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Impeller, Check and Change

WARNING!

Risk of water entry. Close the seawater cocks before
doing any work on the seawater system.

1 Remove the seawater pump lid, and pull the impel-

ler out with universal impeller puller.

2 Check the impeller. If any cracks or other defects

are visible, the impeller must be changed.

3 Lubricate the pump housing and the inside of the

lid with water-resistant grease (which is not aggres-
sive to rubber). The impeller will be easier to work
with if it is put in hot water prior to fitting.

4 Press the impeller in with a circular motion (counter

clockwise). The shaft of the pump has an internal
thread (M8). Screw a stud into the end of the shaft
and press the impeller in using a washer and nut.
Fit the cover, using a new O-ring.

5 Open the sea cock.

IMPORTANT!

Always carry a spare impeller on board.

P0009755

Maintenance

100

47705796 05-2014 © AB VOLVO PENTA

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Summary of Contents for IPS

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

Page 2: ...lvopenta com coupon Se não for possível aceder à internet contacte o seu con cessionário Volvo Penta To παρόν Βιβλίο Χρήσης μπορεί να παραγγελθεί δωρεάν σε άλλη γλώσσα μέχρι 12 μήνες μετά την παράδοση μέσω διαδικτύου http manual volvopenta com coupon Εάν δεν είναι δυνατή η πρόσβαση στο ιαδίκτυο παρακαλούμε επικοινωνήστε με το δικό σας αντιπρόσωπο της Volvo Penta Данное руководство по эксплуатации ...

Page 3: ... 10 Optional 36 Starting 56 Operation 59 Engine Shutdown 64 Fault Handling 67 Fault Code Register 71 In Case of Emergency 75 Maintenance Schedule 81 Maintenance 84 Storage 116 Calibration and Settings 120 Technical Data 129 Alphabetical index 135 47705796 05 2014 AB VOLVO PENTA 1 ...

Page 4: ...d 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 requirement...

Page 5: ...e 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 avoid...

Page 6: ...rious 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 start th...

Page 7: ...own 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 clamps engine...

Page 8: ...ed 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 The rotati...

Page 9: ...se 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 filler cap r...

Page 10: ...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 etc We hope that you will be want to preserv...

Page 11: ...h external systems e g autopi lot is performed via Volvo Penta designed interfaces After market interfaces breach system integrity and may negatively affect vessel performance safety and warranty coverage Volvo Penta does not endorse any direct or indirect connection with other systems or components not being fully tested verified and approved in writing by Volvo Penta Volvo Penta accepts no respo...

Page 12: ... of unauthorized people S The stop position 0 The key can be inserted or removed I Operating position System power is connected II Not used III Start position Starter motor is engaged There is always a helm station with an ignition lock The ignition must be switched on here in order for other helm stations to be used Read the starting instructions in the Starting page 56 chapter to make sure you u...

Page 13: ...down for more that 3 seconds to reach the main menu or browse back to it by pressing the button repeatedly Browse backwards and forwards through the informa tion panel menus by pressing the buttons Hold down a button to scroll through a menu Confirm a selection by pressing the button Settings Browse to the settings menu and press OK to pro ceed to the submenu For further information about settings...

Page 14: ...tations without a start key To start the engine it is necessary for the start key to be in the I operating position Read the starting instructions in chapter Starting page 56 and Engine Shutdown page 64 to ensure you use the correct start procedure Cruise Control Switch on cruise control by pressing the button Make fine adjustments to the locked engine speed by pressing the or buttons to increase ...

Page 15: ...ction can be disconnected so that the control lever only operates the throttle The neutral button disengages the drive reverse gear so that engine speed may be increased without driving the boat warm up mode The drive is disengaged Drive engaged for movement ahead astern Single lever When the single lever function is activated the lever that is moved from its position first becomes the control lev...

Page 16: ... the button locks the helm station To switch off the function hold the button down for 3 seconds Twin instalation Both engines in a twin instalation must be running before the docking station can be activated The helm station is inactive The helm station is active and the docking function is switched on The helm station is locked Start Stop Press the STOP and START buttons to stop and start all en...

Page 17: ...he button if the fault is accompanied by an audible signal the signal will silenced Go to the information panel to get information regarding the alarm For further information on how to handle fault mes sages and recommended actions refer to the Fault Handling page 67 and Fault Code Register chapters Syncronisation panel The engine synchronization function can be switched off at the synchronization...

Page 18: ...ped and elec trical power switched on the battery voltage should be around 24 V 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 gauge displays engine oil pres sure During operations the oil pressure gauge should normally show 3 5 5 bar 43 5 79 8 PSI ...

Page 19: ...te button View Selection The last selected view is shown on start To return to the main menu click Navigate to the desired screen using the arrow buttons My Viewoperating information Engine Viewengine information Fuel economytrip computer Vesselinformation regarding the boat s engine installation Settingssettings display and installed functions Warning Managershows system faults detected and descr...

Page 20: ... Transmission Oil Pressure Transmission oil temperature Propeller Rotation Propulsion Power Trim angle Fuel This is the boat s trip computer and information is shown in two windows Current Fuel and Average fuel Switch between screens by pressing the arrow but tons Current Fuel Instant fuel ratecurrent fuel consumption per hour Instant fuel economybased on current fuel con sumption Remaining in tan...

Page 21: ...n and select Trip Reset Vessel Shows information regarding the boat s installation The information shown can be set under Change gauge Functions are also switched on and off here Depending on the functions installed in the boat the following can be displayed Boat Speed Rudder angle Depthfor setting echo sounder refer to Depth Alarm page 122 Fuel level Sea water temperature Freshwater level ACP Inf...

Page 22: ...s when the control is in the neutral position on and off Info Beep Switches the signal that confirms when a function has been activated or deactivated on and off Info Beeplevel Sets the volume of the Info Beepthat confirms when a function has been activated or deactivated PTA Calibration Calibration and resetting PTA For information regard ing calibration refer to PTA Calibration Trip Reset Zeroes...

Page 23: ... if there is water in the oil the helmsman is alerted by an audi ble alarm and a message is shown on the display simultaneously Every time oil is changed the water in oil sensor must be calibrated refer to Service page 121 Warning Manager If the system discovers a fault the helmsman is alerted by a message on the display The fault message must be acknowledged by pressing OK All fault messages are ...

Page 24: ...U button and select Replace gauge 2 Navigate using to the gauge for replace ment and press 3 Select the gauge for replacement and press Restore Default View The display has a basic setting that it is always possi ble to return to 1 Press the MENU button and select Restore Default View 2 Press Replace gauge Restore Default View Instruments and Controls 22 47705796 05 2014 AB VOLVO PENTA ...

Page 25: ...o sure to strong sunlight can damage the screen and cause function faults The status field 2 on the right of the screen displays the current view active functions and repaired faults Pop up A number of pre set functions can be switched on and off in a pop up Press OK and the functions will show in the lower part of the screen 1 Turn to the desired function and press OK to confirm that the function...

Page 26: ... they are distinguished by different color dials in the instruments Customize Press OK so that the Customize menu is displayed Press OK to access the submenus Add Remove Modify and Return to basic setting Use the knob to browse between menus Adding instruments Turn the knob to Add and press OK Select the desired information is displayed and confirm with OK The new instrument will position itself a...

Page 27: ...oose between Remove removes the instrument Replace changes one instrument for another Turn to the desired instrument and press OK Analogue Numeric specify whether the instru ment will be displayed as analog or digital Restore Default View The screen has a basic setting that can always be returned to by pressing Restore Default View in the Customize menu P0001184 P0001185 P0001097 Instruments and C...

Page 28: ...he following can be displayed Engine Speed Rudder angle Coolant Temperature Voltage battery voltage Engine oil pressure Turbo pressure Engine hours total operating hours Transmission Oil Pressure Transmission oil temperature The information in this view cannot be changed P0012483 Instruments and Controls 26 47705796 05 2014 AB VOLVO PENTA ...

Page 29: ...tion Time to empty operating time with fuel remaining in the tank based on current fuel consumption Trip History Average fuel rate average fuel consumption since the last trip computer zero reset Average fuel economy average since the last trip computer zero reset Trip distance distance travelled since the last trip computer zero rest Trip Time time travelled since the last trip computer zero rest...

Page 30: ...level Freshwater level ACP Info for further ACP information refer to the Optional page 53 chapter Interceptor position for further information refer to the Volvo Penta Interceptor System chapter The information in this view cannot be changed Camera It is possible to connect a camera to the screen e g for monitoring the engine compartment or swimming platform If a camera is installed images will be...

Page 31: ...hen a function has been activated or deac tivated Trip Computer Resetzeroes all values in the trip com puter Service The drive is fitted with a sensor that monitors oil level and quality If the oil level in the drive is low or if there is water in the oil the helmsman is alerted by an audi ble alarm and a message is shown on the display simultaneously Every time oil is changed the water in oil sen...

Page 32: ...ctions on the screen Fuel Tankfuel tank calibration Follow the instructions on the screen ACP Infosetting the ACP protection position PTAPTA calibration Follow the instructions on the screen Warning Manager If the system discovers a fault the helmsman is alerted by a message on the display The fault message must be acknowledged by pressing OK All faults are stored in Warning Manager The fault mess...

Page 33: ...ust be acknowledged by pressing OK For further information on fault messages refer to Fault Handling page 67 Steering gear display The rudder angle view is a monitor that shows drive angle 1 plus status and alerts for Direction of thrust Overload Actuator Brake Power Communication Steering gear status The color of the lamp 2 shows the status of each drive Gray lamp drive stopped Green lamp status ...

Page 34: ... 2 will operate in this range of revo lutions B If one of the control levers is in neutral propulsion the centre propulsion unit 2 is also in neutral C Are the control levers in different positions one engaged for forward motion and the other for reward motion the centre propulsion unit will be in neutral Quadruple Installation Both the adjustment of engine speed and the gear shift function are co...

Page 35: ...fer to Disengag ing shift function in this chapter for further informa tion 5 SINGLE LEVER Switch on the single lever function by pressing the button The lever that is moved from its position first becomes the control lever for both engines The other control lever has no function as long as the single lever function is activated The button lamp lights up to show that the function is active Exit th...

Page 36: ... disengaged and that the lever will only affect engine revolutions To exit neutral mode press the button again Adjusting the friction brake The control lever has a friction brake that can be adjusted for lighter or stiffer lever movement Resist ance in click mode can also be adjusted 1 Switch off the engine 2 Remove the cover 3 3 Adjust the friction brake 1 and or click mode 2 by turning the screw...

Page 37: ...tion refer to Joystick for docking page 39 2 Dynamic Positioning System For operation and further function information refer to Optional page 49 3 Joystick Driving For operation and further function information refer to Joystick Driving page 42 4 High Mode For operation and further function information refer to Joystick for docking page 39 1 2 3 4 P0016686 Instruments and Controls 47705796 05 2014...

Page 38: ...ow speed disengaged The control affects engine speed and propeller revolutions P0012978 Engaging the low speed function 1 Move the lever to the neutral position 2 Press the Low Speed button on the control or on the helm station panel to activate the low speed function An audible signal and the message Lowspeed activated A will be displayed on screen to confirm that the function is on is shown on t...

Page 39: ... Switching on the sport fishing function 1 Move both control levers to neutral 2 Press the sport fishing button on the panel An audible signal and the message Sport fishing activated will be displayed on screen for 5 seconds to confirm that the function is activated If it is not possible to switch on the function check that the controls are in neutral Switching off the sport fishing function When ...

Page 40: ... for both engines The other control lever has no function as long as the single lever function is activated Switching off the single lever function 1 Move the levers to neutral 2 Press the single lever button A double audible sig nal and the message Single lever deactivated will be displayed on screen to confirm that the function is off Clear Wake Exhaust System When running at idle it is possible...

Page 41: ...ks differently depending on if the docking function or steering function is active Practise using all means of steering and throttle under all conditions The docking function is designed to be used when docking or maneuvering in close quarters Use the steering wheel and throttle control levers in all other situations The boat is maneuvered by moving the joystick for ward aft abeam twisting the top...

Page 42: ...king function the following must be fulfilled engines running control levers in neutral helm station active joystick in center position Activating the docking function Activate docking mode by depressing the docking but ton A on the joystick An audible signal will confirm that docking mode is activated and the docking button lamp will light up Exiting the docking function To exit the function pres...

Page 43: ... docking button lights up 2 Activate the High Mode function by depressing but ton B on the joy stick 3 An audible signal confirms that the function is acti vated and the high Mode button lights up Disengage High Model Disengage the function by pressing the button again An audible signal will sound twice to confirm that dock ing mode is deactivated and the light will go out The system is now in nor...

Page 44: ...t the top of the joystick or move it sideways to reengage joystick steering If the autopilot is put in standby mode manually by means of the STBY button joystick steering is switched off and must be reengaged using the button on the joystick Heading adjustments Twist the top of the joystick to change heading incre mentally A short twist changes the heading by a fixed increment while a twist held f...

Page 45: ... obstacle Twist the top of the joystick or move it side ways to re activate joystick steering P 19945 00 Maneuvering Twist the top of the joystick to change rudder angle gradually A short twist changes the rudder one degree while a twist held firm will change course through several degrees The joystick can also be used to steer the boat in the same way as a steering wheel Move the joystick sideway...

Page 46: ...r the last menu used When the autopilot is active the helm steering unit is locked but may always be used for e g changing course or giving way to obstacles The autopilot will then default to stand by mode and must be activated again If the Shadow Drive function is activated in the Set tings menu the autopilot is re activated automatically after a course change has been made manually with steering...

Page 47: ...nd a route or waypoint has been cre ated in the plotter The display shows the distance to the next waypoint along the plotted route Refer to GPS Steering for further information and settings Setting a course The boat s course is set by means of the arrow buttons 10 1 1 10 One click on the button changes the course 1 at a time if the button is held down longer the course is changed in larger steps ...

Page 48: ...pilot a waypoint must be activated in the plotter this point will be the pattern s central marker The selected pattern helm and any other settings are shown on the display Pattern steering is deactivated if the boat s course is changed using the helm or autopilot buttons reactiva tion is manual Orbit The boat is steered on a circular course around the active waypoint The radius of the circle is de...

Page 49: ...es The boat is steered in a circular pattern based on its position when the pattern is activated Setting the helm port or starboard and the time taken to complete a circle 180 turn The boat turns through 180 and then maintains the new course Setting the helm port or starboard for the direction of the turn Man over board MOB Turns the boat to come parallel with the position when MOB was activated S...

Page 50: ...topilot must be manually reactivated Step size Setting the number of degrees a course is changed when the Autopilot menu arrow buttons are held down Dealer autopilot settings Settings in this menu may only be changed by an authorized Volvo Penta dealer System Course Setting a reference for calculating course informa tion Magnetic calculating a course based on magnetic North True calculating a cour...

Page 51: ...PS is active The dynamic positioning system can be affected by strong electromagnetic signals as created by radar and radio transmitters Maintain a safe dis tance with a minimum of 2 boat lengths to any object Show consideration When the DPS is active it gives rise to noise and heavy propeller wash that may annoy those around You are responsible for the wake from your boat WARNING Check that nobod...

Page 52: ...o boat lengths away 2 Move the control levers to neutral 3 Press the DPS button 1 An audible signal con firms that the DPS is active and the button light is lit The screen shows a brief warning message before switching to the DPS image Activating the DPS at the docking station 1 Make sure that swimmers and boats or other objects are more than two boat lengths away 2 Press the DPS button 1 An audib...

Page 53: ...ion status Acknowledge the message by pressing OK on the panel or the knob on the control panel the audible alarm will stop Following is a list of messages resulting from potential disturbances The boat has lost the selected position The DPS is working to find the selected position The boat has lost the selected heading The DPS is working to find the selected heading The DPS function has switched ...

Page 54: ...der to engage the DPS Make sure all engines are running Make sure there are no messages that needs to be acknowl edged and attended to DPS cannot be activated Control lever s not in neutral Move lever s to neutral and activate the DPS The control lever s must be in neutral position in order to engage the DPS DPS cannot be activated The boat speed is too high Reduce speed to 3 knots and start the D...

Page 55: ...ected against cor rosion by means of the secondary system refer to Protection levels The ACP reverts automatically to normal mode after 4 hours should you wish to leave chlorine free mode earlier do so via the settings menu or by switching on the ignition When berthed the boat should be connected to shore power where provided If shore power is lacking the ACP uses the boat s batteries If the batte...

Page 56: ...tteries When the boat is in saltwater or brackish water and if the system remains in this mode for more than 1 2 weeks after shore power is connected or an ade quate battery charge is achieved a system check service should be sought C No Protection No Protection risk of corrosion system alarm Seek system check service D If the ACP is set to inactive the system cannot iden tify ACP status three lin...

Page 57: ... mode may only be used when the boat is taken out of the water is on land or if it is to be run in freshwater Select this mode before the boat is lifted out of the water to avoid false alarms In this mode the IPS no longer monitors corrosion conditions but the IPS is protected by the zinc anode When ignition is switched on the system is re started and goes to Normalmode Settings menu 1 Navigate to...

Page 58: ...re encountered WARNING Never use start spray or similar agents to start an engine This may cause an explosion in the inlet manifold Danger of personal injury Before Starting Check the engine and drive units oil level Check the coolant level Open the sea cock Open the fuel cock Turn the main switches on IMPORTANT Never disconnect the current with the main switches when the engine is running The alt...

Page 59: ...ll stations Turn the ignition on Turn the starter key to position I to switch the ignition on Check the information display If a fault is registered it will be shown in the information display please refer to Fault Handling page 67 for further information and recommended actions Starting 47705796 05 2014 AB VOLVO PENTA 57 ...

Page 60: ...s 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 minutes before making a new start attempt Read the instruments and warm the engine up Allow the engines to idle for the first ten seconds Check that instruments and warning displays show nor...

Page 61: ...r in areas where people could be in the water Reading the Instruments Read all instruments and alarm displays directly after starting and then regularly during the voyage Alarms Alarms and messages are shown in the information display some alarms do also have a sound alarm Is there an alarm instrument installed the lamp in ques tion will flash 1 Read the message 2 Acknowledge the alarm by pressing...

Page 62: ... 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 63: ...upied by press ing 2 The lamp in the control button will light up when the helm station is active If the helm station is inactive the lamp will be extin guished If the padlock symbol 3 flashes the helm station can not be activated Another helm station is active and locked or unlocked with a drive selected not in neu tral Locking unlocking helm stations If a helm station is locked it is only possib...

Page 64: ...tion is subordinate to the local helm station and the main helm station The active helm station must first be unlocked in order to activate the remote helm station Changing helm stations 1 Unlock the active helm station by depressing 1 The padlock 2 will go out on all helm stations 2 Activate the helm station that is to take control by pressing 1 The green lamp on the control will begin flashing I...

Page 65: ...n geit can depend on a number of factors mentioned in the Fault Handling page 69 sedtion Select a propeller with greater pitch if actual enginer evolutions exceed the full throttle range Contact your Volvo Penta dealer for advice Triple installation Since the center propulsion unit is installed in a tunnel a slight efficiency loss for engine 2 is to be expected at cruising speed and wide open thro...

Page 66: ...nics 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 when it is...

Page 67: ...the engine After Engine Shutdown Check the engine and engine bay for leakages Close the fuel taps Close the sea cock 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 STOP P0009744 P0010432 Engine Shutdown 47705796 05 2014 AB VOLVO PENTA 65 ...

Page 68: ...Storage Cold Weather Precautions If the engine bay cannot be kept frost free the raw water system must be drained and the freshwater sys tem coolant must have sufficient frost protection to prevent frost bursting refer to Seawater System Draining page 98 and Maintenance page 94 respectively for more detailed information Check the charge status of the battery A poorly charged battery can freeze and...

Page 69: ...ng the engine Depending on how serious the 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 caus...

Page 70: ... cause of the fault and the remedy 4 Return to the previous menu by pressing Deleting faults from the list Acknowledged faults that have been stored are deleted automatically when the ignition key is turned to the stop position Stop the engine and check that the ignition key is in position 0 at all helm stations When system power is reconnected the diagnostic function checks if there are any fault...

Page 71: ...39 Engine vibrates 24 High fuel consumption 15 16 18 21 36 Black exhaust smoke 19 Blue or white exhaust smoke 21 34 Lubrication oil pressure too low 22 Coolant temperature too high 25 26 27 28 29 30 31 32 Coolant temperature too low 31 No charge or poor charge 2 40 1 Flat batteries 2 Poor contact open circuit in cables 3 Main switch turned off 4 One of the semi automatic circuit breakers in the di...

Page 72: ...ting 25 Coolant level too low 26 Air in the freshwater system 27 Faulty circulation pump 28 Closed seawater inlet 29 Blocked seawater inlet pipe filter 30 Defective impeller in seawater pump 31 Defective thermostat 32 Blocked heat exchanger insert 33 Blocked aftercooler 34 Too high oil level 35 Water entry into engine 36 High back pressure in exhaust system 37 Faulty engine speed sensor 38 Stored ...

Page 73: ...ional If a lamp in the alarm monitor flashes a malfunction is detected 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 the coolant tem perature is to high 4 Is the orange coolant level lamp lit during operation the coolant level is to low ...

Page 74: ...Fuel pressure incorrect Engine performance might be affected Communication failure Gear automatically set to neutral Engine per formance might be affected Oil pressure too low Engine power is reduced Checking Engine Oil Level Refer to Oil level checking and topping up page 87 Check that no leakage occurs Please contact a Volvo Penta workshop if the fault remains Check EVC System Internal fault in ...

Page 75: ...eakage Coolant Temperature Coolant temperature too high Engine power is reduced Check coolant level Refer to Maintenance page 95 Check that the seawater filter is not blocked Refer to Seawater Filter Check and Cleaning page 101 Check the impeller in the seawater pump Refer to Impeller Check and Change page 100 Check that no leakage occurs Engine Oil Level Oil level too low NOTICE In rough followin...

Page 76: ...performance might be affected Please contact a Volvo Penta workshop if the fault remains Steering failure Limited functionality Self test failed Verify hydraulic steering oil level Refer to Transmission lubri cant checking and topping up page 109 Steering failure Engine power is reduced Limited steering The helm station has lost communication with the steering actuator Please contact a Volvo Penta...

Page 77: ...than it normally should be when all engines are working and this could cause excessive wear to the engine s and propulsion unit s Triple installation A boat with a triple installation is not likely to experi ence a serious fault on all engines and propulsion units simultaneously If a serious fault occurs which pre vents one or two engine s and propulsion unit s from working normally it will still ...

Page 78: ...he auxiliary battery and to a place a little distance away from the discharged bat tery e g the start motor s negative terminal WARNING Under no circumstances may the black jumper cabel come in contact with the positive connec tion on the starter motor 4 Start the engine and let it run at fast idle for approximately 10 minutes to charge the batter ies Make sure there is no extra equipment con nect...

Page 79: ...ropulsion unit s will improve the steering ability The operator determines 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...

Page 80: ... 3 Press the switch button 5 down and keep it pressed while turning the crank tool carefully to an end position 6 When the end position is reached stop turning The end position feels like a compres sion spring IMPORTANT Do not force the crank tool beyond the end position it could damage the propulsion unit STOP 6 5 2 1 1 2 3 3 4 P0012503 In Case of Emergency 78 47705796 05 2014 AB VOLVO PENTA ...

Page 81: ...otion 5 Remove the crank tool Disconnect the switch 8 by pressing down the lock and at the same time unplugg the switch by slowly wiggling it Screw back the plug 9 6 Reconnect the cable 10 you disconnected in step 1 10 75 7 8 9 4 5 6 P0012504 In Case of Emergency 47705796 05 2014 AB VOLVO PENTA 79 ...

Page 82: ...uitable engine speed for maneuvring The direction of rotation is determined by the lever which is put in the position for reverse If the boat is to move to starboard the starboard control lever should be put in the position for reverse 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...

Page 83: ...m FSI First Service Inspection C Clean S1 S2 S3 Special Interval Service R Replace A F Type of service regular service A Adjustment L Lubrication I Inspection includes if necessary cleaning adjust ment lubrication and change FSI First Service Inspection After the first 50 100 hours 1 Inspection with VODIA Diagnostic Tool 2 I Coolant level and antifreeze mixture I Drive belts belt tensioner and idl...

Page 84: ...m up engine Engine and transmission abnormal noises I Engine and transmission oil fuel water leakage I 1 Readout if any fault codes and LVD B Every 1000 hours At least every month 12 24 48 Fuel pre filter filter insert R Fuel fine filter R Air Filter R Impeller Seawater Pump R Anodes Charge air cooler and or Heat exchanger Must not be painted R Engine and transmission inspect hoses and cable clamp...

Page 85: ...clearance I Drive Belt R Turbocharger inspect clean as required I E Every 8000 hours At least every month 12 24 48 Coolant VCS yellow 1 R 1 Different types of coolant must not be mixed with each other Maintenance Schedule 47705796 05 2014 AB VOLVO PENTA 83 ...

Page 86: ...ing or removing the engine hatch hood Make it impossible to start the engine by removing the start key and cutting the system voltage with the main switches 1 Expansion tank 2 Coolant filler cap 3 Fuel fine filter 4 Oil filter 5 By pass filter for engine oil 6 Auxiliary stop 7 Air filter indicator 8 Air Filter 9 Alternator 10 Relays 11 Oil filler cap engine 12 Oil dipstick engine 1 13 Heat exchang...

Page 87: ... 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 is started Never direct the jet from a high pressure washer at seals rubber hoses or electrical components Never use the high pressure setting for engine cleaning Air Filter Change 1 If indicator is all red after the e...

Page 88: ...ed Changing the alternator belt 1 Remove the protective cover over the drive belt 2 Put a socket wrench in the tensioning roller square fitting Turn the tensioning roller aside and secure it by inserting a screwdriver or simi lar into the space which opens up 3 Remove the drive belt 4 Install the new drive belt and release the locking of the belt tensioner Make sure the drive belt fits properly in...

Page 89: ...hrough reg ular oil testing Oil level checking and topping up The oil level must be inside the marked area on the dipstick 1 and should be checked daily before the first start Top up the oil through the filling hole on the side of the engine 2 Check that the correct level has been ach ieved Wait a few minutes to allow the oil to run down into the sump IMPORTANT Do not fill up above the maximum oil...

Page 90: ...Replace the oil filter and by pass filter at every oil change refer to the Oil Filter By pass Filter Change page 89 section 4 Fill oil to the correct level vial the filler opening on the side of the engine refer to the Technical Data Lubrication System section for oil quantity IMPORTANT Use only oils of the recommended grades refer to the Oil Grade and Oil Change Interval section 5 Start the engin...

Page 91: ...pass filter 1 and the oil filters 2 with a suitable puller 4 Check that the mating surfaces on the filter bracket are clean and that no remains from the old gaskets are left 5 Moisten the gaskets on the new filters with engine oil 6 Screw on the filter by hand until the rubber gasket touches the filter bracket mating surface Then turn a further 3 4 to 1 turn 7 Start the engine run at low idle and ...

Page 92: ...h one 4 Relieve the pressure inside the filter by opening the drain tap 2 at the bottom of the water separator if fitted with one 5 Unscrew the filter Use a filter tool if necessary 6 Screw off the water separator 3 from the filter 7 Clean the sealing surfaces on the filter holder Make sure that the filter is clean and that the sealing rings are undamaged Moisten the sealing rings with engine oil ...

Page 93: ...ubbles 3 Close and tighten the bleed nipple 4 Start the engine If the engine runs unevenly there might be air left in the fuel system To empty the system of remaining air open the bleed nipple while the engine is run ning WARNING Hot fuel can cause burns WARNING Working with or approaching a running engine is a safety risk Watch out for rotating components and hot surfaces 5 Close the bleed nipple...

Page 94: ...ge 1 that indicates when it is time to replace the filter cartridges The filter cartridges must be replaced according to maintenance schedule recommendations or earlier if the pressure gauge shows a pressure drop of 6 10 in Hg at idle or 16 20 in Hg at full rpm engine load WARNING Working with or approaching a running engine is a safety risk Watch out for rotating components and hot surfaces Drain...

Page 95: ...ilter to be replaced must be shut off using the lever 1 1 Place a vessel under the filters and shut off the filter to be replaced 2 Undo the T bolt 2 and remove the cover 3 3 Carefully remove the cartridge with a turning move ment 4 Empty the water and sediment through the drain hole 4 5 Insert a new filter cartridge and fill the holder with clean fuel 6 Replace the cover gasket and the T bolt O r...

Page 96: ...water alone as the coolant The corrosion protection additives become less effec tive over time which means that the coolant must be changed at regular intervals refer to Maintenance Schedule The cooling system must be flushed when ever the coolant is changed refer to Freshwater sys tem Flushing page 97 Volvo Penta recommend Volvo Penta Coolant VCS Ready Mixed or the concentrate Volvo Penta Coolant...

Page 97: ...lant must be mixed with distilled deionized water The water must fulfil the requirements specified by Volvo Penta refer to Technical Data page 131 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 Make sure that the liquids mix Checking the coolant level WARNING Do not open the coolant filler ...

Page 98: ...ty cooling system 1 Mix a sufficient quantity of coolant in a vessel before filling Note that if a heating system water heater or similar is connected to the engine cooling system a correspondingly greater quantity of coolant will be required 2 Also make sure that any heating system water heater or similar connected to the engine cooling system is vented open the heater regulator valve 3 Fill cool...

Page 99: ...s tap s 3 Also drain the heating system tap water heater etc if connected to the engine s freshwater sys tem 4 Close all drain taps 5 Collect the old coolant and hand it to a re cycling station for destruction Freshwater system Flushing The cooling system should be flushed when the cool ant is changed to avoid loss of cooling performance due to deposits in the cooling system 1 Drain the coolant pl...

Page 100: ...t frost damage WARNING Risk of water entry Close the seawater cocks before doing any work on the seawater system An alternative to draining is to keep the engine bay above freezing temperature by means of a fan heater which is approved for outdoor use 1 Close the sea cock 2 Connect a hose to each drain tap before opening the tap one at a time 3 Open the drain taps remove the drain plugs S and allo...

Page 101: ... them if they have been consumed below 1 3 of their original size If not clean the zinc anodes with emery cloth to remove the oxide layer before re installing them IMPORTANT Use emery paper Do not use a wire brush or other steel tools when cleaning as these may damage the galvanic protection 5 Install the zinc anodes When installing make sure there is good metallic contact between the anode and th...

Page 102: ...g and the inside of the lid with water resistant grease which is not aggres sive to rubber The impeller will be easier to work with if it is put in hot water prior to fitting 4 Press the impeller in with a circular motion counter clockwise The shaft of the pump has an internal thread M8 Screw a stud into the end of the shaft and press the impeller in using a washer and nut Fit the cover using a ne...

Page 103: ...t 4 If the glass vessel 3 needs cleaning from e g algae fouling this must be done from the top with the aid of a suitable brush use soapy water as required The glass vessel must 3 not be removed 5 Screw the cover back on 1 by hand The cover threads should be brushed with silicone based water proof grease e g VP part 828250 annu ally this will ensure that the cover does not seize on removal Mineral...

Page 104: ...er Check that the hole is not blocked CAUTION Burn hazard Steam may evaporate through the drain hole IMPORTANT If a large amount of coolant flows out of the drain hole the charge air cooler must be removed and pressure tested This work must be carried out by an authorized work shop P0009756 Maintenance 102 47705796 05 2014 AB VOLVO PENTA ...

Page 105: ...e current with the main switches when the engine is running the alternator and elec tronics could 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 wi...

Page 106: ... pressing in the circuit breaker 1 IPS The IPS unit has an automatic circuit breaker The circuit breaker cut the power if the drive unit system is overloaded Reset by pressing in the circuit breaker IMPORTANT Always investigate the cause of the overload If the fuse trips frequently contact an authorized Volvo Penta workshop Electrical Connections Check that electrical connections are dry free from...

Page 107: ...cid 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 Contamination and oxi...

Page 108: ...es Always use protective goggles and gloves If battery electrolyte comes into contact with unprotected skin wash 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 IMPORTANT ...

Page 109: ...ircuits in the boats should be done by a person with electrical training or knowledge Installation or work on land current equipment must only be done by a competent electrician in accordance with local regulations for mains electricity The following must always be heeded 1 If shore power is connected it must always be ground protected ashore never in the boat Fur thermore the shore power installa...

Page 110: ...es For simultaneous charging of two independent battery circuits a separate charging distributor accessory should be installed on the standard alternator Electrical Welding Remove the positive and negative cables from the bat teries then disconnect all cables connected to the alternator Always connect the welder ground clamp to the com ponent to be welded and as close as possible to the weld site ...

Page 111: ...hecking and topping up IMPORTANT The drive must be stopped for at least 12 hours before a correct oil level check can be made Check the oil level every day before the engine is started Open the oil filler cap 1 so that excess pressure is released Undo the oil dipstick 3 with the aid of a standard 1 2 extension 2 Dry off the oil dipstick and replace it in the drive do not screw down the oil dipstic...

Page 112: ...ng using an oil drain pump 1 1 Open the oil filler cap 1 and the plug 2 so that excess pressure is released Fit the adapter 3 and connect the oil drain pump suction hose If the suction hose does not fit the adapter also use the sleeve 3A Pump out as much oil as possible approx 22 liters 2 The oil that collects in the bottom of the drive must also be pumped out Remove the adapter from the drive and...

Page 113: ... to the drive and the other to the transom Refer to the illustrations Replace an anode when approximately 1 3 of it has corroded away When the boat is stored ashore corrosion protection deteriorates due to sacrificial anode oxidization Even new anodes oxidize on the surface The anodes must be cleaned before the boat is launched The anode in the exhaust outlet is made of iron and does not need clea...

Page 114: ...ve unit and the hull or the plastic surface of the exhaust cushion B Painting the hull bottom All paints containing anti fouling agents are poisonous and damage the marine environment Avoid these preparations Most countries have introduced legisla tion that regulates the use of anti fouling agents Find out about legislation applicable in the area where the boat is used Always follow these regulati...

Page 115: ...w any signs of malfunction or of being stuck The exhaust cock s lock shall be greased with water resistant grease every year IMPORTANT If it is not possible to make the cocks work properly or if they have other malfunctions please contact your Volvo Penta workshop P0007396 Maintenance 47705796 05 2014 AB VOLVO PENTA 113 ...

Page 116: ...ys out of the ignition locks 2 Remove the spinner 1 using the special tool 3 Undo the propeller nut 2 with the accompanying special tool by unscrew the six socket cap screws 3 Undo the propeller nut with a cranking counterclock wise motion Remove the forward propeller from the propeller shaft 4 Undo the propeller nut 4 for the aft propeller with the accompanying special tool by unscrew the four so...

Page 117: ...28 Nm 17 7 20 7 ft lb 4 Install the forward propeller until it bottoms Attach the propeller nut with a cranking clockwise motion until it bottoms Adjust the position with a reversed crank until the holes for the screws are lining 5 Mount the six socket cap screws Torque 24 28 Nm 17 7 20 7 ft lb 6 Push the spinner into place by hand Install the center screw with Volvo Penta locking fluid 1161053 al...

Page 118: ...ater 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 100 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 111 To avoid fault code...

Page 119: ...vice operations 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 fi...

Page 120: ...ion 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 propeller shaf...

Page 121: ...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 the sacr...

Page 122: ...n menu can be adapted to suit personal preferences in My View 1 Navigate from the settings menu to My View Press to get to the submenu 2 Navigate through the menu using to see available operating information 3 Press to add or remove information for display in the main menu Neutral Beep The neutral beep is an audible signal that sounds when the control is in the neutral position The setting must be...

Page 123: ...mation Service IMPORTANT Every time oil is changed in the drive the water in oil sensor must be calibrated 1 Start the engine and let it run at a speed below 1 000 rpm 2 From the settings menu go to EVC and navigate to Service Press OK to open the settings menu 3 Select Drive oil change and press OK 4 Select the drive for calibration and press OK Select Perform and press OK 5 Press OK to confirm t...

Page 124: ...esponds to the boat s lowest point or the waterline The echo sounder can be placed anywhere between these two points Set the echo sounder waterline or echo sounder lowest point distance to the depth to be displayed The distance between the echo sounder B and the water line A has a positive value The distance between the echo sounder B and the boat s lowest point C has a negative num ber Press to c...

Page 125: ... or backlighting The screen will return automatically to the settings menu Side Selection Set from which engine information is to be show in dis play Units Setting the units information will be shown in 1 Navigate to Units in the settings menu Press to open the settings menu 2 Open US or Metric press and select Ameri can or metric units 3 Navigate to Distance press and then select kilometers nauti...

Page 126: ...at hardware components are installed Press to open the settings menu 4 Software shows what software is installed Press to open the submenu Fuel Tank There are two alternative methods for calibrating the level sensor in the fuel tank Multipoint provides more precise results while Full Fuel Tank Calibration is an approximate method Multipoint calibration is a prerequisite if the trip com puter is to...

Page 127: ... Fuel Tank Calibration and press 3 Fill the fuel tank Confirm that the fuel tank is full by pressing IMPORTANT Settings for Fuel Tank Volume Empty Tank Calibra tion and Fuel Alarm Level should only be carried out by an authorized Volvo Penta workshop 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...

Page 128: ...in high winds or currents that can influence the result of the calibration Allow the boat to run for a fairly long distance during the calibration Hold the joystick firmly in position 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 Calibration and Settings 126 47705796 0...

Page 129: ...ection Correct boat movements by moving the joystick up and down and by turning it 4 When the boat is moving straight abeam depress the docking button once again 5 An audible signal will sound and both lower button lamps on the joystick will flash to confirm that cali bration is complete and stored The system is now in docking mode When the joystick returns to the central position the lamps will s...

Page 130: ...y depressing the dock ing button for 5 seconds An audible signal will confirm that docking mode is activated and the docking button lamp will light up 3 Press the docking button Calibration is now reset which is confirmed by an audible signal The system is now in docking mode Calibration and Settings 128 47705796 05 2014 AB VOLVO PENTA ...

Page 131: ... of cylinders in line 6 in line 6 Bore 131 mm 5 16 131 mm 5 16 Stroke 158 mm 6 22 158 mm 6 22 Displacement 12 78 dm3 779 7 in3 12 78 dm3 779 7 in3 Engine dry weight 1560 kg 3439 lbs 1560 kg 3439 lbs Compression ratio 16 7 1 16 7 1 Low idle r min 2 600 10 600 10 1 According to ISO 8665 2 At delivery the idle speed is adjusted to 600 r min If needed the speed can be adjusted within the range 600 650...

Page 132: ... 12 months 1 Lowest recommended oil grade Engine oil with higher oil grade is always possible to use 2 If sulphur content is more than 1 0 per cent by weight use oil with TBN over 15 3 ACEA E7 has replaced ACEA E5 If available ACEA E5 can be used NOTICE Mineral based oil either fully or semi synthetic can be used on condition that it complies with the quality require ments above ACEA Association d...

Page 133: ...y Mixed green colour are silicate based 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 Iron acc ASTM D1068 0 10 ppm Manganese acc ASTM D858 0 05 ppm Conductivity acc ASTM D1125 500 µS cm Organic content CODMn acc ISO8467 15 mg KMnO4 l coolant vcs ready mixed P0013077 P0002094 Technical Da...

Page 134: ...n recommended may result in increased gear shifting delay and show other handling characteristics than what you are used to with the factory filled Volvo Penta approved oil IMPORTANT For transmissions in the marine environment it is extremely important that the correct transmission oil is used Using an incorrect transmission oil may very quickly affect transmission life and function Extensive test...

Page 135: ... 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 REVERSE GEAR DRIVE UNIT TRANSOM ASSEMBLY ENGINE P0020065 1 2 3 Product designation 1 Specification number 2 Serial number 3 Engine plate B 1 2 4 3 P 20059 00 Product designation 1 Specification number 2 Serial number 3 Output 4 Propulsion Unit C Prod...

Page 136: ... models covered by this declaration EC Type certificate number Volvo Penta IPS 1050 D13 800 Volvo Penta IPS 1200 D13 900 SDVOLV008 noise 68906 13 HH exhaust LR 09 13 issue 01 Essential requirements Standards Used Other normative document used Annex I B Exhaust Emissions Engine identification Volvo Penta std Annex 1 B 1 Exhaust emission requirements EN ISO 8178 1 1996 Annex 1 B 2 Durability Volvo P...

Page 137: ...ing 69 Faults list 68 Freshwater System 94 Freshwater system Flushing 97 Fuel pre filter 92 Fuel System 90 Fuel system bleeding 91 Fuses 104 H Helm Stations 61 I Identification Numbers 133 Ignition Lock 10 Impeller Check and Change 100 Information Beep 121 Information Panel 11 Intake Manifold Checking the Drain Hole 102 J Joystick for docking 39 L Long Term Storage 117 Low speed 36 Lubrication Sys...

Page 138: ......

Page 139: ... 2014 AB VOLVO PENTA Volvo reserves the right to make changes Printed on environmentally friendly paper ...

Page 140: ...47705796 English 05 2014 ...

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