Volvo Penta 5.0GXi-E, 4.3GL-D, 4.3GXi-EF, 5.0GL-E, 5.0GXi-EF Owner's Manual

OPERATOR’S MANUAL

3.0GLP-C

4.3GL-D, 4.3GXi-E, 4.3GXi-EF

5.0GL-E, 5.0GXi-E, 5.0GXi-EF

5.7Gi-E, 5.7Gi-EF, 5.7GXi-F, 5.7GXi-FF

8.1Gi-F, 8.1Gi-FF, 8.1GXi-E, 8.1GXi-EF

ENG

This operator’s manual is available in English.

Complete the form at the end of the operator’s manual to order a copy.

DEU

Diese Betriebsanleitung ist auch auf Deutsch erhältlich. Ein Bestellcoupon ist am Ende der

Betriebsanleitung zu finden.

FRA

Ce manuel d’instructions peut être commandé en

français. Vous trouverez un bon de commande à

la fin du manuel d’instructions.

Este libro de instrucciones puede solicitarse en

español. El cupón de pedido se encuentra al final

del libro.

SVE

Den här instruktionsboken kan beställas på

svenska. Beställningskupong finns i slutet av

instruktionsboken.

ITA

DUT

Dit instructieboek kan worden besteld in het

Nederlands. De bestelcoupon vindt u achter in het

instructieboek.

DAN

Denne instruktionsbog kan bestilles på dansk.

Bestillingskupon findes i slutningen af

instruktionsbogen.

FIN

Tämän ohjekirjan voi tilata myös

suomenkielisenä. Tilauskuponki on ohjekirjan

lopussa.

POR

Este manual de instruções pode ser

encomendado em português. O talão de

requerimento encontra-se no fim do manual.

GRE

Questo manuale d’istruzioni può essere ordinato

in lingua italiana. Il tagliando per l’ordinazione è

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

riportato alla fine del manuale.

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.

¡ıÙ¸ ÙÔ Â„˜ÂÈÒﬂ‰ÈÔ ˜ÒﬁÛÁÚ ‰È·ÙﬂËÂÙ·È

ÛÙÁÌ ·„„ÎÈÍﬁ „Î˛ÛÛ·. √È· Ì·

ð·Ò·„„ÂﬂÎÂÙÂ ›Ì· ·ÌÙﬂÙıðÔ,

ÛıПрОБТ˛ÛÙÂ ÙÁ ˆ¸ÒÏ· ðÔı ‚ÒﬂÛÍÂÙ·È

ÛÙÔ Ù›ÎÔÚ ·ıÙÔ˝ ÙÔı Â„˜ÂÈÒÈ‰ﬂÔı

˜ÒﬁÛÁÚ.

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.

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

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.

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

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

World-wide Dealer Locator

http://dealerlocator.penta.volvo.se/zone.asp

Table of Contents

Safety Information 3

General Information ..................................................4

Warning Symbols Used in this Manual ........................ 4

Safety Precautions (Maintenance and Service)........5

Knowledge.............................................................. 5

Engine Decals ........................................................ 5

Stop the Engine...................................................... 5

Lifting the Engine.................................................... 5

Before Starting the Engine ..................................... 5

Washing the Engine ............................................... 5

Fire and Explosion ....................................................... 6

Fuel and Lubrication Oil ......................................... 6

Non-Original Components...................................... 6

Batteries ................................................................. 6

Start Spray ............................................................. 6

Hot surfaces and Fluids ............................................... 6

Carbon Monoxide Poisoning ........................................ 6

Chemicals .................................................................... 7

Cooling System............................................................ 7

Lubrication System....................................................... 7

Fuel System ................................................................. 7

Electrical System.......................................................... 7

Safety Precautions While Operating the Boat...........8

Your New Boat............................................................. 8

Accidents...................................................................... 8

Maneuvering ................................................................ 8

Emergency Stop Switch............................................... 8

Daily Checklist.............................................................. 8

Refueling...................................................................... 8

Do not Start the Engine................................................ 8

“Station Wagon” Effect & Carbon Monoxide ................ 9

Safety Checklists.....................................................10

Replacement Parts and Tools Checklist .................... 10

Safety Equipment....................................................... 10

Safety Equipment Checklist ................................. 10

Planning Your Trip ..................................................... 10

Trip Checklist........................................................ 10

Basic Safety Rules of Boating.................................... 11

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

High Performance Boat Operation............................. 11

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

Volvo Action Service (VAS)........................................ 17

Doing Your Own Maintenance and Repairs............... 17

Informational Decals and Identification Plates ........... 18

Identification Numbers ............................................... 19

Owner’s Identification Card........................................ 20

Service, Replacement Parts, and Accessories .......... 20

Volvo Penta Dealer Network...................................... 20

Toll-free Dealer Locator Service........................... 20

Volvo Penta on the Internet........................................ 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

Engine Protection Mode .............................................24

Engine Control Module (ECM)....................................24

Master/Slave Arrangement .........................................25

Power Trim/Tilt............................................................25

Trim Instruments.........................................................26

Analog Trim Instrument.........................................26

Optional Digital Trim Instrument............................27

LED Display ..........................................................27

Other Instruments.......................................................27

Trim/Tilt Motor Protection ...........................................28

Impact Protection ..................................................28

Controls 29

Remote Control Unit............................................... 29

Single Lever Control Operation ..................................29

Shifting from Neutral...................................................29

Disengaging the Shift Function...................................29

Twin Unit Maneuvering ...............................................30

How to Shift and Control Speed .................................30

Shifting between Forward and Reverse................31

Cruising Speed .....................................................31

Friction Brake..............................................................32

Side Mount Remote Controls................................32

Top Mount Remote Controls.................................32

Trim Controls ..............................................................33

Operating Trim Controls .............................................33

Control Panel ........................................................33

Remote Control Lever...........................................33

Control Lever with Catch Button (Single)..............33

Control Lever with Catch Button (Dual).................34

Operation 35

Operating the Engine ............................................. 35

Before Starting............................................................35

Starting the Engine (Cold Start)..................................36

GL Models.............................................................36

Gi & GXi Models....................................................36

If the Engine Floods....................................................36

GL Models.............................................................36

Gi & GXi Models....................................................37

Starting the Engine (Warm Start)................................37

Stopping the Engine ...................................................37

Operating Remote Controls ................................... 38

Using the Gear Shift Release Button..........................38

Steering System Operation .................................... 39

Twin Unit Steering ......................................................39

Power Trim and Tilt Operation ............................... 40

Power Trim Operation.................................................40

Determining the Proper Trim ......................................40

Operating in “Bow-up” Position .............................41

Operating in “Bow-down” Position.........................41

Power Tilt Operation...................................................42

Power Trim/Tilt Switch & Gauge Location.............42

Special Boating Situations ..................................... 43

Shallow Water Operation............................................43

High Altitude Operation...............................................43

Operating in Freezing Temperatures..........................43

VPA 7743722 English 10-2004 1

Table of Contents

Salt Water Operation ..................................................44

Trailering Your Boat....................................................44

Features 45

Circuit Breakers and Fuses .................................... 45

Legend of Symbols Used in Engine Diagrams ...........45

3.0GLP-C ............................................................... 46

4.3GL-D, 5.0GL-E .................................................. 48

4.3GXi-E, 5.0GXi-E, 5.7Gi-E, 5.7GXi-F ................. 50

8.1Gi-F, 8.1GXi-E................................................... 52

4.3GXi-EF, 5.0GXi-EF, 5.7Gi-EF, 5.7GXi-FF......... 54

8.1Gi-FF, 8.1GXi-EF .............................................. 55

SX-M Sterndrive ..................................................... 56

DP-S Sterndrive ..................................................... 57

Maintenance Parts List 59

Maintenance 61

Engine Break-in Period .......................................... 61

Break-in Procedures ...................................................61

First Two Hours ..........................................................62

Next Eight Hours.........................................................62

Final Ten Hours ..........................................................63

First Service Inspection (Dealer 20-Hour Check) .......63

Operating After Break-in Period..................................63

Maintenance Schedule........................................... 64

Static Water Line .................................................... 66

Static Water Line Test ................................................66

Preparing for Boating (Launching) ..............................67

Off-Season Storage (Winterization)............................67

Maintenance of Boat’s Systems ............................. 68

Engine Exhaust System..............................................68

Drive Unit Bellows.......................................................68

Fuel System................................................................69

Gasoline Recommendations .................................69

Gasoline Containing Alcohol.................................70

Detonation (Spark Knock) .....................................70

Preventing Gum Formation and Corrosion ...........70

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

Carburetor (GL).....................................................71

Electronic Fuel Injection (Gi, GXi).........................71

Flame Arrestor ......................................................71

Electric Fuel Pumps ..............................................72

Fuel Filter ..............................................................72

Engine Fuel Filter Replacement............................73

Fuel Filter Replacement (V6/V8 Carb Engines) ....74

Fuel Screen Cleaning (3.0 Liter Carb Engines) ....74

Electrical System ........................................................75

Battery Cables.......................................................75

Batteries and Connections ....................................75

Battery Replacement.............................................77

Multiple Batteries and Selector Switch..................78

Distributor Cap and Rotor .....................................78

Circuit Breakers and Fuses...................................78

Spark Plugs...........................................................79

Checking and Changing Spark Plugs ...................79

Belt Adjustments.........................................................81

Serpentine Belt Engines........................................81

V-Belt Engines ......................................................82

V-Belt Tension.......................................................82

Power Steering Pump Belt....................................83

Alternator Belt.......................................................83

Cooling System ..........................................................84

Raw Water System...............................................84

Closed Cooling System (F-Series) ....................... 84

Engine Overheating (Gi & GXi only) ..................... 84

Engine Overheating (All other Models)................. 85

Engine Flush ..............................................................85

Draining the Cooling System......................................86

Raw Water Cooled Engines..................................86

Draining the Closed Cooling System.......................... 87

8.1 Liter Engines (F-Series).................................. 87

4.3 GL Draining Only ............................................ 87

4.3, 5.0, and 5.7 Liter Engines (F-Series)............. 87

Impeller: Checking & Replacing .................................88

Steering System .........................................................88

Power Steering Reservoir Fluid Level .................. 89

Power Trim/Tilt Fluid Level......................................... 89

Shaft Spline and Bearing Lubrication ......................... 89

Tie Rod (Twin Installations Only) ............................... 89

Lubrication System................................................. 90

Engine/Crankcase Oil................................................. 90

Checking Engine Oil Level .........................................91

Changing Engine Oil ..................................................91

Changing the Oil Filter................................................ 91

Drive Components.................................................. 92

Drive Unit Lubrication .................................................92

Checking the Drive Unit Lubricant ........................92

Draining the Drive Unit..........................................92

Filling the Drive Unit.............................................. 93

Sacrificial Anodes.......................................................94

Replacing Sacrificial Anodes ................................94

Replacing Heat Exchanger Anodes...................... 94

Active Corrosion Protection System...........................95

Painting the Drive ....................................................... 97

SX and DP-S Drives .............................................97

Preparation ........................................................... 97

Paint Application................................................... 97

Propeller Care ........................................................ 98

Propeller Replacement — SX .................................... 98

Removing the SX Propeller .................................. 98

Installing the SX Propeller ....................................98

Propeller Replacement — DP-S................................. 99

Removing the DP-S Propeller............................... 99

Installing the DP-S Propeller.................................99

Boat Bottom.......................................................... 100

Bottom Painting ........................................................100

Engine Alignment ................................................. 100

Engine Submersion ..................................................100

Replacement Parts............................................... 101

Troubleshooting 103

Troubleshooting - System Isolation ...................... 103

Engine Troubleshooting Guides ........................... 104

Technical Data 113

Metric Conversion Chart 121

Index 123

2 VPA 7743722 English 10-2004

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.

Safety Information

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:

DANGER! Failure to comply with a danger symbol will result in serious injury or death to boat operator, boat occupants, and/or others.

WARNING! Failure to comply with a warning may result in injury or death to boat operator, boat occupants, and/or others.

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

CAUTION! Failure to comply with a caution may result in failure or damage to the equipment.

NOTE! Used to draw your attention to important information that will facilitate work or oper-

ations.

VPA 7743722 English 10-2004 3

Safety Information

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.

NOTE! 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.

NOTE! 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.

Poisonous: Fluids, gases, or solids that, through a chemical reaction, can damage metals, fabrics, or human tissue.

Electrical: Danger of electrical discharge or shock which can cause burns or other serious injury.

Flammable: Fluids, gases, or solids that can–depending upon the degree of confinement–burn or explode upon ignition.

Explosive: Fluids, gases, or solids that can–depending upon the degree of confinement–burn or explode upon ignition.

Fan Belts: Loose clothing, hair, fingers or a dropped tool can be caught in revolving belts and cause serious personal injury.

Crushing Force: Heavy objects may break loose and fall, causing a crushing blow that can result in serious injury or death.

Rotating Fan: Loose clothing, hair, fingers or a dropped tool can be caught in rotating parts and cause serious personal injury.

Face Mask: Highly recommended that you wear a face shield, goggles, and/or respirator to protect face, eyes, and/or lungs.

Carefully observe the safety alert symbols shown for

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

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!

Warning Symbols Used in this Manual

Following is a list of symbols used in this manual as a quick reference visual warning of the dangers and risks associated with carrying out certain activities.

High Pressure: Fluid or gas may be ejected under a great deal of pressure causing damage to metals, fabrics, or human tissue.

Corrosive: Fluids, gases, or solids that can damage metals, fabrics, or human tissue through decay.

Toxic: Gases or other airborne corrosives that can damage human tissue, cause ill health, or endanger life.

Face Wash: Wash affected body area immediately using plenty of soap and water and seek medical assistance as necessary.

Gloves: Highly recommended that you wear protective gloves while engaging in activities that may harm your hands.

Hot Surface: Hot objects, (engine block, exhaust manifold, starter element, etc.) can cause burns and other serious injury.

No Smoking: By smoking in areas where these signs are posted, you risk starting a fire or causing an explosion.

No Open Flames: By using an open flame in areas where these signs are posted, you risk starting a fire or causing an explosion.

4 VPA 7743722 English 10-2004

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

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

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

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.

Washing the Engine

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.

VPA 7743722 English 10-2004 5

Never use a high-pressure washer when washing the engine.

Safety Information

Fire and Explosion

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.

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.

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 sys-

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

tems 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

Start Spray

Never use start spray or similar agents to start an engine. This may cause an explosion in the inlet manifold.

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.

Carbon Monoxide Poisoning

Only start the engine in a well-ventilated area. If operating the engine in an enclosed space, ensure that

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.

6 VPA 7743722 English 10-2004

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 9 for additional information.

Safety Information

Chemicals

Most chemicals such as anti-freeze, rust-proofing agent, inhibiting oil, 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.

Cooling System

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.

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.

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.

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

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 filter replacement should be carried out on a cold engine to avoid the risk of fire caused by fuel spilling onto the exhaust manifold.

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.

VPA 7743722 English 10-2004 7

Safety Information

Safety Precautions While Operating the Boat

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. 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.

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.

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

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

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.

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.

8 VPA 7743722 English 10-2004

“Station Wagon” Effect & Carbon Monoxide

Safety Information

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.

WARNING! Do not run the engine while

there are people located on or near the swim

platform and transom.

DANGER! DO NOT tow anyone using wa-

ter sports equipment (such as skis and in-

ner tubes) closer than twenty feet (20’) from

the boat. DO NOT, under any circumstanc-

es, 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.

NOTE! For your safety, we recommend that you in-

stall a good quality carbon monoxide detector aboard your boat, in accordance with ABYC recommended practices.

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

22770

VPA 7743722 English 10-2004 9

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 or 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.

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

 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

 Impeller, fuel filters, fuses, tape, and hose clamps.

 Extra propeller and engine oil.

 Tools for any possible repairs while underway.

10 VPA 7743722 English 10-2004

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/CGAUXWEB/PUBLIC/PUBFRAME.HTM.

• 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

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

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!

VPA 7743722 English 10-2004 11

Safety Information

Notes

.....................................................................................................................................................................

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

.....................................................................................................................................................................

12 VPA 7743722 English 10-2004

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 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.

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

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 113. 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 10 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 61.

A First Service Inspection should be carried out after 20–50 running hours. For additional information please refer to the document entitled Warranty Infor- mation North America PN 7796733.

VPA 7743722 English 10-2004 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.

NOTE! 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.

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

22771

14 VPA 7743722 English 10-2004

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.

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

VPA 7743722 English 10-2004 15

Introduction

Notes

.....................................................................................................................................................................

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

.....................................................................................................................................................................

16 VPA 7743722 English 10-2004

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.

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.

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.

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.

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

VPA 7743722 English 10-2004 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.

The engine decal is typically located on the upper-front portion of the engine. The decal may be placed on the engine block, a pulley housing, or on any other flat surface located toward the front of the engine.

22772

The engine plate is typically located on the port side of the engine flywheel housing, slightly below and aft of the exhaust manifold.

22774

The label depicting the serpentine belt configuration is typically mounted on a flat surface located on the side of the alternator/automatic tensioner bracket or on the power steering pump/reservoir.

3863274

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

22773

22776

The California Emission sticker is located on the engine cover.

3.0GL Engines • Above port engine mount on side of engine block.

4.3GL Engines • On port, front face of cylinder head.

5.0GL Engines • On the flat vertical surface of the inlet manifold below

the carburetor pad.

4.3GXi, 5.0 GXi, 5.7 Gi, & 5.7 GXi Engines • On the flat inside face of the combination bracket containing the power steering pump, alternator and serpentine belt tensioner.

8.1 Gi & 8.1 GXi Engines • On the flat outside face of the combination bracket containing the power steering pump, alternator, and serpentine belt tensioner.

The tune-up and color code decal is located on the engine cover.

22775

18 VPA 7743722 English 10-2004

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 shown 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) ..............................................................

Serial No. (B) ...............................................................................

Product 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) ...........................................................................

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

Type (B) ......................................................................................

Ratio (C) ......................................................................................

22772

22774

22778

Serial No. (D) ..............................................................................

22778

Transom Assembly & Drive Unit Stickers

22779

Product Designation (A) .................................... /...................................

Model No. (B) .......................................... /.............................................

Serial No. (C) .......................................... /............................................

22780

NOTE! 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 7743722 English 10-2004 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.

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.

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.

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

Only authorized Volvo Penta dealers may purchase genuine parts and accessories directly from the factory. Volvo Penta does not sell directly to unauthorized dealers or retail customers.

20 VPA 7743722 English 10-2004

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.

NOTE! The instrument panel depicted below is a

sample representation only.

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

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 engines (except 8.1 Gi & GXi) is 155°-178°F (68°-81°C) and 135°-158°F (57°-70°C) for the 8.1 Gi & GXi. 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.

CAUTION! Read the starting instructions in

21181

VPA 7743722 English 10-2004 21

the section entitled Starting the Engine (Cold Start) on page 36.

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.

Instrumentation

Audible Alarm

If an audible alarm 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.

Carbureted Engines - When the ignition switch is turned to RUN (key on, engine off), the audible alarm will sound. The alarm will remain on until the engine starts and the oil pressure reaches normal operating levels. If the alarm persists, it indicates that there is a problem with oil pressure.

EFI Engines - When the ignition switch is turned to RUN (key on, engine off), the alarm emits two 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

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

21182

NOTE! The emergency stop switch can only be ef-

fective 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.

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.

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 forward. 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.

NOTE! If your boat is not equipped with an emer-

gency 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.

22 VPA 7743722 English 10-2004

21194

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 113.

Your boat is equipped with an audible low oil pressure

1

alarm

.

CAUTION! 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 engines (except 8.1 Gi & GXi) is 155°178°F (68°-81°C) and 135°-158°F (57°-70°C) for the

8.1 Gi & GXi. Engines with closed cooling systems will typically run about 30°F (17°C) higher.

21195

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

21196

Your engine is equipped with an engine coolant and exhaust temperature acoustic alarm

1

.

CAUTION! If engine coolant or exhaust temperature is too high: Idle the engine, shift to reverse and then to forward. Idle the engine for 2 - 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 7743722 English 10-2004 23

Instrumentation

21197

Engine Protection Mode

In a low oil pressure, low voltage, engine overheat, or lack of exhaust cooling water situation, the Electronic Fuel Injection (EFI) system will enter an Engine Protection Mode (EPM). In such cases, if an acoustic alarm has been installed with your engine, the alarm (located beneath the dashboard) will sound to notify you of a malfunction.

Under these conditions, engine operation is limited to 2500 RPMs or less. When the EFI system switches on the EPM, there will be a temporary reduction in power until the problem is resolved. In this mode, ignition timing is also adjusted in response to the situation. If the engine drops below 1200 RPMs, normal injector operation and spark timing resume. The engine may now be operated normally, as long as engine speed remains below 2500 RPMs.

For anything above 2500 RPMs, the engine will display poor running characteristics. If the engine is run above 2500 RPMs without any load or with the drive in neutral, the engine will exhibit surging.

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

NOTE! Continuing to run the engine in this mode

without correcting the cause may result in further engine damage.

Use the oil pressure and water temperature gauges to verify a problem exists, then inspect the engine crankcase for proper oil level and check the water inlets for obstructions. The low oil pressure/engine overheat problem must be corrected before the engine will return to normal operation.

To reset the Engine Protection Mode after the problem is corrected, allow the engine to cool and then continue with normal operation.

NOTE! If the problem continues, contact your Volvo

Penta dealer and have the engine inspected.

Engine Control Module (ECM)

The engine control module (ECM) is designed to maintain exhaust emission levels while maintaining excellent drivability and fuel efficiency. The ECM controls the following conditions:

• Fuel, ignition, and idle air control.

• Knock sensor system.

• Various other discrete outputs.

NOTE! Until the engine coolant reaches normal op-

erating temperatures, the RPM rev-limit is reduced to maximize engine life.

24 VPA 7743722 English 10-2004

Instrumentation

Master/Slave Arrangement

For dual engine installations both engine ECMs can be tied together electronically. One engine will then be the “master” engine and the other will be the “slave” engine. The starboard engine or the engine with the power steering pump is always connected as the “master” engine. If one engine has a fault that causes it to go into Engine Protection Mode (low oil pressure or engine overheat), also called Speed Limited Operator Warning (SLOW), the other engine will follow suit.

22803

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

22767

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.

VPA 7743722 English 10-2004 25

Instrumentation

Trim Instruments

The trim instrument indicates the current trim position. Your boat may be equipped with an analog or a digital trim instrument. The SX drive has an analog trim instrument only. The DP-S drive may have either an analog or a digital trim instrument.

Analog Trim Instrument

The analog trim instrument has three main ranges:

22781

22782

22783

• 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.

WARNING! 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.

7743722 - Downloaded from www.volvopenta.com 13/05/2008 20:17:06

26 VPA 7743722 English 10-2004

Volvo Penta 5.0GXi-E, 4.3GL-D, 4.3GXi-EF, 5.0GL-E, 5.0GXi-EF Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual