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Volvo Penta 21182210, Operator'S Manual

The Volvo Penta 21182210 Operator's Manual is your go-to guide for operating this powerful product. For easy access and convenience, you can download this comprehensive manual free of charge from our website. Get acquainted with your equipment and enhance your user experience with this essential resource.

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Troubleshooting

Engine Troubleshooting Guides

The following troubleshooting guide is provided to help you isolate a malfunction of one or more of your boat’s
systems. After determining which systems are affected by the malfunction, refer to the individual system trou-
bleshooting charts to isolate the specific cause.

This guide was written to help you trace the symptoms of the trouble to the source, without having to read through
and prove every possibility. Much of the information here will be familiar to well informed mechanics.

Also, many factors will seem insignificant but when you think of it, usually the toughest problem to troubleshoot
is caused by the smallest error. The greatest aid to solving a service problem is information. Start gathering
information and keep a detailed record of the symptoms of the malfunction. Keep a record of pertinent facts, such
as:

● When did this trouble start?
● How was the boat loaded?
● Did the trouble occur suddenly or did it become apparent gradually?

Whether servicing the boat’s systems yourself or having your product serviced by a certified Volvo Penta dealer,
you will need this record of information to identify potential causes of the malfunction.

Analyze this information and try to match it to similar situations you have experienced in the past. Keep in mind
the fundamental rules:

● COMPRESSION - Mixture inducted into cylinder and compressed.
● SPARK - Proper intensity at the proper time.
● FUEL - Proper mixture of air and fuel.
● EXHAUST - Clear of any obstructions.

Engine Will Not Crank

Starter Circuit – Check:

● The control lever must be in neutral.
● Emergency stop switch.
● Battery switch turned off.
● Battery condition: weak, dead, sulfated, bad cells.
● Battery cables–for loose or corroded connections.
● Circuit breakers and/or fuses.
● Ignition relay.
● Shorted or open ignition switch.
● Wiring, from battery to ignition switch.
● Starter relay.
● Starter motor and solenoid–for shorts, grounds, or open circuits.
● Starter assist solenoid.
● Call for assistance or see Volvo Penta authorized dealer.

114

47700387 06-2009

Summary of Contents for 21182210

Page 1: ...OPERATOR S MANUAL 3 0L 5 0L 5 7L 8 1L SX A DPS A ...

Page 2: ...r gives ikke til tredje part Tämän ohjekirjan suomenkielisen version voi tilata veloituksetta 12 kuukauden sisällä toimituksesta internetistä postin kautta tai faksilla Katso tilauslomake kirjan lopusta AB Volvo Penta tallentaa kaikki tiedot sisäisesti eikä niitä luo vuteta kolmannelle osapuolelle Pode se encomendar uma versão gratuita deste manual de instruções em português até 12 meses após a en...

Page 3: ...struments and Controls 17 Optional 64 Starting 66 Operation 75 Engine Shutdown 97 Fault Code Register 104 In Case of Emergency 112 Troubleshooting 114 Maintenance Schedule 133 Maintenance 138 Storage 156 Calibration and Settings 159 Technical Data 161 Alphabetical index 187 1 ...

Page 4: ...21182210 5 7L 5 7GiC 300 J 5 7GiCE 300 M 5 7GXiC J 5 7GXiCE M 3869459 21182213 3869353 21189867 8 1L 8 1GiC J 8 1GiCE M 3869355 21301407 Fresh Water Cooled Engine Displacement Model Spec No 5 0L 5 0GXiC JF 5 0GXiCE MF 3869352 21182212 5 7L 5 7GiC 300 JF 5 7GXiC JF 5 7GiCE 300 MF 5 7GXiCE MF 3869461 3869354 21182215 21301406 8 1L 8 1GiC JF 8 1GiCE MF 3869356 21301408 2 47700387 06 2009 ...

Page 5: ...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 biodegrada...

Page 6: ...ay result in equipment failure or damage 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 ...

Page 7: ...ose nozzle firmly against the side of the deck filler plate or ground it in some other manner This action prevents static electricity buildup that could cause sparks and ignite fuel vapors DANGER Fuel leakage can contribute to a fire and or explosion Frequently inspect non metallic parts of the engine s fuel system and replace if excessive stiffness deterioration or fuel leakage is found DANGER To...

Page 8: ... 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 it is a boat type with which you are unfamiliar we recommend that you practice controlling the boat away from other vessels docks shallow areas and other obstacles Remember that the person driving a boat is legally required to know...

Page 9: ...olorless odorless and tasteless gas that weighs about the same as air It cannot be expected to rise or fall like some other gases because it will distribute itself throughout the space Do not rely on the sense of smell or sight of other gases to detect CO as it diffuses in the air much more rapidly than easily detectable vapors i e visible and aromatic vapors What Makes Carbon Monoxide Carbon mono...

Page 10: ...victim is not breath ing perform rescue breathing or approved car diopulmonary resuscitation CPR as appropri ate until medical help arrives Prompt action can make the difference between life and death Evacuate the area and move affected person s to a fresh air environment Observe the victim s Administer oxygen if available Investigate the source of CO and take correc tive action Marine CO Detectio...

Page 11: ...r around swim platform Do not swim in the vicinity of exhaust outlet s Since carbon monoxide production is greater when engines are cold versus when they are warm a boat operator should minimize the time spent on getting underway In order to minimize CO buildup do not warm up or run propulsion engine s for extended peri ods while the vessel is stationary A boat operator should be aware that carbon...

Page 12: ...in speeds and under certain operating conditions the low pressure area may form in other regions and permit carbon monoxide to enter the hull through openings that are not at the back of the boat Other factors during boat operation which may affect carbon monoxide concentration include Adding or removing canvas may raise or lower CO levels Image 51618 illustrates desired air flow through the boat ...

Page 13: ...l systems for altitude conditions may cause an increase in CO Reduced power resulting from increased altitude may require adjustments to propeller size Heavy seas or out of trim conditions tend to load engines resulting in reduced performance and increased CO pro duction Portable Generator Sets Do not use this equip ment on boats Gasoline powered portable gen erator sets produce CO These sets disc...

Page 14: ...ranty and registration form is on file at Volvo Penta Please refer to your warranty manual for additional informa tion Keep your owner s identification card with you at all times this will facilitate finding parts and providing service when you visit any Volvo Penta authorized dealer Volvo Action Service VAS Volvo Action Service VAS is a consumer breakdown service available 24 hours each day 365 d...

Page 15: ...and location of your nearest Volvo Penta dealer consult the telephone directory under Boat Dealers search the dealer locator on the internet or call 1 800 522 1959 Volvo Penta on the Internet Whether you re trying to replace a lost operator s man ual searching for updated service information about your engine looking for parts information or simply attempting to locate the nearest authorized Volvo...

Page 16: ...e The EVC system also has a diagnostic function For additional information please refer to EVC Diagnostic Function If you want to supplement the instrumentation if your boat is equipped with instruments not described here or if you are unsure about the functionality of your instrumentation please contact your Volvo Penta dealer Main EVC Components 51268 14 47700387 06 2009 ...

Page 17: ... Throttle Actuator This component operates the throttle and controls engine RPM G Engine Control Module ECM This component controls and monitors the engine H Volvo Penta options not shown The following components can be connected to the EVC system to enable monitoring of non engine data or other func tions Fresh water level sensor Fuel tank level sensor Multisensor for speed water temp and depth A...

Page 18: ...l 4 EVC System Display s or Tachometer s x 3 5 Steering Wheel 6 Control Lever s 51271 Secondary Station Fly Bridge Station There may be as many as three secondary stations They are usually equipped in the same way as the main station but they have a Start Stop panel instead of ignition key s Standard instrumentation and controls 1 EVC System Display s or Tachometer s 2 Gauges optional 3 Start Stop...

Page 19: ...start stop panel is situated on stations other than the main station A Panel for single engine installations B Panel for twin engine installations NOTICE Please refer to the chapters entitled Start ing and Operation before attempting to start the engines The ignition key s on the main station must be in the ON or RUN position I to be able to start the engines with the start buttons on the start st...

Page 20: ...ates the engine oil pressure Normal operating oil pressures are listed in the section entitled Technical Data 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 approxi mately 14 Volts With the engine stopped and the switch on battery voltage is normally indicated as 12 Volts 5 I...

Page 21: ... least one of these instruments is needed when modifying EVC settings 1 EVC System Tachometer with LCD display Information about the tachometer display and how to handle it can be found in EVC Menu 2 Voltmeter 3 Oil Pressure Gauge 4 Coolant Temperature Gauge 5 Rudder Indicator 6 Fuel Level Gauge 7 Fresh Water Level Gauge 8 Analog Trim Instrument 9 Digital Trim Instrument Instruments and Controls 4...

Page 22: ...Indication Serious Fault If the red warning indication is shown during operation a serious fault has occurred For additional information please see Acknowledging Alarms and Messages and the Fault Code Register Amber Warning Indication Fault If the amber alarm indication is shown during opera tion a fault has occurred For additional information please see Acknowledging Alarms and Messages and the F...

Page 23: ... the cool ant temperature is too high Stop the engine if this lamp lights up during operation Check the coolant level For additional information please see Step 6 in the section entitled Before Starting WARNING Do not open the coolant filler cap when the engine is warm Steam or hot fluid could spray out causing severe burns Check that the sea water filter if installed is not blocked Check the impe...

Page 24: ...fer to Disengaging the Shift Function Flooded Engine EVC Engines Emergency Trimming 4 SELECTION WHEEL Alter the information dis played in the EVC Basic Window by spinning the wheel clockwise or counter clockwise Enter a sub menu by pushing the wheel Pushing the wheel will also acknowledge alarms in case of a fault 5 BACK BUTTON Back up a step in the EVC menu levels by pushing the BACK BUTTON 6 MUL...

Page 25: ...ton indicate that the engines are running When off the LEDs indicate that the engines are stop ped The left side LED applies to the Port engine while the right side LED applies to the Starboard engine Flashing LEDs accompanied by the alarm indicate that the engine has stopped without a stop request Silence the alarm using the Alarm Acknowledge button 5 and restart the engine s Alarm Acknowledge Bu...

Page 26: ...System Display A multiple window dis play meaning that several windows can be monitored simultaneously of which the EVC Basic Window of the tachometer is one of the choices available P0001165 7 Color Display A larger color LCD display It provides the same information as the Tach ometer Display in a larger easier to read format Additional information about the color display may be found in the sect...

Page 27: ...uttons on the EVC Control Panel To access the EVC Basic Window from the EVC Sys tem Display press button 2 to enter page MULTI Push repeatedly until the EVC Basic Window is displayed On a twin engine installation with two engines sharing one EVC System Display the upper EVC Basic Win dow represents the port engine while the lower one displays starboard engine information 51274i Instruments and Con...

Page 28: ...on is pushed Some information requires optional equipment If the boat does not have this equipment installed the infor mation will not be available For information on both EVC settings and settings specific to the EVC System Display instrument please refer to Settings EVC System Display Display Contrast 51276b Press button 5 farthest right Then press the appro priate buttons or to adjust the contr...

Page 29: ...ly TRIP INFORMATION 51275c FUEL RATE Instantaneous fuel consumption l h Gal h FUEL ECONOMY Fuel consumption over distance l nm l km l mile Gal nm Gal km Gal mile TRIP FUEL Fuel consumption since last reset l Gal Please refer to Trip Menu FUEL REMAINING Remaining amount of fuel in the tank l Gal DIST TO EMPTY Remaining distance until the tank is empty based on current fuel consumption nm km miles T...

Page 30: ...I page push any button to bring up the guiding icons Push button 5 indicated with an arrow icon and icons representing the windows as highlighted in black will appear Alter the information in a window by pushing the button with the corre sponding icon repeatedly If the selected information is not available the image in the pointer instrument window will lack the gauge needle In a digital number wi...

Page 31: ...installations 50882 Twin engine installations 50883 Enter the GRAPH page by pushing button 4 In this display mode operating information is displayed in the form of a histograph Press button 4 repeatedly to alternate between different operating parameters If an item of operating information is not available that window cannot be chosen If contact with the relevant information is lost during display...

Page 32: ...ton 5 for 5 seconds or more The configuration menu contains SYSTEM INFORMATION Entry to the EVC Basic Window For additional information please see EVC Basic Window SETTINGS Menu for the display settings not the EVC settings which are to be found in the SETTINGS menu of the EVC Basic Window SYSTEM Menu with functions and information intended for service purpose only Bleep Set whether or not the dis...

Page 33: ...displayed with a pointer graph or turn on off the speedometer in display mode MULTI only if a speed sensor is instal led 1 Enter the hidden CONFIGURATION MENU by pressing button 5 for 5 seconds or more When in the CONFIGURATION MENU help icons above the buttons will indicates their function 2 Select SETTINGS and enter 3 Select DISPLAY and enter 4 Select one of the options ENGINE RPM SPEED SPEED or...

Page 34: ...d cause function faults There is a status field on the right of the screen that displays the current view active functions and repaired faults Pop up A number of functions can be switched on and off in a pop up by pressing OK which will display the func tions in the lower part of the screen Turn to the desired function and press OK to confirm that the function is to be switched on or off Active fu...

Page 35: ... lations they are distinguished by different color dials in the instruments Customize Press OK so that the Customize menu is displayed Press OK to access the submenus Add Remove Modify and Return to basic setting Use the knob to browse between menus Adding Instruments Turn the knob to Add and press OK Select the desired information is displayed and confirm with OK The new instrument will position ...

Page 36: ...ed as analog or digital Engine Information concerning the engine and its transmission is displayed in this view Depending on the functions installed in the boat the following can be displayed Engine Speed Power Trim Angle for further information refer to trim control information throughout the book and PTA Calibration in this chapter Rudder Angle Coolant Temperature Voltage battery voltage Engine ...

Page 37: ...nce the last trip computer zero reset Time to Empty operating time with fuel remaining in the tank based on current fuel consumption Distance Remaining trip distance with fuel remain ing in the tank based on current fuel consumption Trip Fuel fuel consumption since the last trip com puter zero rest refer to Pop up earlier in this section Fuel Remaining remaining fuel in the tank To zero all values...

Page 38: ...er to Depth Alarm Optional in the EVC Menu section of this chapter Boat Speed Rudder Angle Fuel Level Fresh Water Level The information in this view cannot be changed Camera It is possible to connect a camera to the screen e g for monitoring the engine compartment or swimming platform If a camera is installed images will be displayed in this view P0001099 P0001175 Instruments and Controls 36 47700...

Page 39: ... off the beeper that sounds when the control is in the neutral position Info Beep Level setting the volume of the signal that confirms when a function has been activated or deac tivated Trip Computer Reset zeroes all values in the trip computer Display Type select the engines for which operating data will be displayed and the type of installation the engines is part of Units setting of units metri...

Page 40: ...he screen Warning Manager If the system discovers a fault the operator is informed by a message on the screen The fault message must be confirmed by pressing OK All faults are stored in the Warning Manager The fault message indicates the drivetrain affected describes the fault and suggests suitable actions For further information on fault messages refer to the chapter entitled Fault Code Register ...

Page 41: ...tings menu selection If there are no faults logged this menu will not appear For additional information please see Retrieving Faults in this chapter Main menu screens shown in the illustration below the faults menu may be viewed based on what has been selected in the My View menu For additional informa tion on how to select these items for viewing please refer to My View Menu in this chapter Some ...

Page 42: ...All faults during a trip are erased when the starter key is turned to the stop position 51264 1 For twin engine installations select which display engine to check for faults Use the DISPLAY SELECTION BUTTON 11 2 While in the main menu turn the SELECTION WHEEL 10 until the faults display 3 Push the SELECTION WHEEL to view the logged fault s The fault will cycle between source of fault cause of faul...

Page 43: ...l Econ Trip Fuel Trip Time and Trip Distance to be reset zeroed out 51467 Trip Fuel Rate Displays average fuel rate per hour since last reset l h gal h 51468 Trip Fuel Econ Displays fuel consumption over distance nm l km l mile l nm gal km gal mile gal Optional multisensor or NMEA 0183 NMEA 2000 compatible component plotter GPS paddle wheel etc required 51469 Trip Fuel Displays fuel consumption si...

Page 44: ...000 compatible component plotter GPS paddle wheel etc required 51475 Fuel Remaining Displays fuel remaining in fuel tank l gal Optional fuel level sender connected to EVC required 51476 Total Fuel Rate Displays the sum of the instan taneous fuel rate per hour for twin engine instal lations l h gal h 51477 Fuel Rate Displays instantaneous fuel rate per hour l h gal h 51478 Fresh Water Lvl Displays ...

Page 45: ...ve Also shown as a popup for two seconds while trimming 51486 Speed Displays boat speed over the water knots mph km Optional multisensor or NMEA 0183 NMEA 2000 compatible component plotter GPS paddle wheel etc required 51487 Depth Displays current depth of the water under the boat ft m Optional Volvo Penta depth sounder multisensor required 51488 Water Temp Displays the temperature of the water su...

Page 46: ... press the SELECTION WHEEL to enter the submenu for that selection Push the BACK BUTTON to return to a previous menu level at any time PTA On Off 51462 Turn the Power Trim Assistant on or off by scrolling to PTA and pressing the SELECTION WHEEL The PTA function may also be turned on or off when viewed in the main menu level NOTICE PTA must be turned off before taking the boat out of the water This...

Page 47: ...he boat depending on what depth you want to monitor The depth sounder may be placed anywhere between these points The depth alarm is dependent on the depth offset A Water line B Lowest point C Depth sounder Adjust the depth offset in increments of 0 1 m or 1 ft by turning the SELECTION WHEEL Set offset by pushing the SELECTION WHEEL 51461 Depth Alarm Pop up The depth alarm pop up will appear when ...

Page 48: ...hered since the last reset was performed My View Menu 51451 The My View menu located within Settings is used to select the information that will be displayed in the main menu level of the EVC Basic Window Following is a list of the informational screens that may be selected in the My View menu Use the SELEC TION WHEEL to scroll through the list of items When an option you wish to have displayed in...

Page 49: ...e display in the EVC sys tem tachometer Each tachometer display in the boat is set separately In the Settings menu turn the SELECTION WHEEL to select Display Contr Press the SELECTION WHEEL to enter the display contrast settings Adjust the level of contrast by turning the SELECTION WHEEL and press to set the level EVC Info The EVC Info function is designed to provide informa tion specific to the E...

Page 50: ...formation in 10 different lan guages This setting needs to be performed only on one display twin installation at one station for the settings to apply to all displays in the boat In the Settings menu turn the SELECTION WHEEL to select Language Press the SELECTION WHEEL to enter Language settings Turn SELECTION WHEEL to highlight the language of your choice Press SELECTION WHEEL to activate the hig...

Page 51: ...TION WHEEL to enter PTA Pos 1 The first position is the trim angle of the drive at idle 7 Now adjust the drive angle for the second posi tion Press the SELECTION WHEEL to confirm 4 Adjust the setting to the desired angle by turning the SELECTION WHEEL then press to confirm Once confirmed you will be returned to the PTA Calibration menu 8 Repeat Steps 5 7 for the remaining PTA posi tions You may re...

Page 52: ...fuel tank capacity and fuel tank empty calibrations In the Settings menu turn the SELECTION WHEEL to select Fuel Tank Press the SELECTION WHEEL to enter Fuel Tank settings Fuel Multipoint Calibration 51458 When the more precise Multipoint Calibr is selected the fuel level sender is calibrated in five equally divided steps 20 full pos 1 40 full pos 2 60 full pos 3 80 full pos 4 and 100 full pos 5 T...

Page 53: ...addle wheel speed sensor can be adjusted with a resolution of 1 from 100 to 100 to apply a correction to the output from the speed sensor Set the speed factor while driving the boat Compare the displayed speed with speed data from the GPS or another boat and adjust the speed factor until they correspond This setting needs to be performed only on one display twin installation at one station for the...

Page 54: ...on 2 Navigate to the upper level EVC menu At this level navigate until you locate the Tow mode screen 3 To enter the tow mode function press the OK button 2 5 display or the selection wheel EVC control panel 51754 4 To activate tow mode press OK or press the selection wheel The screen display will change from Off to On Tow mode is now engaged You may set the speed to your desired maximum engine RP...

Page 55: ... off the non emissions related indicator will light up for 5 seconds 51390 An audible alarm will perform a brief self test when the ignition key is turned to the RUN position The alarm emits three short beeps to indicate that the ECM is performing a check of the sensors If there are any problems detected by the ECM the alarm will sound otherwise it will remain off Whenever either icon lights up it...

Page 56: ...d side display on twin engine applica tion MIL active B Twin engine application both MILs active C Twin engine application port MIL active D Twin engine application starboard MIL active When the MIL becomes active acknowledge the warn ing then follow any on screen instructions for dealing with the problem 51491 In the EVC Basic Display the MIL warning A is an icon that appears in the lower right p...

Page 57: ...dividual or simultaneous adjustments to the drives By trimming out the drive away from the transom the height of the bow will be raised in relation to the hor izontal axis while trimming in the drive will lower the bow of the boat In single engine installations the drive can be oper ated by pressing button 1 or button 4 In twin engine installations both drives can be oper ated simultaneously by pr...

Page 58: ... is any angle over 30 It is used to lift the drive to maximum height but not when the engine is running This range is used for trailing or putting the boat on the trailer Power trim has an automatic stop that cuts the power when its end limit has been reached The stop is reset automatically when activating down trimming NOTICE In Tilt Range engine starts are prevented by a built in safety mode The...

Page 59: ...s first started the digits read 88 and both words TRIM and BEACH are displayed Analog Instrument 50897 This instrument shows the current position of the drive Beach range is marked with an orange zone and Tilt range with a red zone 1 Trim range 2 Beach range orange 3 Tilt range red Tachometer LCD Display 51274j The trim angle may also be viewed in the LCD display of the tachometer if installed For...

Page 60: ...the water This prevents automatic trimming of the drive s if any test runs are performed while the boat is on land Emergency Trimming If a fault occurs which prevents the drive from being trimmed with the power trim control panel it is possible to perform an emergency trimming NOTICE If the power trim function does not work the trim gauges may not work either Before starting an emergency trimming ...

Page 61: ...h remote controls other than those described below If Volvo Penta controls are not used ask your dealer for operating instructions for the remote control used in your boat since operation and function may differ from Volvo Penta remote controls 51260 a 1 Neutral Interlock Button 5 Starboard Trim Tilt Button 2 Trim Tilt Button 6 Port Engine Throttle Control Lever 3 Engine Throttle Control Lever 7 S...

Page 62: ... ignition switch 2 Remove the plastic cover that shields the remote control mechanism 3 Place the control lever in reverse just beyond the reverse detent position and adjust the throttle brake screw to prevent throttle creep 4 Turn the tension screw B clockwise to increase drag and counter clockwise to decrease drag on the control arm 5 Reinstall the plastic cover and remote control lever Top Moun...

Page 63: ...are going to dock must be activated Cruise control if equipped must be turned off 1 Push the docking button A on the joystick A beep sounds and a message appears on the display informing you that the docking function has been activated The LED above the docking button lights up The drives will trim to 0 if they are below 5 tilt If they are above 5 tilt they will remain tilted up for shallow water ...

Page 64: ...be maneuvered with the wheel and control levers only Enabling Boost Mode In situations where normal thrust is insufficient for example when it is windy or there is a strong current the boost mode can be enabled When the boost mode is enabled the operator has more thrust available than in the normal docking mode NOTICE The boost mode should not be used more than necessary 1 Enable the docking funct...

Page 65: ...ng steering Both devices are contained in a black housing A mounted somewhere in the engine com partment When you first turn the ignition key to START key on engine off you may hear clicking noises coming from the engine compartment This is a sound that is emit ted by the hydraulic system when it is functioning nor mally Instruments and Controls 47700387 06 2009 63 ...

Page 66: ...otection system s control box has both red and green LED indicator lights A The lights will indicate the amount of protection that the unit is providing to protect the sterndrive and transom shield NOTICE The active corrosion protection system is designed to adequately protect one drive unit from gal vanic corrosion under normal operating conditions This system will not provide protection from str...

Page 67: ...roded terminals on the electronic unit or battery Clean and tighten connectors Copper bottom paint used and is in contact with the transom shield Remove paint and ensure there is a 25mm 1 in border between transom shield and bottom paint 22863 4 22826 4 If no LEDs are illuminated 4 the unit is not receiv ing power Check the following conditions Dead battery Check battery condition and charge as ne...

Page 68: ...weight to your boat the boat and engine exhaust will sit lower in the water This raises the water level in the exhaust If you add too much weight the water level will be high enough to allow water inges tion NOTICE Water ingestion damage from over loading is not covered by warranty Consider the static water line of your boat before add ing equipment such as generators appliances coolers and other ...

Page 69: ...he water and once it is full of water plug the top of the hose using your thumb or a clamp 5 Measure the vertical distance D from water line E in hose to the top of manifold B Measurement D should not be less than 14 in 35 6 cm 3 Bring plugged end of hose inside the hull C and hold next to and above the manifold B 6 If the static water line does not meet these specifications contact your Volvo Pen...

Page 70: ...t start the engine out of the water unless you have connected a hose with running water to the engine flushing port see Engine Flush in the section entitled After Engine Shutdown for instructions Never use start spray or similar agents to start an engine This may cause an explosion in the inlet manifold Thoroughly familiarize yourself with operation of remote control supplied with your boat before...

Page 71: ...pped with a closed cooling system check the reservoir for coolant level Coolant level must be between MAX 1 and MIN 2 51533 7 Check engine oil level See Checking Engine Oil Level in the section entitled Technical Data 21181 8 Insert the key into the ignition switch O Turn the key one step to the right I to switch on engine system voltage and instrumentation Starting 47700387 06 2009 69 ...

Page 72: ...sure the water intakes are submerged There should be no obstructions in the water near the propellers NOTICE If possible check the drive oil level Starting the Engine Audible Alarm If an audible alarm 2 has been installed on your boat it will perform a brief self test when the ignition key is turned to the RUN position Following is a description of how the alarm performs the self test EFI Engines ...

Page 73: ...ines 21181 51260 c EVC engines are equipped with an auto crank feature Momentarily turning the key to the start position then releasing it back to the ON position I will cause the engine to continue to crank for up to 5 seconds or until the engine starts If you attempt to execute a fast crank turning the key from OFF immediately all the way to START there will be a 3 5 second delay while EVC warms...

Page 74: ...tent position N 2 Turn the ignition switch to START II and hold for no longer than ten seconds or until engine starts If the engine does not start let go momentarily then try again 3 As soon as engine starts release key to ON I RUN Starting 72 47700387 06 2009 ...

Page 75: ...LL THROTTLE T 4 Turn the ignition switch to START II If the engine does not start then try again NOTICE After a second attempt if the engine still does not start return the control lever to the neutral position and try a normal engine start 5 As soon as the engine starts Return the handle to IDLE NEUTRAL N Return the key to ON or RUN I NOTICE Immediately after engine start up look at all instrumen...

Page 76: ...e 2 Turn the ignition switch to START II If the engine does not start then try again In this throttle position with the engine speed below 400 RPM cranking speed the ECM shuts off the fuel injectors so no fuel is delivered 3 Move the throttle back to the neutral position to return to normal operating mode NOTICE Immediately after engine start up look at all instruments If any readings are abnormal...

Page 77: ...oard at the rear of the boat when the engine is running even if the drive is in neutral Personal injury could result from contact with propellers WARNING Check that nobody is in the water before engaging ahead or astern Never drive in or near areas where people could be in the water CAUTION Be sure you have read and understand everything in the section entitled Before Starting prior to continuing ...

Page 78: ...ge or alarm acknowledge it and take the recommended measures If there is a fault please refer to the Fault Code Register The engines will not start unless an alarm is acknowledged Acknowledging Alarms and Messages Alarms of more serious faults and depth alarms are accompanied by a buzzer 1 Silence the buzzer by pushing the SELECTION WHEEL 4 on the control panel 2 Read the alarm message pop up 3 Ta...

Page 79: ...at reduced throttle settings Improves fuel economy Provides smoother drier ride in choppy water Increases maximum speed The power trim is normally used before you accelerate onto plane after you reach the desired RPM or boat speed and when there is a change in water or boating conditions Locate passengers and equipment in the boat so that the weight is balanced fore and aft and side to side Trimmi...

Page 80: ... the boat s bow The lower button moves the drive trim in while lowering the boat s bow Control Lever The control button on the control lever has two func tions Pressing the top half of the button moves the drive trim out while raising the boat s bow Pressing the bottom half of the button moves the drive trim in while lowering the boat s bow Operation 78 47700387 06 2009 ...

Page 81: ...Watch the tachometer and speedometer readings and the ride action of the boat Operating in Bow up Position The bow up A position is normally used for cruising running with a choppy wave condition or running at full speed In a full bow up position the boat may tend to self steer You may have to compensate with the steer ing wheel to keep the boat in a straight ahead path In this position the boat s...

Page 82: ...waves the bow of the boat will plow into the water CAUTION The boat may tend to bow steer or spin about rapidly and possibly eject occupants The boat trim should be adjusted to provide balanced steering as soon as possible each time you get under way Some boat engine and propeller combinations may encounter boat instability and or high steering tor que when operated at or near the limits of the bo...

Page 83: ...ou are backing up You trailer your boat You launch your boat NOTICE Impact damage is more likely to occur when you are in a turn where side loads are placed on the drive unit If you strike a solid object Throttle back and shut off the engine immedi ately Closely inspect the boat and drive unit especially the transom shield assembly that contains steer ing system components Check the engine compart...

Page 84: ...ngine is rou tinely exceeding the WOT maximum RPM or is fre quently at the RPM limiter controlled by engine com puter the boat should be taken to the dealer to check for proper propeller size If the engine will not reach the WOT range the boat may be overloaded or over propped and should be taken to the dealer for correc tion Disengaging the Shift Function 51264 The gear shift can be disengaged so...

Page 85: ...dle speed F Drive forward gear engaged for forward move ment ahead R Drive reverse gear engaged for backward move ment astern T Throttle engine speed control NOTICE The engine can be started only if the drive is in neutral Shifting from Neutral To move the remote control lever from the neutral detent position simply move the control lever in the desired direction Operation 47700387 06 2009 83 ...

Page 86: ...ine systems before leaving the dock Move control handle s to the neutral detent posi tion N Check in front and behind boat for people or obstructions before shifting To go from forward to reverse or reverse to for ward always pause at neutral N and allow engine speed to return to idle After shifting is completed continue to move the control handle slowly in the desired direction to increase speed ...

Page 87: ...ugh the under water exhaust outlet and cause serious engine dam age Do not attempt to plane boat while operating on a single engine operating with a single engine at full throttle could cause engine or transmission damage Engine Synchronization Function The engine synchronization function makes the engines in a twin installation operate at the same engine speed RPM It improves fuel economy and ope...

Page 88: ...ling Active Station 51504 Shifting adjusting speed trimming and performing EVC settings and calibrations is only possible on an active station On a boat with one station the station is always active On a boat with two or more stations the main station automatically becomes active when the EVC system is started up with the ignition key s If the engine is started from a secondary station that statio...

Page 89: ...but the control lever on the station that is activated is not in the neutral position Move the control lever into the neutral posi tion and it will start to function normally On twin engine installations move both control levers If either of the LEDs above the ACTIVATION BUTTON flashes the station has a fault A fault pop up will also appear in the display s to indicate this For additional informat...

Page 90: ...e to wind and current This is normal and may be overcome by anticipating bow direction and cor recting with steering wheel A slightly higher throttle and trim setting may also lessen the tendency to wan der Changing weight distribution aft to forward can also affect slow speed steering Twin Unit Steering Twin engine boats may have only one engine with a fully operational power steering system That...

Page 91: ...rd the starboard control lever should be moved into reverse NOTICE Both engines must be running during close maneuvering while changing gears or when travel ling at slow speeds If only one engine is running water may be forced back through the underwater exhaust outlet and cause serious engine damage Steering the Boat 51312 Put the control levers into forward gear Use a suitable engine speed for m...

Page 92: ...nother possibility is that the propellers become fouled e g anchor line tow rope etc and cause the engine to stop In all situations where the engines stop running you will lose all steering control If you are driving straight forward the boat will eventually coast to a standstill If you are turning the boat may straighten out and eventually will come to a standstill In some instances only one engi...

Page 93: ...r and the screen will display the normal window 3 You can return to the fault codes view any time by switching to fault code review mode For additional information please see Retrieving Faults in the chapter entitled Instruments and Controls Steering System General Messages Low Steering Oil Temperature 51650 For the electronic steering to operate normally the oil must reach a certain temperature W...

Page 94: ...er The boat will continue to move in the selected direction even after the joystick has been released Compensate for this movement by moving the joystick in the opposite direction NOTICE The joystick and it s functions are only to be used when docking In all other cases the wheel and control levers should be used A Move straight forward E Traverse diagonally B Move straight backward F Rotate to St...

Page 95: ...51318 51319 51320 Operation 47700387 06 2009 93 ...

Page 96: ...t any speed above idle will allow water to be ingested into the engine causing serious engine damage Using this switch is simple and should not interfere with normal operation of the boat CAUTION Care must be taken to avoid accidentally pulling the lanyard during boat operation Unexpected loss of forward motion will occur which could cause occupants to be thrown forward In an emergency situation a...

Page 97: ...age to the engine and exhaust mani folds NOTICE Freeze damage to the engine package is not covered by your Volvo Penta limited warranty Upon completion of engine operation drain the engine as described below For raw water cooled engines drain the engine block and manifold For engines with closed cooling systems drain only the manifold Shallow Water Operation You may tilt the drive unit to reduce t...

Page 98: ...n operating at high speeds remember that other boaters may not realize the speed at which you are trav elling 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 surro...

Page 99: ...y to OFF 0 NOTICE Do not stop the engine at speeds above idle or speed up the engine while turning off the ignition Do not stop the engine while in gear or while the boat is moving Engine damage could result from water being sucked back up through the exhaust ports NOTICE Always keep the drive tilted in the down position when the drive is not in use except when trailering WARNING If your engines a...

Page 100: ...anel 51273 Push the stop button Release the button when the engine has stopped Use both buttons for twin engines If a station is active and locked the engine s can only be stopped from that station Engine Shutdown 98 47700387 06 2009 ...

Page 101: ... greater 1 If the engine is running shut it down 2 Remove the blue plastic cap from the hose that is clamped to the starboard side of the engine It is marked with the running engine flush symbol 1 NOTICE On 3 0L engines the flush port is on the front starboard side of the engine 3 Connect a water hose from a fresh water source to the flush connector on the engine 2 4 Turn water on full and start t...

Page 102: ... exterior with fresh water NOTICE Before moving the trailer tilt the drive as high as possible and secure it in place NOTICE Be very careful of high or low spots when backing up or crossing railroad tracks there is a possibility that the sterndrive may hit the ground 4 When you have reached your destination if the boat will be stored on the trailer the drive should be tilted down Engine Shutdown 1...

Page 103: ...ne level This will provide for complete drain age of the block and manifold If the engine is not level some water may remain trapped 2 After the water has completely drained reinstall the drain plugs and tighten securely 51534 a 3 Loosen the hose clamps and remove the hoses from the raw water pump 51604 4 Loosen the hose clamp on the large diameter hose and remove it from the circulation pump 2377...

Page 104: ...ock and manifold If the engine is not level some water may remain trapped NOTICE When draining the starboard manifold take care to direct the drained water away from the starter to prevent water damage to the starter 2 After the water has completely drained reinstall the drain plugs and tighten securely 51534 3 Loosen the hose clamps and remove the hoses from the raw water pump 51604 4 Loosen the ...

Page 105: ...e is not level some water may remain trapped NOTICE When draining the starboard manifold take care to direct the drained water away from the starter to prevent water damage to the starter 2 After the water has completely drained reinstall the drain plugs and tighten securely 51534 3 Loosen the hose clamps and remove the hoses from the raw water pump 4 Loosen the heat exchanger drain cap located on...

Page 106: ... first moving the boat to a safe location preferably anchoring mooring or docking and then shutting down the engine s When following the steps outlined in the Operator Actions if the fault ceases there may be no need to go to the dealer However after following the steps if the fault persists see your dealer as soon as possible Fault Code 1 Symptom 2 EVC Action 3 Operator Action 4 Color 5 Lamp 6 Al...

Page 107: ...ult red or amber lamp Red warning lamp Cannot throttle up or down Operator Action RED Check the electrical connectors for the control lever Contact a Volvo Penta dealer AMBER Check Engine Symptom Miscellaneous engine faults EVC Action Some faults will cause the engine to reduce RPMs Operator Action RED AMBER When safe to do so shut off and restart engine s If engine s operate normally leave engine...

Page 108: ...nes AMBER If engine cannot be operated from the chosen control panel use an alternate control panel Contact a Volvo Penta dealer Check Multilink Symptom Multilink communication error Possible engine synchronization loss or loss of one or more display s EVC Action None Operator Action AMBER When safe to do so shut off and restart engine s If performance is not affected leave engine s running Contac...

Page 109: ... ceases the exhaust hose should be inspected internally and replaced if the hose shows signs of damage Contact a Volvo Penta dealer if the fault persists Engine Oil Press Symptom Engine oil pressure too low EVC Action Engine power is reduced Operator Action RED Check the oil level in the engine Check that the oil filters are not blocked Check that no leakage occurs Contact a Volvo Penta dealer if ...

Page 110: ... box and replace if nec essary Contact a Volvo Penta dealer if the fault persists Key Failure Symptom Key or start panel inoperative Possible short in electrical cables EVC Action None Operator Action AMBER If the engine cannot be started from the chosen control panel use an alternative control panel Contact a Volvo Penta dealer Lever Calib Incorrect Symptom Incorrect lever calibration EVC Action ...

Page 111: ...s lose communications with both drivelines EVC Action Engine RPM reduced to idle Gears are shifted to neutral Steering is deactivated and left in current position Operator Action RED When safe to do so shut off and restart engines Check circuit breakers relays Check for loose electrical connections Contact a Volvo Penta dealer No Steering Limited Engine RPM Symptom Fault s in both drivelines EVC A...

Page 112: ...im sensor fault resulting in no readings EVC Action Power trim assist function is turned off Normal trimming may be disabled in some situations Operator Action RED If normal trimming does not function use emergency trimming procedure For additional information please see Emergency Trimming Contact a Volvo Penta dealer AMBER Start Relay Symptom Faulty relay EVC Action None while engine is operating...

Page 113: ... Steering oil overheat situation Functionality remains unaffected If the situation persists or gets worse it will result in a different code EVC Action None Operator Action AMBER Check steering oil level Check for leaks in steering system Check for kinked hoses Contact a Volvo Penta dealer SUS SCU Battery Voltage Low Symptom Electrical power level provided to steering control unit SCU is low or th...

Page 114: ...drive oil level and qual ity If the oil is milky white water has entered the drive and it must be inspected by an authorized Volvo Penta workshop Replace the propeller if it is damaged To prevent galvanic corrosion any paint damage on the drive and propeller should be repaired before launching the boat again Tie Rod Twin Installations Only Check the tie rod connecting the drive units particu larly...

Page 115: ...ater and seek medical attention as soon as possible 1 Check that the auxiliary battery has the same voltage as the engine system voltage 2 Connect the red positive cable to the plus ter minal on the discharged battery and then to the plus terminal on the auxiliary battery 3 Connect the black start cable to the negative terminal on the auxiliary battery and to a place a little distance away from th...

Page 116: ...e boat loaded Did the trouble occur suddenly or did it become apparent gradually Whether servicing the boat s systems yourself or having your product serviced by a certified Volvo Penta dealer you will need this record of information to identify potential causes of the malfunction Analyze this information and try to match it to similar situations you have experienced in the past Keep in mind the f...

Page 117: ...restricted boat fuel lines Fuel pump relay and circuit breaker operation Call for assistance or see Volvo Penta authorized dealer Hard Starting Cold Engine Check Fuel lines for obstructions For debris inside fuel tank For clean fuel filter Water in fuel Fuel quality deterioration Fuel system for leaks dirt or obstructions Ignition system Call for assistance or see Volvo Penta authorized dealer Har...

Page 118: ...mproper tuning see dealer Cap and rotor for corrosion see Do It Yourself manual Proper octane fuel is used Call for assistance or see Volvo Penta authorized dealer Cooling System Check Supply pump Loose belts and or pulleys See section entitled Cooling System Call for assistance or see Volvo Penta authorized dealer Mountings Check Loose broken or worn engine mounts Loose lag screws holding mounts ...

Page 119: ...assistance or see Volvo Penta authorized dealer Engine Dies Out Refer to the section entitled Engine Protection Mode Loss of Fuel or Out of Fuel Check Fuel level in tank Water or debris in fuel Plugged fuel filter Fuel pickup tube and screen blockage Fuel tank vent blockage Air leak on suction side of fuel system Fuel leak on pressure side of fuel system DANGER Be extremely careful around fuel lea...

Page 120: ...ance or see Volvo Penta authorized dealer Low Oil Pressure or Engine Knock Engine Components Check Oil quality dirt or water in oil Oil quantity Oil type and weight Call for assistance or see Volvo Penta authorized dealer Low Battery Voltage After Short Storage To Charge Check all battery and starter cable connections to ensure they are clean and tight Use a fully charged battery to jump start the...

Page 121: ... 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 The propeller originally installed is frequently one that is ...

Page 122: ...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 reduce engine speed to idle allow the engine to cool and then continue with normal opera tion If you are unable to locate and resolve the problem you may be able to continue operating the engine at above idle speed keeping in mind t...

Page 123: ...ed by your warranty If safe to do so shut off the engine and allow oil to settle for five minutes Use the dipstick to check engine crankcase oil level If there is too much oil siphon out the excess until it reaches recommended levels If you are unable to remove oil from the engine make way at reduced speed only If there is not enough oil add more until it reaches recommended levels If you are unab...

Page 124: ...can cause engine damage and or equipment failure which may not be covered by your warranty If the situation persists contact your Volvo Penta dealer for assistance Water in Bellows OceanX OXi drives are equipped with a sensor that detects water intrusion in the bellows If water is detected inside the bellows an alarm horn will sound for one second every sixty seconds If this alarm sounds please co...

Page 125: ...fter Engine Shutdown Engine Flush in the chapter entitled Engine Shut down 21181 51735 1 Ensure that the drive is trimmed to six degrees or below and that the cavitation plate is as close to level as possible 2 Turn the engine off and allow the oil to settle for at least 30 minutes 3 Remove the gear shift cover using a 12mm socket to loosen and remove the five screws holding it in place 4 Insert t...

Page 126: ...e only when the engine is cranking or running If a pump does not function check the fuses and replace them if necessary See your Volvo Penta dealer if further service is required NOTICE A loud whining noise at idle may be due to a restricted fuel filter causing a noisy fuel pump Oper ating the engine with a restricted filter may damage the pressure regulator or fuel pumps See your Volvo Penta deal...

Page 127: ...d Relay Box Layout Several spare fuses and relays are located on the inside of the fuse and relay box cover In case of malfunctioning or faulty fuses and relays use the spares provided 23672 A Trim Down Relay F3 20 Amp Fuse Fuel Pump B Trim Up Relay F4 15 Amp Fuse Ignition C Starter Relay F5 5 Amp Fuse Vessel Switch D Fuel Pump Relay F6 20 Amp Fuse ECM E Ignition Relay F7 40 Amp Fuse Instrument Pa...

Page 128: ... displays They must be acknowledged to stop appearing in the display Please refer to Acknowledging Alarms and Messages Alarm for Faults 50905a This type of alarm appears as a Caution Warning or Danger pop up that alternates between source of fault cause of fault and action to take It appears in the display representing the engine with the fault If the fault is more serious the fault pop up is also...

Page 129: ...e of sensor mal function the alarm signal loss pop up will appear Messages 51283 There are a variety of message pop ups that appear to attract the operator s attention to different matters regarding the handling of the boat or the status of communications in the EVC system These mes sages disappear automatically if they are not acknowledged Engine Status Panel Function The engine icon below when l...

Page 130: ...A ON YES YES Engine RPMs limited to idle speed only Return to port as soon as possible Engine and or emis sion system should be inspected by authorized service technician as soon as possibleE ON ON A ON YES YES Engine RPMs limited to idle speed only Return to port as soon as possible Engine and or emis sion system should be inspected by authorized service technician as soon as possibleE ON A ON YE...

Page 131: ...EUTRAL 3 Coat full length of prop shaft and inside of prop hub with Volvo Penta prop shaft grease removal of prop will be difficult if this is not done 4 Ensure thrust bushing 1 is on prop shaft with inner taper toward gearcase to match taper on prop shaft 5 Install the prop 2 onto the prop shaft aligning splines and push prop onto thrust bushing until splines are exposed 6 Install thrust washer 3...

Page 132: ...ponents could result in loss of the propeller and damage to the drive unit the next time the boat is operated 1 Ignition switch must be OFF 2 Make sure remote control is in FORWARD 3 Coat full length of prop shaft and inside of prop hub with Volvo Penta prop shaft grease removal of prop will be difficult if this is not done 4 Install front prop 1 5 Install front prop nut 2 and tighten it until the...

Page 133: ...icate all internal parts All electrical devices must also be dried and inspected for water damage 3 Frequently check engine compartment for gaso line fumes and excessive water accumulation In addition make sure that the water depth in the bilge is kept well below the flywheel housing NOTICE Delay in completing the above actions will result in extensive engine damage Trim Tilt Motor Protection If t...

Page 134: ...luid level in the power steering pump reservoir The level must be between the Min and Max lines Check that all hose clamps on the power steering system are securely tightened Check all fittings to ensure they are securely tight ened Check all hoses and fittings for leaks pinches Troubleshooting 132 47700387 06 2009 ...

Page 135: ...ired to determine warranty coverage If the boat is sold these records should be transferred to the new owner Safety and Preventative Maintenance Checklists The following checklists provide the preventative maintenance program for the engine and power package suc cessful preventative maintenance is a key element of safe boat operation Preventative maintenance combined with regular completion of the...

Page 136: ...ower Steering Fluid Check level Remote Control and Shift System Check for proper operation 1 Fresh water cooled versions Owner s Checklist Check Each Month 1 Check Correct Fill Lube Adjust Tighten Clean Change Replace Batteries and Connections Batteries hold charge connections clean and tight Drive Unit Oil Exhaust Hoses and Bellows Check for damage leaks and loose clamps Bellows U joint and Exhau...

Page 137: ...these items to deter future problems If any items fail the checks the dealer should correct them as needed Scheduled maintenance and any corrective work performed are part of normal maintenance and as such are not part of warranty Exceptions may occur based on what the dealer finds during the service work Always insist that your dealer use genuine Volvo Penta parts oils and lubricants when servici...

Page 138: ...lt Wear tension PCV Valve 1 Check Oil and Filter 2 3 4 Change Fuel Pump and System Check for leaks Flame Arrestor Properly secured Fuel Filter Replace Exhaust Hoses and Bellows Check for damage leaks loose clamps Exhaust Manifolds Risers Pipes Check for cor rosion damage leaks Oxygen Sensors Dealer to replace every 300 hours Reference Anodes Visual inspection replace if eroded more than 30 Cooling...

Page 139: ...ge Miscellaneous Batteries and Connections Batteries hold charge connections clean and tight Engine Alignment Check General Inspection All engine and drive hard ware clamps screws nuts etc Power Steering Check for proper operation check hoses and components for leaks Power Steering Fluid Check level Steering System Cable s Check for proper oper ation lubricate Steering Control Unit Sterndrive Joys...

Page 140: ...osions In your Volvo Penta product certain fuel and electrical system components have been designed to comply with U S Coast Guard and other regulations for explosion prevention Parts or components that comply with these regulations are designed so they will not emit fuel vapors or cause ignition of fuel vapors in the engine compart ment To prevent explosion or fire do not substitute automotive or...

Page 141: ...nning be undertaken by an authorized Volvo Penta workshop Starting the Engine After Service 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 Fire and Explosion F...

Page 142: ...ids in supply lines and hoses when the engine has just been turned off and is still hot Hot oil can cause burns Avoid skin contact with hot oil Never start or operate the engine with the oil filler cap removed hot oil could spray out Cooling System CAUTION Avoid opening the filler cap for engine coolant system freshwater cooled engines when the engine is still hot Steam or hot coolant can spray ou...

Page 143: ...not be modified in any way except with accessories and service kits approved by Volvo Penta Only genuine Volvo Penta replacement parts may be used No modifications to the exhaust pipes and air supply ducts for the engine may be under taken The servicing of ignition timing and fuel injec tion systems must always be carried out by an authorized Volvo Penta workshop Seals may only be broken by author...

Page 144: ... pulley D raw water pump pulley E and circulating pump pulley F Check the indicators located on the automatic ten sioner housing to determine the amount of tension loss When tick marks G and H coincide it s time to replace the serpentine belt As long as mark G is between marks H and I the belt has adequate tension on it Also check the serpentine belt for Regularly spaced cracks Regularly spaced mi...

Page 145: ...odes in the exhaust system These anodes must be checked at least once every six months or whenever you drain the raw water sys tem to determine the amount of erosion that has occurred If there is a substantial amount of erosion between checks this could be an indication that the exhaust system is not adequately protected against corrosion NOTICE It is extremely important that the reference anodes ...

Page 146: ...ck at least once per season or whenever you drain the raw water system 3 Anode Manifold elbow Anodes 5 0 5 7 8 1L Engines 51700 5 0L 5 7L 8 1L engines use the following anodes installed in the locations indicated 1 Anode Manifold end caps 2 Reference Anode Marked blue Check at least once per season or whenever you drain the raw water system 3 Anode Manifold elbow Maintenance 144 47700387 06 2009 ...

Page 147: ...nch When installing tighten the anode all the way by hand then turn an additional quarter turn using a wrench Engine Alignment Because of the special tools required a Volvo Penta dealer must do the engine alignment This should be done during off season storage preparations NOTICE Failure to periodically check engine align ment may result in premature failure of the engine cou pler Maintenance 4770...

Page 148: ...epared to catch any excess fuel that may spill from fuel pump or filter 5 Using clean engine oil lightly lubricate the gasket C and inner seal D on the new fuel filter 6 Screw on fuel filter and hand tighten 7 Clean up any spilled fuel If possible remove the old fuel filter containers and absorbant rags from the boat Dispose of safely and according to local environmental reg ulations 8 Turn on the...

Page 149: ...e 4 Remove thermostat housing 4 5 Remove thermostat 5 O ring 6 and gasket 7 from intake manifold 8 Discard gasket and ther mostat Inspect O ring and if damaged replace 6 Clean intake manifold and thermostat housing surfaces where the gasket makes contact Remove any remnants of the old gasket NOTICE Take care not to drop any debris into the intake manifold Place a rag in the intake manifold to keep...

Page 150: ...mostat and O rings into the groove in the cross over pipe housing 5 Replace upper thermostat housing 6 Install bolts and washer and torque to 18 30 ft lb 25 41 Nm 3 0 Liter Engines 50535 1 Loosen hose clamp 2 2 Remove hose 1 from thermostat housing 5 3 Remove O ring 3 and thermostat 4 from housing Discard thermostat Inspect O ring and if dam aged replace 4 Insert new thermostat and O ring into hou...

Page 151: ... bolts to 25 29 ft lb 33 39 Nm 6 Install the hoses and hose clamps If you closed the seacock be sure to reopen it before restarting the engine Electrical System Battery Maintenance and Replacement 22827 DANGER 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...

Page 152: ...hese procedures The service life of your battery depends largely on how it is maintained Keep batteries and battery terminals dry and clean Oxidation or dirt on the battery and battery terminals may cause short circuits voltage drops and discharges especially in damp weather Tighten all battery connections Loose battery connections may cause damage to the engine s electrical system Spark Plugs You...

Page 153: ... It Yourself manual 3 Check O ring on dipstick for wear or nicks Replace if needed Tighten dipstick to 48 72 in lb 5 4 8 1 Nm During oil level check inspect oil for signs of water intrusion The oil should be amber in color Milky look ing oil indicates water mixed with the oil Also check for metal or other debris in oil If moisture or metal flakes appear in the drive unit oil take the boat to your ...

Page 154: ... to the shift cable hose located inside the transom shield just behind the engine Once you have located the pitot tube hose remove the speedometer hose C from the plastic barb fitting B 2 Attach the hose from an air compressor to the barb fitting 3 Have someone assist you by placing a rag in front of the pitot tube at the leading edge of the lower unit 4 Blow air pressurized to no more than 116 PS...

Page 155: ... the drive anode is a good indication of the condition of the transom shield anode Inspect anodes see Maintenance Schedule for fre quency If an anode is 2 3 its original size 1 3 eroded replace it If additional electronic or electrical equipment is instal led each item should have an individual anode or grounding device and all grounding devices must be interconnected Follow equipment manufacturer...

Page 156: ...r based paint on your boat bottom leave a 1 inch border between the paint and the transom shield Failure to follow this instruction will result in severe corrosion of the transom shield and drive system Propeller Propeller Care A damaged or unbalanced propeller will cause exces sive vibration and a loss of boat speed Under these conditions stop the engine and check the propeller for damage If the ...

Page 157: ...y sit uations while in the water will be very difficult or impos sible Please refer to the section entitled Troubleshoot ing Propeller Replacement for additional information Steering Power Steering Reservoir Fluid Level Whenever you check the engine oil also check the steering reservoir fluid level The fluid level must be above the Min line and below the Max line If needed add Volvo Penta Power Tr...

Page 158: ...Your dealer will provide the proper servicing and maintenance to ensure that your equipment is treated and stored properly Short Term Storage Overnight or up to two months Flush engine with fresh water Raw Water Cooled Engines Only Drain raw water from manifolds and engine block See information on draining the engine in the section entitled Engine Shutdown Draining Raw Water Cooled Engines Closed ...

Page 159: ...information on draining the engine in the section entitled Engine Shutdown Draining Raw Water Cooled Engines Closed Cooing Engines Only Drain and replace engine coolant Drain raw water from manifolds See information on draining the engine in the section entitled Engine Shut down Draining Raw Water Side of Closed Cooling System Engines Store battery as recommended by manufac turer 1 After adding fu...

Page 160: ...install battery and attach bat tery cables Open the fuel shut off valve and check fuel system for leaks Check the flame arrestor and clean if nec essary please see the Do it Yourself manual for additional information Pump the bilge dry and air out engine com partment Federal state and or local regu lations prohibit the pumping of oil into any navigable waters Check all oil and fluid levels and fil...

Page 161: ...TI Push repeatedly until the EVC Basic Window is dis played For additional information please see MULTI Page Button 2 in the section entitled Multiple Window Display Entering the Settings Menu 51264 Most settings can only be performed if the station is activated Activate the station with the ACTIVATION BUTTON 8 For additional information please see Station Handling in the chapter entitled Operatio...

Page 162: ... one of its end positions Correct the boat s incorrect move ment by turning and or moving the joystick as illustrated in examples A D Combinations of the examples shown can occur Let the boat move for quite a long distance during the calibration routine Hold the joy stick in position 4 When the boat is moving directly sideways push the docking button 1 The new calibration is stored and this is con...

Page 163: ...Technical Data Engines Disclaimer Volvo Penta of the Americas Inc reserves the right to make changes in weight construction materials or specifications without notice or obli gation 47700387 06 2009 161 ...

Page 164: ...ue Delco EST See Tune up and Color Code Decal on engine cover or Parts Catalog 0 050 inches 1 50 mm 20 ft lb 27 Nm COOLING SYSTEM Raw water pump Recirculating pump Thermostat Crankshaft mounted variable volume flexible impeller pump Fixed impeller belt driven pump on engine 143 F 62 C OIL FILTER Engine oil filter Volvo Penta spin on can OIL CAPACITY NOTICE Overfilling the oil can cause engine and ...

Page 165: ...n engine cover or Parts Catalog 0 060 inches 1 50 mm 20 ft lb 27 Nm COOLING SYSTEM Raw water pump Recirculating pump Thermostat J Series Thermostat JF Series Coolant Type Crankshaft mounted variable volume flexible impeller pump Fixed impeller belt driven pump on engine 150 F 66 C 170 F 77 C closed cooling heat exchanger mounted on engine Ethylene glycol OIL FILTER Engine oil filter Volvo Penta re...

Page 166: ...on engine cover or Parts Catalog 0 060 inches 1 50 mm 20 ft lb 27 Nm COOLING SYSTEM Raw water pump Recirculating pump Thermostat M Series Thermostat MF Series Coolant Type Crankshaft mounted variable volume flexible impeller pump Fixed impeller belt driven pump on engine 150 F 66 C 170 F 77 C closed cooling heat exchanger mounted on engine Ethylene glycol OIL FILTER Engine oil filter Volvo Penta r...

Page 167: ...al on engine cover or Parts Catalog 0 060 inches 1 50 mm 20 ft lb 27 Nm COOLING SYSTEM Raw water pump Recirculating pump Thermostat J Series Thermostat JF Series Coolant Type Crankshaft mounted variable volume flexible impeller pump Fixed impeller belt driven pump on engine 150 F 66 C 170 F 77 C closed cooling heat exchanger mounted on engine Ethylene glycol OIL FILTER Engine oil filter Volvo Pent...

Page 168: ...cal on engine cover or Parts Catalog 0 060 inches 1 50 mm 20 ft lb 27 Nm COOLING SYSTEM Raw water pump Recirculating pump Thermostat M Series Thermostat MF Series Coolant Type Crankshaft mounted variable volume flexible impeller pump Fixed impeller belt driven pump on engine 150 F 66 C 170 F 77 C closed cooling heat exchanger mounted on engine Ethylene glycol OIL FILTER Engine oil filter Volvo Pen...

Page 169: ...Code Decal on engine cover or Parts Catalog 0 060 inches 1 50 mm 20 ft lb 27 Nm COOLING SYSTEM Raw water pump Recirculating pump Thermostat J Series Thermostat JF Series Coolant Type Crankshaft mounted variable volume flexible impeller pump Fixed impeller belt driven pump on engine 150 F 66 C 170 F 77 C closed cooling heat exchanger mounted on engine Ethylene glycol OIL FILTER Engine oil filter Vo...

Page 170: ...l for procedure See Tune up and Color Code Decal on engine cover or Parts Catalog 0 060 inches 1 50 mm 20 ft lb 27 Nm COOLING SYSTEM Raw water pump Recirculating pump Thermostat J Series Thermostat JF Series Coolant Type Crankshaft mounted variable volume flexible impeller pump Fixed impeller belt driven pump on engine 160 F 71 C 170 F 77 C closed cooling heat exchanger mounted on engine Ethylene ...

Page 171: ...al for procedure See Tune up and Color Code Decal on engine cover or Parts Catalog 0 060 inches 1 50 mm 20 ft lb 27 Nm COOLING SYSTEM Raw water pump Recirculating pump Thermostat M Series Thermostat MF Series Coolant Type Crankshaft mounted variable volume flexible impeller pump Fixed impeller belt driven pump on engine 160 F 71 C 170 F 77 C closed cooling heat exchanger mounted on engine Ethylene...

Page 172: ...lvo Penta gasoline engine oils approved for catalytic converters These oils are engi neered to meet all of the requirements of your catalyst engine and are formulated specifically for marine engines These oils are available at Volvo Penta deal ers If the Volvo Penta oils are not available use high qual ity oil that meets API SM and or ILSAC GF 4 specifi cations Viscosity should be SAE 10W30 or hig...

Page 173: ... This includes re filling the crankcase as part of changing the engine oil Adding Oil if Low Adding Oil During Break in Period 51216 NOTICE All oil used for oil changes or added between changes must meet the Engine Oil Specifications During the engine break in period until the piston rings have seated somewhat higher oil consumption is nor mal Check the oil level before each trip during the break ...

Page 174: ...occurs first After the first 150 hours or three years synthetic oil can be used in the engine If Volvo Penta synthetic oil for gasoline engines is used the change interval is every year or every 200 hours whichever occurs first When an engine has been run on synthetic oil our recommendation is to continue with synthetic oil do not change back to mineral oil Oil added between changes must be synthe...

Page 175: ...e unleaded gasoline with the following minimum octane rating In the U S R M 2 AKI 87 Outside the U S RON 90 NOTICE Engine damage resulting from the use of lower octane gasoline below 87 AKI or 90 RON is considered misuse of the engine and is not covered by the warranty All Volvo Penta gasoline engines are engineered to operate on AKI 87 RON 90 octane fuel Mid grade and premium fuels contain inject...

Page 176: ...he fuel system is not cov ered by the warranty Volvo Penta gasoline engines are equipped with a water separating fuel filter see Engine Fuel Filter Replacement in the section entitled Maintenance The use of an additional water separating fuel filter between the fuel tank and the engine is recommended The filter must be approved for gasoline inboard installations and be installed in accordance with...

Page 177: ...d requires no periodic mainte nance or adjustment If operational problems occur see your Volvo Penta dealer Detonation Spark Knock Detonation or spark knock is continually monitored by the electronic fuel injection EFI system The EFI s computer ECM will automatically alter spark advance to help prevent engine damage if knock is detected and there will be a slight loss of power Technical Data 47700...

Page 178: ...ace the battery with one that has the same or better cold cranking amps and reserve capacity as the battery installed in your boat by the boat builder If you are unsure of the battery to be used consult your dealer NOTICE Failure to use a battery of recommended specifications could result in poor starting and electri cal component damage NOTICE Do not use deep cycle batteries to start the engine A...

Page 179: ...rvice GL 5 synthetic gearcase lubricant Sterndrive Oil Capacity All SX A Models 2 58 quarts 2 44 liters All DPS A Models 2 38 quarts 2 25 liters NOTICE If your drive is equipped with a Drive Spacer you will need to add more oil than the recommended amount We urge you to check the oil level with the dipstick whenever you are changing or topping up the oil Technical Data 47700387 06 2009 177 ...

Page 180: ...decal is located on the engine cover 22774 The engine plate is typically located on the port side of the engine flywheel housing slightly below and aft of the exhaust manifold 3863274 The label depicting the serpentine belt configuration is typically mounted on a flat surface located on the front of the alternator automatic tensioner bracket 22773 a The California Emission sticker is located on th...

Page 181: ...22775 The tune up and color code decal is located on the engine cover Technical Data 47700387 06 2009 179 ...

Page 182: ...ne Decal Product Designation A Specification No B Serial No C 22772 1 Engine Plate Product No A Type B Serial No C 22774 1 Transom Shield Plate Product No A Type B Ratio C Serial No D 22778 1 Drive Product No A Type B Ratio C Serial No D 22778 1 Transom Assembly Drive Unit Stickers Product Designation A Specification No B Serial No C 22780 1 The Transom Assembly Drive Unit Stickers shown above sho...

Page 183: ...ational Craft Propulsion Engines Declaration of Conformity for Recreational Craft Pro pulsion Engines with the sound and exhaust emission requirements of Directive 94 25 EC as amended by 2003 44 EC Technical Data 47700387 06 2009 181 ...

Page 184: ...kW EXVOL007 SDVOL014 Essential Requirements Standards Used Other Normative Documents Used Annex I B Exhaust Emissions Engine identification Volvo Penta std Annex I B 1 Exhaust emission requirements EN ISO 8178 1 1996 Annex I B 2 Durability Volvo Penta std Annex I B 3 Operator s manual ISO 10240 2004 Annex I B 4 Annex I C Noise Emissions Sound emission levels EN ISO 14509 2000 prA1 2004 Annex I C 1...

Page 185: ... 201 kW EXOVL006 SDVOL015 5 0 GXiCE 21182210 201 kW EXVOL006 SDVOL015 5 0 GXiCE F 21182212 201 kW EXVOL006 SDVOL015 Essential Requirements Standards Used Other Normative Documents Used Annex I B Exhaust Emissions Engine identification Volvo Penta std Annex I B 1 Exhaust emission requirements EN ISO 8178 1 1996 Annex I B 2 Durability Volvo Penta std Annex I B 3 Operator s manual ISO 10240 2004 Anne...

Page 186: ...21182215 224 kW EXVOL009 SDVOL016 5 7 GXiC 3869353 239 kW EXVOL009 SDVOL016 5 7 GXiC F 3869354 239 kW EXVOL009 SDVOL016 5 7 GXiCE 21189867 239 kW EXVOL009 SDVOL016 5 7 GXiCE F 21301406 239 kW EXVOL009 SDVOL016 Essential Requirements Standards Used Other Normative Documents Used Annex I B Exhaust Emissions Engine identification Volvo Penta std Annex I B 1 Exhaust emission requirements EN ISO 8178 1...

Page 187: ... 280 kW EXVOL008 SDVOL017 8 1 GiCE 21301407 280 kW EXVOL008 SDVOL017 8 1 GiCE F 21301408 280 kW EXVOL008 SDVOL017 Essential Requirements Standards Used Other Normative Documents Used Annex I B Exhaust Emissions Engine identification Volvo Penta std Annex I B 1 Exhaust emission requirements EN ISO 8178 1 1996 Annex I B 2 Durability Volvo Penta std Annex I B 3 Operator s manual ISO 10240 2004 Annex ...

Page 188: ......

Page 189: ...he Engine 101 Drive 151 Drive Components 177 Electric Fuel Pumps 124 Electrical System 149 176 Electronic Fuel Injection 175 Electronic Steering Control Unit 63 Emergency Stop Switch 94 Enabling Boost Mode 62 Enabling the Docking Function 61 Engine Alignment 145 Engine Flush 99 Engine Fuel Filter Replacement 146 Engine Overheating EFI Engines 122 Engine Status Panel 53 Engine Status Panel Function...

Page 190: ...and Speed Control 84 Short Term Storage 156 Single Control Lever Operation 83 Spark Plugs 150 Special Boating Conditions 95 Starting the Engine 70 Starting the Engine After Service 139 Starting Using Auxiliary Batteries 113 Starting Using the Start Stop Panel 71 Static Water Line 66 Static Water Line Test 67 Station Handling 86 Steering 132 155 Steering System 63 Steering System Fault Messages 91 ...

Page 191: ...ddress and desired language http www volvopenta com manual coupon Document Distribution Center Order Department ARU2 Dept 64620 SE 405 08 Göteborg Sweden Fax 46 31 545 772 Publication Reference 47700387 Name Address Country E mail English Svenska Deutsch Français Español Italiano Nederlands Dansk Soumi Português Ελληνικά Русско Türkçe ...

Page 192: ...VPA 47700387 English 06 2009 47700387 ...

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