Volvo Penta 3.0GS/SX Owner'S Manual Download | Manualshive

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Fuel system

Fuel pumps

WARNING! Frequently check fuel pumps for
signs of fuel leakage. Should this occur, have it
serviced immediately by your Volvo Penta dea-
ler.

All carburettor models except the 3.0GL have a sing-
le electric fuel pump installed at the front of the engi-
ne on the starboard side. The pump wiring is protec-
ted by a 6 A circuit breaker (A). The model 3.0GL
has a mechanical fuel pump.

EFI engines have two electric fuel pumps; a low
pressure pump to bring fuel from the boat tank to the
engine, and a high pressure pump to supply the fuel
injectors both pumps are protected by a single 20
amp circuit breaker (A).

All the fuel pumps operate only when the engine is
running.

If a pump does not operate and/or the engine will not
start, check and reset the circuit breaker. See your
Volvo Penta dealer if further service is required.

IMPORTANT! Do not run engine out of fuel or
run the electric fuel pumps dry more than 20 se-
conds. Running the electric fuel pumps dry will
damage the fuel pumps.

A fuel pump sucks fuel from the fuel tank through the fuel filter to the fuel injection system or to the carburetor.
The fuel pump and fuel injection system are fused, see Electrical System.

IMPORTANT! All work on the engine fuel injection system must be carried out at an authorized workshop.

WARNING! Be extremely careful when replacing fuel filters or other service work on the fuel system. Ga-
soline is highly inflammable and can be extremely explosive in certain circumstances. Before starting
work: switch off the ignition and allow the engine to cool completely. There must be no smoking, naked fla-
mes or sparks in the immediate vicinity. Place a rag under fuel connectors and filters when removing.
Remove the rag and any fuel spillage immediately and dispose of it in a safe place. When work has finis-
hed: check carefully that there are no leaks. Check both before and after starting the engine. Run the engi-
ne compartment fan for at least 4 minutes before starting the engine.

To prevent fire and explosion, Volvo Penta fuel system components meet requirements for fuel and fuel
vapour containment. Do not substitute automotive or other non-approved parts.

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Summary of Contents for 3.0GS/SX

Page 1: ...OWNER SMANUAL 3 0GS SX 4 3GL SX DP S 4 3GS SX DP S 4 3Gi SX DP S 5 0GL SX DP S 5 0Gi SX DP S 5 7GS SX DP S 5 7GSi DP S ...

Page 2: ...7738812 Downloaded from www volvopenta com 8 2 2009 1 19 46 AM ...

Page 3: ...S SX 4 3GL SX DP S 4 3GS SX DP S 4 3Gi SX DP S 5 0GL SX DP S 5 0Gi SX DP S 5 7GS SX DP S 5 7GSi SX DP S This Owner s Manual is intended for markets outside North America only 7738812 Downloaded from www volvopenta com 8 2 2009 1 19 46 AM ...

Page 4: ...st class performance reliability and durability have been upheld We believe that this also reflects what you require and expect from your new marine engine To help you fulfill your expectations we want you to read through this instruction manual carefully and take our advice about operating and maintaining the engine before you cast off on your maiden voyage Best regards AB VOLVO PENTA 1997 AB VOL...

Page 5: ... shift and control speed 31 Twin unit maneuvering 31 Cruising speed 32 Power Trim 32 After Use 35 Stopping the engine 35 Salt water operation 36 Cold weather precautions 36 Laying up 36 Transporting on a trailer 37 Laying up on land 37 Other Product Information 38 Fuel requirements 38 Electronic engine control 39 Maintenance and Care 40 Engine 40 Lubrication system 43 Cooling system 45 Fuel system...

Page 6: ...mbol is used in the book and on the engine to make you aware of safety information Always read these safety precautions very carefully In the Instruction Manual warning texts have the following priority WARNING If these instructions are not followed there is a danger of personal injury exten sive damage to the product or serious mechanical malfunction IMPORTANT Used to draw your attention to somet...

Page 7: ...e and engine compartment visually before operating the boat be fore the engine is started and after operating the boat after the engine has been stopped This will help you to quickly detect fuel coolant and oil leaks and spot anything else unusual that has or is about to happen Maneuvering Avoid violent and unexpected changes in course and gear engagement There is a risk that someone aboard will f...

Page 8: ...a boat moves forward through the water a va cuum is created behind it to a greater or lesser ex tent In some circumstances this vacuum effect can be so great that the boat s own exhaust gases are sucked into its cockpit or cabin This poses a risk of carbon monoxide poisoning to those on board This problem is greatest for high wide beamed boats with a vertical stern However it can be a problem for ...

Page 9: ... other and as per pendicular as possible to the top of the engine Note that extra equipment mounted on the engine can change its center of gravity Special hoists may be necessary to balance the engine and make handling it safe Never carry out work on an engine suspen ded on a hoist Before starting the engine Reinstall all protective components that have been removed before starting the engine Chec...

Page 10: ...d the coolant filler cap or a cock open or a coolant hose disconnected open the coo lant filler cap carefully and slowly to release pressure before removing the cap completely Note that the coolant may still be hot and can cause burns 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 Neve...

Page 11: ... Responsibility for the environment We all want to live in a clean environment Where we can breathe clean air see healthy trees have clean water in our lakes and oceans and enjoy the sunshi ne without worrying about our health Unfortunately this is no longer something we can take for granted we must work hard together for the environment As a manufacturer of marine engines Volvo Penta has a partic...

Page 12: ... Penta must be observed Only Volvo Penta genuine replacement parts in tended for the certificated engine may be used The servicing of ignition timing and fuel injection systems gasoline or injector pumps pump set tings and injectors diesel must always be carried out be an authorized Volvo Penta workshop The engine must not be modified in any way apart from with accessories and service kits develop...

Page 13: ...ignation A Serial Number B Product Number C Drive Shield Product Designation A Serial Number B Product Number C Gear Ratios D Propeller designation Boat Model Serial Number Extra equipment Type Approval Number A type approval number is assigned to an engine model when it is certified for exhaust emissions There are two certification decals placed on the engine to verify engine certification one on...

Page 14: ...and on the inside of the port valve cover 4 3 5 0 and 5 7 models Location of drive shield type plate SX DP S The drive type plate is located on the drive unit behind the port trim tilt cylinder The shield type plate is located on the top of the inner transom shield 3 0 4 3 5 0 5 7 7738812 Downloaded from www volvopenta com 8 2 2009 1 19 46 AM ...

Page 15: ... engine does not have the drive shown refer to another engine with the relevant drive for an introduction to the transmission 11 Fuel Filter 12 Cover for flame arrestor and carburetor 13 Generator GEN 14 Cover for flame arrestor and throttle housing and electronic controls 15 Power Steering Pump 22 19 20 9 8 13 16 21 15 23 17 SX C SX M Drive 16 Draining Oil 17 Seawater Intake 18 Sacrificial Anodes...

Page 16: ...Seawater Pump 11 Fuel Filter 12 Cover for flame arrestor and carburetor 13 Generator GEN 14 Cover for flame arrestor and throttle housing and electronic controls 15 Power Steering Pump 3 22 18 16 21 17 23 15 8 12 14 13 5 2 SX C SX M Drive 16 Draining Oil 17 Seawater Intake 18 Sacrificial Anodes 19 Oil Level Dipstick 20 Topping Up Oil 21 Trim Cylinder 22 Type Plate 23 Sacrificial Anode SX C 7738812...

Page 17: ...ld See page 12 10 Seawater Pump 11 Fuel Filter 12 Cover for flame arrestor and carburetor 13 Generator GEN 14 Cover for flame arrestor and throttle housing and electronic controls 15 Power Steering Pump 12 14 5 15 2 8 21 20 13 18 22 17 16 3 DP S DP SM Drive 16 Draining Oil 17 Seawater Intake 18 Sacrificial Anodes 19 Oil Level Dipstick 20 Topping Up Oil 21 Trim Cylinder 22 Type Plate 7738812 Downlo...

Page 18: ...revolutions per minute Integral Hours run meter only on separately installed instrument Displays the engine s operating time in hours and tenths of an hour Engine speed range See chapter Operation 2 Temperature gauge Indicates the engine coolant temperature Normal operating temperature is approx 70 90 C 158 194 F 3 Oil pressure gauge Indicates the oil pressure in the engine Normal operating oil pr...

Page 19: ...ut I Operating and running position System voltage connected II Starter position spring loaded The starter motor is engaged IMPORTANT Read the starting instructions in the chapter Starting the engine The ignition keys are marked with a key code used when ordering extra keys Make a note of this key code so that keys can be ordered if the old keys get lost Keep the code in a safe place where unautho...

Page 20: ... the engine Just press in and hold the emergency stop switch button then follow normal starting procedure When the button is released the engine will stop IMPORTANT The emergency stop switch can only be effective when in good working condi tion Observe the following Lanyard must always be free of entanglements that could hinder its operation Once a month check the switch for proper operation With ...

Page 21: ...e not to engage the drive by mistake The shift function and engine speed control are combined in one lever The shift function can be simply disengaged so that only engine speed is affected The Volvo Penta controls are available for top or side mounting The control levers have an adjustable friction brake A neutral position switch is available as an accessory this will only permit the engine to be ...

Page 22: ...rward reverse l Remove the cover over the control For side mounted controls the lever must first be removed l Adjust the friction brake by turning the screw at the arrow see figure l Turn clockwise for more friction and counterclockwise for less friction l Reinstall the cover and lever 7738812 Downloaded from www volvopenta com 8 2 2009 1 19 46 AM ...

Page 23: ...rimming i e raising and lowering the drive can either be done by means of a separate control panel on the instrument panel the control button on the control lever or the control buttons on the port control lever in a twin installation The current trim position of the drive is indicated on a special trim gauge Operation Control panel The control panel 1 has three buttons The centre button moves the...

Page 24: ...bow by pressing the top half and to lower the bow by pressing the lower half of the button To put the drive in the Beach position you have to press a separate switch to bypass the catch which prevents entry to the Beach area This switch is on the instrument panel Note The switch does not have any function if the drive does not have a trim limiter Control with catch button There is a tumbler switch...

Page 25: ...3 Lift range The lift range is used for lifting the drive to its maxi mum angle however this cannot be used during operation This range is used for transporting the boat and to minimize fouling of the drive The Power Trim has an automatic stop which cuts off the current when the stop position is reached The stop is auto matically reset when trimming down Digital trim instrument DP S Displays a fig...

Page 26: ... engine must not be run with the drive in this position BEACH hold function Boats with digital trim instruments and separate swit ches for bypassing the catch which prevents entry to the Beach area can be equipped with a further switch with warning lamp a so called hold function optional Trimming to and inside the Beach area is done as follows Press the button to activate the hold function At the ...

Page 27: ... can occur in either forward or reverse directions Care must be taken l When operating in forward or reverse l When backing at low speed l When trailering boat l When launching boat Impact damage is more likely to occur when in a turn where side loads are placed on the drive unit If the drive unit strikes a solid object throttle back and shut off engine immediately Closely inspect the boat and dri...

Page 28: ...ngine coolant or oil leaks l Check the engine oil level See section on Main tenance l Switch on the main switches IMPORTANT Never break the circuit with the main switches while the engine is running The generator and engine electronics injection eng ines may be damaged l Insert the key in the ignition switch Turn the key one step to the right operating position I this swit ches on the engine syste...

Page 29: ...r a maximum of 10 seconds if the engine does not start release the key and try again after a few seconds IMPORTANT Never turn the key to the starter position with the engine running l Immediately after the engine has started check that the oil pressure and battery charge instru ments are reading normal NOTE Your boat may be equipped with a low oil pressure and high engine coolant temperature acous...

Page 30: ... prepared to quickly move the control handle to the idle position once the engi ne starts This will avoid overspeeding and pos sible damage to the engine GL GS models Disengage the shift control and move the handle to the full throttle position Turn the key switch to the START position Immediately move the control hand le to the idle position when the engine starts IMPORTANT Be prepared to quickly...

Page 31: ...ormal operating oil pressure is approx 150 500 kPa 21 71 psi At engine idle this is normally lower Your boat may be equipped with a low oil pressure acoustic alarm and warning lamp accessory IMPORTANT If oil pressure is too low Stop the engine immediately and investigate Engine coolant temperature The temperature gauge should read between 70 90 C 158 194 F normally Your boat may be equipped with a...

Page 32: ...ntinue contact your nearest Volvo Penta dealer and have the engine checked Master slaveinstallation Gi GSi For twin unit installations both engine EMCs 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 stee ring pump is always connected as the master engine If one engine has a fault...

Page 33: ...NT Carefully check function of all control and engine systems before leaving the dock Move control handle to the neutral detent idle po sition Check in front and behind boat for people or obstructions before shifting To go forward Briskly move the shift handle for ward Throttle movement will begin after forward gear engagement To go in reverse Briskly move the shift handle re arward Throttle movem...

Page 34: ... characteristics that are also affected by external factors When you have got to know your boat thoroughly you can experiment with the best trim angles for different speed load and sea conditions It can generally be said that when the boat feels well balanced easy to steer and pleasant to operate then that is the optimal trim angle for the boat For information about the Power Trim controls and ins...

Page 35: ...igh est engine speed The throttle opening can then be slightly reduced to retain the original speed In choppy seas or running against a heavy sea Trim drive so the bows drop This will provide more comfortable running WARNING High speed running in a heavy sea is dangerous High speed running in a heavy sea requires the driver s maximum attention and a boat of the right size and design for this type ...

Page 36: ...nning astern backward After running aground check for damage to the drive or propeller and for vibrations from the drive If this is the case then the boat if possible should be run to harbor at reduced speed and taken out of the water Check the oil level in the drive If it is colored gray then water has entered the drive If this is the case or if other damage has occurred to the drive it must be i...

Page 37: ...stead Stopping the engine Move control handle to the NEUTRAL position Turn ignition key to the OFF position NOTE Do not stop engine at speeds above idle or speed up engine while turning off ignition Engine damage could result Safety measures Inspect the engine and engine compartment for any leaks Close the fuel cock IMPORTANT Do not forget to open the cock be fore the engine is started again Switc...

Page 38: ...er Cold weather precautions To prevent freezing damage the seawater system must be drained and the freshwater system acces sory coolant must have sufficient anti freeze protec tion See chapter Maintenance Cooling systems IMPORTANT A poorly charged battery may burst as a result of freezing Laying up If the boat is not going to be used for some time but be left in the water the engine must be run ho...

Page 39: ...ge Before transporting the boat by trai ler always secure the drive in the lift position with a Trailer Kit accessory or similar so that it cannot drop down Laying up on land Where boats are kept laid up on land when not in use for example trailer boats there is a lower level of galvanic corrosion protection due to oxidation on the sacrificial anodes Before launching the boat the sacrificial anode...

Page 40: ...NOTE In certain areas Lake Constance for ex ample the use of leaded fuel is not permitted IMPORTANT Never use lead additives as these may leave deposits on injectors and car buretor jets Alcohol in the petrol especially methanol causes rubber and plastic components to age more quickly This can result in fuel leakage Fuels containing me thanol should therefore not be used to avoid da mage to fuel s...

Page 41: ...act your Volvo Penta dealer if service is required NOTE The electronics in the EEC require protection from false signals and interference Never mount radio transmitter antennas or sender cables near the EEC and never ground any wiring to the engine If electrical connections are reversed or wires are disconnected when the key switch is on or the engine is running sensitive electrical components may...

Page 42: ...e product quite literally bit by bit WARNING To prevent personal injury the engine must be turned off before starting maintenance work Belt adjustments General WARNING Ensure that the ignition is off and the ignition key out before inspecting and tightening belts NOTE The belts used for the alternator water supply pump and power steering pump are heavy duty Do not replace with automotive belts Che...

Page 43: ...pulley 4 and the crankshaft pulley 5 To increase belt tension Loosen mounting bracket to water pump screws Pivot water pump away from engine to increase belt tension While maintaining pressure on water pump re tighten top and bottom screws Recheck belt tension Frequently check engine compartment for fuel fumes and excessive water accumulation water depth in bilge should be kept well below flywheel...

Page 44: ... re move the power steering oil fill cap and check the fluid level Wipe dipstick and note the HOT and COLD fluid levels Maintain the appropriate level using ATF oil Exhaust system Periodically inspect engine exhaust system Check for deteriorated or burned hoses loose clamps and evidence of water leaks WARNING Replace damaged defective com ponents and securely tighten all clamps Any exhaust leak mu...

Page 45: ... maintained Check oil level daily IMPORTANT Fill to the Max mark and no hig her The level must not drop below the Min mark A B 4 3 5 0 and 5 7 models A B 3 0 models The engine has a pressurized lubrication system The oil pump sucks oil from the oil pan and then pumps it to the moving parts in the engine The oil is cooled in the oil cooler not all models and cleaned in the oil filter Al ways use Vo...

Page 46: ...ber gasket with a little oil Screw on the new filter by hand until it is in contact with the mating surface And then a further half turn but no more Top up oil to correct level Start the engine and let it idle Stop the engine Check that there are no leaks round the oil filter and the oil level top up if necessa ry See chapter Technical Data for the grade of oil NOTE Collect up the old oil and filt...

Page 47: ...unted on front of the engine sucks in water through the water inlets lo cated on both sides of the lower gear unit Water pumped to the engine by the seawater pump is circulated th rough the engine by the engine circulating pump A thermostat determines the amount of water to be taken in recirculated and discharged to control engine operating temperatures Water is discharged through an idle ex haust...

Page 48: ...with a wire Loosen clamp F and remove manifold hose Waterpump Loosen and slide clamps back Remove hoses from the rear of water pump and drain Turn the engine over on the starter motor for a second do not allow the engine to start so that the water remaining in the seawater pump comes out Reattach water pump ho ses 7738812 Downloaded from www volvopenta com 8 2 2009 1 19 46 AM ...

Page 49: ...ter can run out freely Remove the drain plug 4 from the cylinder block then clean the drainage hole Remove both hoses 5 from the seawater pump and drain them Turn the engine over on the starter motor for a second do not allow the engine to start so that the water remaining in the seawater pump comes out Refit all the hoses and drain plugs Check the tight ness of all the hose clips Do not forget to...

Page 50: ... screen for obstructions Oil coolers Remove the lower water hose from the oil cooler If cooler is mounted horizontally remove either hose loosen mounting bolt and tip open end of cooler down to drain IMPORTANT Failure to completely drain the cooling system will result in serious damage to the engine exhaust manifolds pivot housing and drive unit when temperatures go below free zing To assure compl...

Page 51: ...y NOTE Ensure that nobody is splashed with water spraying out of the exhaust outlet To avoid corrosion in the coolant water ducts these should be filled with either a 50 50 mixture of fres hwater and glycol or emulsifying oil Fill a bucket with either the 50 50 mixture or the oil If possible fix up an overflow return to the bucket or another buck et Start the engine and let it idle Stop the engine...

Page 52: ... pump sucks fuel from the fuel tank through the fuel filter to the fuel injection system or to the carburetor The fuel pump and fuel injection system are fused see Electrical System IMPORTANT All work on the engine fuel injection system must be carried out at an authorized workshop WARNING Be extremely careful when replacing fuel filters or other service work on the fuel system Ga soline is highly...

Page 53: ...amaged flame trap se curely installed Throttle body fuel injection TBI Gi GSi models The function of this fuel metering system is to deliver the correct amount of fuel to the engine under all operating conditions Fuel is delivered by two elec tronic fuel injectors mounted in the throttle body that is attached to the intake manifold The fuel injectors are controlled by the ECM It requires no period...

Page 54: ...r bowl screw securely Clean up any spilled fuel Start the engine and check for leakage C Fuel filter Replacement 4 3 5 0 and 5 7 models All models have a fuel filter C in the fuel line before the fuel pump IMPORTANT Volvo Penta EFI engines require a special marine filter with a 5 10 micron filtering capability Do not substitute any other type of fil ter WARNING Accumulation of water and other fuel...

Page 55: ...tments ignition timing including spark plug gap and the state of the flame trap must be checked NOTE The engine should be hot when idling speed and fuel mixture are adjusted An authorized Volvo Penta Service workshop should set the fuel mixture A workshop tachometer should be used when setting idling speed Carburetor filter 3 0 models Carburetor filter 4 3 5 0 and 5 7 models Clean up any spilled f...

Page 56: ...n the engine compartment Ignition cables and distributor cap Clean ignition cables and distributor cap Check that the cables are in good condition and that the distribu tor cap is not cracked Replace if damaged Other distributor components are maintenance free WARNING To minimize the risk of fire and ex plosion Volvo Penta ignition components meet national and marine safety standards The use of co...

Page 57: ...B 3 2 1 3 4 5 6 1 2 8 8 7 6 5 4 D 3 2 1 1 2 7 5 6 3 4 3 0 engines 4 3 engines 5 0 and 5 7 engines 1 3 4 2 1 6 5 4 3 2 1 8 4 3 6 5 7 2 Firing orders 7738812 Downloaded from www volvopenta com 8 2 2009 1 19 46 AM ...

Page 58: ...ff all power consuming equipment connec ted to that battery and be turned off when power is no longer needed The engine or drive must not be electrically connected to other equipment such as the trim plane bathing steps etc The engine and trans mission must not be used as ground points for radio or navigation installations or other electrical equip ment with separate ground cables All separate gro...

Page 59: ...hile the engine is running To simul taneously charge two independent battery circuits fit a Volvo Penta charge distributor accessory to the regular generator IMPORTANT Turn the engine off and switch off power at the main switches before carrying out work on the electrical system Generator Check belt tension regularly replace belt if they ap pear worn See under heading Engine Batteries Never mix up...

Page 60: ...RNING Danger of explosion Never allow an open flame or sparks near the battery area Battery electrolyte levels The electrolyte should be 5 10 mm 0 2 0 4 in over the plates in the battery Top up if necessary using distilled water Charge the battery after top ping up for at least 30 minutes by running the engine at fast idle NOTE Certain maintenance free batteries have special instructions which mus...

Page 61: ...ads to remove oxi dation using a steel brush Tighten the cable termin als well and spray the battery terminals and connec tions with anti corrosive agent or coat them with Va seline Also check that all other electrical connections are dry and free of oxidation and that there are no loose connections If necessary spray these connec tions with a water repellent spray Volvo Penta Uni versal oil WARNI...

Page 62: ...for up to 5 A and one not fused for up to 20 A The engine has two 8 A fuses A in the instrument panel that protect the starter and system power See chapter Instrumentation Inline fuse B 5 A in the control lever and integrated Power Trim switch cabling protects the Power Trim switch IMPORTANT Always carry extra fuses on board Inline fuse C 10 A in the Power Trim pump cabling SX M DP SM drives prote...

Page 63: ...necabling Automatic fuse C is 12 5 A and protects the engine control module EEC Gi GSi models only The fuses are located to starboard of the engine Automatic fuse D protects the fuel pump s A 50A B 60A 50A on GL and GS models C 12 5A Not fitted on GL GS models D 20A 6A on GL and GS mo dels 7738812 Downloaded from www volvopenta com 8 2 2009 1 19 46 AM ...

Page 64: ...al sacrificial anodes may be required to handle the added corrosion potenti al SX C drive Inspect anode C in the exhaust pas sage once a season or every 100 hours replace if necessary Remove two short and one long TORX screws Tighten the new anode so that there is a good electri cal contact Where boats are kept laid up on land when not in use there is a lower level of galvanic corrosion protection...

Page 65: ...for protection is very low If the light is flas hing once per second the demand is high and the system is operating at maximum capacity The Vol vo Penta Active Corrosion Protection System is de signed to adequately protect one drive unit from gal vanic corrosion The system works by keeping the voltage potential in the area around the drive unit in a range that is not corrosive to aluminum This is ...

Page 66: ...propeller gear housing and let the oil run out in to a suitable container Reinstall the plug and gasket If oil is colored grey then water has entered the drive Contact authorized service per sonnel NOTE Deposit the used oil at a properly designated disposal site Trim the drive up slightly Remove the rear cover by removing the three retaining screws Remove the oil level plug C Top up oil through th...

Page 67: ... Data NOTE If unable to fill the drive unit through oil drain plug B the drive can be filled by trimming it up a few degrees and filling through the oil level plug C When filled to the proper level install oil level dipstick and oil level plug first to prevent excessive oil loss then the oil drain plug Tighten oil level and drain plugs securely Reinstall oil level plug and place drive in the run d...

Page 68: ...ase until it is forced out of the bearing If the old grease indicates water contamination the bearing must be inspected and replaced if damaged WARNING Removal of the drive requires spe cial knowledge and tools A falling drive can cause serious personalinjury Please contact your nearest authorized Volvo Penta dealer for assistance IMPORTANT Failure to lubricate the gimbal bearing and universal joi...

Page 69: ...if necessary using ATF oil Cleanliness is extreme ly important no dirt may enter the drive when topping up with oil Tighten the filler plug Power Trim pump Oil level SX M and DP SM drives At the beginning of each boating season check the oil level in the reservoir as follows Trim the drive in as far as possible Check the oil level is between the MAX and MIN markings on the oil reservoir Top up if ...

Page 70: ...ion of rotation of the drive units in twin installation In Duo Prop drive unit twin installation the drive unit must be adjusted so operation is free from cavitation To adjust measure the distance A between the center line of the two transom shields Adjust tie bar so the distance B between the center of the cavitation plate is equal to distance A Engine alignment Engine alignment requires special ...

Page 71: ...ystem cannot be corrected on board proceed at a reduced speed The boat will be steerable but with increased effort See your Volvo Penta dealer as soon as possible to correct your power steering system At slow speeds no wake your boat may tend to wander This is normal and may be overcome by anticipating bow direction and correcting with steering wheel A slightly higher throttle and trim setting may...

Page 72: ...damaged Do not operate DP models with only one propeller this can cause damage to propeller shafts Propeller selection SX drive When you choose a propeller it is important to know whether it should be for right hand or left hand rota tion The directions of rotation are shown in the illus tration Boat yards normally use right hand rotation and have set the trim fin for right hand rotation For trim ...

Page 73: ...nless steel propeller sets should be used in these applications Propelleridentification DP S drive The type designation A and the FRONT and REAR identification B are stamped on the end of the propeller hubs When replacement of the propeller is required either a forward or rear propeller can be pur chased to maintain the matched set Always order replacement propel lers by the part number Propeller ...

Page 74: ... the bushing F with the inner cone turned toward the propeller shaft cone Install the propeller E Press the propeller against the bushing until the spline edges can be seen and install the spacer D on the splines Shift the control lever in the FORWARD position to lock the propeller shaft Install the nut C and tighten using a torque of 96 108 Nm Install the locking tab washer B so the split pin can...

Page 75: ...re to install propellers as shown could result in the loss of the rear propeller and damage to the drive unit when boat is operated D C B A Propeller replacement DP S drive Removal WARNING Ignition switch must be OFF Place remote control in the FORWARD position to lock propeller shafts Remove rear propeller nut A Remove the rear propeller B Place remote control in the REVERSE position to lock prop...

Page 76: ...ricate Every 200 operating hours or at least once a year Spark plugs Replace Ignition cables and distributor cap Check and clean Drive belts Check Carburetor filter Check Flame trap Clean Seawater pump Check Controls Check adjust Anti fouling paint Check Every other year Seawater pump Replace impeller Drive Replace U joint and exhaust bellows Regular maintenance is necessary if the engine and tran...

Page 77: ...h rust inhibi tor Steering shaft bearing Lubricate Change oil in the drive Repair any damaged areas of paintwork with Volvo Penta original paint Note Read the special ins tructions on painting the drive under the heading Painting the drive and keel Remove the propeller s for storage Grease the propeller shaft using water repellant grease Check the U joint and exhaust bellows Replace every other ye...

Page 78: ...d batteries Paint drive and hull See following section Immediately before launching the drive s sacrificial anodes must be cleaned off with emery paper If an anode is 2 3 its original size 1 3 eroded it should be replaced IMPORTANT Do not use steel brushes or any steel tools for cleaning the anodes This can re sult in reduced galvanic protection Reinstall the propeller s Launch the boat Check ther...

Page 79: ...n first teflon Teflon is the registered trademark of the Du Pont Corp Paint the keel with a suitable paint or pure Teflon agent All types of paints with anti fouling properties are poisonous and more or less damaging to the mari ne environment Avoid the use of such agents Most countries have introduced legislation controlling the use of anti fouling agents for paint boats Always abi de by these re...

Page 80: ... see that remote control is in NEUTRAL position See your Volvo Penta dealer Replace filters See your Volvo Penta dealer See your Volvo Penta dealer Check for damaged propeller Check for weeds on propeller or gearcase Reduce or redistribute load Adjust trim Drain bilge Clean boat hull See your Volvo Penta dealer Fill tank with proper fuel See your Volvo Penta dealer Possible cause No fuel in tank o...

Page 81: ...on the dipstick liters 1 0 1 0 Oil grade in accordance with the API system Service SG Service SG Viscosity at 5 50 C SAE 20W 50 SAE 20W 50 SAE 15W 50 SAE 15W 50 Temperature based on constant ambient temperature Single grade oil can also be used at temperatures above 0 C SAE 30 should be used Ignition system Firing order 1 3 4 2 1 6 5 4 3 2 Ignition timing 0 0 GL GS 8 Gi Spark plugs P N Volvo Penta...

Page 82: ... 1 0 Oil grade in accordance with the API system Service SG Service SG Viscosity at 5 50 C SAE 20W 50 SAE 20W 50 SAE 15W 50 SAE 15W 50 Temperature based on constant ambient temperature Single grade oil can also be used at temperatures above 0 C SAE 30 should be used Ignition system Firing order 1 8 4 3 6 5 7 2 1 8 4 3 6 5 7 2 Ignition timing 10 BTDC 8 BTDC Spark plugs P N Volvo Penta 3851831 38518...

Page 83: ...1 0 1 0 Oil grade in accordance with the API system Service SG Service SG Viscosity at 5 50 C SAE 20W 50 SAE 20W 50 SAE 15W 50 SAE 15W 50 Temperature based on constant ambient temperature Single grade oil can also be used at temperatures above 0 C SAE 30 should be used Ignition system Firing order 1 8 4 3 6 5 7 2 1 8 4 3 6 5 7 2 Ignition timing 8 BTDC 8 BTDC Spark plugs P N Volvo Penta 3851831 385...

Page 84: ...RON unleaded fuel 4 3Gi 93 Octane RON unleaded fuel 5 0GL 93 Octane RON unleaded fuel 5 0Gi 93 Octane RON unleaded fuel 5 7GS 93 Octane RON unleaded fuel 5 7GSi 93 Octane RON unleaded fuel If 93 octane RON is not available gasoline down to 90 octane RON can be used Leadedgasolinecanbeusedifunleadedisunavailable WARNING Fuel is extremely flammable and highly explosive under certain conditions Alway...

Page 85: ...________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ _____________________________...

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Page 88: ...7738812 2 English 09 2001 AB Volvo Penta SE 405 08 Göteborg Sweden www volvopenta com ...

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