective cap to the

bleed nipple.

Fuel Pre-filter, Change

WARNING!

Working with or going close to a running engine is a
safety risk. Watch out for rotating components and hot
surfaces.

1 Close the fuel stop cock on the fuel tank. Place a

container beneath the fuel filter.

2 Remove the cover by loosening screw (

3 Replace the insert and refit the cover.

4 Open the fuel stop cock and bleed the fuel system,

see section

“Fuel system, bleeding”

5 Start the engine and check for leaks.

6 Hand in the scrapped filter at a recycling depot.

Maintenance

7748921 04-2008

Summary of Contents for D4-260

Page 1: ...OPERATOR S MANUAL Volvo Penta IPS ...

Page 2: ...formular i slutningen af bo gen Alle oplysninger gemmes internt hos AB Volvo Penta og overgives ikke til tredje part Tämän ohjekirjan suomenkielisen version voi tilata veloituksetta 12 kuukauden sisällä toimituksesta internetistä postin kautta tai faksilla Katso tilauslomake kirjan lopusta AB Volvo Penta tallentaa kaikki tiedot sisäisesti eikä niitä luovuteta kolmannelle osapuolelle Pode se encome...

Page 3: ... Instruments and Controls 12 Optional 26 Starting 31 Operation 34 Engine Shutdown 38 Fault Handling 41 Fault Code Register 45 In Case of Emergency 57 Maintenance Schedule 65 Maintenance 67 Storage 98 Calibration and Settings 102 Technical Data 114 Alphabetical index 120 1 ...

Page 4: ...ughly and consider the advice we give on running and maintenance before your maiden voyage so that you will be ensured of fulfilling your expectations Please pay attention to the safety instructions contained in the manual 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 req...

Page 5: ...ave the following order of priority DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious personal injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate personal injury IMPORTANT Indicates a situation which if not...

Page 6: ...cause serious mal functions power loss or stop the engine Daily checks Make it a habit to give the engine and engine bay a visual check before driving before starting the engine and after operation when you have stopped the engine This helps you to quickly discover whether any leakage of fuel coolant oil or any other abnormal event has happened or is about to happen Do not start the engine Do not ...

Page 7: ...taking down opening the hood or modifying it in some other manner Ask your boat dealer for advice about the best solution for your particular boat P0003073 Remember Safety equipment Life jackets for everybody aboard communication equipment emergency rockets approved fire extinguisher first aid kit life buoy anchor paddle torches etc Spare parts and tools Impeller fuel filters fuses tape hose clamp...

Page 8: ...e required in order to maintain the correct balance and make the engine safe to handle Never carry out work on an engine suspended on a hoist Before starting the engine 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 Never start a turbocharged engine without installing the air cleaner ACL Th...

Page 9: ...olant hose disconnected open the cool ant filler cap carefully and slowly to release pressure before removing the cap completely Note that the coolant may still be hot and can cause burns Lubrication system Hot oil can cause burns Avoid skin contact with hot oil Ensure that the lubrication system is not under pressure before commencing work on it Never start or operate the engine with the oil fill...

Page 10: ...ately this is not self evident these days it is something all of us must work hard for As a manufacturer of marine engines Volvo Penta has particular responsibility and for this reason envi ronmental care is a core value in our product devel opment Volvo Penta has a wide engine programme these days where considerable progress has been made in reducing exhaust fumes fuel consumption engine noise et...

Page 11: ...e manufacturer guarantees that all engines made of the same type are equivalent to the certified engine This makes special demands on the care and maintenance you give your engine as follows Maintenance and service intervals recom mended by Volvo Penta must be complied with Only Volvo Penta original spares may be used Service on injection pumps pump settings and injectors must always be done by an...

Page 12: ...e Maneuvering and handling The reasons for the amazing maneuverability are The Volvo Penta IPS drive units are steerable turning and pointing the entire thrust in the desired direction This results in much higher efficiency and far greater response to driver commands Two counter rotating propellers on each propul sion unit means that there are no lateral forces to consider and that tracking is com...

Page 13: ...latest design in modern diesel technology The engines have common rail fuel injec tion system double overhead camshafts 4 valves per cylinder turbocharger compressor Volvo Penta IPS 500 and aftercooler The interaction of these the large swept volume and the EVC system results in exceptional diesel performance combined with low emissions Installation The Volvo Penta IPS system can be installed in v...

Page 14: ...ople S Stop position 0 The key can be inserted or removed I Operating position System voltage is connected II Not used III Start position Start motor is engaged Read the starting instructions in chapter Start ing page 31 to ensure you use the correct start procedure Start Stop Panel The start stop panel is used for starting and stopping the engine To start the engine it is necessary for the start ...

Page 15: ... 14 V When the engine is stopped and elec trical power switched on the battery voltage should be around 12 V If a 24 V system is installed the charge voltage should be around 28 V during operations 3 Coolant temperature gauge The instrument shows engine coolant temperature During operations coolant temperature should nor mally be between 75 90 C 167 194 F 4 Oil pressure gauge The oil pressure gaug...

Page 16: ...ly be con trolled from this station Flashing Another station is locked Neutral button The neutral button is used to disengage the drive ena bling the engine rpm to increase without affecting the drive to warm up the engine The lamp above the neu tral button shows the status of the station Green lamp Gear in neutral The drive is in neutral position and the engine runs at idle speed Lamp off The dri...

Page 17: ...n the docking station is activated Please refer to the section Joystick page 23 for fur ther information on docking Docking station can only be activated when the engines are running Always push the buttons firmly and for at least one second Activation button Push this button on the docking station panel to acti vate and lock unlock the docking station Please refer to section Instruments and Contr...

Page 18: ...button The lamp above the button stops flashing and lights continuosly The buzzer is silenced 2 Activate a station that is equipped with displays in order to read and acknowledge the fault pop up 3 Take the recommended actions Please refer to Fault Code Register page 45 EVC System Display In the EVC system display it is possible to show mul tiple windows with different information There are four d...

Page 19: ...gine button 1 Rpm and speed is shown in the upper part of the dis play In the lower part it will show trip computer and a fuel level indicator if these function are installed If speed information is missing coolant temperature will be shown instead Navigate in the trip computer by repeatedly press but ton 1 Fuel Rate fuel consumption per hours Fuel Economy fuel consumption per distance Trip Fue fu...

Page 20: ...on is shown Trip button 3 The display works as trip computer and shows Trip Fuel since last reset Fuel Rate fuel consumption Trip hours since last reset Engine hours total amount of operating hours Reset by pressing button 3 for three seconds until a beep is heard The values from the engines are summarized except for engine hours that are shown for each engine Graph button 4 The information is sho...

Page 21: ...enu see Instruments and Controls page 20 Bleep On Off setting if pressing the instrument buttons will be followed by a beep or not Engine Setting of what kind of installation the dis play is a part of and which engine is to be shown inthe display Display Setting of intervals unit settings are made in the EVC menu see Instruments and Con trols page 20 Rpm interval 2500 9000 rpm in steps of 500 rpm ...

Page 22: ...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 pressing Press repeatedly to return to the main menu alternatively hold down the button for a couple of seconds A This field displays engine operating data B This field displays warning symbols and active func tio...

Page 23: ...enus 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 Han dling page 41 P0001015 P0001315 Instruments and Controls 7748921 04 2008 21 ...

Page 24: ...sconnected so that the control lever only operates the throttle 1 Put the control lever in neutral N 2 Depress the neutral button N and keep it depressed at the same time as the lever is moved forwards to the gearshift position F 3 Release the neutral button The green indicator will flash as confirmation that the gearshift function is disconnected and the that lever will only affect engine revolut...

Page 25: ... 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 sideways diagonally forward and backward Learn to handle the joystick in a safely and correct manner before you start using the function in a marina When the docking function is active the engine speed is reduced and the boat can only be maneuv...

Page 26: ... con trols is moved out of neutral Activating the boost function If the driver needs extra power e g in windy weather or if there is a strong currant the boost function can be activated 1 Activate the boost function by pressing the boost button B on the joystick 2 A sound signal confirms that the function is active and the lamp by the button is lit 3 Inactivate the function press the boost button ...

Page 27: ...ick 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 P0001191 Instruments and Controls 7748921 04 2008 25 ...

Page 28: ...on on the panel The acti vation of the function is acknowledged by an acous tic signal and the lamp next to the button lighting An image stating that the sport fish function is active is shown on the display for 5 seconds 3 If the lamp flashes all is not in order e g the control levers are not in neutral 4 When the function is activated the wheel is discon nected and the boat is steered with the c...

Page 29: ...ay for 5 seconds 3 When the function is activated the control lever that is moved first steers the boat and steers both engines The other control lever now has no func tion as long as the single lever function is activated 4 To inactivate the function the control levers must again be in roughly the same position Press the single lever button that the function is inactive is confirmed by an acousti...

Page 30: ...everts automatically to normal mode after 4 hours earlier reversion can be arranged in the settings menu see below or when ignition is switched on Protection levels The ACP has three protection levels the active level is displayed in the EVC menu Good Protection the IPS unit is optimally protected by the ACP function Limited Protection secondary protection the IPS has complete corrosion protection...

Page 31: ...three lines during one minute after ignition is turned on thereafter it will show cur rent protection level P0001015 P0001015 P0001022 P0001022 Settings ACP has three function modes these are set in the EVC menu under Settings ACP Refer to Settnings menu page 102 section ACP Normal means that the system is active and working in the optimal manner Chlorine Free means that the system has switched ov...

Page 32: ...des 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 P0003049 P0003049 Optional 30 7748921 04 2008 ...

Page 33: ...ow 5 C 41 F are encountered WARNING Never use start spray or similar products as starting aid Explosion risk Before Starting Check the engine and drive units oil level Check the coolant level Open the sea cocks Position A open Position B closed Open the fuel cock Turn the main switches on IMPORTANT Never disconnect the current with the main switches when the engine is running The alternator and el...

Page 34: ...key s If the engine s is are started from another station this station automati cally becomes active instead Put the drive in neutral Put the drive in neutral by moving the control levers to neutral at all stations Turn the ignition on Turn the starter key of each engine to position I to switch the ignition on Check the tachometer display If a fault is registered it will shown in the tachometer di...

Page 35: ... the button as soon as the engine has started If you start from a secondary station the starter keys at the main station must be in position I Overheating protection If the starter motor is engaged for its maximum activa tion time 30 seconds the starter motor circuit is cut automatically to protect the starter motor from over heating If possible leave the starter motor to cool for at least five mi...

Page 36: ...y after starting and then regularly during the voyage Values from the analog instruments are also shown in the tachometer display Alarms Alarms and messages are shown in the display some alarms do also have a sound alarm Is there an alarm instrument installed the lamp in question will flash If a malfunction is discovered the sound alarm starts and the lamp in question in the alarm instrument flash...

Page 37: ... 1500 rpm Always do a forwards reverse operation as follows 1 Reduce engine speed to idle and let the boat more or less lose way WARNING Never shift to reverse when the boat is planing 2 Move the control lever to neutral with a rapid dis tinct movement Make a brief pause 3 Then move the control lever to reverse with a rapid distinct movement and increase engine speed IMPORTANT It is important all ...

Page 38: ...ation can not be activated Another station is either active and locked or active with the gear engaged not in neutral A flashing light above the activation button 2 indicates a fault that limits the functionality of the station The fault is also indicated by a pop up appearing in the dis play please refer to section Fault handling Locking Unlocking station Is a station locked it is only possible t...

Page 39: ...h 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 When the synchronization function is activated the engine speed rpm of the starboard engine is auto matically adjusted t...

Page 40: ...elec tronics could be damaged IMPORTANT Make sure the starter key is in 0 position or removed before main switches are switched off Otherwise the alternator and electronics could be damaged Stop with key 1 Disengage the drive by putting the control lever in neutral 2 Turn the keys to stop position S Keep the key turned until the engines stops The key will auto matically return to the 0 position wh...

Page 41: ... 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 preven tive maintenance according to the maintenance schedule Turn off the main switches before any long stop page A U X S T O P P0003709 A B B A P0002849 Engine Shutdown 7748921 04 2008 39 ...

Page 42: ...with emery paper to remove any oxi dation 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 IMPORTANT Use emery paper Do not use a wire brush or other steel tools when cleaning as these may damage the galvanic protection Cold Weather Precautions If the engine bay cannot be kept frost free the raw water system must be drained and the fres...

Page 43: ... malfunction is the effect on the engine varies Minor malfunction which does not damage the engine or transmission Affect on engine None Serious malfunction which will not immediately dam age the engine or transmission e g high coolant temperature Affect on engine Engine power is reduced until faulty value becomes normal Serious malfunction which will cause serious dam age to engine or transmissio...

Page 44: ...g in the pop up danger warnign and caution Danger If the Danger pop up is shown during operation a seri ous fault has occured Acknowledge the alarm and stop the engine immedi ately Warning If the Waring pop up is shown during operation a fault has occured Acknowledge the alarm and stop the engine at once Caution If the Caution pop up is shown during operation a fault has occured Acknowledge the al...

Page 45: ...ased every time the starter key is turned to the stop position S Stop the engine and check that the ignition key s is are in position 0 in all control positions When system voltage is switched on again the diag nostic function checks whether there are faults in the EVC system If this is the case new fault pop ups are shown Faults which have been attended to or have disap peared are automatically e...

Page 46: ...lack exhaust smoke 10 Blue or white exhaust smoke 12 22 Low oil pressure 13 14 Engine coolant temperature too high 17 18 19 20 21 No charge or poor charge 2 23 1 Flat batteries 13 Lubricating oil level too low 2 Poor contact open circuit in cables 14 Blocked oil filter 3 Fuse tripped 15 Defective incorrect propeller 4 Lack of fuel 16 Defective engine mounting 5 Fouled fuel filter 17 Too little coo...

Page 47: ...isplay A Explanation Battery voltage too low B D P0005024 Symptom None C Action Check the batteries fluid level Check belt tension Please contact a Volvo Penta workshop if the fault remains 1 Is the orange water in fuel lamp lit there is to much water in the water separator on the fuel pre filter 2 Is the charging lamp lit the alternator has stopped charging 3 Is the coolant temperature lamp lit t...

Page 48: ...P0001200 CAUTION Water in Fuel See Operator s Manual 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 Air Temperature Explanation Charge air temperature too high P0005011 WARNING Air Temperature See Operator s Man ual Reduce rpm Symptom Engine power is reduced Action Please contact a ...

Page 49: ...heck that the seawater filter is not blocked Please refer to Seawater Filter Check and Cleaning page 83 Check the impeller in the seawater pump Please refer to Impeller Check and Change page 81 Check that no leakage occurs If the cooling water flow ceases the exhaust hose should be inspected internally and replaced if the hose shows signs of damage Please contact a Volvo Penta workshop if the faul...

Page 50: ... pressure too low P0005018 WARNING Engine Oil Pressure See Operator s Manual Stop Engine Symptom Engine power is reduced Action Check the oil level in the engine Please refer to Oil level checking and topping up page 72 Check that the oil filters are not blocked Replace filters if nec essary Check that no leakage occurs Please contact a Volvo Penta workshop if the fault remains Check drive oil Exp...

Page 51: ... Explanation Battery voltage too low P0005024 WARNING Battery Voltage See Oper ator s Manual Symptom None P0002364 Action Check the batteries fluid level Check belt tension Please contact a Volvo Penta workshop if the fault remains Auxiliary Stop Explanation External stop signal P0005025 WARNING Auxiliary Stop See Opera tor s Manual Symptom Engine stops or can not be started Action Check emergency...

Page 52: ...efer to Drive Belt Check and Change page 70 Please contact a Volvo Penta workshop if the fault remains SUS Battery Voltage Low Explanation Low supply voltage to SUS unit P0007711 WARNING SUS Battery Voltage Low See Operator s Manual Symptom Engine power is reduced Limited steering Action Check the batteries fluid level Check belt tension Please contact a Volvo Penta workshop if the fault remains F...

Page 53: ...ation use an alternative station Please contact a Volvo Penta workshop if the fault remains P0005032 CAUTION Check Control LeverSee Operator s Manual Lever Calibration Explanation Incorrect lever calibration P0005033 CAUTION Lever Calibration Incorrect See Operator s Manual Symptom Impossible to select active station Action Restart engine s Please contact a Volvo Penta workshop if the fault remain...

Page 54: ...from the chosen station use an alternative station Please contact a Volvo Penta workshop if the fault remains P0005035 CAUTION Check EVC SystemSee Operator s Manual Check Engine Explanation Miscellaneous system faults P0005036 CAUTION Check Engine See Opera tor s Manual Symptom None Action Restart engine s Please contact a Volvo Penta workshop if the fault remains Fault Code Register 52 7748921 04...

Page 55: ...use an alternative station Please contact a Volvo Penta workshop if the fault remains P0005038 CAUTION Check JoystickSee Opera tor s Manual Check Steering Wheel Explanation Faulty steering wheel unit P0005039 CAUTION Check Steering Wheel See Operator s Manual Symptom Engine power is reduced Action Restart engine s Please contact a Volvo Penta workshop if the fault remains Fault Code Register 77489...

Page 56: ...5041 WARNING Limited steering Limited Engine RPM See Operator s Manual Symptom Engine power is reduced Limited steering Action Restart engine s Please contact a Volvo Penta workshop if the fault remains No Steering Explanation Faulty steering wheel unit P0005042 DANGER No Steering Limited Engine RPM See Operator s Manual Symptom Engine power is reduced No steering Action Restart engine s Please co...

Page 57: ...lm Restarted Explanation Lost active helm during crank P0001206 CAUTION Helm Restarted See Oper ator s Manual Symptom None Action Restart engine s Check Corrosion Status Explanation Corrosion protection not guaranteed P0001209 CAUTION Check Corrosion StatusSee Operator s Manual Symptom None Action Check that the batteries are charged by land current or by the alternator Please contact a Volvo Pent...

Page 58: ...ne Action Please contact a Volvo Penta workshop Check Multilink Explanation Fault in multilink communication P0001204 CAUTION Check Multilink See Opera tor s Manual Symptom Possible loss of engine synchronization or loss of display s Action Please contact a Volvo Penta workshop Fault Code Register 56 7748921 04 2008 ...

Page 59: ...ar in neutral and engine speed is limited to 1500 rpm no steering The engine stops If fault occurs acknowlege any alarm and take the rec ommended measures Please refer to chapter Fault Code Register page 45 Running Aground If the boat has been run aground or into an object in a way that may have damaged any of the propulsion units or propellers the boat must be run if possible at reduced speed or ...

Page 60: ...the auxiliary battery and to a place a little distance away from the discharged battery e g the start motor s negative terminal WARNING Under no circumstances may the black jumper cabel come in contact with the positive connection on the starter motor 4 Start the engine and let it run at fast idle for approx imately 10 minutes to charge the batteries Make sure there is no extra equipment connected...

Page 61: ...h 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 NOTICE The marking P Primary is for forward gear and the marking S Secondary is for reverse gear In Case of Emergency 7748921 04 2008...

Page 62: ...1 2 turn counter clock wise The gear is now engaged for forward motion and cannot be disengaged by the control lever Manual disengagement 4 Lock the spring loaded button in position by pushing and at the same time turning it clockwise 1 2 turn The gear is now disengaged Manual engagement disengagement reverse gear Use the same procedures as above but engage dis engage with the valve marked S rever...

Page 63: ... whether the alignment is necessary or not in order to maneuver the boat in a safe way to the nearest harbor If steering is out of order on all propulsion units align all propulsion units and use control levers to steer the boat The tools needed during this operation are delivered in a special tool box together with the boat WARNING Working with or going close to a running engine is a safety risk ...

Page 64: ...end posi tion When the end position is reached stop turn ing 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 62 7748921 04 2008 ...

Page 65: ...nits and use the steering method descri bed below to reach nearest habor If one or several propulsion units can be operated by the steering wheel the steering method described below is not needed Rotate the boat Put one control lever in the position for forward and put the other control lever in the position for reverse Use a suitable engine speed for maneuvring The direction of rotation is determ...

Page 66: ...ring 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 In Case of Emergency 64 7748921 04 2008 ...

Page 67: ...Engine Oil and Oil Filters By pass filter R Restart engine Oil pressure oil leakage I 1 Or within 180 days of the date of delivery or the end of the first season whichever comes first Daily Before First Start Engine and engine room General inspection I Checking Engine Oil Level I Check coolant level I Drive unit oil level I Leakage and function check I Every 14 days Drive belts wear I Seawater Fil...

Page 68: ...eck hoses pipes unions and hose clamps I Inspection with VODIA Diagnostic Tool I C Every 400 hours at least once every 12 Months included in extended protection Drive unit Oil and oil filter R Drive unit Function check of seawater cock I Drive unit and transom Corrosion protection sacrificial anodes I Drive unit antifouling coating Repair as required I D Every second year Coolant R E Every 600 hou...

Page 69: ...h hood 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 2 3 4 5 6 7 8 9 10 p0006597 1 Volvo Penta IPS Servo Unit 2 Turbocharger 3 Crankcase ventilation filter 4 Air filter 5 Oil filler cap 6 Engine control unit 7 Alternator 8 Compressor 9 Water shut off valve propulsion unit 10 Oil filter ...

Page 70: ... electrical cables and hoses This inspection only takes a few minutes and can prevent serious malfunctions and expensive repairs WARNING Accumulations of fuel oil and grease on the engine or in the engine room is a fire hazard and must be removed immediately they are detected WARNING If an oil fuel or coolant leak is detected the cause must be investigated and the fault rectified before the engine...

Page 71: ... 4 Screw the cover back in place IMPORTANT Scrap the old filter They may not be cleaned Air Filter Change 1 Unscrew the air filter cover and remove the old filter 2 Clean the air filter cover housing as necessary Be careful to prevent contamination from entering the engine 3 Install the new filter and air filter cover IMPORTANT Scrap the old filter They may not be cleaned p0003704 Maintenance 7748...

Page 72: ...ll always be changed together Adjusting replacement of drive belts The standard alternator and water pump are driven by a poly V belt for the best function and lifespan Replace tension the belt as follows 1 Loosen the screws 1 on the tension roller bracket Remove and replace the belt as required 2 Tension the belt by applying a torque to the ten sioning roller square fitting 2 of 70 Nm 52 lbf ft L...

Page 73: ...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 Oil quantity and grade see section Technical Data page 115 IMPORTANT The oil level shall be between the MAX and MIN marks on the dipstick Compressor oil change 1 Run the engine until it reaches normal operating temperature 2 Pull up the oil dipstick 3 R...

Page 74: ... a correct oil level check can be performed Wait 15 minutes if the engine has been run at normal operating temperature Wait an hour if the engine has been idling The oil level shall be between the MAX and MIN marks on the dipstick Levels that are higher or lower than these marks can damage the engine IMPORTANT Do not fill over the limit for max oil level Use only oil of the recommended grade refer...

Page 75: ...efore check ing the oil level Top up as needed Hand in the old oil and oil filter to a re cycling station Oil Filter By pass Filter Change The oil filter and by pass filter must be replaced at every oil change Deposit the old filter at a waste management facility WARNING Hot oil and hot surfaces can cause burns 1 Put a suitable container under the filter to collect any spilled oil 2 Clean the filt...

Page 76: ...t and install a suitable vessel under the filter 3 Remove the connector piece 1 from the water separator 2 Unscrew the filter Use a filter wrench if necessary 4 Clean the sealing surfaces on the filter holder Make sure that the filter is clean and that the sealing rings are undamaged Moisten the seal rings with engine oil IMPORTANT Do not fill the new filter with fuel before installation Dirt may ...

Page 77: ... hand pump can feel heavy but this is completely normal and necessary to bleed the sys tem 4 Remove the hose and fit the protective cap to the bleed nipple Fuel Pre filter Change WARNING Working with or going close to a running engine is a safety risk Watch out for rotating components and hot surfaces 1 Close the fuel stop cock on the fuel tank Place a container beneath the fuel filter 2 Remove th...

Page 78: ... fuel filter and carefully unscrew the water separator 2 sufficiently for the water to run out Then screw in the water separator until it bottoms against the filter Then tighten an additional 1 4 to 1 2 turn 4 Refit the connecting piece 1 Draining the fuel pre filter extra equipment 1 Place a container beneath the fuel filter 2 Open the bleed screw 1 on the fuel filter about 4 turns 3 Drain the wa...

Page 79: ...o risk for frost damage so that the engine always has complete corrosion protection Future warranty claims related to engine and accessories may be refused if an unsuitable coolant has been used or if the instructions for coolant mixture have not been followed The corrosion protection additives become less effec tive over time which means that the coolant must be changed at regular intervals refer...

Page 80: ...lycol concentration the freezing point is lowered to 54 C 65 F Never mix more than 60 concentrate Volvo Penta Coolant in the coolant A greater concentration pro vides reduced cooling effect with the risk for overheat ing and reduced frost protection The coolant must be mixed with distilled deionized water The water must fulfill the requirements specified by Volvo Penta refer to Water Quality page ...

Page 81: ...nd let it cool before starting work on the cooling system Hot fluids and hot surfaces can cause burns WARNING All coolant is hazardous and harmful to the environ ment Do not consume Coolant is flammable 1 Remove the filler cover on the expansion tank to speed up the coolant drainage 2 Loosen the hose 1 mounted on the intercooler and connect to the drain cock 2 on the heat exchanger Open the cock 2...

Page 82: ...and if this is not possible A Open B Closed Seawater System Draining WARNING Risk of water entry Close the seawater cocks before doing any work on the seawater system To prevent frost damage the raw water system must be drained during cold weather if there is a risk for frost An alternative to draining is to keep the engine room warm using an approved heater fan Draining 1 Close the sea cocks 2 Op...

Page 83: ...tallic contact between the anode and the metal contact point 6 Close the drain cocks 7 Open the sea cock s before starting the engine 8 Check that there are no leaks Impeller Check and Change WARNING Risk of water entry Close the seawater cocks before doing any work on the seawater system 1 Remove the cover from the raw water pump and remove the impeller If the impeller is cracked or damaged it mu...

Page 84: ... nect a draining hose with one end dipped into to a bucket filled with fresh water Keep the bucket filled IMPORTANT The impeller could be damaged if the pump runs dry 3 If the procedure is performed up on land check that nothing will get splashed by the water from the exhaust outlet on the propulsion unit If the procedure is performed in the water secure a container at the end of the exhaust outle...

Page 85: ...g WARNING Risk of water entry Close the seawater cocks before doing any work on the seawater system If the water where the boat is used contains contami nants seaweed etc the filter should be checked more frequently than stated in the maintenance schedule Otherwise there is a risk that the filter may be blocked resulting engine overheating 1 Close the sea cock 2 Unscrew the cover 1 and remove the ...

Page 86: ...ld be damaged The main switches must never be switched off before the engine has stopped If the circuit between the alter nator and the battery is disconnected when the engine is running the alternator and electronics can be dam aged For the same reason the charging circuits must never be re connected with the engine running Fuses 12 volt system engine The engine is fitted with automatic circuit b...

Page 87: ...fuse trips frequently contact an authorized Volvo Penta workshop IPS The drive unit has an automatic circuit breaker 2 The circuit breaker cut the power if the drive unit system is overloaded Reset by pressing in the circuit breaker 2 IMPORTANT Always investigate the cause of the overload If the fuse trips frequently contact an authorized Volvo Penta workshop Electrical Connections Check that elec...

Page 88: ... If battery acid comes in contact with the eyes flush immediately with plenty of water and obtain medical assistance without delay Connecting and disconnecting the battery Connecting 1 Connect the cable red to the pole on the bat tery 2 Connect the cable black to the pole on the battery Disconnecting 1 Remove the cable black 2 Remove the cable red Cleaning Keep the batteries clean and dry Contamin...

Page 89: ... batteries Always use protective goggles and gloves If battery electrolyte comes into contact with unprotected skin whas off immediately using plenty of water and soap If battery acid comes in contact with the eyes flush immediately with plenty of water and obtain medical assistance without delay WARNING Never confuse the positive and negative poles on the batteries Risk of arcing and explosion IM...

Page 90: ...ost charging Boost charging can shorten battery life and should there fore be avoided Electrical Installations An incorrectly carried out electrical installation may generate leakage current from the electrical system Leakage current can in turn render galvanic protection insufficient in respect of propellers propeller shafts rudder posts keel etc and may cause damage through electrochemical corro...

Page 91: ...that is not connected to the engine or reverser gear IMPORTANT The engine and reverse gear must never be used as earth planes 4 The start battery must have a main switch 1 con nected to the battery s plus side The main switch must break the circuit to all equipment and be switched off when the boat is not in use 5 If an auxiliary battery is used a main switch must be placed between the auxiliary b...

Page 92: ... and topping up IMPORTANT The propulsion unit must be shut down for at least 12 hours before a correct oil level check can be done Check the oil level every day before starting the engine Open the oil filler cap 1 slowly so that any overpres sure is released Remove the dipstick 2 by turning it anti clockwise Dry off the dipstick and reinstall it in the propulsion unit screw it into place Remove th...

Page 93: ...Never over fill the propulsion unit The oil level must always be within the recommended levels otherwise the gear change function will be impaired Corrosion protection checking and changing Check the corrosion protection between the housing and the lock plate Check that the space between the drive housing and the lock plate is completely covered by corrosion pro tection Volvo Penta part 9510227 Fo...

Page 94: ...boat is launched The anode in the exhaust outlet is made of iron and does not need cleaning IMPORTANT Use emery paper Do not use a wire brush or other steel tools when cleaning as these may damage the galvanic protection Replacing corrosion protection All anodes are secured by bolts or nuts Remove the anode retaining bolts or nuts Clean the contact sur face and secure the new anode Tighten the new...

Page 95: ...tes the use of anti fouling agents Find out about legislation applicable in the area where the boat is used Always follow these regulations In many cases it is strictly forbidden to use anti fouling agents on leisure craft e g in freshwater Tin based agents TBT paints may not be used On boats that are relatively easy to take out of water we recommend treatment using Teflon alone in con junction wi...

Page 96: ...ge to the propulsion unit Operating the boat with a damaged propeller should be undertaken with extreme care and only at reduced engine speeds Propulsion unit propellers NOTICE A special tool A for removing and fitting the propellers is supplied together with the propulsion unit Please refer to the figure Dismantling 1 Take the igniton keys out of the ignition locks 2 Remove the spinner 1 using th...

Page 97: ...ing 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 7748921 04 2008 95 ...

Page 98: ... 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 Torque 24 28 Nm 17 7 20 7 ft lb Maintenance 96 7748921 04 2008 ...

Page 99: ...e 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 Maintenance 7748921 04 2008 97 ...

Page 100: ...er pump is run dry the impeller could be damaged Always check the impeller after dry runs Please refer to chapter Impeller Check and Change page 81 If the boat is kept up on land the sacrificial anodes on the propulsion unit and on the transom must be cleaned to remove any oxidation before launching the boat Please refer to Corrosion protection checking and changing page 91 To avoid fault codes in...

Page 101: ...erations in a safe and correct manner The following should be carried out on each engine when the boat is in the water Change the engine oil and replace the oil filter Replace the fuel filter Replace the fuel pre filter if installed Run the engine to normal operating temperature The following are carried out on each engine when the boat is either in or out of the water Clean the seawater filter Cl...

Page 102: ...es ervation the boat must still be taken out of the water to perform these points shortly before starting to use the boat again Clean the hull directly after taking up the boat before it dries Clean the outside of the propulsion unit directly after taking up the boat before it dries IMPORTANT Be careful when cleaning with a high pressure water spray The spray must not be pointed towards the propel...

Page 103: ...new oil and change the oil filter Drain the antifreeze from the seawater system Install the impeller in the seawater pump Replace if the old one looks worn Close tighten the drain cocks plugs Check the tension and condition of the drive belts Check the condition of rubber hoses and tighten the hose clamps Check the engine coolant level Top up if necessary Connect the fully charged batteries Check ...

Page 104: ...Only installed functions are shown in the set tings menu 1 Turn clockwise until Settings is shown on the dis play 2 Press the wheel to access the settings menu 3 Navigate by turning the wheel 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 1 Activate the station 2 Turn until Depth Alarm is shown in the settings me...

Page 105: ...correspond to the boat s deepest point or the boat s waterline depending on the depth to be displayed The echo sounder can be placed anywhere between these two points 6 Turn the wheel to set depth compensation If the number is positive the distance between the echo sounder and the water line is set if the num ber is negative it is the distance between the echo sounder and the lowest point Press th...

Page 106: ...n the alarm level Confirm the selection by depressing the navigation wheel 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 Trip Reset Zeroing trip information 1 Activate the station 2 Turn to Trip reset in the settings menu 3 Press the wheel twice to zero the trip information P0005855 P000103...

Page 107: ...ound indication controls in neutral position The sound may be set on or off The sound level is set under Information beep The setting must be entered at each station If the sta tion has several displays the setting need only be made at one display 1 Turn until Neutral Beep is shown in the settings menu 2 Press the wheel to select On or Off Display Contrast Adjusting the tachometer display contrast...

Page 108: ... boat is displayed here 1 Turn to EVC About in the settings menu and press the wheel to reach the submenu 2 Features shows what accessories are installed Press the wheel to access the submenu 3 Components shows what hardware components are installed Press the wheel to access the sub menu 4 Software shows what software is installed Press the wheel to access the submenu Units Setting operating infor...

Page 109: ...on one display for it to be shown at all stations and on all dis plays 1 Activate the station 2 Turn until Language is shown in the settings menu Press to reach the language menu 3 Turn to the desired language and press to confirm the selection The display will return to the settings menu Information Beep Adjusting the volume of the integral tachometer alarm 1 Turn until Info Beep is shown in the ...

Page 110: ...acity Calibration is carried out in 5 steps POS 1 20 full tank POS 2 40 full tank POS 3 60 full tank POS 4 80 full tank POS 5 100 full tank 1 Activate the station 2 Turn to Fuel Tank in the settings menu and press to access the calibration menu 3 Turn to Multipoint Calibr and press the wheel 4 Fill the tank with the quantity shown in the display POS 1 5 Fill the tank up to the level shown in the d...

Page 111: ...is full by depressing the wheel Speed Factor The speed factor must be set while the boat is under way Compare the displayed boat speed value with GPS data or another boat and adjust the speed factor until the values agree On boats with more than one station and with several displays it is enough to enter the setting on one display for it to be shown at all stations and on all displays 1 Activate t...

Page 112: ...for a fairly long distance during the calibration Hold the joystick firmly in position Calibration can only be carried out at a helm station that is equipped with both a joystick and a control panel Calibration need only be done in one direction port or starboard 1 Move the control lever s to neutral 2 Activate docking mode by depressing the docking button 3 An audible signal will confirm that doc...

Page 113: ...le 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 7748921 04 2008 111 ...

Page 114: ... 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 2 An audible signal will confirm that docking mode is activated and the docking button lamp will light up 3 Simultaneously press both buttons on the joystick for 5 seconds P0006292 Calibrat...

Page 115: ...y 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 Calibration and Settings 7748921 04 2008 113 ...

Page 116: ...ards inclination 10 10 Max rearwards inclination in operation 20 20 Max sideways inclination in operation 30 30 No of cylinders 6 6 Bore 103 mm 4 06 103 mm 4 06 Stroke 110 mm 4 33 110 mm 4 33 Compression ratio 17 5 1 17 5 1 Volvo Penta IPS system designa tion Engine model after market designation Crankshaft power kW hp Propellershaft power kW hp Dry weight with IPS kg lbs IPS 350 D4 260 D B 191 26...

Page 117: ...l DHD 1 3 or VDS 2 and API CH 4 3 or VDS 2 and API CI 4 3 200 hr or 12 months 100 hr or 12 months NOTICE Mineral based oil either fully or semi synthetic can be used on condition that it complies with the quality requirements above 1 Lowest recommended oil grade Engine oil with higher oil grade is always possible to use 2 If sulphur content is 1 0 by weight use oil with TBN 15 3 When oil quality s...

Page 118: ...K 2204 Sulfur content Complying with legal requirements in each country Low density fuel urban diesel in Sweden and city diesel in Finland can cause a loss of up to 5 of power and an increase in fuel consumption of about 2 3 Cooling System Water Quality ASTM D4985 Total solid particles 340 ppm Total hardness 9 5 dH Chloride 40 ppm Sulfate 100 ppm pH value 5 5 9 Silica acc ASTM D859 20 mg SiO2 l Ir...

Page 119: ...8 lb in3 battery recharged at 1 24 g cm3 0 0448 lb in3 1 20 g cm3 0 0434 lb in3 1 24 g cm3 0 0448 lb in3 1 20 g cm3 0 0434 lb in3 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 MAX 0 5 liters 0 13 US gals 0 5...

Page 120: ...he appearance and location of the type plates is shown below The figures in brackets refer to the location of the identification number on the type plate Engine A Product designation 1 Product number 2 Serial number 3 Propulsion Unit B N xxxxxx 1 xxxxxx 2 xxxxxxxxxx 3 P0006167 Product designation 4 Gear ratio 5 Serial number 6 Product number 7 The numbers refer to the position of the identificatio...

Page 121: ...sign on behalf of the engine manufacturer or his authorised representative Signature and title or an equivalent marking Date and place of issue yr month day 2007 04 26 Göteborg This declaration of conformity is issued under the sole responsibility of the manufacturer I declare on behalf of the engine manufacturer that the engine s mentioned above complie s with all applicable essential requirement...

Page 122: ... EVC Menu 20 EVC System Display 16 Fault Tracing 44 Freshwater System 77 Freshwater System Draining 79 Fuel Pre filter Change 75 Fuel System 74 116 Fuel system bleeding 75 Fuel Tank 108 Fuses 84 Identification Numbers 118 Ignition Lock 12 Impeller Check and Change 81 In Case of Emergency 57 Information Beep 107 Joystick 23 110 Long Term Storage 99 Lubrication System 72 115 Main Switch 84 My View 1...

Page 123: ...921 Name Address Country E mail http vppneuapps volvo com manual coupon Document Distribution Center Order Department ARU2 Dept 64620 SE 405 08 Göteborg Sweden Fax 46 31 545 772 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 ...

Page 124: ...7748921 English 04 2008 ...

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