Volvo 5.7GiE300-J, 5.7GXiE-J, 5.7OSXiE-J, 8.1GiE-J, 8.1GXiE-J Operator's Manual
...
OPERATOR’S MANUAL
5.0L, 5.7L, 8.1L
SX-A, DPS-A, XDP-B
DAN
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CALIFORNIA PROPOSITION 65 WARNING
Engine exhaust, some of its constituents, and a broad range of engine parts are known to the
State of California to cause cancer, birth defects, and other reproductive harm. Additionally, lubricants, fuels, and other fluids used in engines–including any waste created through the wearing of engine parts–contain or produce chemicals known to the State of California to cause
cancer and birth defects or other reproductive harm.
Battery posts, terminals, and related accessories contain lead and lead compounds. Wash your
hands after handling. Used engine oil contains chemicals that have caused cancer in laboratory
animals. Always protect your skin by washing thoroughly with soap and water.
Copyright © 2007 Volvo Penta of the Americas, Inc. All rights reserved. This publication may not be copied, photocopied, reproduced, or converted to any electronic or machine-readable form in whole or in part without the express written consent from
Volvo Penta of the Americas, Inc.
This manual applies to the following engines and sterndrives.
Raw Water Cooled
Model Spec. No. Drive
5.0L
5.7L
8.1L
5.0L
5.0GXiE-J 3869446
5.0OSiE-J 3869451 XDP-B
5.7GiE300-J
5.7GXiE-J
5.7OSiE300-J
5.7OSXiE-J
8.1GiE-J
8.1GXiE-J
8.1OSiE-J 3869454 XDP-B
3869447
3869448
3869452
3869453
3869449
3869450
SX-A
DPS-A
SX-A
DPS-A
XDP-B
DPS-A
Closed Cooling System
Model Spec. No. Drive
5.0GXiE-JF 3869431
5.0OSiE-JF 3869432 XDP-B
SX-A
DPS-A
5.7L
8.1L
5.7GiE300-JF
5.7GXiE-JF
5.7OSiE300-JF
5.7OSXiE-JF
8.1GiE-JF
8.1GXiE-JF
8.1OSiE-JF 3869438 XDP-B
3869433
3869435
3869434
3869436
3869437
3869439
SX-A
DPS-A
XDP-B
DPS-A
Notes
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21169
Welcome Aboard
Congratulations on choosing a new boat equipped with a
Volvo Penta marine engine. Volvo Penta has been building
marine engines since 1907. Quality, operating reliability,
and innovation have made Volvo Penta a world leader in the
marine engine industry. From engineering design and
manufacturing to support activities in Parts, Service, and
Sales, high standards have been set to ensure your pride
and satisfaction as the owner of a Volvo Penta product.
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.
We wish you many pleasant voyages.
Our Core Values: Quality, Safety,
Environmental Care
The values and qualities that Volvo Penta expresses are
what make the company unique. From the very beginning,
safety and quality have stood at the heart of the
development of all of our products, processes, and services.
It is on these values and qualities that the Volvo Penta
corporate identity, brand position and legal status have
been founded. Today’s core values of quality, safety, and
care for the environment remain central to Volvo Penta.
They express what we believe in as a company and will
ultimately help us to survive.
Quality is a value that traditionally referred to product
quality but now encompasses all aspects of our products
and services. In today’s competitive environment, Volvo
Penta’s quality commitment extends beyond industrial
craftsmanship and engineering ingenuity to embrace care
for the customer throughout the life of the product.
Safety will always be our most distinguishing core value.
Historically embedded in the quality of all Volvo products, it
also encompasses personal, family, business, and
environmental values.
Environmental Care in all operations, from design to
production, distribution, service, and recycling, is an integral
part of the Volvo quality commitment towards customers,
employees, and the community. By embracing the
environment as a core value, Volvo demonstrates its
understanding of the environmental impact its products
have upon nature and the shared urban and rural
surroundings.
Volvo Penta continually commits a considerable part of its
development resources toward minimizing the
environmental impact of its products. Examples of areas
where we are always looking for improvements are exhaust
emissions, noise levels, and fuel consumption.
Regardless of whether your Volvo Penta engine is installed
in a boat used for pleasure or commercial operation,
incorrect operation or improper maintenance of the engine
will result in disturbance or damage to the environment.
In this owner’s manual there are a number of service
procedures, which, if not followed, will lead to an increase in
the engine’s impact on the environment, and on running
costs and a reduction in service life. Always observe
recommended service intervals and make a habit of
checking that the engine is operating normally every time
you use it. Contact an authorized Volvo Penta dealer if you
cannot correct the fault yourself.
Remember that most chemicals used on boats are harmful
to the environment if used incorrectly. Volvo Penta
recommends the use of biodegradable degreasing agents
for all cleaning. Always dispose of engine and transmission
oil waste, old paint, degreasing agents and cleaning residue
etc. at proper disposal areas so that they do not harm the
environment.
Adapt speed and distance during your boat trips so that
swell and noise generated by the boat do not disturb or harm
wildlife, moored boats, docks, etc. Wherever you land or
cruise, please show consideration and always leave the
areas you visit as you would like to find them yourself.
CONTACT INFORMATION
Consumer Affairs Department
Volvo Penta of the Americas, Inc.
1300 Volvo Penta Drive
Chesapeake, Virginia 23320, USA
Phone: (757) 436-5100 • Fax: (757) 436-5153
http://www.volvopenta.com
Volvo Action Service - North America
P.O. Box 26113
Greensboro, North Carolina 27402-6113
Toll Free: (877) 33-PENTA • Phone: (336) 393-4966
http://myactionservice.com/English/VAS_Penta.asp
World-wide Dealer Locator
http://www.volvopenta.com
Table of Contents
Table of Contents
Safety Information 5
General Information ..................................................5
Safety Precautions (Maintenance and Service)........6
Knowledge ................................................................... 6
Engine Decals.............................................................. 6
Stop the Engine............................................................ 6
Lifting the Engine ......................................................... 6
Before Starting the Engine........................................... 6
Washing the Engine..................................................... 6
Fire and Explosion ....................................................... 7
Fuel and Lubrication Oil ......................................... 7
Non-Original Components...................................... 7
Batteries ................................................................. 7
Start Spray ............................................................. 7
Hot Surfaces and Fluids............................................... 8
Cooling System............................................................ 8
Fuel System ................................................................. 8
Lubrication System....................................................... 8
Electrical System.......................................................... 8
Carbon Monoxide Poisoning ........................................ 8
Chemicals .................................................................... 8
Safety Precautions While Operating the Boat...........9
Your New Boat............................................................. 9
Accidents...................................................................... 9
Maneuvering ................................................................ 9
Emergency Stop Switch............................................... 9
Daily Checklist.............................................................. 9
Refueling...................................................................... 9
Do not Start the Engine................................................ 9
“Station Wagon” Effect & Carbon Monoxide ...........10
Safety Checklists.....................................................11
Planning Your Trip ..................................................... 11
Trip Checklist........................................................ 11
Safety Equipment....................................................... 11
Safety Equipment Checklist ................................. 11
Replacement Parts and Tools Checklist .................... 11
Basic Safety Rules of Boating.................................12
High Performance Boat Operation............................. 12
Introduction 13
Care of the Environment .........................................13
Fuel and Oils ...........................................................13
Breaking-in..............................................................13
Certified Engines.....................................................14
Power Ratings.........................................................15
Load Condition (Speed of Planing Hull) ..................... 15
General Information 17
Warranty Information...............................................17
Warranty Registration Form....................................... 17
Doing Your Own Maintenance and Repairs............... 17
Volvo Action Service (VAS)........................................ 17
Volvo Penta Dealer Network...................................... 17
Toll-free Dealer Locator Service........................... 17
Volvo Penta on the Internet........................................ 17
Informational Decals and Identification Plates ........18
Identification Numbers ............................................... 19
Owner’s Identification Card........................................ 20
Service, Replacement Parts, and Accessories.......20
Instrumentation 21
Instrument Panel .................................................... 21
Audible Alarm .............................................................22
Emergency Stop Switch..............................................22
Checking Instruments.................................................23
Oil Pressure ..........................................................23
Engine Coolant Temperature................................23
Voltage/Charge .....................................................23
Power Trim/Tilt............................................................24
Trim Instruments.........................................................24
Analog Trim Instrument.........................................24
Trim/Tilt Motor Protection ...........................................25
Impact Protection ..................................................25
Engine Protection Mode ......................................... 26
Engine Control Module (ECM)....................................26
Other Instruments .................................................. 26
Controls 27
Remote Control Unit............................................... 27
Single Lever Control Operation ..................................27
Shifting from Neutral .............................................27
Disengaging the Shift Function .............................27
Twin Unit Maneuvering...............................................28
Neutral Interlock Button ..............................................28
Shifting between Forward and Reverse......................29
Cruising Speed ...........................................................30
How to Shift and Control Speed .................................30
Trim Controls ..............................................................31
Operating Trim Controls .............................................31
Control Panel ........................................................31
Remote Control Lever...........................................31
Friction Brake..............................................................32
Side Mount Remote Controls................................32
Top Mount Remote Controls.................................32
Operation 33
Operating the Engine ............................................. 33
Before Starting............................................................33
Starting the Engine .....................................................34
If the Engine Floods....................................................35
Stopping the Engine ...................................................35
Steering System Operation .................................... 36
Twin Unit Steering ......................................................36
Power Trim and Tilt Operation ............................... 37
Power Trim Operation.................................................37
Determining the Proper Trim ......................................38
Operating in “Bow-up” Position .............................38
Operating in “Bow-down” Position.........................39
Power Tilt Operation...................................................39
Power Trim/Tilt Switch & Gauge Location.............39
Special Boating Situations ..................................... 40
Shallow Water Operation............................................40
High Altitude Operation...............................................40
Operating in Freezing Temperatures..........................41
Salt Water Operation ..................................................41
Trailering Your Boat....................................................41
VPA 7748131 English 09-2007 1
Table of Contents
Features 43
Circuit Breakers and Fuses.................................... 43
Fuse and Relay Box Layout........................................43
Legend of Symbols Used in Engine Photos ...............43
5.0GXiE-J(F), 5.0OSiE-J(F), 5.7GiE300-J(F),
5.7GXiE-J(F), 5.7OSiE300-J(F),
5.7OSXiE-J(F) .............................. 44
8.1GiE-J(F), 8.1GXiE-J(F), 8.1OSiE-J(F)............... 46
SX-A Sterndrive ..................................................... 48
DPS-A Sterndrive................................................... 49
XDP-B Sterndrive................................................... 50
Maintenance Parts List 51
Engine Parts & Accessories ................................... 51
Engine Parts & Accessories (Continued) ............... 52
SX-A/DPS-A Drive Parts & Accessories ................ 53
XDP-B Drive Parts & Accessories.......................... 54
Maintenance 55
Engine Break-in Period .......................................... 55
Break-in Procedures...................................................55
First Two Hours.....................................................56
Next Eight Hours...................................................56
For the Next Ten Hours.........................................57
First Service Inspection (Dealer 50-Hour Check) .......57
Operating After Break-in Period..................................57
Preparing for Boating (Launching)..............................58
Off-Season Storage (Winterization)............................58
Static Water Line.................................................... 59
Static Water Line Test ................................................59
Maintenance Schedule........................................... 60
Maintenance of Boat’s Systems ............................. 63
Engine Exhaust System ......................................... 63
Drive Unit Bellows.......................................................64
PCV Valve ..................................................................65
Checking the PCV Valve.......................................65
Fuel System ........................................................... 66
Gasoline Recommendations.......................................66
Gasoline Containing Alcohol.................................67
Leaded Fuels ........................................................67
Electronic Fuel Injection..............................................68
Detonation (Spark Knock)...........................................68
Preventing Gum Formation and Corrosion.................68
Flame Arrestor............................................................69
Electric Fuel Pumps....................................................69
Fuel Filter....................................................................70
Engine Fuel Filter Replacement............................70
Electrical System.................................................... 71
Battery Cables ............................................................71
Batteries and Connections..........................................71
Battery Replacement ..................................................73
Multiple Batteries and Selector Switch..................73
Distributor Cap and Rotor...........................................73
Spark Plugs ................................................................74
Checking and Changing Spark Plugs ...................74
Circuit Breakers and Fuses ........................................75
Belt Replacement................................................... 76
Serpentine Belt Engines .............................................76
Cooling System ...................................................... 77
Raw Water System.....................................................77
Closed Cooling System (F-Series)............................. 77
Engine Overheating.................................................... 78
Replacing the Engine Thermostat.............................. 78
5.0–5.7L Engines (Raw Water Cooled) ................78
5.0–5.7L Engines (Closed Cooling System) .........79
8.1 Liter Engines (Raw Water Cooled) .................79
8.1 Liter Engines (Closed Cooling System) ..........80
Engine Flush .............................................................. 80
Draining the Cooling System...................................... 81
Raw Water Cooled Engines..................................81
Draining the Closed Cooling System.......................... 82
5.0–5.7 Liter Engines (F-Series)........................... 82
8.1 Liter Engines (F-Series).................................. 83
Impeller: Checking & Replacing .................................83
Lubrication System................................................. 84
Engine/Crankcase Oil................................................. 84
Checking Engine Oil Level....................................85
Changing Engine Oil.............................................85
Changing the Oil Filter..........................................86
Shaft Spline and Bearing Lubrication......................... 86
Tie Rod (Twin Installations Only) ...............................86
Steering System.........................................................87
Power Steering Reservoir Fluid Level .................. 87
Power Trim/Tilt-Fluid: SX-A/DPS-A............................88
Power Trim/Tilt Fluid: XDP-B .....................................88
Drive Components (SX-A/DPS-A).......................... 89
Drive Unit Lubrication (SX-A/DPS-A) .........................89
Checking the Drive Unit Lubricant (SX-A/DPS-A) 89
Draining and Filling the Drive Unit (SX-A/DPS-A) 89
Alternate Fill Procedure (SX-A/DPS-A) ................ 91
Sterndrive Oil Capacity (SX-A/DPS-A) .................92
Pitot Tube (Speedometer Port) ..................................92
Drive Components (XDP-B) ................................... 93
Drive Unit Lubrication (XDP-B)...................................93
Checking the Drive Unit Lubricant (XDP-B).......... 93
Draining the Drive Unit (XDP-B) ...........................93
Filling the Drive Unit (XDP-B) ...............................94
Sacrificial Anodes................................................... 95
Replacing Anodes (SX-A/DPS-A) ..............................95
Replacing Anodes (XDP-B)........................................ 96
Replacing Heat Exchanger Anodes ........................... 96
Active Corrosion Protection System
(SX-A/DPS-A Only)....................... 97
Painting the Drive (SX-A/DPS-A Only)................. 100
Preparation...............................................................100
Paint Application (SX-A/DPS-A Only) ......................100
Painting the Drive (XDP-B Only) .......................... 101
Preparation...............................................................101
Paint Application (XDP-B Only)................................ 101
Propeller Care ...................................................... 102
Propeller Replacement — SX-A...............................102
Removing the SX-A Propeller............................. 102
Installing the SX-A Propeller...............................102
Propeller Replacement — DPS-A ............................103
Removing the DPS-A Propeller ..........................103
Installing the DPS-A Propeller ............................103
Propeller Replacement — XDP-B ............................104
Removing the XDP-B Propeller ..........................104
Installing the XDP-B Propeller ............................104
2 VPA 7748131 English 09-2007
Table of Contents
Boat Bottom ..........................................................105
Bottom Painting........................................................ 105
Engine Alignment..................................................105
Engine Submersion.................................................. 105
Replacement Parts................................................106
Troubleshooting 107
Troubleshooting - System Isolation.......................107
Engine Troubleshooting Guides............................108
Technical Data 115
Metric Conversion Chart 121
General Torque Specifications 122
Appendix – EVC
EC
User’s Guide 123
Features................................................................123
Main EVC Components............................................ 123
Stations .................................................................... 124
Main Station ....................................................... 125
Secondary Station (Fly Bridge Station) .............. 125
Instrumentation .....................................................126
Start/Stop Panel ....................................................... 126
Power Trim Control Panel ........................................ 126
EVC Control Panel................................................... 127
EVC Displays ........................................................... 128
EVC Basic Window ............................................ 128
Alarm Display (Optional) .......................................... 129
General Warning: Red or Amber Indicator......... 129
Oil Pressure: Red Indicator ................................ 129
Water in Fuel ...................................................... 130
Battery: Amber Indicator..................................... 130
Coolant Temperature: Red Indicator .................. 130
Coolant Level ..................................................... 130
Oil Level ............................................................. 130
Gauges (Optional).................................................... 131
Main Menu ............................................................... 132
Menu Structure................................................... 132
Trip Menu................................................................. 134
Gauges Menu........................................................... 135
Multiple Window Display .......................................... 136
Display Contrast ................................................. 136
Connection Fault ................................................ 136
ENGINE Page (Button 1) ................................... 137
MULTI Page (Button 2) ...................................... 138
Trip Page (Button 3) ........................................... 139
Graph Page (Button 4) ....................................... 139
Operation ..............................................................140
Checking the Control Panel LEDs............................ 140
Checking the Display(s) ........................................... 140
Acknowledging Alarms and Messages............... 140
Clear Flood Before Starting the Engine.............. 140
Starting Using the Start/Stop Panel.................... 140
Operation (Continued)
Station Handling .......................................................141
Active Station ......................................................141
Changing and Activating Station.........................141
Locking/Unlocking Stations.................................142
Disengaging the Shift Function ...........................142
Engine Synchronization Function........................142
Stopping Using the Start/Stop Panel...................142
Power Trim ...............................................................143
Power Trim Buttons.............................................143
Trim Ranges........................................................144
Power Trim Instrument and Displays ..................145
Power Trim Assistant ..........................................146
Emergency Trimming..........................................146
Troubleshooting ................................................... 147
Diagnostic Function ..................................................147
Alarms and Messages ..............................................147
Alarm for Faults...................................................147
Alarm for Fuel or Depth (Optional)......................148
Acknowledging Alarms and Messages ...............149
Retrieving Faults.......................................................150
Fault Register ...........................................................151
Calibrations and Settings ..................................... 154
EVC Settings ............................................................154
Entering the Settings Menu.................................154
Contents of the Settings Menu .................................155
PTA (On/Off).............................................. 156
Neutral Beep .......................................................156
Depth Alarm (Optional) .......................................157
Units..........................................................................159
US or Metric ........................................................159
Distance ..............................................................159
Fuel Tank Calibration................................................160
Fuel Multipoint Calibration...................................160
Fuel Full Tank Calibration ...................................161
Approximated Trip Data ......................................161
Fuel Alarm Pop-up ..............................................161
Fuel Level Signal Loss ........................................161
Select Language.......................................................162
Display Contrast .......................................................162
PTA Calibration.........................................................163
Speed Factor (Optional) ...........................................164
Information Beep ......................................................164
Settings – EVC System Display................................165
Display Contrast..................................................165
Configuration Menu.............................................165
Bleep...................................................................165
Engine.................................................................166
Display (Interval) .................................................166
Index 167
VPA 7748131 English 09-2007 3
Table of Contents
Notes
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4 VPA 7748131 English 09-2007
Safety Information
Read this chapter carefully. It concerns your safety. This section describes how safety information is presented in
the operator’s manual and on the engine. It also gives a general account of basic safety precautions to be taken
when operating the boat and maintaining the engine.
Check that you have the correct operator’s manual before you read on. If this is not the case please contact
your Volvo Penta dealer.
This symbol is used in the book and on the engine to make you aware of safety information. Always read
these safety precautions very carefully.
Incorrectly performed operations could result in personal injury, damage to property, or harm the engine.
Read the operator’s manual carefully before operating or servicing the engine. If anything is unclear, please
contact your Volvo Penta dealer for assistance.
In the operator’s manual warning texts have the following priority:
Safety Information
DANGER! Failure to comply with a danger symbol will result in death.
WARNING! Failure to comply with a warning may result in serious injury.
CAUTION! Failure to comply with a caution may result in injury.
NOTICE! Special attention should be used to prevent incorrect assembly, disassembly, or use. Failure to
comply with a notice may result in equipment failure or damage.
General Information
This manual contains information you need to operate your boat engine and drive safely. Check that you have the
correct manual for your engine and drive.
This manual also contains a considerable amount of information concerning model identification, preventive
maintenance recommendations, fuel and oil recommendations, and other important points. Please keep this book
with your boat at all times.
It is important that this manual stays with the boat when it is sold. Important safety information must be
passed to the new owner. The service information provided in the manual gives the owner important
information about maintaining the engine and transmission.
If you do not understand or are uncertain about any operation or information in this owner’s manual, please contact
your Volvo Penta dealer. He will be able to help you with an explanation or will demonstrate the operation.
Federal law requires manufacturers to notify owners in the event that a safety related defect is discovered
on any of their products. If you are not the original owner of this engine, please notify us at our address
or through an authorized Volvo Penta dealer about the change in ownership. This is the only way we will
be able to contact you if necessary.
Carefully observe the safety alert symbols shown for dangers, warnings, and cautions. They warn you of possible
dangers or important information contained in this manual. However, warnings alone do not eliminate hazards, nor
are they a substitute for safe boat handling and proper accident prevention measures!
VPA 7748131 English 09-2007 5
Safety Information
Safety Precautions (Maintenance and Service)
The following sections summarize the risks associated with carrying out certain activities while operating or
maintaining your boat and engine and the safety precautions you should always observe while engaged in these
activities.
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.
Engine Decals
Check that the warning or information decals on the
engine are always clearly visible. Replace decals that
have been damaged or painted over.
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 engine, remove the
ignition key, turn off the power supply to the engine at
the main switches, and lock them in the OFF position,
or disconnect the battery cables from the battery 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 that is running
is dangerous. Loose clothing, hair, fingers or a
dropped tool can be caught in the rotating parts of the
engine and cause serious personal injury. We recommend that all servicing with the engine running be undertaken by an authorized Volvo Penta workshop.
Lifting the Engine
To ensure safe handling and to avoid damaging engine components on top of the engine, use a lifting
beam to raise the engine. All chains and cables should
run parallel to each other and as perpendicular as
possible in relation to the top of the engine. Always
check that lifting equipment is in good condition and
has sufficient load capacity to lift the engine and any
extra equipment installed.
If extra equipment is installed on the engine, which alters its center of gravity, a special lifting device is required to achieve the correct balance for safe
handling. 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. Make a point of
familiarizing yourself with other risk factors, such as
rotating parts and hot surfaces (exhaust manifold,
starter, etc.). Check that no tools or other items have
been left on the engine.
DANGER! To prevent a possible explosion
hazard, operate the engine compartment/
bilge blower as recommended by the boat
manufacturer before starting the engine. If
the engine compartment is not equipped with
a blower, open the engine cover or hatch before starting so as to disperse any gasoline
fumes that may be present. Leave the hatch
open until after the engine is running.
Washing the Engine
Never use a high-pressure washer when washing the
engine.
6 VPA 7748131 English 09-2007
Fire and Explosion
Safety Information
Fuel and Lubrication Oil
All fuels, most lubricants, and many chemicals are
flammable. 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. Fuel
soaked rags can self-ignite under certain conditions.
Do not smoke when filling fuel, oil, or while in the proximity of a filling station or in the engine room.
Certain engine oils are flammable. Some of them are
also dangerous if inhaled. Whenever you use these
agents, follow the manufacturer’s instructions on the
product packaging. Ensure that ventilation in the work
place is good. Use a protective mask when spraying.
Non-Original Components
Components in the electrical, ignition, and fuel systems on Volvo Penta products are designed and constructed to minimize the risk of fire and explosion.
Using non-original Volvo Penta parts that do not meet
the above standards can result in fire or explosion on
board. Damage caused by using non-original Volvo
Penta replacement parts will not be covered under
any warranty provided by Volvo Penta.
Batteries
Never allow an open flame or electric sparks near the
battery or batteries. Never smoke in proximity to the
batteries. The batteries give off hydrogen gas during
charging which, when mixed with air, can form an explosive gas. This gas is easily ignited and highly volatile.
Incorrect connection of the battery can cause a spark,
which would be sufficient to cause an explosion. Do
not disturb battery connections when starting the engine (spark risk) and do not lean over batteries.
Always ensure that the positive and negative battery
leads are correctly installed on the corresponding terminal posts. Incorrect installation can result in serious
damage to electrical equipment.
Always use protective goggles or a face mask when
charging and handling batteries. Battery electrolyte
contains sulphuric acid, which is highly corrosive. If
battery electrolyte comes into contact with unprotected skin, wash it off immediately using plenty of water
and soap. If battery acid comes in contact with the
eyes, immediately flush with an abundant amount of
water and obtain medical assistance.
Start Spray
Never use start spray or similar agents to start an engine. This may cause an explosion in the inlet manifold.
VPA 7748131 English 09-2007 7
Safety Information
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 and manifold, oil pan, starter element,
hot coolant, and hot oil in oil lines and hoses.
Always turn off the engine before starting service procedures. Avoid hot surfaces and liquids in supply lines
and hoses when the engine has just been turned off
and is still hot.
Cooling System
There is a risk of flooding when working on the seawater system. Turn off the engine and close the sea
cock (where installed) before starting work on the system.
Avoid opening the filler cap for engine coolant system
(freshwater cooled engines) when the engine is still
hot. Steam or hot coolant can spray out as system
pressure is lost.
If opening the filler cap or drain/venting cock, or removing a plug or engine coolant line from a hot engine, open the filler cap slowly and release coolant
system pressure gradually; otherwise, steam or hot
coolant can spray out. Note that the coolant may still
be hot and can cause burns.
Fuel System
Always use protective gloves when tracing leaks. Liquids ejected under pressure can penetrate body tissue and cause serious injury. There is also a danger
of blood poisoning.
Always cover the alternator if it is located under the
fuel filter. The alternator can be damaged by spilled fuel.
Fuel filter replacement should be carried out on a cold
engine to avoid the risk of fire caused by fuel spilling
onto the exhaust manifold.
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; hot
oil could spray out.
Electrical System
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.
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. Please see ““Station Wagon” Effect &
Carbon Monoxide” on page 10 for additional information.
Chemicals
Most chemicals such as anti-freeze, rust-proofing
agents, inhibiting oils, degreasing agents, etc., are
hazardous to your health. Read and follow the instructions on the packaging.
Some chemicals such as inhibiting oil are flammable
and toxic if breathed. 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.
8 VPA 7748131 English 09-2007
Safety Precautions While Operating the Boat
Safety Information
Your New Boat
Read the operator’s manuals and other information
supplied with your new boat. Learn to operate the engine, controls and other equipment safely and correctly. If this is your first boat, or is a boat type with which
you are not familiar, we recommend that you practice
controlling the boat in peace and quiet, away from other vessels, docks, shallow areas, and other obstacles.
Learn how the boat behaves at different speeds, in
varying weather conditions, and alternating loads before casting off for your “real” maiden voyage.
Remember that the person driving a boat is legally required to know and follow the current rules regarding
traffic and safety at sea. Make sure you know the rules
that apply to you and the waters you are sailing in by
contacting the relevant authorities or organization. A
good piece of advice is to take a course in seamanship. We recommend that you contact your local boating organization to find a suitable course.
Accidents
Statistics show that poor maintenance of boats and
engines and a lack of safety equipment are often the
main causes of accidents at sea. Ensure that your
boat is maintained in accordance with the relevant user’s documentation and that the necessary safety
equipment is on-board and is serviceable.
Maneuvering
Avoid violent and unexpected changes in course and
gear engagement. This could cause someone on the
boat to lose their balance and fall over or overboard. 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. Avoid trimming an outboard drive too much, as steering will be severely reduced.
Emergency Stop Switch
We recommend that you install and use an emergency stop switch (accessory), especially if your boat can
travel at high speeds. The emergency stop switch acts
as a safety breaker and stops the engine if the driver
falls down and loses control over the boat.
NOTICE! When testing the emergency stop switch,
do so at engine idle speed only. Activating
the emergency stop switch at any speed
above idle will allow water to be ingested
into the engine, causing serious damage.
Daily Checklist
To prevent a possible explosion or fire, make a habit of
checking the engine and engine compartment visually
before operating the boat (before the engine is started) and after operating the boat (after the engine has
been stopped). Also, smell for the presence of gas
fumes. This will help you to quickly detect fuel, coolant, or oil leaks and to spot anything else unusual that
has occurred or is about to happen.
If the engine compartment is not equipped with a
blower, open the engine cover or hatch before starting
it to disperse any gasoline fumes that may be present.
Leave the hatch open until after the engine is running.
Refueling
When refueling there is always a danger of fire and explosion. Smoking is forbidden and the engine must be
switched off. Never overfill the tank. Close the fuel
tank filler cap properly.
Always use fuel recommended by Volvo Penta. The
use of lower quality fuels can damage the engine.
Poor fuel quality can also lead to higher maintenance
costs.
Do not Start the Engine
Do not start or run the engine with a suspected fuel or
LPG leak in the boat, nor when you are close to or in
a discharge of explosive media, etc. There is risk of
fire and/or explosion in explosive surroundings.
VPA 7748131 English 09-2007 9
Safety Information
“Station Wagon” Effect & Carbon Monoxide
When a boat is moving forward, it will cause a certain
vacuum to form behind the boat. In unfortunate circumstances, the suction from this vacuum—called
“station wagon” effect—can be so great that the exhaust gases from the boat are drawn into the cockpit
or cabin, causing carbon monoxide poisoning.
This problem is most prevalent on boats with sheer,
broad transoms and high superstructures. In certain
conditions, however, this suction can be a problem on
other boats (e.g., when running with the cover up).
Other factors that can increase the effect of the suction are wind conditions, load distribution, swells, trim,
open hatches and portholes, and so on.
Most modern boats, however, are designed in such a
way that this problem is very rare. If suction should
arise anyway, open forward hatches or portholes. Try
changing speed, trim, or load distribution instead. Try
disassembling, opening, or in any other way changing
the setup of the cover as well.
If you suspect that your boat exhibits this “station wagon” effect, please contact your Volvo Penta dealer for
help in achieving the best solution for your boat.
DANGER! Do not run the engine while
there are people located on or near the swim
platform and transom.
DANGER! DO NOT tow anyone using water sports equipment (such as skis and inner tubes) closer than twenty feet (20’) from
the boat. DO NOT, under any circumstances, allow people to “body surf” using the
swim platform as a means of being pulled
along.
Travelling at slow or idle speeds may cause carbon
monoxide to accumulate in and around the boat, especially if there is a tailwind.
Carbon monoxide accumulation is particularly likely
when running the engine while docked. Be sure to
minimize the amount of time spent at the dock while
the engine is running.
For your safety, we recommend that you install a
good quality carbon monoxide detector aboard
your boat, in accordance with ABYC recommended practices.
22770
10 VPA 7748131 English 09-2007
Safety Information
Safety Checklists
Planning Your Trip
Everyone wants to have a problem-free and pleasant time when they take their boat out. To help you do
this, we have provided a pre-journey checklist below. Take extra time to check the engine and its equipment and the general maintenance of the boat.
Trip Checklist
Get up-to-date charts for the planned route.
Calculate distances and fuel consumption.
Note places where you can refuel along your planned course.
Listen to the weather reports.
Tell friends or relatives about your route (that is, file a “float plan”). Remember to inform them if
your plans have changed or been delayed.
Safety Equipment
The following list of recommended safety equipment can be expanded or modified as necessary because safety equipment and other requirements vary depending on the type of boat and how it is used.
Safety Equipment Checklist
Life jackets for all passengers.
Communication equipment.
Emergency rockets or flare gun.
Approved fire extinguisher, checked and charged.
First-aid equipment.
Life belt.
Anchor, paddles, flares, and so on.
Tell your passengers and crew where the safety equipment is stored and how to operate it.
Make sure you are not the only person on board who knows how to start the boat and operate
it safely.
Replacement Parts and Tools Checklist
Extra propeller & prop hardware, impeller, fuel filters, fuses, tape, hose clamps, thermostat &
gaskets, cap & rotor, start pump & fuel pump relays, and engine oil.
Tools for any possible repairs while underway.
VPA 7748131 English 09-2007 11
Safety Information
Basic Safety Rules of Boating
We recommend that you contact your local boating organization for more detailed information on safety
afloat.
• Shut off the engine when people who are in the
water come near the boat.
• Propellers are inherently dangerous and, as such,
are potential safety hazards. Make sure that the
propeller is not operating when people who are in
the water come near the boat.
• Avoid standing up or shifting weight suddenly in
small, lightweight boats.
• Keep your passengers seated in seats. The boat’s
bow, gunwale, transom, and seat backs are not
intended for use as seats.
• Insist on the use of personal flotation devices by
all passengers at all times.
• Know the “rules of the road” and obey them. If you
are not familiar with the “rules of the road,” take
the U.S. Coast Guard’s boater safety course. You
may find information about boating safety at
WWW.USCGBOATING.ORG and
WWW.CGAUX.ORG.
• Prevent explosion and fire by maintaining your fuel
delivery system in top condition. Fuel vapor is volatile; handle fuel with care.
• Keep your boat and equipment neat and in top
operating condition. Carry a selection of spare
parts for the engine. (Volvo Penta’s on-board kit
contains a selection of essential items that a boat
owner should carry at all times. See your Volvo
Penta dealer.)
• NEVER OPERATE THE BOAT IF YOU ARE
UNDER THE INFLUENCE OF DRUGS OR
ALCOHOL.
• If boating in waters that are unfamiliar, obtain
appropriate charts to avoid damage from underwater objects.
High Performance Boat Operation
High performance is not only defined by engine size,
but by a combination of engine power (horsepower),
hull design, and the size of the boat. Your new engine(s) produce a high power output. Depending on
the boat type, the top speed may be much higher than
what you are accustomed to.
High speed operation requires an experienced operator who has mastered handling of high performance
boats. It is advisable that you learn the boat’s behavior
before you take passengers on board. Inform your
passengers about your boat’s characteristics and the
maneuvers you intend to do. Use the boat’s performance with due consideration and care!
When operating at high speeds, remember that other
boaters may not realize the speed at which you are
travelling, especially when you close in on another
boat from astern or from ahead. Always keep a good
distance to allow for the unexpected! Always be prepared for what other boaters may do unexpectedly.
High speed driving requires the driver to give a high
degree of attention to boat operation and surrounding
conditions.
A boat travelling at a speed of approximately 70
M.P.H. (60 knots) covers about 101 feet (30 meters) in
1 second. The faster you go the quicker things will
happen. High speed driving requires a lot of water and
a good distance from possible hazards! Always allow
for adequate reaction time. Always reduce speed
when visibility is reduced for whatever reason.
When driving, make sure that all passengers are safely seated. Emphasize this especially if you have a larger, high performance cabin cruiser where one
normally moves about during operation. Reduce
speed considerably, or stop completely if someone
needs to move about the boat.
The driver should always use the emergency stop
switch! The emergency stop switch lanyard which is
securely connected to the driver, immediately shuts
off the engine(s) should the driver be thrown from the
driving position. Even if the risk of being thrown overboard is practically nonexistent in your type of boat,
the risk of the driver falling and being dazed in rough
seas can be even greater.
Remember, even when the engine(s) is stopped in a
high performance boat that is planing, it will travel approximately 325 feet (100 meters) before dropping
through the planing threshold and stopping!
12 VPA 7748131 English 09-2007
Introduction
This operator’s manual has been compiled to help you get the most from your Volvo Penta engine. It contains
information you need in order to operate and maintain your engine safely and correctly. Please read the operator’s
manual carefully and learn how to operate the engine, controls, and any other equipment safely.
Always have the operator’s manual available. Keep it in a safe place and do not forget to give it to the new owner
if you sell your boat.
Introduction
Care of the Environment
We would all like to live in a clean and healthy environment—somewhere where we can breathe clean air,
see healthy trees, have clean water in our lakes and
oceans, and are able to enjoy the sunshine without
being worried about our health. Unfortunately, this
cannot be taken for granted nowadays; we must work
together to achieve this vision.
As a manufacturer of marine engines, Volvo Penta
has a special responsibility, where care of the environment is a core value in our product development. Today, Volvo Penta has a broad range of engines on
which progress has been made in reducing exhaust
emissions, fuel consumption, engine noise, and other
detrimental side-effects. We hope you will take care in
preserving these qualities.
Always follow any advice given in the manual—concerning fuel grades, operation, and maintenance procedures—and you will avoid unnecessarily harming
the environment. Get in touch with your Volvo Penta
dealer if you notice any changes such as increased
fuel consumption or exhaust smoke.
Adapt speed and distance to avoid wash and noise
disturbing or injuring animal life, moored boats, jetties,
etc. Leave islands and harbours in the same condition
as you want to find them.
Remember to always leave hazardous waste such as
waste oil, coolant, paint and wash residue, flat batteries, and other toxic disposables at a suitable disposal
site or destruction plant.
Our joint efforts will make an invaluable contribution to our environment.
Fuel and Oils
Only use the fuel and oils recommended in the chapter entitled Technical Data on page 115. Other grades
of fuel and oil can cause operating problems, increased fuel consumption and—in the long-term—a
shorter engine service life.
Always change oil, oil filters, and fuel filters at the recommended intervals.
Breaking-in
The engine must be broken-in for its first 20 operating
hours as follows:
• Operate the engine normally.
• Do not operate it at full load except for short peri-
ods.
• Never run the engine at a constant engine speed
for long periods during the breaking-in period.
• Check the oil level more often than is normally
recommended; the engine can be expected to
use more engine oil during the breaking-in
period than would otherwise be normal.
For a more detailed explanation of the break-in period,
please refer to the appropriate section in the chapter
entitled Maintenance on page 55.
A First Service Inspection should be carried out after
50 running hours. For additional information please
refer to the document entitled Warranty Infor mation
North America PN 7796733.
VPA 7748131 English 09-2007 13
Introduction
Certified Engines
If you own an engine certified for any area where exhaust emissions are regulated by law, the following is
important:
Certification means that an engine type is inspected and approved by the authorities. The engine manufacturer
guarantees that all engines manufactured of that type correspond to the certified engine.
This places special requirements for maintenance and service as follows:
• The maintenance and service intervals recom-
mended by Volvo Penta must be observed.
• Only genuine Volvo Penta replacement parts
may be used.
• The servicing of ignition, timing, and fuel injec-
tion systems must always be carried out by an
authorized Volvo Penta workshop.
• The engine must not be modified in any way
except with accessories and service kits
approved by Volvo Penta.
• No modifications to the exhaust pipes and air
supply ducts for the engine may be undertaken.
• Seals may only be broken by authorized person-
nel.
Otherwise the general instructions contained in this
Operator’s Manual concerning operation, service, and
maintenance must be followed.
NOTICE! Late or inadequate maintenance/service or
the use of spare parts other than Volvo
Penta original spare parts will invalidate
Volvo Penta’s responsibility for the engine
specification being in accordance with the
certified variant.
Volvo Penta accepts no responsibility or liability for
any damage or costs arising due to the above.
22771
14 VPA 7748131 English 09-2007
Introduction
Power Ratings
A great number of environmental factors, such as barometric pressure, ambient temperature, humidity, the
quality of fuel, and exhaust back pressure can affect
engine performance. When it comes to quoting and
comparing ratings, it is important that there is a unified
set of standards for measurement.
In September 1989, all major marine engine manufacturers agreed to quote engine power output according
to a common set of conditions. These conditions are
referred to as ISO 8665. All Volvo Penta engines meet
the ISO 8665 standard. This ISO standard outlines the
following fixed values or common conditions for determining the rating of the engine.
Condition Value
Air temperature .........................25°C (77°F)
Barometric pressure.................. 100 kPa (14.504 PSI)
Relative humidity....................... 30%
A gasoline engine operates with very little surplus air.
When conditions deviate from the standard values,
the result can be a loss of power at full load. It can also
cause a rise in exhaust emissions due to incomplete
fuel combustion.
Marine engines can be rated according to one of several power standards, but power output itself is quoted
in kilowatts (KW) or horsepower (HP), for a given engine speed, usually at maximum revolutions per
minute (RPM).
Load Condition (Speed of Planing Hull)
The overall weight of the boat is another important
factor in performance. Any increase in boat weight will
slow down the boat speed, particularly on boats with
planing and semi-planing hulls.
For example, a new boat tested with fuel and water
tanks only half filled, and without any load, can easily
drop 2 to 3 knots in speed when tested fully fuelled
and loaded with all normal equipment and supplies for
safe and comfortable cruising. This is because the
propeller installed originally is frequently one that is
designed to give maximum speed when the boat is
new. For this reason it is often advisable to reduce the
propeller pitch by as much as an inch or more in order
to counter the effects of the increase in overall weight
encountered in normal cruising, particularly in hotter
climates. Although this will reduce top speed somewhat, overall ride conditions will improve and you
should achieve greatly enhanced acceleration.
In considering the influence of weight, it is worth remembering that fiberglass boats absorb a significant
amount of water into their hulls while left afloat for any
length of time and so become progressively heavier.
Another negative influence on boat performance is
marine growth beneath the water line–a problem that
is often overlooked.
VPA 7748131 English 09-2007 15
Introduction
Notes
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16 VPA 7748131 English 09-2007
General Information
General Information
Warranty Information
Volvo Penta’s warranty package can be found in the
accompanying warranty booklet. Along with the warranty information you will find other checklists and reports for Volvo Penta products.
Your new Volvo Penta marine engine is covered by a
limited warranty according to the conditions and instructions contained in the document entitled Warran-
ty Information North America PN 7796733.
Note that Volvo Penta’s liability is limited to that contained in Warranty Information North America. Read
this book as soon as you take delivery of the engine.
It contains important information about warranty
cards, service, and maintenance which you must be
aware of, check, and carry out. Liability covered in the
warranty may otherwise be refused by Volvo Penta.
The Volvo Penta International Warranty may apply
outside the U.S. This warranty may contain different
terms and conditions determined by prevailing national legislation and regulations. Information about these
conditions can be obtained from Volvo Penta importers and dealers in those areas. Please contact your
local Volvo Penta representative for a copy.
Warranty Registration Form
The Warranty Registration Form should always be
filled out and sent in by the dealer. Make sure that this
has been done, since delay of warranty claims can occur if no proof of the delivery date can be provided.
Please contact your Volvo Penta dealer if you
have not received a copy of Warranty Information
North America PN 7796733 and a customer copy
of the warranty card.
Doing Your Own Maintenance and Repairs
If you plan to do your own maintenance and repairs on
your Volvo Penta products, you should purchase a set
of service manuals that pertain to your particular engine and drive. Keep in mind, however, that there are
certain tasks which should only be performed by your
Volvo Penta dealer. The dealer has the tools, expertise, and most current information needed to properly
perform these tasks.
Volvo Action Service (VAS)
Volvo Action Service (VAS) is a consumer breakdown
service available 24 hours each day, 365 days per
year. If your engine breaks down, the VAS coordinator
will quickly locate your nearest dealer. If you need a
tow, parts, or mechanic, the VAS coordinator will
make all arrangements necessary to get you back underway as soon as possible.
Membership to Volvo Action Service is provided automatically to all Volvo Penta engine owners. As long as
your Volvo Penta engine is under factory warranty,
this service covers Volvo Penta-related repairs. Refer
to the accompanying warranty literature for detailed
information regarding coverage.
If you have a question about Volvo Action Service, or
need additional information, please call toll-free 1877-33-PENTA.
Volvo Penta Dealer Network
The Volvo Penta worldwide network of authorized
dealers are at your service. They are specialists in
Volvo Penta products and have the accessories, original replacement parts, test equipment, and special
tools necessary for high quality service and repair
work.
Always take your Volvo Penta product to an authorized Volvo Penta servicing dealer for repair. Our dealers have the knowledge, factory-trained technicians,
and special tools to take care of any necessary repairs. Ideally, take your product back to your selling
dealer — he also knows you and your equipment.
Toll-free Dealer Locator Service
If you are away from your home waters, take your Volvo Penta product to the nearest Volvo Penta servicing
dealer. For the name and location of your nearest Volvo Penta dealer, consult the Yellow Pages under Boat
Dealers, search the dealer locator on the internet, or
call 1-800-522-1959.
Volvo Penta on the Internet
The URL address for Volvo Penta of the Americas is
http://www.volvopenta.com.
VPA 7748131 English 09-2007 17
General Information
Informational Decals and Identification Plates
The following images provide graphical representations of various engine decals. The areas described are general
locations and are intended to be guides only. Engine models and configurations do vary and, depending on the
amount of space available, the exact locations of engine decals tend to vary also.
22772
22774
3863274
22773
The engine decal is located on the engine cover.
The engine plate is typically located on the port side of
the engine flywheel housing, slightly below and aft of
the exhaust manifold.
The label depicting the serpentine belt configuration is
typically mounted on a flat surface located on the front
of the alternator/automatic tensioner bracket.
The California Emission sticker is located on the engine cover.
The Emission Control Information sticker is located on
22776
the flat outside face (port side of engine) of the alternator support bracket.
22775
18 VPA 7748131 English 09-2007
The tune-up and color code decal is located on the engine cover.
General Information
Identification Numbers
Always provide the engine, transom shield, and drive identification numbers when ordering service or replacement
components. The engine identification numbers are on informational decals located in the spots described on the
previous page. Make a note of the information on the lines provided below. Make a copy of this page and store
the information so that it is available in event of the boat being stolen.
Engine - Decal
Product Designation (A) ..............................................................
Specification No. (B) ...................................................................
Serial No. (C) ..............................................................................
Engine - Plate
Product No. (A) ...........................................................................
Type (B) .......................................................................................
Serial No. (C) ..............................................................................
Transom Shield Plate
Product No. (A) ...........................................................................
Type (B) .......................................................................................
Ratio (C) ......................................................................................
Serial No. (D) ..............................................................................
Drive
Product No. (A) ...........................................................................
Type (B) .......................................................................................
Ratio (C) ......................................................................................
22772
22774
22778
Serial No. (D) ..............................................................................
22778
Transom Assembly & Drive Unit Stickers
22779
Product Designation (A) .................................... /...................................
Specification No. (B) .................................. /..........................................
Serial No. (C) .......................................... /............................................
22780
The Transom Assembly & Drive Unit Stickers shown above should be located on the Engine Decal. Your Volvo
Penta dealer will have attached these stickers at the time that the transom assembly and drive unit were mounted
on your boat and attached to the engine.
VPA 7748131 English 09-2007 19
General Information
Owner’s Identification Card
When you purchased your boat the dealer was required to register your power package with Volvo Penta. Your
dealer should provide you with proof of ownership in the form of an Owner's Registration Card or a print-out of the
Volvo Penta computer on-line registration screen. This provides proof of ownership and is required to validate
warranty, should warranty service become necessary. Warranty coverage may be delayed until the warranty and
registration form is on file at Volvo Penta.
Service, Replacement Parts, and Accessories
Genuine Volvo Penta parts are the result of many hours of strenuous testing and fulfill Volvo Penta’s strict quality
and safety requirements. Also, Volvo Penta marine engines are designed for high operational reliability and a long
service life. They are manufactured to withstand the marine environment while also affecting it as little as possible.
Through regular service and the use of Volvo Penta original spare parts, these qualities will be retained.
When replacements are required, use only Volvo Penta genuine parts. Always follow the maintenance intervals
contained in the operator’s manual. Remember to state the engine/transmission identification number when
ordering service and replacement parts.
Purchase all Volvo Penta replacement parts, accessories, coolants, and lubricants from an authorized Volvo Penta
dealer. The dealer has needed parts in stock for routine maintenance, as well as the information needed to order
special parts and accessories for you.
20 VPA 7748131 English 09-2007
Instrumentation
Instrumentation
Instrument Panel
The following section contains a general description of the instrument panel. Please note that instrument panels
are installed by the boat builder and will vary depending on the model installed. Commonly, instrument panels are
equipped with a tachometer, temperature gauge, oil pressure gauge, voltmeter, instrument panel lighting switch,
and an ignition switch.
Instruments and ignition switches can also be supplemented with extra Volvo Penta instruments such as:
synchronization tachometers, fuel gauge, fresh water gauge, clock, speed log, or rudder indicator.
Note that the instrument cluster which is shown here installed in the instrument panels can be installed in other
positions on some boats. If your boat is fitted with instruments not described here and you are not sure of their
function, please get in touch with your boat dealer.
NOTICE! The instrument panel depicted below is a
sample representation only.
21179
1. Tachometer—Shows the engine RPM rate. Multiply this value by 100 or 1000 (depending on model) for
revolutions per minute. Integral “Hours run” meter (optional and separately installed) displays the engine’s
operating time in hours and tenths of an hour.
2. Temperature Gauge—Indicates engine temperature. Normal operating temperature for all 5.0–5.7L
engines is 155°-178°F (68°-81°C) and 135°-158°F
(57°-70°C) for 8.1L engines. Engines with closed cooling systems will typically run about 30°F (17°C) higher.
3. Oil Pressure Gauge—Indicates the engine oil
pressure. Normal operating oil pressure should be approximately 18 psi (124 kPa) minimum at 2000 RPM
on a warm engine. Lower oil pressure is normal and
should be expected at idle after a sustained cruise.
4. Voltmeter—Indicates the charge voltage from the
alternator which should normally be approximately 14
Volts. With the engine stopped and the switch on, battery voltage is normally indicated as 12 Volts.
5. Instrument Lighting—On Volvo Penta instrument
panels, turns panel lights on or off (varies, depending
on product manufacturer).
6. Ignition Switch—The ignition switch has three positions (varies, depending on product manufacturer):
0 The key can be inserted or removed.
I RUN: Ignition is ON and engine is OFF. System
voltage connected.
II START position (momentary). The starter mo-
tor is engaged and starting the engine.
NOTICE! Read the starting instructions in the section
21181
The ignition keys are marked with a code for use when
ordering extra keys (varies, depending on product
manufacturer). Record the code so that replacement
keys can be ordered. Keep the code in a safe place
where unauthorized persons do not have access to it.
VPA 7748131 English 09-2007 21
entitled Starting the Engine on page 34.
Instrumentation
Audible Alarm
If an audible alarm1 has been installed on your boat, it
will perform a brief self-test when the ignition key is
turned to the RUN position. Following is a description
of how the alarm performs the self test.
EFI Engines - When the ignition switch is turned to
RUN (key on, engine off), the alarm emits three short
beeps to indicate that the ECM is performing a check
of the sensors. If there are any problems detected by
the ECM, the alarm will sound; otherwise, it will remain off.
Emergency Stop Switch
An emergency stop switch, also called a safety breaker, may be a feature of your boat. Use of this switch is
highly recommended. To properly use this feature, attach the lanyard to clothing that will NOT tear away
before the lanyard is pulled from the switch to stop the
engine. If the lanyard is too long, shorten it by knotting
or looping it. DO NOT cut and re-tie the lanyard.
21182
The emergency stop switch can only be effective
when in good working order. Observe the following:
• Lanyard must always be free of entanglements
that could hinder its operation.
• Once a month, check the switch for proper oper-
ation. With engine running at idle speed, pull
lanyard. If engine does not stop, see your dealer
for repairs.
Using this switch is simple and should not interfere
with normal operation of the boat. Care must be tak-
en to avoid accidentally pulling the lanyard during
boat operation. Unexpected loss of forward motion will occur, as well as possible damage to the
engine. This could cause occupants to be thrown for-
ward. In an emergency situation, any occupant of the
boat may attempt to restart the engine by pressing in
and holding the emergency stop switch button, followed by normal starting procedures. When the button
is released, the engine will stop.
If your boat is not equipped with an emergency stop
switch and it falls into one of the following categories,
installation of an emergency stop switch is recommended.
• High performance sport boats
• Small runabouts
• Boats with sensitive steering
• Boats where the distance from the top of the
gunwale down to the driver’s seat is less than
one foot (30 cm).
Contact your Volvo Penta dealer for installation of an
emergency stop switch.
1. While Volvo Penta provides an audible alarm with every engine, its installation is determined by the manufacturer of your boat. If your
boat does not have an audible alarm available, we strongly recommend that you contact your dealer to have one installed.
22 VPA 7748131 English 09-2007
51274c
Instrumentation
Checking Instruments
Check instruments regularly. Stop the engine if there
is an abnormal reading or if the engine alarm sounds.
Oil Pressure
All engines have what is considered a normal operating oil pressure range. At engine idle this is normally
lower than at higher RPMs. For the normal operating
oil pressure range for your model engine, please refer
to the section entitled Technical Data on page 115.
Your boat is equipped with an audible low oil pressure
1
alarm
.
NOTICE! If oil pressure is too low: Stop the engine
immediately and investigate. Operating the
engine with oil pressure too low will damage the engine.
Engine Coolant Temperature
All engines have what is considered a normal operating temperature range. At engine idle this is normally
lower than at higher RPMs. Normal operating temperature for all 5.0–5.7L engines is 155°-178°F
(68°-81°C) and 135°-158°F (57°-70°C) for 8.1L engines. Engines with closed cooling systems will typically run about 30°F (17°C) higher.
51274d
51274e
Your engine is equipped with an engine coolant and
exhaust temperature acoustic alarm
1
.
NOTICE! If engine coolant or exhaust temperature is
too high: Idle the engine, shift to reverse
and then to forward. Idle the engine for 2 to
3 minutes and shut off the engine if the temperature does not decrease. Investigate
and correct the malfunction. Operating an
engine with temperatures too high will damage the engine.
Voltage/Charge
The operating charge is approximately 14 V. When the
engine is stopped and ignition is on, battery voltage is
approximately 12 V. With the ignition turned off, the
voltmeter will not register a charge.
1. While Volvo Penta provides an audible alarm with every engine, its installation is determined by the manufacturer of your boat. If your
boat does not have an audible alarm available, we strongly recommend that you contact your dealer to have one installed.
VPA 7748131 English 09-2007 23
Instrumentation
Power Trim/Tilt
Your Volvo Penta sterndrive is equipped with a power
trim/tilt system as standard equipment. The power
trim/tilt allows you to change the angle of the drive unit
from the helm. Changing the angle of the drive unit in
relation to the boat bottom is called trimming. Trimming provides these benefits:
• Improves acceleration to planing.
• Keeps the boat on plane at reduced throttle set-
tings.
• Improves fuel economy.
• Provides smoother and/or drier ride in choppy
water conditions.
• Increases maximum speed.
If you do not wish to use this feature, you may leave
the drive unit trimmed to the position that works best
for you.
22781
22782
Trim Instruments
The trim instrument indicates the current trim position.
Your boat may be equipped with an analog or a digital
trim instrument.
Analog Trim Instrument
The analog trim instrument has three main ranges:
• Trim Range–Use trim range for maximum com-
fort, under normal operation, from start to maximum speed.
• Beach Range–Use beach range for operating at
reduced speed in shallow water, where water
depth is uncertain. Also use this range when you
launch and take your boat out of water onto a
trailer ramp.
• Lift Range–Use lift range for lifting the drive to
its maximum angle; however, this range cannot
be used during boat operation. Use this range
ONLY when you are transporting your boat.
CAUTION! Operating in beach range or lift
range will cause significant loss of maneuverability.
NOTICE! The maximum safe engine speed in the
Beach Range is 1000 RPMs. Operating in
beach range above idle speed, or for prolonged periods of time, may cause serious
drive damage. Always check that the cooling water intake is below the surface of the
water when running in Beach Range.
22783
24 VPA 7748131 English 09-2007
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