Volvo Penta Penta, 7.4 GL, 7.4 Gi, 8.2 GL Owner's Manual

WELCOME ABOARD

Please study this manual to completely understand how
your Volvo Penta manne engine operates and to enable
you to take full advantage of its many built=in features.

Boating Responsibilities

Most countries have reguJations controlling boating Al­ways make sure you follow these regulationsI As a boat
owner, you have cattam responsibilities to others. Be
sure that all operators read this manual.

You are legally responsible for all occupants of your
boat Instruct at least one of your passengers in the be-

sic fundamentals of handhng your boat ~n case of an
emergency Show all hands the location of emergency

equipment and how to use it In the U.S. you are re-

quired by law to have one U S Cost Guard approved
hie jacket for each person aboard, plus one approved

throwable device for man overboard protecbon Other

countries may have regulations that differ, contact Boat
foundations in your country for detaded mformahon

Learn the waterway rules of the locality in which you

are going to operate your boat Navigable waterways
are controlled by Federal (national) regulations while in­land lakes are controlled by local jurisdictions. Obey
these regulabons to protect yourself, your passengers
and fellow boating enthusiasts.

Thoroughly familiarize yourself with weather bureau

warning system sagnals and waterway traffic signs

in the U.S. contact your local U S. Coast Guard stabon

and take advantage of their seasonal boat mspecbens
and train=ng courses For other countries, contact Boat

foundations for inforrnabon.

Our Joint ResponsibUity

Volvo Penta continualIy invests considerable develop­ment resources to minimize the effects on the env=ron­ment caused by our products Examples of this continu­ous work are the improvements in exhaust emassions,
sound levels and fuel consumption

Whether your Volvo Penta engine is used to power a
pleasure boat or is used in a commercial application it
can, if used incorrectly or maintained insufficiently, dis­turb or damage the environment

This Owner’s Marque{ cove~ several servtca checks
that, if not performed correctly, can cause a deteriora-

tion of the engine a~ectlng the environment, Its service
life and operating economy Always follow the recom-

mended service intervals and make it a hab{t to check
for anything abnormal each t{me you use the engine
An example of this is excess=ve exhaust smoke Con-

tact an Authorized Volvo Penta Servtca Dealer if you
cannot remedy the cause yourself.

Remember that most chemical products used to main­tain your boat and engine are harmful to the enwron­merit, if used incorrectly. Volvo Penta recommends the
use of biodegradable degreasing agents during all
cleaning. Always dispose correctly of used engine and
transmission eel, paint, degreasing agents and washing

fluids etc., so that they cannot harm the environment.

When using your boat, always adjust the speed and

d~stanca to prevent the wake or sound level from dis­turbing wildlife, moored boats, pontoons, etc. Leave the

waters and natural harbors In the condition you yourself
would like to find them.

We thank you for your choice of Volvo Penta marine

engine and we wish to continue to supply you with
maintenance and adwee to help you get the best possi-

ble performance from your engine. Contact your near­est Authonzed Volvo Penta Servme Dealer for assis­tance.

We wish you pleasant trips with your boat.

AB VOLVO PENTA

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Identification Numbers

Record your engine and reverse gear model and senal numbers immediately after purchase. This w~ll enable you to
have them available for quick reference when ordering parts or literature.

Engine Model No .........................................

Reverse Gear Model .......................................

ignition Key No ............................................

Boat Model No ...............................................

Serial No ............................................

Serial No ...........................................

Recommended Propeller Size ..............................

Hull Identification No. CHIN) .............................

Toll Free Dee|or Locater Service for U.S.A.
To locate the an authorized Volvo Penta servicing

dealer, consult the Yellow Pages under "Boat Dealers"
or call ’1-8(}0-522-’1 $59

Owner’s Manual

Marine engines

7.4 GL, 7.4 Gi,
8,2 GL

Contents

Introduction

Features 7 4 Gi
Features 7 4 GL, 8 2 GL

Instruments
Control umts

Operation

Starting 6
After use .. 7
Measures when freezmg ts imminent 7

Z~ important information

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Stop the engine before openmg the hatch
to the eng!ne compartment There are ro-

tahng parts on an engine whtch are danger­ous to approach when the engine is run-

ning
Bear ~n mnd the nsk of fire All engine fuel

ts tnfiammable Alcohol, e~ther methanol or
ethanol ts somettmes added to fuel, espe-

cially to unleaded gasohne These add[hves
shorten the hfe of rubber and plastic com-

ponents m the fuel system Inspect regulaPj
for leaks and cracks

Regular Maintenance

2 Eng[ne maintenance

3 Transmission HS1

4 Boat maintenance
5 Troubleshooting chart

Maintenance schedule

Laying up

Laytng up & Off season storage
Pre- Eunch & launching

Technical data

Models 7 4 G[ 25
Models 7 4 GL, 8 2 GL 27

The engine ~s flu=d°cooled Dra~n the cool~ng sys­tem when the engine has been stopped if there

is a nsk o~ freez.ng Note that siphoning achon
can occur wtth certarn work on the coolmg sys-

tem Close all dratnage points when the boat ,s
not under constant supervJston Incorrectly per-

formed drainage may cause the boat to become
filled with water and sink, in addition to damaged

engine parts
Read this Owne,’s Manual carefully before put-

tmg your engine into operation The engines cov­ered m ths manual have as standard equ=pment

the Volvo Penta HS 1 hydrauhc reverse gearbox
As an optton the engines can be equrpped w[th
reverse gears from other manufacturers Please

consult the manufacturer of the reverse gear for
owner and serv=ce inforrnat~on

10

t£

19

2o

21

COrn

24

Features, Model 7.4 Gi

1 Ot[ filler, engine

2 Oil filler, reverse gear
3 Dipst~ck, engine
4 DEpstick, reverse gear
5 Oil withdrawal tube

6 Oil filter, reverse gear

7 Water cooled exhaust elbow
8 Od filter engrne

9 Fuel filter

10

\

2, 4

Fuel pumps

10
11 ECM

12 Backfire flame arrestor
13 Seawater pump

14 Circuit breakers
15 Alternator

16 Oil cooler, reverse gear

17 Serral number, reverse gear

18 Thermostat housing

11

14

18

3

12

15

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13

17

Features, Model 7.4 GL I 8.2 GL

1 Oll filler, engine

:20=E filler, reverse gear
3 D~pstlck, eng+ne

,4 Dipstick, reverse gear
5 Oil withdrawal tube

O~[ filter, reverse gear

7 Water cooled exhaust elbow

Oil filter engine

9 Fuel filter

Fuelpump

10
11 Carburetor

12 Backfire flame arrestor

13 Seawater pump
14 CIrcmt breakers
15 Alternator

16 Otl cooler, reverse gear
17 Senal number, reverse gear

18 Thermostat housing

7 14

2, 4

12

1 7

15

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\

3

13

11

6

17

instruments, Main paneg

Rev counter

This shows the engine speed =n revolut=ons per mrnute x I00

Speed

It is important that the engine reaches the maximum speed
w=th a normal load The full throttle RPM range =s 4000-4400
rpmforthe74GL For models74G[and82GLthefull

throttle range is 4200-4600 RPM A recommended maxtmum
crutsmg speed is around 300-500 rpm below the maximum
speed achteved

NOTEI Growth on the hull reduces the speed

Temperature gauge

Dunng normal use, the temperature gauge should dtsplay 158­195°F (70-90°C) Your boat may be equtpped w~th an audtble

alarm to alert the operator to an engine coohng overheat

if the engine overheats, reduce the speed and shift

A

into neutral. Find out what is blocking the water sup­ply to the engine if the temperature does not drop.

Stop the engine if necessary and rectify the fault.

Oil pressure gauge

The oil pressure gauge should normally show about 40-45 psi

(275-300kPa) when the engine ts runnmg It [s normal for the

gauge to show a lower reading at low speeds Your boat may

be equipped wtth an audible alarm to alert the operator to low

engme o~l pressure

If the oil pressure is too low, stop the engine imme-

,~

diately and determine the cause,

Voltmeter

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The voltmeter shows the system voltage When the engine is

running it should be 14 0-14 4 V The voltage is 12 V when the

engine ts switched off

Main panel fuses

The instrument panel has two replaceable 8 Amp fuses The

fuse protected circuits are System voltage and Starting c~rcu~t

WARNING! Always keep spare onfuses board

A

Push button, instrument lighting

Control units.
Ignition switch

@

The tgnition switch has three positions.
6 = Stop position. Everything connected across the key ts

switched off. The key can be withdrawn from the lock

I = Drive position. Sytem voltage connected

II = Start position. Starter motor acttvated

WARNING! The tgmtlon key must only be in the drive po-

A

stt=on when the engine ts to be started and when the en­gine IS runmng Carry out the starting procedure in one

operation

Single lever control

The Volvo Penta control is designed to operate the speed,
forward and reverse gears by moving the lever in the

desired direction, The engine speed can be controled wrthout

selecting forward or reverse by pressing the button m the center
of the control hub and moving the lever slightly forward
Release the button and only the engine speed can be

controlled When the lever ~s returned to the neutral poslt~on, it
comes out of neutral automatically and the speed, forward and

reverse can now be regulated
F = FORWARD. Simultaneous control of speed and movement

R = REVERSE Srmultaneous control of speed and movement

High performance boat driving

F-hgh performance rs not only defined by engine size, but by a combmatron of the engine power, hull des=gn,
and the stze and waight of the boat Your new engine(s) produce a htgh power output Depending on the

boat type. the top speed may be much higher that what you are used to
F-hgh speed operation requ=res an expenenced driver who has mastered handling of high performance boats

It is advisable that you learn the boat’s behavior before takmg passengers on board Inform your passengers
about the boat’s charactenstlcs and the maneuvres 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 reahze the speed you are travelling at,

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especially when you close in on another boat from astern or from ahead. Always keep a good distance to al­13w for the unexpected1 Always be prepared for what other boaters may do unexpectedly High speed dnvmg

requires the driver to gtve a high degree of attention to boat operatton
A boat travehng at a speed of 70 mph (60 knots) covers 101 feet (30 meters ) durmg 1 second The faster

you go, the qutcker thmgs wt]l happen High speed driving requires a lot of water and good distance to
possible hazards. Always allow a 3 - 4 second reaction hme

When dnwng, make sure that all passengers are safely seated. Emphasize this espectally i[ you have a larg-
er cabin cruiser where one normally moves about dunng operation Reduce the speed considerably, or stop

completely if someone needs to move about m the boat
The driver should always use the safety kill switch! The sw~tch, whch is connected to the driver,

immediatety shuts off the engine(s) should the dnver be thrown from the driving position Even ff the risk
falling overboard ts practically nonexistent tn your type of boat, the risk of the driver falling and beLng dazed

~n rough seas can be even greater
Remember, even when the engine(s) is stopped in a high performance boat that is p~aning, it will

travel about 325 ft (100 meters) before dropping through the planing threshold and stopping.

Safety equipment and personal gear.

Equip your boat with all safety items required by law, U S. Coast Guard regulations or other national regula­tions Added to this, followtng safety equ=pment =s wtal in a high performance boat

Life Jackets of an approved make for all those on board Note: The life jacket should be designed for
the speed the boat can reach.

Helmef_ A helmet shoutd be worn for all advanced boat driving at h~gh speeds. Use an approved type for use
in boats

Wet Suit. When operating In cold waters
Eye Protection. If the boat ~s not equJpped wJth an adequate windshield, the drrver qeeds eye protechon of

approved shatterproof type

On inboard engine installations.

WARNING! Volvo Penta recommends use of a properly installed sea strainer or raw filter to provide

A

engine and reverse gear with an unrestricted flow of filtered cooling water Regular inspection and
cleantng of this strainer is required Operation =n areas where seaweed, sea grass, sand etc or other

foreign matter m=ght block intake of filter require more frequent maintenance.

Driving

Starting
I Check the o~1 leve~ Jn the engine

NOTE! High performance engines normally have
a higher o=l consumpttop, when compared w~th a

standard marine engEne of the similar displace­ment Apart from lubncatton the most important

task of the oil is to cool lubncated engtne parts

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Htgh performance engines develop more heat

compared with standard marine engines. There-

fore, tt is very important never to fall below the
mcnimum required od level m order to have an op-

hmal engine hfe Check the oil leveB daily!

If equlped with an opttonal closed coohng system,
check the fresh water level m the cooling system

The level should be up to the lower edge of the

filler pipe FIll with antifreeze mixture to the cor-

rect level Always use antifreeze even if there is
no nsk of low temperatures The anttfreeze en-

sures the cooling system corrosion protection

and running with fresh water only can result ~n

severe corrosion damage to the component parts
of the coohng system Refer to "Engine Mam-

tence" for coolant mExture

3 Turn on the main switch

Start the engine room tan (blower) Let it run for
four minutes Open all sea water cocks for the

engine coohng water intake

5 Release the control lever. Idhng position

Start the engine (See "Ignition switch" ) If the engine

6

is cold, run at high idle (900-1200 rpm) for 1-2 min­utes until engine Is at operating temp

NOTE! 7 4 Gi The fuet rejection system is controlling
the engine speed during warm-up phase and thus the

engine speed control should remam set on Jdle

Reduce the engine speed to idle and read the instru-

7

ments. If the readings are abnormal, stop the engine
and determtne the cause

8 Check for obstructions in front of and behind the boat

before selecting "Forward" or "Reverse"
The maximum cruising speed ~s 300-500 rpm below

maximum speed Good operating economy rs
achieved if full throttle ;s avoided

7.4 Gi, 8.2 GL models
WARNING! Your engine(s) develops a considera-

A

ble output even at idlrng Depending on the hull
design your engine(s) can push your boat at idle

and wtth the gear engaged at a speed of 6-9 mph
(5-8 knots) Therefore, you might need to adjust

your speed by shifting into neutral and reverse
more frequently that what you are used to when

operating the boat in harbors, shallow waters, and

when moonng, etc If you are not operating the

gear shft frequently when runmng the boat at en­gine idle speed you mrght exceed the maximum

allowed speed ~n harbors and ~n narrow passages

Running in shallow waters

9 If you are uncertain of the water depth or when oper-

ating in shallow waters we recommend that you de­crease speed to ~dle

WARNLNG! Inboard propulsion systems normally

A

have no collision protectlon for the propeller(s) and
propeller shaft In case of grounding or hitting an

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obstacle in the water, check carefully that nothing

ts damaged and there is no water leakage nto the
boat Check that the propellers are not damaged

and that there are no vibrations If operation is ab­normal, return to port at reduced speed and have
the vessel hauled onto land for a closer inspec-

tion

11 Stop the engine using the ignition switch

Switcf" off the ma=n battery switch Close all
sea water cocks

WARNING! Never sw=tch off the mare

~

battery switch before stopping the en­gine This could damage the alternator

On the 7 4 Gi model electronic compo­nents ~n the fuel injection system may be

damaged

Before Ieaving the boat

12 Check for leaks around the engine and that

everything else fn the engine compartment
appears normal If leakage occurs, fred the

cause and correct it tmmedlately
NOTE! When usrng the bilge pump be ob-

servant that the bilge warer does not contain

oil or other chemicals that can be harmful to

e environment

~

WARNING! Be observant of the water
depth Under no conditions, such as low

water etc shall there t:,e any risk that the
hull hits the bottom when the boat is tted

up

CoKd weather precautions

13

Before leavtng the boat, the coohn9 water
(raw water) must be drained from the engine
to prevent freeze damage

WARNNNG! Be obsen/ant for any water

,~

leakage into the boat Close all sea water
cocks before draining the cooling system

Incorrectly performed drainage may
cause the boat to become filled with wa-

ter and sink

After use

10 After use and when the boat is tied up, it is important

for the engine to idle for at least 1 minute before shut

down to avoid boiling of the coolant

Drain the cooling system in the following se-

quence Reverse gear HS I: Close the bot-

tom cock and remove the hose on o~1 coolers
port side