Volvo Penta IPS 600 Operator's Manual

OPERATOR’S MANUALVOLVO PENTA IPS 350/400/450/500/600

IntroductionThis operator’s manual has been compiled to help you get the most from your Volvo Penta engine. It contains all the information you need i

Malfunction messages Steering systemTachometer display Pop-ups Steering SystemIf the diagnostic function discovers a malfunction in steering system a

No steering wheel responseIf there is no ability to steer the boat with the steering wheel, this pop-up is shown.There is a fault or several faults in

No gear/throttle and steeringIf there are multiple errors unabling the system to con-trol both steering and propulsion this pop-up is shown .Steering

Malfunction message engine and EVC-systemIf the diagnostic function discovers a malfunction, it warns the driver by showing pop-ups in the tachom-eter

Faults are stored and malfunctions have been registeredFaults listA faults list can be viewed from the MAIN MENU in the tachometer, if a fault is regi

Engine speed R Explanation: Fault in engine speed sensor. Reaction: Engine power is reduced. Action: • Please contact a Volvo Penta

Air temperature R Explanation: Charge air temperature too high.Reaction: Engine power is reduced. Action: • Please contact a Volvo

Fuel pressure R Explanation: Fuel pressure too low. Reaction: Engine power is reduced.Action: • Check the fuel level.• Open the fu

Engine oil temperature R Explanation: Engine oil temperature too high. Reaction: Engine power is reduced.Action: • Check the oil

Battery voltage O Explanation: Battery voltage too low. Reaction: Action: • Check battery fluid level.• Check belt tension.• Ple

WarrantyYour new Volvo Penta marine engine is covered by a limited warranty according to the conditions and instructions contained in the Warranty and

EMS supply fuse R Explanation: Fuse is broken. Reaction: Action: • Please contact a Volvo Penta workshop.Extra supply fuse

System failure R Explanation: Miscellaneous fault. Reaction: Action: • Restart engine(s).• Please contact a Volvo Penta workshop i

No steering wheel response R Explanation: Fault in steering wheel unit. Reaction: Engine power is reduced on both sides. No steering. A

Technical DataEngine General informationVolvo Penta IPS system designation ... D4 - See table below D6- See table belowEngine m

SAE5W/30−−−−−30−−−−−20−−−−−10 ±0 +10 20 30 40−−−−−22−−−−− 4+++++14 32 50 68 86 104−−−−−15oCSAE15W/40−−−−−25oCSAE10W/30−−−−−10oCSAE20W/30±0oCSAE30SAE40

Notes113

Notes114

NB! This offer is valid for a period of 12 months from delivery of the boat. Availability after this period will be as far as supplies admit.Post or f

Si ricorda che l’offerta è valida per 12 mesi dalla data di consegna dell’imbarcazio-ne; dopo il suddetto periodo l’offerta resta valida solo in base

Denk eraan dat het aanbod geldt gedurende 12 maanden na de datum waarop de boot werd afgeleverd, daarna alleen indien nog verkrijgbaar.Stuur of fax de

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

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NB! Bu teklif, teknenin teslim edilmesinden itibaren 12 aylýk bir süre için geçerlidir.Bu süre sonunda ürün daðýtýmý stoklarla sýnýrlýdýr.Bu kuponu şu

7747996  English  06-2007

Identification numbersAlways provide the engine and transmission identification numbers when ordering service or replacement com-ponents. The identificat

PresentationVolvo Penta IPS – Inboard Performance SystemVolvo Penta IPS overvieiw Volvo Penta IPS is setting a new standard:– Much improved efficiency

ComfortVolvo Penta IPS new technology leads to major im-provements for all comfort enhancing factors.– The propulsion forces and vibrations are absor

Engine technical descriptionVolvo Penta’s D6 is developed from the latest design in modern diesel technology. The engine has common rail fuel injectio

Engine monitoring system The engines are equipped with common rail system and electronically controlled injectors.The injectors contain an electro-mag

The EVCEC systemThe Electronic Vessel Control (EVC) system is a so called distributed system. The principle of a distrib-uted system is to have "

Fuel levelFuel level can be displayed on the EVC system ta-chometer if a (0-180 ohm or 240-30 ohm) fuel level sender is installed in the fuel tank. Th

CALIFORNIAProposition 65 WarningDiesel engine exhaust and some of its constituents are knownto the State of California to cause cancer, birth defects,

(D4)/D6-IPS, starboard1. Oil filter, drive-unit2. Water shut off valve, drive-unit (only D6)3. Turbocharger4. Crankcase ventilation filter5. Air fil

121415161718192022232413D6-IPS, port12. Sea water filter13. Sea water pump14. Fuel filter15. Oil dipstick, engine16. Oil bypass filter17. Oil filter18. Ch

InstrumentsThis chapter describes the instrument and control panels sold by Volvo Penta for your engine. If you want to supplement the instrumentation

Start/stop panelThe start/stop panel is used to start or stop the en-gine. The starter key on the main helm station must be in position “I” (driving p

Alarm display (extra optional) The following warning lamps should never light up during operation. On the other hand, the warning lamps light up when

Battery. (orange indication) The battery lamp lights up if the alternator is not charging. Stop the engine if this lamp lights up during operation.

Coolant level (orange indication) The coolant lamp lights up when the coolant level is too low. Check coolant level. Please refer to “Maintenanc

Tachometer display selection (twin installa-tion, port or starboard tachometer)Is used to select which of the engines menu systems should be navigabl

Docking Station PanelThe docking station panel allow stopping and restarting of the engines and handling of faults when operating the boat from a dock

Main menu structureEVC System TachometerIntroductionVolvo Penta EVC System Tachometer presents rele-vant boat and engine information to the helmsman.

Welcome aboardVolvo Penta marine engines are used all over the world. They are used in all possible operating conditions for professional as well as l

Trip menu (extra optional)In the TRIP MENU the user gets trip information from the EVC System and the user is allowed to select which view that should

Gauges menuIn GAUGES MENU the user gets information from analogue senders, placed on the engine. If the data is not available the parameter will not b

Settings menuIn the SETTINGS MENU the user is allowed to set various options for the EVC system and to calibrate various parameters. IMPORTANT! For

DEPTH ALARM, ON/OFFDepth alarm can be switched ON/OFF.SET DEPTHAdjust the depth alarm value by turning the NAVIGA-TION WHEEL. The value can be adjuste

Select units and language Choose which units and languages to display. NOTE! Language and unit settings must be performed in all EVC system tachomete

Fuel tank calibrationThere are two possible calibration methods for the fuel tank. One approximative, FULL TANK CALIBRATION, and one more precise, FUE

FUEL FULL TANK CALIBRATIONWhen FUEL FULL TANK CALIBRATION is selected, the fuel level sender is calibrated in one step. This only gives an approximate

Speed factorThe speed factor for the boat´s paddle wheel speed sensor can be adjusted at a resolution of 1% and is used by the EVC to apply a correcti

EVC System Display (extra optional)IntroductionVolvo Penta EVC system display is an instrument which displays operating information about the engine a

Display after starting screenDisplay mode ENGINE (button 1) is always shown af-ter the starting screen when the display is first started up (more infor

Safety Information ... 3-7General ... 3Boa

Set display contrastPress button 5 (furthest right) to set display contrast. Then press the appropriate buttons to adapt the le-vels, then save the se

SettingsMenu SETTINGS is used to do various settings for the display.- Language: This is where you select the langu-age that the display should use (

ment intervals of the speedometers and tachome-ters. Rpm engine: [2500 rpm: 9000 r/min] in stages of 500 rpm - Speed: Change speed display (on/off)

Menu, trip computerFuel consumption (L/N.M.) - If information about speed is available > 2 knot Trip fuel consumption (L)Button 1 Changes display

Display mode Multi (button 2) This display mode shows operating information in four different windows (see below). The user can choose the operating i

Window with curve for single engine installation (shows engine speed)Window with curve for twin engine installation (shows engine speed)Figure for sin

ControlsThis chapter describes the controls sold by Volvo Penta for your engine. Disengaging the shift functionThe shift function can be disengaged s

Friction brakeThe control has a friction brake which can be adjusted as necessary to provide lighter or heavier lever action.Adjusting the friction br

Starting the engineMake it a habit to give the engine and engine bay a visual check before starting. This will help you to discover quickly if anythin

Starting methodTurn the ignition onTurn the starter key to position I to switch the ignition on. Check LEDsEach time the ignition is turned on, all L

Safety InformationRead this chapter carefully. It concerns your safety. This section describes how safety information is presented in the operator’s m

Start the engineStart using the ignition switchTurn the key to position III. Release the key and let it key spring back to position I as soon as the e

OperationLearn to handle the engine, controls and other equipment in a safe and correct manner before you cast off on your maiden voyage. Remember to

Cruising speedAvoid operation at full throttle, for best fuel economy. We recommend a cruising speed which is at least 10% below the maximum engine sp

Changing the helm stationThe first time you change control panel after starting the EVC system, a bulb check is done automatically. All LEDs and bulbs

OperationShifting between forward and reverse should be done at idling. Shifting at higher engine speeds can be un-comfortable for passengers and caus

Steering with control leversNOTE! Engine speed is limited to 1500 rpm .Rotate the boatPut one control lever in the position for forward and put the ot

Docking (Joystick)The Volvo Penta IPS docking function (joystick) makes it possible to rotate the boat and maneuver it in any direction – sideways, di

Enabling boost modeIn situations where normal thrust is insufficient, for ex-ample when it is windy or there is a strong current, the boost mode can be

Maneuvering with the joystick WARNING! A rotating propeller can cause serious injury. Ensure that there is no one in the water before you enable dock

Turn RotateDiagonally57Operation

Safety precautions to be taken when operating the boat Your new boatRead operator’s manuals and other information supplied with your new boat. Learn t

Calibrating joystick functionThis calibration only needs to be performed if the boat movement does not corresponds to the movement of the joystick.Cal

Stopping the engineThe engine should be run for a few minutes at idle (in neutral) before turning it off. This will avoid boiling and even out the tem

Laying up on landWhere boats are kept laid up on land when not in use, for example, trailer boats, there is a lower level of galvanic corrosion protec

Maintenance scheduleGeneral information Your Volvo Penta engine and its equipment are designed for high reliability and long life. They are built to

Every 200 hours / at least once a year, included in extended protection:● Crankcase ventilation filter. Change ...

MaintenanceThis chapter describes how to carry out the above maintenance. Read the instructions carefully before starting work. Maintenance intervals

Changing air filterRemove the air filter cover. Remove the old air filter. Clean the air filter cover/housing if necessary. Take care not to allow impurit

Checking drive belts WARNING! Stop the engine before commencing maintenance work.GeneralCheck belt tension and condition regularly. If the belt is to

Compressor. Checking oilChecking and topping upUnscrew and remove the dipstick. Wipe off oil. Screw the dipstick down fully and then remove it again.

Lubrication system, Engine IMPORTANT! With a new or reconditioned engine, the oil and oil filters must be changed after 20–50 hours of operation. Use

Carbon monoxide poisoningWhen a boat is moving forward, it will cause a certain vacuum to form behind the boat. In unfortunate cir-cumstances, the su

Changing engine oilAlways observe the recommended oil change interval. IMPORTANT! Only use a recommended grade of oil. Please refer to the “Technic

Changing oil filter and bypass filter. Change the oil filter and bypass filter during each oil change.Remember to hand the old filters in to a re-cycling

Freshwater systemThe fresh water system is the engines’ internal cooling system, which ensures that the engine operates at the correct temperature. It

Coolant. Mixture WARNING! All glycol is hazardous and harmful to the environment. Do not consume! Glycol is flammable. IMPORTANT! Ethylene glycol mus

Draining fresh water systemRemove the filler cap on the expansion tank (to allow the coolant to run out faster). Use a suitable recep-tacle while drain

Checking/Changing impeller WARNING! Risk for water penetration.Remove the cover from the seawater pump and re-move the impeller (1). If there are cra

Cleaning seawater filter WARNING! Risk for water penetration.Screw off cover (1) and remove seal plate (2). Lift out and clean the insert (3). IMPORT

Checking/Changing sacrificial anodes WARNING! Risk of water entering. Close the seawater cock before starting work on the sea-water system.1. Close t

Seawater system. Cleaning and inhibitingTo prevent the build up of deposits and salt crystals in the seawater system it must be flushed with freshwa-te

Fuel systemThe engine fuel system is a so-called common rail-system. The advantage of the common rail-system is that the engine control unit controls

Safety precautions for maintenance and service operations PreparationsKnowledgeThe operator’s manual contains instructions on how to carry out gener

Bleeding the fuel system The fuel system must be bled e.g. after changing fuel filter, if the fuel tank has been run dry and after long stops. WARNING

Fuel pre-filter. Changing filter insertClose fuel cock at the fuel tank. Position a container under the fuel filter.Remove the cover by slackening off sc

Electrical systemThe engine is equipped with a two-pole system electrical system which means that the voltage (minus) is re-turned directly from the s

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

Battery. Charging WARNING! Danger of explosion! The batteries give off hydrogen gas during charging which when mixed with air can form an explosive g

Electrical installationsLeakage current from the electrical system can be caused by incorrect installation of electrical equip-ment. Leakage current c

4. There must be a main switch connected to the starter battery positive (+) terminal. The main switch should cut off power to all power consum-ing e

Volvo Penta IPS drive-unitThe drive-unit is hydraulic, which means that forward/reverse engagement and disengagement is hydraulically activated. The d

Checking/changing the corrosion protection – Sacrificial anodesCheck the sacrificial anodes regularly. There are two anodes per drive-unit, one is atta

PropellersFor best performance and fuel economy the engine speed should be within the maximum RPM range: See chapter “Operation”. If the engine speed

Hot surfaces and fluidsThere is always a risk of burns when working with a hot engine. Beware of hot surfaces. For example: the exhaust pipe, Turbo u

Assembly1. Apply water-resistant grease, part no. 828250 to the splines and thread on both propeller shaft.4B5A32D2. Install the aft propeller. Then

Laying up/LaunchingBefore taking the boat out of the water for winter/out-of-season storage have an authorized Volvo Penta work-shop inspect the engin

Bringing out of storage● Check oil level in the engine and the drive-unit. Top up if necessary. If there is inhibiting oil in the system drain and fil

Repairing the drive-unit antifouling coatingThe propulsion unit and propellers have an antifoul-ing coating applied from delivery. Inspect the coating

In case of emergency Despite regular maintenance according to the maintenance schedule and perfect operation, faults may occur which must be attended

Emergency shiftingIf a fault occurs which prevents the drive-unit from being operated (shifted) with the control lever it is possible to shift manuall

Alignment of drive-unitIf a fault occurs which prevents the drive-unit from be-ing operated with the steering wheel it is possible to align the drive-

4. Turn the crank tool back 75 turns. The drive-unit is now aligned straight forward.5. Remove crank tool. Disconnect the switch by pressing down th

Fault-tracingA number of symptoms and possible causes of engine malfunctions are described in the table below. Always contact your Volvo Penta dealer

Diagnostic functionThe diagnostic function monitors and checks that the engine, drive-unit and EVC system function normally. The diagnostic function