Volvo Penta IPS, IPS 350, IPS 400, IPS 450, IPS 500 Operator's Manual

OPERATOR’S MANUAL

Volvo Penta IPS

An English version of this Operator’s Manual may

be ordered free of charge up to 12 months after delivery, via
internet, mail or fax. Refer to the order form in the back of
the book.

All information is stored internally at AB Volvo Penta and will
not be passed on to third parties.

Diese deutsche Version dieses Handbuches kann

innerhalb von 12 Montane ab Lieferung kostenlos online,
per Brief oder per Fax bestellt werden. Bitte Bestellformular
hinten im Buch verwenden.

Alle Angaben werden bei AB Volvo Penta gespeichert und
nicht Dritten übermittelt.

Une version française de ce manuel d’instructions

peut être commandée gratuitement, jusqu’à 12 mois après
la date de livraison, via Internet, la poste ou par fax. Voir à

la n de ce document.

Toutes les informations sont stockées en interne chez AB
Volvo Penta et ne sont divulguées à aucun tiers.

Hay disponible una versión en español gratuita de

este manual de instrucciones, la cual puede pedirse, a tra­vés de Internet, correo postal o fax, en el plazo de 12 meses
después de la entrega del producto. Véase el formulario de
pedido en las últimas páginas del manual.

Todos los datos recibidos son almacenados de forma in-

En svensk version av denna instruktionsbok kan

beställas kostnadsfritt, upp till 12 månader efter leverans,
via internet, post eller fax. Se beställningsformulär i slutet av
boken.
Alla uppgifter lagras internt hos AB Volvo Penta och lämnas

inte ut till tredje part.

Een Nederlandse versie van dit instructieboek kan

kosteloos worden besteld tot 12 maanden na aevering, in­ternet, post of fax. Zie het bestelformulier achterin het boek.

Alle gegevens worden intern opgeslagen bij AB Volvo Penta
en niet verstrekt aan derden.

En dansk version af denne instruktionsbog kan

bestilles gratis, op til 12 måneder efter levering, via internet,
post eller telefax. Se bestillingsformular i slutningen af bo­gen.

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 encomendar uma versão gratuita deste

manual de instruções em português, até 12 meses após a
entrega, através de Internet, correio ou fax. Consultar o for-

mulário de encomenda no m do manual.

Todas as informações são armazenadas internamente pela
Volvo Penta e não são partilhadas com terceiros.

Εντός 12 μηνών από την παράδοση μπορείτε να

παραγγείλετε μέσω Internet, ταχυδρομικής επιστολής ή φαξ
μια ελληνική έκδοση του Βιβλίου χρήσης χωρίς χρέωση.
Χρησιμοποιήστε το δελτίο παραγγελίας στο τέλος του
βιβλίου.

Όλες οι πληροφορίες αποθηκεύονται από την AB Volvo Pen-

Вариант настоящего руководства по

эксплуатации на русском языке можно заказать
бесплатно в течение 12 месяцев после доставки по
Интернету, электронной почте или по факсу. См. бланк
заказа на обложке руководства.

Вся информация используется компанией AB Volvo Pen­ta конфиденциально и не передается третьим сторонам.

Bu Kullanım Kılavuzunun Türkçe versiyonu teslim-

den 12 ay sonrasına kadar internet, posta veya faks yoluya
sipariş edilebilir. Kitabın arka kısmında bulunan sipariş for­muna bakınız.

Tüm bilgiler AB Volvo Penta’da saklıdır ve üçüncü kişilere

verilmez.

Una versione in lingua italiana di questo manuale di

istruzioni può essere ordinata gratuitamente, no a 12 mesi

dopo la consegna, via internet, per posta o via fax. Vedere il

modulo per l’ordinazione alla ne del manuale.

Tutti i dati forniti saranno memorizzati internamente presso
AB Volvo Penta e non saranno divulgati a terzi.

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and

other reproductive harm.

Content

Foreword ...................................................................................................... 2

Safety Information ...................................................................................... 3

Introduction ................................................................................................. 8

Presentation .............................................................................................. 10

Instruments and Controls ........................................................................ 12

Optional ..................................................................................................... 26

Starting ...................................................................................................... 31

Operation ................................................................................................... 34

Engine Shutdown ...................................................................................... 38

Fault Handling ........................................................................................... 41

Fault Code Register .................................................................................. 45

In Case of Emergency .............................................................................. 57

Maintenance Schedule ............................................................................. 65

Maintenance .............................................................................................. 67

Storage ....................................................................................................... 98

Calibration and Settings ......................................................................... 102

Technical Data ......................................................................................... 114

Alphabetical index .................................................................................. 120

1

Foreword

Volvo Penta marine engines are used all over the world. They are used in all possible operating conditions for
professional as well as leisure purposes. This is not a coincidence. After 100 years as an engine manufacturer
the Volvo Penta name has become a symbol of reliability, technical innovation, top of the range performance and
long service life. We also believe that this is what you demand and expect of your Volvo Penta engine.

We would like you to read this operator’s manual thoroughly 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 requirements and replacement parts. Please
contact your nearest authorized Volvo Penta dealer for assistance.

You will find your closest dealer at our home page on the Internet www.volvopenta.com - amongst other
useful information about your Volvo Penta engine - we invite you to visit!

2 7748921 04-2008

Safety Information

Read this chapter very carefully. It has to do with your safety. This describes how safety information is presented
in the instruction book and on the product. It also gives you an introduction to the basic safety rules for using and
looking after the engine.

Check that you heave received the correct instruction book before you read on. If not, please contact your
Volvo Penta dealer.

!

This symbol is used in the instruction book and on the product, to call your attention to
the fact that this is safety information. Always read such information very carefully.

Safety texts in the instruction book have 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 avoided, could result in property damage.

NOTICE! Used to draw attention to important information that will facilitate work or
operations.

This symbol is used on our products in some cases and refers to important information
in the instruction book. Make sure that warning and information symbols on the engine
are clearly visible and legible. Replace symbols which have been damaged or painted
over.

7748921 04-2008 3

Your new boat

Read the instruction books and other information
carefully, which came with your new boat. Learn to
handle the engine, controls and other equipment in a
safe and correct manner.
If this is your first boat, or a type of boat you are not
experienced in using, we recommend that you prac­tice operating the boat in peace and quiet. Get to know
the way the boat reacts to sea and to the controls
under different speed, sea and loading conditions
before you cast off for your first “real” maiden voyage.
Remember that the captain of every boat is required
by law to know and to observe applicable rules for
traffic and safety at sea. Get to know the rules which
apply to you and your waters, by contacting the rele­vant authority or sea safety organization.
It is a good idea to go on some kind of boat operation
course. We recommend that you contact a regional
boat or sea safety organization to find a suitable
course.

Fuel filling

There is always a risk of fire and explosion during fuel
filling. Smoking is not permissible, and the engine
should be stopped.
Never over-fill the tank. Shut the tank cap securely.
Only use the fuel recommended in the instruction
book. The wrong grade of fuel can cause serious mal­functions, 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 the engine if you suspect a fuel or LPG
leak in the boat, close to explosive media, or if there
is a spillage of explosive media. An explosive envi­ronment entails a risk of fire and/or explosion.

Manoeuvring

Avoid sudden or surprising rudder movements and
gear shifting. There is a risk that passengers could fall
over, or overboard.
A rotating propeller can cause severe injury. Check
that there is nobody in the water before you engage
forward / astern (reverse) drive. Never drive close to
bathers or in areas where you could reasonably
expect that people could be in the water.

Accidents and near misses

Life saving statistics show that inadequate care of
boats and engines, and deficiencies in safety equip­ment are frequent causes of accidents and near
misses at sea.
Make sure that your boat and engine are maintained
in accordance with the advice in each instruction
book, and that the necessary safety equipment is on
board, and is in working condition.

Safety Information

4 7748921 04-2008

Carbon monoxide poisoning

When a boat moves forwards, an area of low pressure
air forms behind the boat. In adverse conditions, this
low pressure can be so strong that the boat’s own
exhaust fumes are sucked into the cockpit or cabin,
which entails a risk of carbon monoxide poisoning for
all aboard.
The problem of low-pressure suction is worst in high,
wide boats with a square transom. But even in other
types of boats, low-pressure suction can be a problem
in some conditions, such as if you drive with the hood
up. Other factors which increase the low-pressure
effect are wind conditions, load distribution, pitching,
trimming, open windows and ventilators etc.

Most modern boats are designed so that the problem
of low-pressure suction is very rare, however. If low­pressure suction does occur anyway, do not open
hatches or ventilators in the forward part of the boat.
Strangely enough, this makes the problem worse. Try
changing speed, trimming or load distribution instead.
Also try 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 clamps, engine oil, propeller and
tools for the jobs you could be expected to have to do.

• Take your chart out and study your planned route. Calculate distance and fuel consumption.
Listen to weather reports.

• Tell your friends/relatives about route plans if you undertake a long journey. Remember to
notify changed plans or delays.

• Inform everybody aboard about where the safety equipment is located, and how it works. Make
sure that there is more than one person aboard who can start and operate the boat safely.

This list can be extended, since the need for safety equipment varies with the type of boat, and
where or how it is used etc. We recommend that you ask a regional boat or sea safety organization
for more detailed maritime safety information.

Safety Information

7748921 04-2008 5

Preparations

Knowledge

The operator’s manual contains instructions on how
to carry out general maintenance and service opera­tions safely and correctly. Read the instructions care­fully before starting work.

Service literature covering more complicated opera­tions is available from your Volvo Penta dealer.

Never carry out any work on the engine if you are
unsure of how it should be done, contact your Volvo
Penta dealer who will be glad to offer assistance.

Stop the engine

Stop the engine before opening or removing engine
hatches. Unless otherwise specified all maintenance
and service must be carried out with the engine stop­ped.

To prevent accidental start of the boat engine, remove
the ignition key, turn off the power supply to the engine
at the main switches and lock them in the OFF posi­tion before starting work. Put up a warning sign in the
control position that work on the engine is being car­ried out.

Approaching or working on an engine which is running
is a safety risk. Loose clothing, hair, fingers or a drop­ped tool can be caught in the rotating parts of the
engine and cause serious personal injury. Volvo
Penta recommend that all servicing with the engine
running should be undertaken by an authorized Volvo
Penta workshop.

Lifting the engine

When lifting the engine, use the lifting eyes installed
on the engine. Always check that lifting equipment is
in good condition and has sufficient load capacity to
lift the engine (engine weight including any extra
equipment installed). For safety’s sake lift the engine
using an adjustable lifting beam. All chains and cables
should run parallel to each other and as perpendicular
as possible in relation to the top of the engine. Bear
in mind that extra equipment installed on the engine
may alter its center of gravity. Special lifting equip­ment may then be 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). The rotating compressor in the
Turbocharger unit can cause serious personal injury.
Foreign objects can also be sucked in and cause
mechanical damage to the unit.

Fire and explosion

Fuel and lubrication oil

All fuel, most lubricants and many chemicals are
inflammable. Read and follow the instructions on the
packaging.

When carrying out work on the fuel system, make sure
the engine is cold. A fuel spill onto a hot surface or
electrical components can cause a fire.

Store fuel soaked rags and other flammable material
so that there is no danger of them catching fire. Fuel­soaked rags can self-ignite under certain conditions.

Do not smoke when filling fuel, oil or in proximity of a
filling station or in the engine room.

Non-original components

Components used in the fuel and electrical systems
on Volvo Penta products are designed and con­structed to minimize the risk of fire and explosion.

Using non-original Volvo Penta parts can result in fire
or explosion on board.

Batteries

The batteries contain and emit oxyhydrogen gas,
especially during charging. This gas is easily ignited
and highly volatile.

Do not under any circumstances smoke or use naked
flame or allow sparks in the vicinity of the batteries or
battery compartment.

An incorrect connection of a battery terminal cable or
jump-start cable can cause a spark which in its turn
can be sufficient to cause an explosion.

Start spray

Never use start spray or similar agents to start an
engine equipped with air pre-heating (glow plugs/
starter element). This may cause an explosion in the
inlet manifold. Danger of personal injury.

Safety Information

6 7748921 04-2008

Hot surfaces and fluids

There is always a risk of burns when working with a
hot engine. Beware of hot surfaces. For example: the
exhaust pipe, turbo unit, oil pan, charge air pipe,
starter element, hot coolant and hot oil in oil lines and
hoses.

Carbon monoxide poisoning

Only start the engine in a well-ventilated area. If oper­ating the engine in an enclosed space, ensure that
there is proper ventilation in order to remove exhaust
gases and crankcase ventilation emissions from the
working area.

Chemicals

Most chemicals such as anti-freeze, rustproofing
agent, inhibiting oil, degreasing agent etc. are haz­ardous to health. Read and follow the instructions on
the packaging.

Some chemicals such as inhibiting oil are inflammable
and dangerous if breathed in as well. Ensure good
ventilation and use a protective mask when spraying.
Read and follow the instructions on the packaging.

Store chemicals and other hazardous materials out of
the reach of children. To protect the environment,
please dispose of used or leftover chemicals at a
properly designated disposal site for destruction.

Cooling system

There is a risk of flooding when working on the sea­water system. Turn off the engine and close the sea
cock before starting work on the system.

Avoid opening the coolant filler cap when the engine
is hot. Steam or hot coolant can spray out and cause
burns.

If work must be carried out with the engine at operat­ing temperature and the coolant filler cap or a cock
open or a coolant hose disconnected, open the cool­ant 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 removed,
oil can spray out.

Fuel system

Always use protective gloves when tracing leaks. Liq­uids ejected under pressure can penetrate body tis­sue and cause serious injury. There is a danger of
blood poisoning.

Always cover the generator if it is located under the
fuel filter. The generator can be damaged by spilled
fuel.

Steering system

The boat has a advanced steering system. DO NOT
change connectors, wiring or splice of the compo­nents.

Service must be done by approved workshops which
have certifed personnel with qualified professional
training.

Electrical system

Cutting off power

Always stop the engine and break the current using
the main switches before working on the electrical
system. Isolate shore current to the engine block
heater, battery charger, or accessories mounted on
the engine.

Batteries

The batteries contain an extremely corrosive electro­lyte. Protect your skin and clothes when charging or
handling batteries. 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 into contact with
the eyes, flush immediately with plenty of water and
obtain medical assistance without delay.

Safety Information

7748921 04-2008 7

Introduction

This Operator's Manual has been prepared to give you the greatest possible benefit from your Volvo Penta marine
engine. It contains the information you need to be able to operate and maintain the engine safely and correctly.
Please read the Operator's Manual carefully and learn to handle the engine, controls and other equipment in a
safe manner before you cast off on your maiden voyage.
Always have the Operator's Manual available. Store it safely and do not forget to hand it over to the next owner
if you sell your boat.

The Operator’s Manual describes the engine and equipment sold by Volvo Penta. The illustrations in this book
covers several varieties and might differ, the essential information is always correct though. Installations with e.g.
different controls and instrumentation might occur, in these cases we refer to this products manual.

Warranty

Your new Volvo Penta marine engine is covered by a
limited warranty, under the conditions and instructions
compiled in the Warranty and Service book.
Please note that AB Volvo Penta’s liability is limited to
the specification in the Warranty and Service book.
Read it carefully, as soon as possible after delivery. It
includes important information about warranty cards,
service, maintenance, which it is the responsibility of
the owner to know, check and carry out. If this is not
done, AB Volvo Penta may fully or partly refuse to
honour its warranty undertakings.

Please contact your Volvo Penta dealer if you
have not received a Warranty and Service book,
or a customer copy of the warranty card.

Environmental care

All of us want to live in a clean, healthy environment.
Where we can breathe clean air, see healthy trees,
have clean water in lakes and seas, and be able to
enjoy the sunlight without fearing for our health.
Unfortunately, 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, envi­ronmental care is a core value in our product devel­opment. 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 preserve these val­ues. Always observe the advice in the Operator's
Manual about fuel grades, operation and mainte­nance, to avoid unnecessary environmental impact.
Please contact your Volvo Penta dealer if you notice
any changes such as increased fuel consumption or
increased exhaust smoke.

Moderate your speed and distance so that wake and
noise do not disturb or damage animal life, moored
boats, jetties etc. Leave the archipelago and harbours
in the same state you would like to find them. Remem­ber to always hand in drained oil, coolant, paint and
wash residue, used batteries etc. for destruction at a
recycling station.
If we all pull together, we can make a valuable con­tribution to the environment together.

Running in

The engine must be “run in” during its first 10 hours,
as follows:
Use the engine in normal operation. Full load should
only be applied for short periods. Never run the engine
for a long period of time at constant speed during this
period.
Higher oil consumption is normal during the running
in period. For this reason, check the oil level more
frequently than normally recommended.
After the first period of operation, the specified war­ranty inspection “First service inspection” can be
done. For more information: Please refer to the Main­tenance Schedule.

Fuel and oils

Only use the fuels and oils recommended in the Oper­ator's Manual. Other grades can cause malfunctions,
increased fuel consumption and eventually even
shorten the life of the engine.
Always change the oil, oil filters and fuel filter at the
specified intervals.

8 7748921 04-2008

Service and spare parts

Volvo Penta marine engines are designed for high
reliability and long life. They are built to withstand a
marine environment, but also to have the smallest
possible environmental impact. Through regular serv­ice and use of by Volvo Penta approved spare parts,
these qualities are retained.
Volvo Penta’s world-wide network of authorised deal­ers is at your service. They are Volvo Penta product
specialists, and have the accessories, original spares,
test equipment and special tools needed for high qual­ity service and repair work.
Always observe the maintenance intervals in the
Operator's manual, and remember to note the engine/
transmission identification number when you order
service and spare parts.

Certified engines

If you own or operate an emission certified engine it
is important to be aware of the following:

Certification means that an engine type has been
checked and approved by the relevant authority. The
engine 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 recom­mended 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 authorised
Volvo Penta workshop.

• The engine must not be converted or modified,
except for the accessories and service kits
which Volvo Penta has approved for the engine.

• Installation changes to the exhaust pipe and
engine air inlet ducts must not be done.

• No seals may be broken by unauthorised per­sonnel.

The general advice in the Operator's manual about
operation, care and maintenance apply.

Late or inadequate maintenance/service or the use of
spare parts not approved by Volvo Penta will invalid­ate AB Volvo Penta’s responsibility for the engine
specification being in accordance with the certificated
variant.
Volvo Penta accepts no responsibility or liability for
any damage or costs arising due to the above.

Introduction

7748921 04-2008 9

Presentation

Volvo Penta IPS - Inboard
Performance System

p0006599

Volvo Penta IPS overview

Volvo Penta IPS is setting a new standard:

- Much improved efficiency, higher top speed,
reduced fuel consumption/extended range and
great acceleration.

- Low-speed maneuvering is easier than ever
before, and high speed handling is a dream.

- Onboard comfort is greatly enhanced thanks to
much lower levels of sound and vibrations.

- Installation is greatly simplified.

- More space available for accommodation.

- Improved safety and quality.

- Ease of service and a complete system sup­ported by one supplier.

- Improved overall environmental care.

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 propul­sion unit means that there are no lateral forces
to consider and that tracking is completely
straight.

- Electronic controls give a distinct and precise
feeling, and shifting is immediate. Thanks to the
progressive electronic steering, the wheel spins
easier at low speed, further reducing driver
effort.

All this is combined with the usual benefits of a tradi­tional inboard such as a robust, high strength con­struction, excellent corrosion resistance and the
propellers under the hull.

10 7748921 04-2008

Comfort

Volvo Penta IPS new technology leads to major
improvements for all comfort enhancing factors.

- The propulsion forces and vibrations are absor­bed by the combined rubber suspension and
sealing.

- A U-joint in the drive shaft makes it possible to
have the engine soft suspended, which effi­ciently reduces engine vibrations.

- The propellers are working in undisturbed water
with no cavitation, and have good clearance
from the hull.

- There is an increased number of propeller
blades to distribute the forces. This means that
the pulses created by the propellers have very
little effect on the hull.

- Exhaust fumes are truly minimized. First of all,
the new engine has very low exhaust emissions,
and secondly, the exhausts are emitted through
the propulsion unit into the prop wash and car­ried well behind the boat.

Environmental care

The Volvo Penta IPS has been developed as a com­plete system with excellent environmental perform­ance as one of the main design targets. The very high
efficiency of the Volvo Penta IPS system gives greatly
reduced overall emissions.
Volvo Penta’s new D4/D6 in-line engines have been
developed from the latest design in modern diesel
technology. The engines have common rail fuel injec­tion 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 vari­ous ways, either as a compact system or with an
extended jackshaft, giving opportunities for different
boat designs.
The system is always used in twin engine installation
configuration.

Safety and quality

Heavy duty material throughout means excellent cor­rosion resistance. Everything in contact with seawater
is either made from a specially formulated nickel-alu­minum- bronze alloy or stainless steel. Propulsion
unit, bearings, couplings, etc. are all robustly dimen­sioned to cope with the unexpected and ensure a
really long and trouble-free service life.
EVC handles all communication and monitoring
including shift, throttle and steering. Several safety
functions in the system minimize the risk of damage
to engine or propulsion unit.
The Volvo Penta IPS system is designed with full
redundancy, i.e. even if you have a total breakdown
in one driveline, the remaining one will bring you home
safely.

Presentation

7748921 04-2008 11

Instruments and Controls

This chapter describes the instruments, panels and controls Volvo Penta sells for your engine.
If you would like to complement your instrumentation, or if your boat is equipped with instruments not described
here, we ask that you contact your Volvo Penta dealer.

Ignition Lock

The start keys are supplied with a plate bearing the key
code to be used when ordering spare keys. Keep the
code beyond the reach of unauthorized people.

S = 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 Start­ing 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 key at
the main station to be in the ”I” operating position. The
engine can only be stopped from an activated control
panel.
Read the starting instructions in chapter Start-
ing page 31 to ensure you use the correct start
procedure.

12 7748921 04-2008

Gauges

Tachometer

The tachometer displays engine speed; multiply the
value shown on the dial by 1,000 to get the number of
engine revolutions per minute.
Boat and engine information is displayed in the tach­ometer window. Information displayed depends on
engine type, the number of sensors and which acces­sories are installed.

Optional instruments

These instruments are sold as engine options by Volvo
Penta.

1 Fuel level gauge

The fuel level gauge shows the quantity of remain­ing fuel.

2 Voltmeter, battery charging

The meter shows the alternator charge current.
During operations the charge voltage should be
around 14 V. When the engine is stopped and elec­trical 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 nor­mally be between 75-90°C (167-194°F).

4 Oil pressure gauge

The oil pressure gauge displays engine oil pres­sure. During operations the oil pressure gauge
should normally show 4-5.5 bar. At idle, lower val­ues are normal.

5 Rudder position indicator

The instrument shows rudder position.

6 Fresh water level sensor

Freshwater tank level gauge.

7 Alarm monitor

The alarm monitor gives a visual warning to call
attention to any alarms that occur.

1

P0005255

Instruments and Controls

7748921 04-2008 13

Control Panel

The control panel is used for station handling, disen­gaging the drive and to navigate the EVC system
menu.
Always push the buttons firmly and for at least one
second.

Activation button

The control panel and station are activated by pushing
the activation button once. Push twice to lock the sta­tion. On boats with only one station, this is always
active.
The lamp above the activation button shows the status
of the station.

Red lamp: Active station.
Lamp off: Station not activated.
Lamp flashing: A fault that limits the function of the

station has been detected.

Padlock

The padlock symbol lights when the station is locked
with the activation button or if change of stations is
under way, please refer to section Helm Sta-
tions page 36.
Lit: The station is locked and the boat can only be con­trolled from this station.

Flashing: Another station is locked.

Neutral button

The neutral button is used to disengage the drive ena­bling the engine rpm to increase without affecting the
drive, to warm up the engine. The lamp above the neu­tral 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 drive is engaged for movement forward/
astern.
Flashing lamp: The drive is disengaged and the
engine speed can be adjusted.

Knob

Navigate the display menu by turning the knob.
Push the knob to confirm a selection or acknowledge
an alarm.

Tachometer Display Selection

Boats with one tachometer for port engine and one for
starboard can choose which engine menu to handle
from the station. The lamp above the button shows
which engine is chosen, green lamp for starboard
engine and red lamp for port engine.

Lamp off: Menu inactivated.
Lamp lit: Menu activated.

Instruments and Controls

14 7748921 04-2008

Multifunction Button

With the multifunction button the instruments and pan­els backlighting is adjusted.
Push the button for over a second to turn the back­lighting on or off. The backlighting can be adjusted in
five stages by repeatedly pushing the multifunction
button quickly (less than 1 second).
If the button is pressed on an inactive station, operating
information is shown on the display(s) and the menu
structure is activated.

Back Button

Used to return a step up in the menu structure.

Docking Station Panel

The docking station panel allow stopping and restart­ing of the engines and handling of faults when operat­ing the boat from a docking station.
The docking function (maneuvering with the joystick)
is enabled when the docking station is activated.
Please refer to the section Joystick page 23 for fur­ther 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 acti­vate and lock/unlock the docking station. Please refer
to section Instruments and Controls page 14 for further
information.

Stop and start buttons

Push these buttons to stop or restart the engines.
Both engines must be running when using the docking
function.
Lamp above the button: White
Lit: Port engine (1)/Starboard (2) engine are/is running.
Off: Port engine (1)/Starboard (2) engine are/is shut
off. Flashing and accompanied with a buzzer: The
engine(s) has stopped without a stop request. Silence
the buzzer with the Alarm acknowledge button and
restart the engine(s).

1

1

2

2

Instruments and Controls

7748921 04-2008 15

Alarm acknowledge button

Push this button to acknowledge an alarm of a fault. A
fault is always indicated with a flashing lamp above the
button and a more serious faults is also indicated with
a buzzer. When the fault is acknowledged the lamp will
light continuously and the buzzer will silence. The fault
pop-up must be read and acknowledged on a station
that is equipped with displays. Please refer to the
“Operation” chapter, section “Acknowleging alarms
and messages”.

Lamp above the button: Red
Flashing: Port (1)/Starboard (2) engine has a fault. Lit:
The fault is acknowledged.

Acknowledging faults on Docking Station

Since a docking station is not equipped with displays
and a control panel, an alarm of a fault is handled in a
different way.
On a docking station a fault is always indicated with a

flashing red lamp above the

Alarm acknowledge

button the docking station panel. The flashing lamp
indicates which engine (1/2/3) is faulty. A more serious
fault is also indicated with a buzzer.

1

Acknowledge the fault with the

Alarm acknowl-

edge 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 mul­tiple windows with different information. There are four
display modes that can be chosen with the buttons on
the instrument.

Button 1–4 shows the different display modes. Button
5 i used to adjust the contrast and to access the con­figuration menu. Please refer to section Konfiguration-
smeny.

The EVC menu can be shown in the display by entering
Systeminformation (se section Multi, button 2) or the
Configuration menu. In this mode the display works the
same way as the display in the tachometer and is han­dled via the separate control panel, see chapter Instru-
ments and Controls page 20. If there is no tachom­eter installed the EVC meny can be reached by
pressing the knob on the control panel. To get back to
the display modes, press

.

At start up, the display performs a self-test. If an con­stant signal is heard, the system has discovered a

P0002383

Instruments and Controls

16 7748921 04-2008

malfunction. The display will work but may act in an
unexpected way.

NOTICE! Only installed functions will be shown in the
display.

Display modes

Press button 1–4 to view the function menu for the
buttons, apperaring in the lower part of the display.

Press button 1–4 to choose the desired display mode.

1 Engine

2 Multi

3 Trip

4 Graph

To leave the menu, wait a few seconds or press button
5 (EXIT).

Contrast

In the display modes Engine, Trip and Graph, it is pos­sible to adjust the contrast.
Press button 5 outside the menu and then + (button 4)
and – (button 3).

Engine, button 1

Rpm and speed is shown in the upper part of the dis­play. 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 but­ton 1.

•

Fuel Rate, fuel consumption per hours

•

Fuel Economy, fuel consumption per distance

•

Trip Fue, fuel used since last reset

•

Fuel Remaining, remaining fuel in tank

•

Dist. to Empty, remaining distance until tank
isempty, based on fuel consumption per distance

•

Trip Distance, trip distance since last reset

1 2

3

4 5

G H

P0002382

P0002403

ENGINE

FUEL RATE

SPEED

0

0

2

4

6

8

10

1

2

RPM KTS

L/H

29

x1000

P0002401

Instruments and Controls

7748921 04-2008 17

Multi, button 2

In the multi mode the information can be shown in sev­eral windows, analogue or digital. The display can
show windows with different information or be divid­edto show windows and system information. To handle
the system information, see chapter Instruments and
Controls page 20. To go between the different dis­play modes press button 2 repeatedly.

By pressing button 5, the right arrow, you choose what
information to be shown in the different windows. Press
repeatedly on the button that correspond to the win­dow, until desired information 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 shown as graphs. Press button 4
repeatedly to choose what information will be shown.
The time interval is set in the Configuration menu.
If the connection is broken there will be a straight linein
the display.

The port engine is shown as a black line and the star­board engine as a grey line.

P0002418

P0002421

Instruments and Controls

18 7748921 04-2008

Configuration menu

Press button 5 for five seconds to enter the Configu­ration menu. Navigate with the up and down arrows,

select with the right arrow.

NOTICE! The port engine, or both engines must have
the ignition on when display settings are made.

System information

System information shows the EVC-menyn and is han-
dled by the knob on the control panel. For more infor­mation, see chapter Instruments and Con-
trols page 20.

Settings

- Language: Setting of what language the informa­tion is to be presented in are made in the EVC­menu, 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 dis­play 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
Speed, on/off
Speed interval, 10–100 knots, in steps of 10 knots
Graph interval, 2 min, 10 min, 30 min, 60 min, 2 h,4
h or 8 h

BACK

SETTINGS

LANGUAGE

BLEEP
ENGINE
DISPLAY

ENGLISH

OFF

PORT

P0002408

BACK

UNITS

SPEED

OIL PRESSURE
TURBO PRESSURE
FUEL RATE

DISTANCE

KM/H

KM
kPa
kPa

L/H

P0002409

Instruments and Controls

7748921 04-2008 19

EVC Menu

The EVC menu can be shown in both the EVC system
display and the tachometer display. The main menu
shows operating information, the settings menu and
the fault menu (only shown when a fault in the system
is detected).

Only installed functions are shown in the menu.

Turn the knob to navigate through the menus.

Press the knob to access sub menus and to confirm
selections in the settings menu.

It is always possible to return to the previous menu by
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-

tion symbols.

A

B

P0001006

Instruments and Controls

20 7748921 04-2008

Settings

Turn the control panel wheel until the start screen for
the settings menu is displayed. Press the wheel to
reach the sub menus.
Turn to move between the available setting functions.
For further information, refer to section Settnings
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

Controls

Single Lever Control

Maneuvering

A single-lever control operates both gearshift and
throttle functions with the same lever.
The engine can only be started with the control lever
in the neutral position.

N = Neutral position. Reverse gear/drive disengaged

and engine at idle.

F = Reverse gear/drive engaged for forward motion.
R = Reverse gear/drive engaged for rearward

motion.

T = Engine rpm control (throttle).

Disconnecting the gearshift function

The gearshift function can be disconnected 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 revolutions.

The gear shift function is reconnected automatically
when the lever is returned to the neutral position. This
is confirmed by the green indicator shining continu­ously.

CAUTION!

Take care not to engage the gear by mistake.

P0006664

Instruments and Controls

22 7748921 04-2008

Adjusting the friction brake

The lever is fitted with a friction brake to allow adjust­ment for easier or stiffer movement as required. The
friction brake only affects movement of the throttle con­trol lever.

1 Stop the engine.

2 Move the control lever forward so that the groove

in the lever hub is accessible.

3 Remove the plug with the aid of a screwdriver.

4 Adjust the friction brake (wrench, 8 mm) by turning

the bolt clockwise (+) for stiffer lever movement,
and counterclockwise (–) for easier movement.

5 Reinstall the plug.

Joystick

Volvo Penta IPS Joystick is a control used for docking
and maneuvering in low speed. The joystick makes it
possible to rotate the boat and maneuver the boat in
different directions – 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 maneuvered with
the joystick.

Activating the docking function

Before activating the docking function the following has
to be fulfilled:

•

the engines must to be running

•

the controls must to be in neutral

•

the helm station must be active

•

the joystick in its middle position

A

B

p0005186

A. Docking (ON/OFF)
B. Boost (ON/OFF)

Instruments and Controls

7748921 04-2008 23

1 Activate the docking function by pressing the dock-

ing button (A) on the joystick.

2 A sound signal confirms that the docking function is

active and the lamp by the docking button is lit.

3 To inactivate the function press the docking button.

To confirm that the function is inactivated the signal
sounds twice and the lamp goes out.

4 The docking function is also deactivated if the 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. To

confirm that the function is in active the signal
sounds twice and the lamp goes out.

4 The system is now back in docking mode.

P0006292

Instruments and Controls

24 7748921 04-2008

Maneuvering with joystick

To maneuver the boat move the joystick forwards, back­wards, sideways or by turning the top of the joystick, see
figure.

IMPORTANT!

The boat keeps moving even after the joystick is
released, compensate this by moving the joystick in
opposite direction.

P0001191

Instruments and Controls

7748921 04-2008 25

Optional

Sport Fishing Mode

Volvo Penta's sport fish function has been developed
by deep-sea fishermen. When the function is activated,
the IPS units are angled outwards and the helmsman
can quickly rotate and maneuver forward/backwards
to follow the movement of the fish. When activated, the
wheel is disconnected and the boat is maneuvered
solely via the control lever.

When the function is disengaged, both the IPS units
are set to straight forward.

The single-lever function used together with the sport
fish function makes it possible to control both engines
with just one of the control levers.

Activating the sport fish function

1 Move both control levers to neutral.

2 Press the sport fish button on the panel. The acti-

vation of the function is acknowledged by an acous­tic 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 control
lever.

5 Exit the function by pressing the sport fish button

on the panel. Inactivation of the function is acknowl­edged by an acoustic signal and the lamp next to
the button going out. An image stating that the func­tion is inactive is shown on the display.
It is also possible to exit the function by turning the
wheel more than 30 degrees.

WARNING!

There is a risk that the boat may take in water if the
movements are too violent.

P0001219

SINGLE LEVER

SPORT FISH

P0001215

26 7748921 04-2008

Activating single-lever function

1 In order to activate the single-lever function, the

control levers must be roughly the same position,
max 10% difference.

2 Press the single lever button. The activation of the

function is acknowledged by an acoustic signal and
the lamp next to the button lighting. An image stat­ing that the function is active is shown on the display
for 5 seconds.

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 func­tion 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 acoustic signal and the lamp going
out. An image stating that the function is inactive is
shown on the display.

SINGLE LEVER

SPORT FISH

P0001214

Optional

7748921 04-2008 27

ACP

Volvo Penta ACP (Active Corrosion Protection) pro­tects against galvanic corrosion by controlling an elec­tric current that can be monitored by the engine
electrical system.

It is preferable to connect the boat to shore supply, if
such is available. If shore power is unavailable, ACP
utilizes the batteries, as it is connected to the boat's 12
V/24 V system. If the batteries begin to discharge, the
ACP switches from primary to secondary protection.
The IPS is then protected by the consumption of a
sacrificial zinc anode installed in the ACP unit on the
transom.

When the primary protection is in use, a small quantity
of chlorine gas is produced by the ACP; if desired it can
be switched off temporarily. The ACP then switches
over to secondary protection.
The ACP reverts 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 via the sacrificial
anode.
Check that the batteries are being charged by shore
power; alternatively, start the engine so that the
alternator charges the batteries.
There is no risk of corrosion as the sacrificial anode
protects the IPS. However, seek service for system
checks at the first suitable opportunity if the system
remains in the limited protection mode for more than
approx. 2 hours.
If the system remains in this mode for a longer break
in operations, more than 8 weeks, service should be
sought for system checks.

P0001217

P0003747

Optional

28 7748921 04-2008

•

No Protection; risk of corrosion, system gives warn­ing alarm. The display switches between the two
screens.
Seek service for system checks.

•

If the ACP is set to inactive, the system cannot iden­tify ACP status and three lines will be shown on the
display.
If this should occur when the system is not set to
inactive, seek service for checks.
ACP will also show the three lines during one minute
after ignition is turned on, thereafter it will show cur­rent 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
over to protection by the zinc anode for 4 h, resulting
in no chlorine gas being given off.

P0001218

P0001203

P0001203

P0001021

P0001021

Optional

7748921 04-2008 29

•

Inactive; this mode should only be used when the
boat is taken out of the water on to dry land.
To avoid fault codes, select inactive mode before
lifting the boat out of the water. In this mode the ACP
no longer monitors the corrosion condition, but the
IPS is protected by the zinc anode.
The system is re-started when the ignition is
switched on; inactive mode switches to normal
mode.

P0003049

P0003049

Optional

30 7748921 04-2008

Starting

Make a habit of visually checking the engine, engine bay and transmission before start. This will help you to
discover quickly if anything abnormal has happened, or is about to happen. Also check that instruments and
warning displays show normal values when you have started the engine.
To minimize cold start smoke we recommend the installation of an engine heater or engine bay heater if temper­atures below +5°C (41°F) are encountered.

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 elec­tronics could be damaged.

•

Start the engine bay fan, where fitted, and allow it to
run for at least four minutes.

•

Check there is sufficient fuel for the planned trip.

1

0

P0002431

A

A

B

B

P0002851

7748921 04-2008 31

Starting the Engine

Shifting, adjusting speed and performing EVC settings
and calibrations is only possible at an active station.
On a boat with one station the station is always active.
On a boat with two or more stations the main station
automatically becomes active when the EVC system
is started up with the ignition key(s). If the engine(s) is/
are started from another station this station automati­cally becomes active instead.

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
display, please refer to Fault Handling page 41 for
further information and recomended actions.

Starting

32 7748921 04-2008

Check lamps

Each time the ignition is turned on, all lamps in the
alarm instrument are illuminated. Check that all lamps
light up and go out. If a lamp flashes a fault has been
registred, please refer to section Fault Han-
dling page 41 for further information and reco­mended actions.
If the boat has more than one station, it has to be acti­vated before the lamps can be checked.

Start the engines

If a station is locked the engines can only be started
and stopped from this station

Start using the ignition switch

Turn the key of each engine to position III. Release the
key and let it spring back to position I as soon as the
engine has started.
If repeated start attempts are needed, the key must be
turned back to position 0 first.

Starting with the starter button

Press the starter button for each engine. Release 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 activa­tion time (30 seconds), the starter motor circuit is cut
automatically to protect the starter motor from over­heating. 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 normal val­ues. Check that no alarms are displayed and no warning
lamps are flashing. If an alarm is registred, please refer
to section Fault Handling page 41 for further informa­tion and recomended actions.
Warm the engine up at low speed and low load, so nor­mal operating temperature is reached before full power
is used.

IMPORTANT!

Never race the engine when it is cold.

!

!

+

-

P0002435

START

STOP

P0005860

Starting

7748921 04-2008 33

Operation

Learn to handle the engine, controls and other equipment in a safe and proper manner before casting off on your
maiden voyage. Remember to avoid sudden and extreme rudder maneuvers and gear shifts. There is a risk for
passengers and crew falling over or falling overboard.

WARNING!

A rotating propeller can cause serious injury. Check that nobody is in the water before engaging ahead or astern.
Never drive near bathers or in areas where people could be in the water.

Reading the Instruments

Read all instruments and alarm displays directly 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
flashes. The display will show a fault message.

1 Read the alarm/fault message.

2 Acknowledge the alarm by pressing the knob on the

control panel.

3 Take the indicated actions, see chapter Fault Code

Register page 45.

The fault will be stored as long as the fault remains. It
is possible to read out the fault code at an upcoming
service.

34 7748921 04-2008

Maneuvering

Shifting between forward and reverse should be done
at idling. Shifting at higher engine speeds can be
uncomfortable for passengers and cause unnecessary
stress on the transmission or cause the engine to stop.
If you attempt to shift gear at an excessive engine
speed, a safety function cuts in automatically, and
delays shifting until engine speed has fallen to 1500
rpm.

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 engines are running during reversing
maneuvers, to avoid the risk of water entry via the
exhaust pipe into the stationary engine.

1

2

3

P0005856

Operation

7748921 04-2008 35

Helm Stations

Changing stations

1 Put the gear in neutral.

The lamp above the neutral button (1) is lit when the
gear is in neutral.

2 Unlock, if locked, the station you leave by pushing

the activation button (2).

3 Activate the station you change to by pressing the

activation button (2).
The lamp above the activation button lights when
the station is active.

An active station is indicated by the lit lamp above the
activation button.
Is the light above the activation button off, the station
is inactive.
If the padlock sign (3) flashes the station 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 dis­play, please refer to section “Fault handling”.

Locking/Unlocking station

Is a station locked it is only possible to start or stop the
engine and change stations from this station.
Lock an active station by pressing the activation button
(2). Unlock an active, locked station by pressing the
activation button (2). The padlock sign (3) on the con­trol panel indicates whether the station is locked (lit) or
not (off).

3

2

1

P0006366

Operation

36 7748921 04-2008

Cruising Speed

For best fuel economy operations at full must be
avoided. We recommend a cruising speed that is at
least 10% below the maximum engine revolutions at
top speed (full throttle).
Depending on hull type, the choice of propeller, the
load and sea state etc., the maximum revolutions at
top speed may vary, but they should be within the full
throttle range; refer to the “Technical data” chapter.

If the engine does not reach its maximum throttle range
it can depend on a number of factors mentioned in the
“Fault tracing” chapter.
Select a propeller with greater pitch if actual engine
revolutions exceed the full throttle range. Contact your
Volvo Penta dealer for advice.

Synchronizing Engine Speed

When driving with twin engines, both the operating
economy and comfort will be increased when the
engines are operating at the same engine speed (rpm).
When the synchronization function is activated, the
engine speed (rpm) of the starboard engine is auto­matically adjusted to that of the port engine. The syn­chronization function is activated automatically if the
following conditions are met.

1 The engine speed levers for both engines are in

(approximately) the same position.

2 The engine speed on both engines exceeds 800

rpm.

NOTICE! The synchronizer is disengaged as soon as
the conditions are no longer met.

Operation

7748921 04-2008 37

Engine Shutdown

Allow the engine to run at low idle, in neutral, for a few minutes after operations are completed. In this way after­boiling is avoided at the same time as temperature equalization takes place. This is especially important when
the engine has been run at high rpm or under heavy load.

Stop the Engine

If a station is active and locked the engines can only
be started and stopped from that station.

IMPORTANT!

Never disconnect the current with the main switches
when the engine is running. The alternator and elec­tronics 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 auto­matically return to the “0” position when it is
released and can then be removed.
The starter keys must be in the “0” position or
removed before main switches are switched off.

Stopping with the stop button

1 Disengage the drive by putting the control lever in

neutral.

2 Push the stop buttons. Release the buttons when

the engines have stopped.

38 7748921 04-2008

Auxiliary stop

If the engine cannot be stopped in a normal procedure,
it is possible to stop the engine via auxiliary stop
mounted on the side of the engine.

After Engine Shutdown

•

Check the engine and engine bay for leakages.

•

Close the fuel taps.

•

Close the two sea cocks at each propulsion unit.
Position A open. Position B closed.

•

Take an hour meter reading and carry out preven­tive maintenance according to the maintenance
schedule.

•

Turn off the main switches before any long stop­page.

A

U

X

S

T

O

P

P0003709

A

B

B

A

P0002849

Engine Shutdown

7748921 04-2008 39

Operation break with the boat in water

If the boat is not used, but left in the water, the engine
must be warmed up at least once every fortnight. This
prevents corrosion damage in the engine.
If you expect the boat to be unused for two months or
more, it must be laid up, please refer to Stor-

age page 98

Operation break with the boat out of water

Where boats are kept laid up on land when not in use,
there is a lower level of galvanic corrosion protection
due to oxidation on the sacrificial anodes. Before
launching the boat the sacrificial anodes on the drive
must be cleaned with emery paper to remove any oxi­dation.
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 freshwater sys­tem coolant must have sufficient frost protection to
prevent frost bursting; refer to the sections Seawater

System, Draining page 80 and Mainte­nance page 77 respectively for more detailed infor-

mation.
Check the charge status of the battery. A poorly­charged battery can freeze and burst.

C

0

10

10

F

32

50

10

20

70

20

20

60

P0005905

Engine Shutdown

40 7748921 04-2008

Fault Handling

Despite regular maintenance according to the maintenance schedule and perfect operation conditions faults may
occur which must be attended to before the boat can travel further. This chapter describes alarms and fault
handling.

Alarm handling

Fault information from engine and EVC
system

If a malfunction is discovered the driver is warned by a
buzzer sounding and a pop-up showing in the display.
The pop-ups will toggles between cause of fault and
tasks to perform.

Information regarding ”cause of fault” and ”measures
to take” is found in chapter Fault Code Regis-
ter page 45.

The engine, transmission and EVC system is moni­tored by the diagnostic function. Should the diagnostic
function discover a malfunction it protects the engine
and ensures continued operation by affecting 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 dam­age 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 dam­age to engine or transmission.
Affect on engine: Engine power is reduced.

•

Serious malfunction which makes it impossible to
control the engine or transmission.
Affect on engine: Transmission is disengaged and
engine speed is reduced.
It is possible to perform emergency shifting, please
refer to In Case of Emergency page 59.

•

Serious malfunction on transmission or in the engine
fuel injection system.
Affect on engine: Engine is stopped.
It is possible to perform emergency shifting, please
refer to In Case of Emergency page 59. In emer­gency situations it is also possible to start the engine
with gear engaged after acknowledging the alarm.

!

!

+

-

P0006368

7748921 04-2008 41

Acknowledging alarm

1 Push the knob on the control panel to ackowledge

the alarm. The buzzer becomes silent.

2 Read the alarm or message in the pop-up.

3 Push the knob on the control panel again and the

pop-up disappears.

NOTICE! The alarm has to be acknowledged before
the engine can be started.

Popup windows

There are three levels of fault messages showing in
the pop-up: danger, warnign and caution.

Danger

If the Danger pop-up is shown during operation, a seri­ous fault has occured.

Acknowledge the alarm and stop the engine immedi­ately.

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 alarm.

P0004987

DANGER! Stop the engine immediately.

P0004986

WARNING! Stop the engine.

P0004985

CAUTION! See operator's manual.

Fault Handling

42 7748921 04-2008

Faults list

Is a fault registered the display shows Faults in the
EVC menu along with the number of faults.

Push the knob on the control panel to open the menue.
Turn the knob to see all faults registred.
The popup toggles between cause of fault and tasks
to perform.

Erasing faults in faults list

Acknowledged faults that has been stored automati­cally erased every time the starter key is turned to the
stop position (S).
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 diag­nostic 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 disap­peared are automatically erased.
Faults which have not been attended to must be
acknowledged every time the system voltage is
switched on.

P0004375

Fault Handling

7748921 04-2008 43

Fault Tracing

A number of symptoms and possible causes of engine malfunctions are described in the table below. Always
contact your Volvo Penta dealer if problems occur which you can not solve by yourself.

NOTICE! Read through the safety advice for care and maintenance work in chapter Safety Information page 6
before starting work.

Symptoms and possible causes

Pop-ups are shown in the tachometer display See chapter Fault Code Register page 45

Starter motor not turning (or slow) 1, 2, 3, 24

Engine does not start 4, 5, 6, 7, 24

Engine starts but stops again 6, 7, 24

Engine difficult to start 4, 5, 6, 7

Engine does not reach correct speed at wide open
throttle (WOT)

5, 6, 7, 8, 9, 10, 11, 15, 18, 19, 20, 21, 24

Engine knocks 4, 5, 6, 7

Engine runs unevenly 4, 5, 6, 7, 10, 11

Engine vibrates 15, 16

High fuel consumption 8, 9, 10, 12, 15

Black 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 coolant

6. Air filter in the fuel injection system 18. Blocked seawater intake/pipe/filter

7. Water/contaminants in the fuel 19. Circulation pump drive belt slipping

8. Boat abnormally loaded 20. Defective impeller

9. Fouling on underwater hull/propulsion unit/pro­peller

21. Defective/incorrect thermostat

22. Lubricating oil level too high

10. Insufficient air supply 23. Alternator drive belt slipping

11. Engine coolant temperature too high 24. Stored diagnostic fault codes

12. Engine coolant temperature too low NOTICE! The codes can only be read and erased

by a service technician.

Fault Handling

44 7748921 04-2008

Fault Code Register

CAUTION!

Read the safety precautions for maintenance and service in the Safety Information chapter before starting work.

When a malfunction i discovered the driver is warned by a sound alarm and at the same time a pop-up window
is shown in the display. The fault message gives information about what has caused the fault and what actions
to take.
This chapter gives a more detailed description of cause and actions.

Explanation of fault message

A Description of current fault, affect on the system and

measures to take.

B Current warning lamp which flashes during an

alarm. O/R means that an orange or red lamp
flashes.

C Audible warning.

D Fault pop-up which is shown on the EVC tachometer

display.

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 the coolant tem-

perature is to high.

4 Is the orange coolant level lamp lit during operation

the coolant level is to low.

5 Is the orange oil level lamp lit during operation the

engine oil level is to low.

6 Is the red (R) warning lamp lit during operation a

serious malfunction has been discovered.
Is the orange (O) warning lamp lit during operation
a malfunction has been discovered.

7 Is the red oil pressure lamp lit during operation the

engine oil pressure is to low.

1

2

3

4

5

6

7

P0004761

7748921 04-2008 45

Engine Speed

Explanation:

Fault in engine speed sensor.

P0005008

DANGER! Engine Speed See Opera­tor's Manual
Stop engine

Symptom:

Engine power is reduced.

Action:

Please contact a Volvo Penta workshop.

Water in Fuel

Explanation:

Water in water trap in fuel filters.

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 Man­ual

Reduce rpm

Symptom:

Engine power is reduced.

Action:

Please contact a Volvo Penta workshop.

Fault Code Register

46 7748921 04-2008

Coolant Level

Explanation:

Coolant level too low.

R

P0005012

WARNING! Coolant Level See Opera­tor's Manual

Symptom:

None.

Action:

• Check coolant level. Please refer to Coolant Level, Checking

and Topping Up page 79.

• Check that no coolant leakage occurs in auxiliary equipment

connected to the engine cooling system.

• Please contact a Volvo Penta workshop if the fault remains.

Coolant Temperature

Explanation:

Coolant temperature too high.

P0005014

WARNING! Coolant Temperature See
Operator's Manual
Reduce rpm

Symptom:

Engine power is reduced.

Action:

• Check coolant level. Please refer to Coolant Level, Checking

and Topping Up page 79.

• Check 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 fault remains.

Fuel Pressure

Explanation:

Fuel pressure too low.

P0005015

WARNING! Fuel Pressure See Opera­tor's Manual
Reduce rpm

Symptom:

None.

Action:

• Check fuel level.

• Open the fuel taps and check that no leakage occurs.

• Check that the fuel filters are not blocked. Replace filters if

necessary. Please refer to Maintenance page 74.

• Please contact a Volvo Penta workshop if the fault remains.

Fault Code Register

7748921 04-2008 47

Engine Oil Level

Explanation:

Oil level too low.

P0005017

WARNING! Engine Oil Level See Oper­ator's Manual

NOTICE! In rough following seas or head seas, the system can
incorrectly sense that the engine oil level is too low. If this happens,
acknowledge the fault, and check the points below for safety rea­sons.

Symptom:

None.

Action:

• Check the oil level in the engine. Please refer to Oil level,
checking and topping up page 72.

• Check that no leakage occurs.

• Please contact a Volvo Penta workshop if the fault remains.

Engine Oil Pressure

Explanation:

Oil 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 nec­essary.

• Check that no leakage occurs.

• Please contact a Volvo Penta workshop if the fault remains.

Check drive oil

Explanation:

Oil level too low.

P0001194

CAUTION!Check drive oilSee Opera­tor's Manual

Symptom:

Engine power is reduced.

Action:

• Check the oil level. Please refer to Maintenance page 90.

• Fill up with oil to the right level.

• Check that no leakage occurs.

• Please contact a Volvo Penta workshop if the fault remains.

Fault Code Register

48 7748921 04-2008

Transmission Oil Pressure

Explanation:

Reverse gear oil pressure too low.

P0005023

WARNING! Transmission Oil Pressure
See Operator's Manual

Symptom:

None.

Action:

• Check the oil level. Please refer to Oil level, checking and top-

ping up.

• Check that the oil strainer is not blocked.

• Check that no leakage occurs.

• Please contact a Volvo Penta workshop if the fault remains.

Battery Voltage

Explanation:

Battery voltage too low.

P0005024

WARNING! Battery Voltage See Oper­ator'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 Opera­tor's Manual

Symptom:

Engine stops or can not be started.

Action:

• Check emergency stop button if any. Reset if necessary.

Please refer to Engine Shutdown page 38.

• Please contact a Volvo Penta workshop if the fault remains.

Fault Code Register

7748921 04-2008 49

Primary Battery

Explanation:

Poor batteries or charging.

P0005026

WARNING! Primary Battery See Oper­ator's Manual

Symptom:

None.

Action:

• Check the batteries fluid level Please refer to Battery, Mainte­nance page 86.

• Check belt tension. Please refer to Drive Belt, Check and
Change page 70.

• Please contact a Volvo Penta workshop if the fault remains.

SUS, Battery Voltage Low

Explanation:

Low supply voltage to SUS unit.

P0007711

WARNING! SUS, Battery Voltage Low­See 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.

Fault Code Register

50 7748921 04-2008

Check Control Lever

Explanation:

Fault in control lever.

P0005031

WARNING!Check Control Lever
See Operator's Manual

Symptom:

Engine in emergency mode. Gear to neutral.

Action:

• Restart engine(s).

• If the engine can not be operated from the chosen station, use

an alternative station.

• Please contact a Volvo Penta workshop if the fault remains.

P0005032

CAUTION!Check Control LeverSee
Operator's Manual

Lever Calibration

Explanation:

Incorrect lever calibration.

P0005033

CAUTION! Lever Calibration Incorrect­See Operator's Manual

Symptom:

Impossible to select active station.

Action:

• Restart engine(s).

• Please contact a Volvo Penta workshop if the fault remains.

Fault Code Register

7748921 04-2008 51

Check EVC System

Explanation:

Internal fault in EVC system.

P0005034

WARNING!Check EVC SystemSee
Operator's Manual

Symptom:

Engine power is reduced.

Action:

• Restart engine(s).

• If the engine can not be operated from the chosen station, use
an alternative station.

• Please contact a Volvo Penta workshop if the fault remains.

P0005035

CAUTION!Check EVC SystemSee
Operator's Manual

Check Engine

Explanation:

Miscellaneous system faults.

P0005036

CAUTION! Check Engine See Opera­tor's Manual

Symptom:

None.

Action:

• Restart engine(s).

• Please contact a Volvo Penta workshop if the fault remains.

Fault Code Register

52 7748921 04-2008

Check Joystick

Explanation:

Faulty joystick.

P0005037

WARNING!Check JoystickSee Opera­tor's Manual

Symptom:

Engine power is reduced.

Action:

• Restart engine(s).

• If the engine can not be operated from the chosen station, use

an alternative station.

• Please contact a Volvo Penta workshop if the fault remains.

P0005038

CAUTION!Check JoystickSee Opera­tor'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

7748921 04-2008 53

Limited Engine RPM

Explanation:

Fault in steering system.

P0005040

CAUTION! Limited Engine RPM See
Operator's Manual

Symptom:

Engine power is reduced.

Action:

• Restart engine(s).

• Please contact a Volvo Penta workshop if the fault remains.

Limited steering

Explanation:

Fault in steering system.

P0005041

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 contact a Volvo Penta workshop if the fault remains.

Fault Code Register

54 7748921 04-2008

No Gear/Throttle, No Steering

Explanation:

Fault in steering system.

P0005043

DANGER! No Gear/Throttle, No Steer­ing
Restart Engines See Operator's Man­ual

Symptom:

No steering. No drifting.

Action:

• Restart engine(s).

• Please contact a Volvo Penta workshop if the fault remains.

Helm Restarted

Explanation:

Lost active helm during crank.

P0001206

CAUTION! Helm Restarted See Oper­ator'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 Penta workshop if the fault remains.

Fault Code Register

7748921 04-2008 55

Key Failure

Explanation:

Key or start panel out of order.

P0001199

CAUTION! Key FailureSee Operator's
Manual

Symptom:

None.

Action:

Please contact a Volvo Penta workshop.

Check Multilink

Explanation:

Fault in multilink communication.

P0001204

CAUTION! Check Multilink See Opera­tor'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

In Case of Emergency

In Case of Emergency

Despite regular maintenance according to the mainte­nance schedule and perfect operation, faults may
occur which must be attended to before the boat can
travel further. This chapter contains tips for rectifying
some of the possible faults. There are safety functions
which are activated when certain faults occur, to pro­tect the engine.

The following can occur:

•

Engine can not be started.

•

Gear in neutral and engine speed is limited to 1500
rpm, no steering.

•

The engine stops.

If fault occurs, acknowlege any alarm and take the rec­ommended 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 towed to the nearest harbor. Take
the boat out of the water and let an authorized Volvo
Penta workshop inspect the propulsion units and pro­pellers. Undetected damage could lead to serious pro­pulsion unit damage.

7748921 04-2008 57

Starting Using Auxiliary
Batteries

WARNING!

Explosion hazard. Batteries contain and give off an
explosive gas which is highly flammable and explosive.
A short circuit, open flame or spark could cause a vio­lent explosion. Ventilate well.

WARNING!

Never confuse the positive and negative poles on the
batteries. Risk of arcing and explosion.

1 Check that the auxiliary battery has the same volt-

age as the engine system voltage.

2 Connect the red positive cable to the plus (+) ter-

minal on the discharged battery and then to the plus
terminal on the auxiliary battery.

3 Connect the black start cable to the minus (–) ter-

minal on 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 to the
electrical system.

WARNING!

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

WARNING!

Do not touch the connections during the start attempt:
Risk of arcing.

Do not bend over any of the batteries either.

5 Turn off the engine. Remove the start cables in the

exact opposite order to their connection.

P0002107

In Case of Emergency

58 7748921 04-2008

Emergency Shifting

If a fault occurs which prevents gear shifting with the
control levers, it is possible to shift manually using the
description below.

NOTICE! The following procedure can be performed
with the engine(s) shut down or running.

WARNING!

In emergency shifting, the unit is locked in forwards
operation and the revers gear can not be disengaged
with the control lever. Forward motion can only be cut
off by stopping the engine with the ignition key or stop
button.

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 59

Manual engagement – forward gear:

1 Undo the two connectors, marked “Secondary” and

“Primary”, from the solenoid valves.

2 Remove the cap nut from the lower solenoid valve

marked “P” (forward gear).

3 Release the spring loaded button by pushing and

at the same time turning it 1/2 turn counter-clock­wise. 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/dis­engage with the valve marked “S” (reverse gear)
instead.

3 4

1

2

In Case of Emergency

60 7748921 04-2008

Emergency Alignment, Propulsion
Unit

If a fault occurs which prevents one or several propul­sion units from being operated with the steering wheel
it is possible to align the propulsion unit(s) for straight
forward operation manually using the description
below.

If one or several propulsion units can be operated by
the steering wheel, this emergency operation is not
necessary. However, it could be that the steering ability
is badly unbalanced if the non working propulsion unit
(s) is locked in a disadvantageous angle, then align­ment of the non working propulsion 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.

WARNING!

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

The following procedure can be carried out with the
engines running, even though it is not recommended.
Wear hearing protection when in the engine room as
there is a risk of harmful sound levels.

1 Unscrew and remove the plug (1). Disconnect the

cable by pressing down the lock (2) and at the same
time wiggle the connector in “forward” position.

In Case of Emergency

7748921 04-2008 61

2 Connect the switch and fit the red crank tool.

3 Press the switch button down and keep it pressed

while turning the crank tool carefully to an end posi­tion. When the end position is reached, stop turn­ing. The end position feels like a compression
spring.

IMPORTANT!

Do not force the crank tool beyond the end position,
it could damage the propulsion unit.

4 Turn the crank tool back 75 turns. The propulsion

unit is now aligned for straight forward motion.

In Case of Emergency

62 7748921 04-2008

5 Remove the crank tool. Disconnect the switch by

pressing down the lock and at the same time
unplugg the switch by slowly wiggling it (please
refer to procedure in step 1).
Screw back the plug.

6 Reconnect the cable you disconnected in step 1.

Emergency steering with control
levers

If a fault occurs which prevents all propulsion units from
being operated with the steering wheel, align all the
propulsion units and use the steering method descri­bed below to reach nearest habor.

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 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.

In Case of Emergency

7748921 04-2008 63

Steering the boat

Put the control levers in forward. Use a suitable engine
speed for maneuvring.

The direction of the steering is determined by the use
of the control levers. If the boat is to turn to starboard,
reduce speed on starboard engine. The greater the
difference in speed between the control levers the
more the boat turns. To make a sharp turn, move one
of the control lever to reverse for a moment.

In Case of Emergency

64 7748921 04-2008

Maintenance Schedule

C
R
A
L
I

=
=
=
=
=

Clean
Replace
Adjust
Lubricate
Inspect (Clean, Adjust, Lubricate or Replace if nec­essary)

FSI, S2 = First time Service Inspection
A, B, C, D, E = Type of service (regular service)

FSI

First service inspection, after 20–50 running hours

1)

Coolant level and antifreeze mixture I

Drive belt (tension) I

Seawater filter I C

Drive-unit, oil level I

Corrosion protection (space between IPS-housing and clamping ring) I

Instrument panel function I

Start and warm up engine

Inspection with VODIA (Diagnostic Tool) I

Engine and transmission, oil / fuel / water leakage I

Engine and transmission, abnormal noises I

Stop Engine

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 Filter, Check and Cleaning I C

Batteries, electrolyte level I

A

Every 100–200 hours / at least every 12 months, included in extended protection

Engine Oil and Oil Filters / By-pass filter

1)

R

Primary Fuel Filter, Draining Water / Contamination I

1)

Oil change intervals vary, depending on engine type, oil grade and sulfur content of the fuel. Se kapitel Technical

Data page 115. Change the filters during each oil change.

7748921 04-2008 65

B

Every 200 hours / at least once a year, included in extended protection

Crankcase ventilation filter R

Air filter insert R

Fuel pre-filter and fuel fine filter R

Drive belt (tension) I

Compressor, oil level I

Seawater pump impeller I

Sacrificial anodes (charge air cooler and heat exchanger) I

Corrosion protection (space between IPS-housing and clamping ring) I

Engine and propulsion unit. Clean and touch up paintwork as required I C

All hoses and pipes – Check the condition and re-tighten the hose clamps I

Exhaust hose and cooling water hoses

- Check 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 hours / at least every 5 years

Turbocharger, inspect / clean as required I C

Drive-unit. Function and wear

- Propellershaft (check straightness)

- Steering

I

F

Every 1200 hours / at least every 5 years

Drive Belt R

Drive belt, compressor R

Compressor, oil R

Heat exchanger I C

Charge air cooler I C

Propellershaft seal R

Maintenance Schedule

66 7748921 04-2008

Maintenance

This chapter contains general technical information and instructions on how the prescribed maintenance items
must be carried out. Read through the instructions carefully before starting work. The times when maintenance
items must be carried are indicated in the Maintenance Schedule page 65.
Read through the safety precautions for maintenance and service in the Safety Information page 4 chapter before
work on the engine is begun.

WARNING!

Care and maintenance work should be done with the engine stopped unless otherwise specified. Stop the engine
before opening 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.

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, propulsion unit

11 Expansion tank

12 Sea water filter

13 Fuel filter

14 Aux stop

15 Oil bypass filter

16 Oil filter

17 Charge air cooler

18 Oil filler cap, propulsion unit

19 Oil dipstick, propulsion unit

20 Water shut off valve, propulsion

unit

21 Cooling water intake unit

22 Oil dipstick, engine

23 Sea water pump

Volvo Penta IPS, port

p0006598

11 12 13 14 15 16 17 18

19

20

21

22

23

7748921 04-2008 67

Engine, General

General inspection

Make a habit of visually checking the engine and
engine bay before starting, and after operations when
you have stopped the engine. This will help you to dis­cover abnormalities quickly, or if something is about to
happen.
Look especially carefully for oil, fuel and coolant lea­kages, loose bolts, worn or poorly-tensioned drive
belts, loose cable connections, damaged electrical
cables and hoses. 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
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.

Maintenance

68 7748921 04-2008

Crankcase Ventilation, Filter
Change

1 Unscrew the cover and remove the old filter.

2 Clean the filter cover/housing as necessary. Be

careful to prevent contamination from entering the
engine.

3 Install the new filter.

4 Screw the cover back in place.

IMPORTANT!

Scrap the old filter. They may not be cleaned.

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

7748921 04-2008 69

Drive Belt, Check and Change

WARNING!

Stop the engine before doing any maintenance work.

General

Check belt tensions and condition regularly. A belt that
is tensioned too tightly may damage bearings, while a
belt too-loosely tensioned may slip.

Check and adjust the belt after operation, while the belt
is still warm.

IMPORTANT!

Always replace a belt that appears worn or has cracks
(belts that work in pairs shall always be changed
together).

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).
Lock the tensioning roller using screws (1). The
screws must be tightened to 50 Nm (37 lbf.ft).

3 Repeat the procedure when the engine is warm:

Loosen screws (1) and tension the belt.

Maintenance

70 7748921 04-2008

Compressor, checking oil

Checking and filling

1 Unscrew and lift up the oil dipstick. Dry the oil off.

Screw the oil dipstick down as far as it will go and
then unscrew and lift up.

2 Check that the oil level is between the MAX and

MIN marks. Check that the dip stick is screwed fully
home so that the reading is correct. If the dipstick
is not screwed fully home, the oil level will be above
the MIN mark even if the oil level is correct.

3 Fill with oil as required, use the dipstick hole. 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 Remove the plug and let the oil run out.

4 Replace the plug and fill with oil to the correct level.

P0002655

Maintenance

7748921 04-2008 71

Lubrication System

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

Oil change intervals must never exceed a period of 12
months.

If you want longer oil change intervals than given in the
table Technical Data page 115, the condition of the
oil must be checked by the oil manufacturers through
regular oil testing.

Oil level, checking and topping up

The oil level must be within the marked area on the oil
dipstick and must be checked daily before the first
start.

Check the oil level a while after the engine has been
switched off. The oil in the engine needs some time to
return to the sump before 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 to Technical
Data page 115.

1 Fill the oil slowly via the filling hole on the top of the

engine.

2 Wait 5 minutes to allow the oil time to reach the

sump before checking the level again.

3 Then check the level again.

NOTICE! The volume between MAX and MIN is about

3.5 litre (0.9 US gal).

Engine Oil, Change

Always follow the recommended oil change interval.
Use only oils of the recommended grades; refer to
Technical Data page 115.

P0002089

P0003706

Maintenance

72 7748921 04-2008

WARNING!

Hot oil and hot surfaces can cause burns.

1 Run the engine until warm so that the oil is easier

to pump. Then stop the engine and wait 10 minutes.

2 Connect the oil suction pump to the draining pipe.

Pump out the oil.

3 Replace the oil filter and by-pass filter at every oil

change, see sectionOil Filter/By-pass Filter,
Change page 73.

4 Fill with oil to the correct level through the filling hole

on the top of the engine. Oil quantity, see section
Technical Data page 115.

5 Start the engine. Run the engine until it reaches

normal operating temperature. The oil level shall be
checked with the engine warm.
Check that the low oil pressure lamp goes out and
that there are no leaks around the oil filter.

6 Turn off the engine. Wait ten minutes before 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 filter bracket.

3 Unscrew the by-pass filter (1) and the oil filter (2)

with a suitable filter puller.

4 Check that the mating surfaces on the filter bracket

are clean and that no remnants of 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
tighten an additional 3/4 turn.

7 Start the engine, run at low idle, and check that no

leakage occurs. Check the oil level after the engine
has stopped.

Maintenance

7748921 04-2008 73

Fuel System

Only use the grades of fuel recommended in the fuel
specification, see Technical Data page 116. Always
observe the greatest cleanliness during re-fuelling and
work on the fuel system.
All work on the unit injectors of the engine must be
carried out by an authorized workshop.

WARNING!

Fire hazard. When carrying out work on the fuel system
make sure the engine is cold. A fuel spill onto a hot
surface or an electrical component can cause a fire.
Store fuel soaked rags so that they can not cause fire.

Engine Fuel Filter Replacement

1 Close the fuel tap(s).

2 Clean the filter bracket 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 get into the system and cause damage and
malfunctions.

5 Screw on the new filter by hand until the gasket just

bottoms on the sealing surface. Then tighten a fur­ther 1/2 turn. Install the water separator and con­nect the union.

6 Open the fuel cock.

7 Bleed the fuel system, see section “Fuel system,

bleeding”.

8 Start the engine and check that there are no leaks.

Maintenance

74 7748921 04-2008

Fuel system, bleeding

The fuel system must be bled after a filter change, if
the fuel tank has been run dry and after a long-term
stoppage.

IMPORTANT!

Never disconnect the pressure pipe.

1 Connect a transparent hose to the bleed nipple

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

2 Open the bleeding nipple and pump fuel with the

hand pump (2) until the fuel is free from bubbles.
Close and tighten the bleed nipple.

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

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

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 (1).

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 75

Water in Fuel

If the EVC system warns for too much water in the fuel
pre-filter, the water separator needs emptying.

IMPORTANT!

Do not continue operating if there is water in the water
separator, it can damage the engine.

Draining the fuel filter

1 Stop the engine and remove the ignition key from

the ignition lock.

2 Remove the connector piece from the water sepa-

rator (1).

3 Place a container under the 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 water and contaminants via the plug in the

bottom of the filter.

4 Bleed the fuel system.

NOTICE! Wait a few hours after switching the engine
off before draining the filter.

Maintenance

76 7748921 04-2008

Freshwater System

The freshwater system is the engine's internal cooling
system that ensures that the engine operates at the
correct temperature. It is a closed system that must
always be filled with a mixture of concentrated coolant
and water in order to protect the engine against internal
corrosion, cavitation and frost bursting.

We recommend “Volvo Penta Coolant, Ready Mixed”,
or “Volvo Penta Coolant” (concentrated) mixed with
pure water according to specifications. Refer to the
table Water Quality page 116. Only coolant of this
grade is suitable for, and approved by, Volvo Penta.
The use of anti-corrosion agents alone is not permitted
in Volvo Penta engines. Never use water alone as the
coolant.

IMPORTANT!

Coolant of a suitable chemical composition must be
used all year round. This applies even when there is
no 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 effec­tive over time, which means that the coolant must be
changed at regular intervals; refer to the Maintenance
Schedule page 65. The cooling system must be
flushed whenever the coolant is changed, refer to the
Freshwater system, Flushing section.

“Volvo Penta Coolant” is a concentrated coolant that
must be mixed with water. It has been prepared to work
best with Volvo Penta engines and offers excellent
protection against corrosion, cavitation damage and
frost bursting.

“Volvo Penta Coolant, Ready Mixed” is a ready­mixed coolant, 40% “Volvo Penta Coolant” and 60%
water. This mixture protects the engine from corrosion
damage, cavitation damage and frost bursting down to
–28°C (–18°F).

Maintenance

7748921 04-2008 77

Coolant, Mixing

WARNING!

All coolant is hazardous and harmful to the environ­ment. Do not consume. Coolant is flammable.

IMPORTANT!

Volvo VCS coolant (yellow in color) must not be used
in Volvo Penta engines.
Different kinds of coolant must not be mixed with each
other!

Mix: 40% “Volvo Penta Coolant” (conc. coolant)
and 60% water

This mixture protects against internal corrosion, cavi­tation and frost bursting down to –28°C (–18°F). At
60% glycol 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 pro­vides reduced cooling effect with the risk for overheat­ing 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 116.
It is extremely important that the system is filled with
the correct coolant concentration. Mix in a separate
clean vessel before filling the cooling system. Make
sure that the liquids mix.

Maintenance

78 7748921 04-2008

Coolant Level, Checking and
Topping Up

WARNING!

Do not open the coolant filler cap when the engine is
warm, except in emergencies, this could cause serious
personal injury. Steam or hot fluid could spray out.

1 Turn the filler cover slowly counter-clockwise and

release any pressure from the system before
removing the cover completely.

2 Top the coolant up as necessary. The coolant level

shall be between the MAX and MIN marks on the
expansion tank.

3 Screw the filler cover on.

Freshwater System, Draining

WARNING!

Stop the engine and 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 environ­ment. 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). Let all the coolant run out into a
container.

3 Screw in the stop cock.

4 Move the hose to the drain cock (3) on the engine

block and continue draining the coolant.

5 Close the cock and put the hose back on the inter-

cooler.

6 Collect the old coolant and hand it to a re-cycling

station for disposal.

Maintenance

7748921 04-2008 79

Seawater System

The raw water system is the engine's external cooling
system. On IPS engines, the raw water pump sucks in
water via the IPS cooling water inlet, through the IPS
unit oil cooler to the raw water pump. The water then
passes through the raw water filter before being
pumped through the fuel cooler, intercooler, engine oil
cooler and heat exchanger. Finally the water is fed out
through the exhaust elbow, where it is mixed with the
exhaust gases.

WARNING!

If the boat is in the water while working on the seawater
system the two seawater cocks on the propulsion units
must be closed. Otherwise there is a risk of flooding of
the engine compartement and sinking of the boat. The
boat must be brought up on land 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 Open the drain stop cock (1) by unscrewing it care-

fully.

3 Drain the coolant into a container. Screw in the stop

cock by hand.

4 Move the hose on the stop cock (1) and connect to

stop cock (2).
Open stop cock (2) and drain all coolant. Close the
stop cock.

5 Refit the drain hose to stop cock (1).

6 Remove hose clamp (3) and release the end of the

hose. Drain the coolant from the hose and oil
cooler.
Refit the end of the hose.

7 Open the sea cocks and check for leaks.

A

B

B

A

P0002849

2

1

3

P0006575

Maintenance

80 7748921 04-2008

Zinc Anodes, Check and Change

WARNING!

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

1 Close the sea cock(s).

2 Drain the raw water as described in Seawater Sys-

tem, Draining page 80.

3 Remove the zinc anodes from the heat exchanger

(1) and intercooler (2).

4 Check the zinc anodes and replace if consumed to

more than 1/3rd of original size. If not, clean the zinc
anodes with Emery cloth to remove the oxide layer
before re-installing them.

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. Make sure there is good

metallic 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 must be
replaced.

2 If the pump shaft can be turned by hand, the flange

must be replaced.

3 Lubricate the pump housing and inside of the cover

with a little glycerin.

IMPORTANT!

The impeller will be damaged if other types of lubri­cant than glycerin are used.

4 Press the impeller in with an anti-clockwise rotating

movement.

5 Fit the sealing washer on the center bearing of the

shaft. Install the cover with a new O-ring.

1

2

P0003705

Maintenance

7748921 04-2008 81

Seawater System, Cleaning and
Inhibiting

To prevent the build up of deposits and salt crystals in
the seawater system it must be flushed with freshwa­ter. The system must also be preserved when the boat
is going to be layed up on land for longer periods than
two month.

This procedure can be performed with the boat either
in or out of the water.

WARNING!

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

1 If the procedure is performed up on land, open the

outlet seawater cock on the propulsion unit..
If the procedure is performed in the water, detach
the exhaust outlet hose from the (closed) outlet
sewater cock.

2 Detach the hose from the seawater pump and con-

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 outlet hose.

4 Set the gear control lever in the neutral position.

Check that nobody is near the propellers. Start the
engine. Let it run at fast idle for a few minutes. Stop
the engine.

5 For preservation fill a bucket with antifreeze mixture

40% anti freeze and 60% freshwater to inhibit the
system. Secure a container at the exhaust outlet.

6 Connect the inlet seawater hose to the seawater

pump.
If the procedure is performed in the water also con­nect the exhaust outlet hose on the outlet seawater
cock.

Maintenance

82 7748921 04-2008

7 The antifreeze mixture should be left in the system

while the boat is not used. Before starting to use the
boat again drain the mixture and clean the system
using the same procedure as above.

8 Deposit antifreeze mixture at a properly designated

waste site.

9 Check that the system is intact and that there are

no leaks.

Seawater Filter, Check and Cleaning

WARNING!

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

If the water where the boat is used contains contami­nants, 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 sealing plate

(2).

3 Lift out the insert (3) and clean it.

4 Replace parts as illustrated.

5 Open the sea cock and check for leaks.

Maintenance

7748921 04-2008 83

Electrical System

The engine is equipped with a 2-pole electrical system
and an alternator. System voltage is 12V or 24V.

WARNING!

Always stop the engine and break the current using the
main switches before working on the electrical system.
Isolate shore current to the engine block heater, bat­tery charger or accessories mounted on the engine.

Main Switch

IMPORTANT!

Never disconnect the current with the main switches
when the engine is running, the alternator and elec­tronics could be damaged.

The main switches must never be switched off before
the engine has stopped. If the circuit between the alter­nator and the battery is disconnected when the engine
is running, the alternator and electronics can be dam­aged. 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 breakers. The
circuit breakers cut the power if the system is over­loaded.

If it is not possible to start the engine or if the instrument
stops working while running, the circuit breaker may
have been activated.
Resetting will take place automatically.

Maintenance

84 7748921 04-2008

24–volt system (engine)

The engine is fitted with two automatic circuit breakers
(1). The circuit breakers cut the power if the system is
overloaded.

If it is not possible to start the engine or if the instrument
stops working while running, the circuit breaker may
have been activated. Reset by pressing in the circuit
breakers (1) (red button).

IMPORTANT!

Always investigate the cause of the overload. If the
fuse trips frequently, contact an authorized Volvo
Penta workshop.

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

Maintenance

7748921 04-2008 85

Battery, Maintenance

WARNING!

Risk of fire and explosion. Never allow an open flame
or electric sparks near the battery or batteries.

WARNING!

Never confuse the positive and negative poles on the
batteries. Risk of arcing and explosion.

WARNING!

The battery electrolyte contains extremely corrosive
sulfuric acid. Protect your skin and clothes when charg­ing or handling batteries.

Always use protective goggles and gloves. 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.

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
oxide on the batteries and battery poles can cause
stray currents, voltage drop and discharge, especially
in wet weather. Remove oxidation from the battery
poles and terminals, using a brass brush. Tighten the
terminals securely and grease them with terminal
grease or petroleum jelly.

P0002107

Maintenance

86 7748921 04-2008

Filling

The electrolyte level should be 5–10 mm (0.2– 0.4”)
above the cell plates in the battery. Top up with distilled
water as required.

After filling, the battery should be charged for at least
30 minutes by running the engine at idle.

Some maintenance-free batteries have special
instructions, which must be followed.

Battery, Charging

WARNING!

Risk of fire and explosion. Never allow an open flame
or electric sparks near the battery or batteries.

WARNING!

The battery electrolyte contains extremely corrosive
sulfuric acid. Protect your skin and clothes when charg­ing or handling batteries.

Always use protective goggles and gloves. 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.

IMPORTANT!

Observe the instruction manual for the battery charger
carefully. To avoid the risk of electrochemical corrosion
when an external charger is connected, the battery
cables should be removed from the batteries before
the charger is connected.
Always switch off the charging current before the
charging clips are removed.

P0002110

P0002107

Maintenance

7748921 04-2008 87

•

Charge batteries if they have become discharged.
During charging, unscrew the cell plugs but leave
them in the plug holes. Ventilate well, especially if
the batteries are charged in an enclosed space.

•

If the engine is not used for a longer period of time,
the batteries should be fully charged, then possibly
trickle charged (please refer to the battery manu­facturer’s recommendations). Batteries are dam­aged by being left discharged, and can also freeze
and burst easier in cold weather.

•

Special instructions apply to boost charging. Boost
charging can shorten battery life, and should there­fore 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 corrosion.

WARNING!

Work on the low voltage circuits 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.

P0002111

Maintenance

88 7748921 04-2008

Always consider the following:

1 If shore power is connected it must always be

ground protected ashore, never in the boat. Fur­thermore, the shore power installation should be
equipped with a ground fault interrupter.
The shore power installation (transformer, inverter,
battery charger etc.) must be designed for marine
use where the high-tension side is galvanically

separated from the low-tension side.

2 Electrical cables must be run and clamped such

that there is no risk of exposure to chafing, damp or
bilge water.

3 Ground protection for radios, navigation instru-

ments, rudder, boarding ladders or other equipment
where separate cables for ground protection are
present, must be clustered to a common ground
connection 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 battery's plus (+) ter­minal and the circuit breaker panel for the boat's
electrical equipment. The main switch must break
the circuit to all equipment connected to the auxili­ary battery and must be switched off when power is
no longer required. All equipment connected to the
auxiliary battery must have separate main
switches.

For simultaneous charging of two independent battery
circuits a separate charging distributor (accessory)
should be installed on the standard alternator.

P0002900

Maintenance

7748921 04-2008 89

Drive

The propulsion unit has an electronically controlled
hydraulic clutch. Two soleniod valves, primary (for­ward gear) and secondary (reverse gear), is controlled
by electrical signals from the operator’s control levers.

The propulsion unit's lubrication system is equipped
with an oil filter and an oil cooler.

The propulsion unit is protected against galvanic cor­rosion. This protection consists of sacrificial anodes.
An active corrosion protection, ACP, is optional. Faulty
electrical installation can also cause the breakdown of
the galvanic protection. Damage due to electrolytic
corrosion occurs rapidly and is often extensive. For
further information please refer to Mainte-
nance page 84.

Oil level, checking 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 overpres­sure 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 the oil dip­stick again and check the oil level. The correct oil level
is inside the marked area.

If necessary, top up the oil through the filling hole (1).
For oil grades and volume, please refer to Technical
Data page 115.

While checking the oil level, ensure there are no signs
of water dilution. The oil should have a golden brown
hue. If the oil is thin and greyish it is probable water
diluted. If so, always let the propulsion unit be checked
by a Volvo Penta workshop.

1

2

P0003981

Maintenance

90 7748921 04-2008

Changing oil and filter

1 Open the oil filling (1) cap slowly so that any over-

pressure is released. Unscrew the draining plug
(3) and allow the oil to run out.

2 Change the filter.

3 Refit the drain plug with a new gasket.

NOTICE! Always replace the gasket when the drain
plug has been removed.

4 Measure up the correct quantity of oil and fill the

propulsion unit with the oil via the oil filling hole. For
oil grades and volume, please refer to Technical
Data page 115.

IMPORTANT!

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 pro­tection, Volvo Penta part # 9510227. Follow the
instructions below if the protection needs renewing:

1 Clean and dry the surface between the housing and

the lock plate.

2 Spray a liberal coating of corrosion protection in the

space between the housing and the lock plate.

3

P0003997

Maintenance

7748921 04-2008 91

Inspection/replacing corrosion protection
– Sacrificial anodes

Check the sacrificial anodes regularly. There are two
anodes per stern drive; one is fixed to the drive and the
other to the transom. Refer to the illustrations. Replace
an anode when approximately 1/3 of it has corroded
away.

When the boat is stored ashore, corrosion protection
deteriorates due to sacrificial anode oxidization. Even
new anodes oxidize on the surface. The anodes must
be cleaned before the boat is launched.

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 sur­face and secure the new anode. Tighten the new
anode so that it makes good electrical contact.

ACP, Active Corrosion Protection

Boats equipped with ACP (option) have a zinc anode
integrated in the ACP unit; see illustration. Replace the
anode when about 1/3 has corroded away.

p0006680

Maintenance

92 7748921 04-2008

Inspect the drive unit paint

Volvo Penta recommends ”Prop speed ®” coating.
Instructions regarding the application of ”Prop speed
®” coating are included with the product.
Inspect the coating every year and scrape away any
loose coating and apply new.

Do not apply coating in the groove (A) between the
drive unit and the hull or to the exhaust cushion (B).

Allow the coating to dry before launching the boat.

Painting the hull bottom

All paints containing anti-fouling agents are poisonous
and damage the marine environment. Avoid these
preparations. Most countries have introduced legisla­tion that regulates 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 con­junction with mechanical cleaning several times per
season. However, for larger boats this is not practica­ble. If the boat is in an area where the water causes
fast fouling, paint with anti-fouling agents will most
likely be necessary.

Do not paint in the groove (A) between the drive unit
and the hull or the exhaust cushion (B).

Allow the paint to dry before launching the boat.

Maintenance

7748921 04-2008 93

Propeller

WARNING!

Make sure the engine can not start during work on
propeller(s); remove ignition key(s) and shift drive
into forward or reverse.

NOTICE! Damaged propellers should be replaced

immediately otherwise there is high risk of serious
damage to the propulsion unit. Operating the boat with
a damaged propeller should be undertaken with
extreme care and only at reduced engine speeds.

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 the special tool.

Maintenance

94 7748921 04-2008

3 Undo the locking ring with the accompanying spe-

cial tool by unscrew the four socket cap screws
(2). Remove nut (B) and locking ring (3). Remove
the forward propeller from the propeller shaft.

4 Undo the locking ring for the aft propeller with the

accompanying special tool by unscrew the four
socket cap screws (4). 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

Assemble propellers

1 Apply water-resistant grease, P/N 828250 to the

splines and threads on both propeller shafts.

2 Install the aft propeller. Then install the aft nut (C)

and tighten it by hand until it bottoms. Install locking
ring (5). Tighten the locking ring with the accompa­nying special tool and four socket cap screws (4).

Torque 24-28 Nm (17.7-20.7 ft. lb.).

Maintenance

96 7748921 04-2008

3 Install the forward propeller on the propeller shaft.

Tighten nut (A) by hand and install locking ring (3).
Tighten the locking ring with the accompanying
special tool and four socket cap screws (2).

Torque 24-28 Nm (17.7-20.7 ft. lb.).

4 IMPORTANT!

Tighten the screw (D) until it bottoms. Otherwise it
will not be possible to change the propeller without
damaging the spinner.

5 Push the spinner into place by hand.

Maintenance

7748921 04-2008 97

Storage

Short Term Storage

If the boat is not going to be used for a shorter period,
the engines must be run up to normal operating tem­perature at least once every 14 days. This prevents
corrosion in the engines.

WARNING!

If the engines must be run up to normal operating tem­perature with the boat kept up on land, make sure to
provide the seawater system with water during the
operation. If the seawater pump is run dry the impeller
could be damaged. Always check the impeller after dry
runs.

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 the ACP function, select inac­tive mode (see Instruments and Controls page 20)
before lifting the boat out of the water. In this mode the
ACP no longer monitors the corrosion condition.

98 7748921 04-2008