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Volvo Penta V8-380, Operator'S Manual

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Volvo Penta V8-380 Operator'S Manual Download Page 52

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.

Troubleshooting

50

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Summary of Contents for V8-380

Page 1: ...OPERATOR S MANUAL V8 380 ...

Page 2: ...ancer birth defects and other reproductive harm Additionally lubricants fuels and other fluids used in engines including any waste created through the wearing of engine parts contain or produce chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Battery posts terminals and related accessories contain lead and lead compounds Wash your hands after ...

Page 3: ...Optional 21 Starting 23 Operation 29 Engine Shutdown 42 In Case of Emergency 46 Troubleshooting 49 Maintenance Schedule 63 Maintenance 68 Storage 91 Technical Data 95 Operator s Manual Order 106 Alphabetical index 107 1 47702842 Downloaded from www volvopenta com 10 27 2012 8 15 23 PM ...

Page 4: ... the site will provide you with the correct manual The publication search will also provide you with all of the other publications that are available for your power package These publications such as workshop man uals and parts catalogs can be purchased for a small fee When reading sections of this manual that contain headings without model designation below the head ing the information provided i...

Page 5: ...service life Always observe recommended service intervals and make a habit of checking that the engine is operating normally every time you use it Contact an authorized Volvo Penta dealer if you cannot correct the fault yourself Remember that most chemicals used on boats are harmful to the environment if used incorrectly Volvo Penta recommends the use of biodegradable degreasing agents for all cle...

Page 6: ...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 book with your boat at ...

Page 7: ...t 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 fuel system parts and replace if fuel leakage or parts deterioration are found DANGER To prevent fire and explosion perform all service procedures with th...

Page 8: ...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 and follow the current rules reg...

Page 9: ...as 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 monoxide is produced any time a mater...

Page 10: ...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 Detection Systems Even with the best of b...

Page 11: ...m 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 monoxide is emitted from any boa...

Page 12: ...ting 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 As shown in image 51619 certain c...

Page 13: ... 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 discharge their exhaust products in l...

Page 14: ...al 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 days per year If your engine breaks down the VAS coordinator will quickly locate your nea...

Page 15: ...call 1 800 522 1959 US only 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 Penta dealer Volvo Penta on the Internet is the web site to visit Additionally you will find a wealth of infor mation related to our co...

Page 16: ...es depicted below are sample representations only 1 Tachometer Shows the engine RPM Multiply this value by 100 or 1000 depending on model for revolutions per minute Integral Hours run meter optional and separately installed displays the engine s operating time in hours and tenths of an hour 2 Temperature Gauge Indicates engine tempera ture Normal operating temperatures are listed in the section en...

Page 17: ...or emission control system Volvo Penta provides an engine status panel with every engine its installation is determined by the manufacturer of your boat If your boat does not have an engine status panel available we strongly rec ommend that you contact your dealer to have one installed 51388 The emissions related indicator light is an amber colored engine icon When lit it is an indication that the...

Page 18: ...bottom is called trimming Trimming provides the following benefits Improves acceleration to planing Keeps the boat on plane at reduced throttle set tings Improves fuel economy Provides smoother and or drier ride in choppy water conditions Increases maximum speed If you do not wish to use this feature you may leave the drive unit trimmed to the position that works best for you NOTICE Avoid over tri...

Page 19: ...oth drives can be oper ated simultaneously by pressing buttons 2 3 or but tons 5 6 Trimming out the Drive Press button 1 on the control panel or the trim button s on the control lever to raise the bow of the boat drive trimmed out The drives can be operated separately by pressing button 2 on the control panel for the port drive and button 3 for the starboard drive Trimming in the Drive Press butto...

Page 20: ...his range is used for running at reduced speed in shallow water or where water depth is uncertain NOTICE Maximum safe engine speed when running in beach range is 1000 rpm Make sure the drive s coolant inlet is never trimmed out of the water Tilt Range Tilt range 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...

Page 21: ...ase refer to Trim Ranges in the previous section Analog Instrument 51727 The analog trim instrument B shows the current posi tion of the drive This instrument has three ranges 1 Trim range 2 Beach range 3 Tilt range For an explanation of trim ranges please refer to Trim Ranges in the previous section Instruments and Controls 47702842 04 2012 19 47702842 Downloaded from www volvopenta com 10 27 201...

Page 22: ...w 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 P0008705 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 Starboard Engine Throttle Control Lever 4 Port Tr...

Page 23: ...ate 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 stray cur rents emitted by a malfunctioning AC power source on your boat the pier or other boats in ...

Page 24: ... 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 necessary Loose connection or corro...

Page 25: ...ser height and the height of the engine in the hull If you add 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...

Page 26: ...of water plug the top of the hose using your thumb or a plug 5 Measure the vertical distance D from water line E in hose to the top of manifold B Measurement D should be 13 in 33 cm or greater 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 Penta dealer for information on high r...

Page 27: ...er 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 proceeding 51421 1 Turn main bat...

Page 28: ...ll damage the fuel pumps P0002141 9 Lower the drive unit to normal run position make sure the water intakes are submerged There should be no obstructions in the water near the propellers Starting the Engine Audible Alarm If an audible alarm has been installed on your boat it will perform a brief self test when the ignition key is turned to the RUN position Following is a description of how the ala...

Page 29: ...the engine floods during a warm start sim ply follow the directions provided in the following sec tion to restart the engine NOTICE Risk of starter damage do not run the starter for extended periods 20 sec Allow time to cool between start attempts Auto crank The engine will auto crank when the key is moved to the start position Auto crank will allow you to release the key from the start position a...

Page 30: ...ry to start the engine turn the ignition switch to S Start If the engine does not start quickly release the key and then try again 4 After the engine starts move the throttle back to the neutral position to return to normal operating mode 21183 1 P0016544 Starting 28 47702842 04 2012 47702842 Downloaded from www volvopenta com 10 27 2012 8 15 23 PM ...

Page 31: ... or overboard CAUTION Be sure you have read and understand everything in the section entitled Before Starting prior to continuing with this section Replacement Parts and Tools Checklist For your safety and to ensure minimal interruption of your boating we strongly recommend that you carry the following spare parts and tools aboard your boat Extra propeller prop hardware Ignition starter and fuel p...

Page 32: ...rrecting the cause of the problem may result in engine damage or equipment failure Any engine or drive damage that occurs or is worsened due to ignoring an alarm may not be covered by your warranty For a detailed explanation of the problems mentioned above and the steps to take to deal with them please refer to the chapter entitled Troubleshooting Volvo Penta provides an audible alarm with every e...

Page 33: ...ment panel Center button Moves the drive trim out while raising the boat s bow The lower button moves the drive trim in while lowering the boat s bow The top button optional disconnects a catch so that the drive can be trimmed into the BEACH and TILT positions Press this button and the center button at the same time Determining the Proper Trim CAUTION Avoid trimming the sterndrive too much as stee...

Page 34: ...another boat s wake Excessive bow up trim may result in the boat s bow rising rapidly and possibly throwing the boat s occupants into the water Operating in Bow down Position The bow down B position is normally used for accel eration onto plane operating at slow planing speeds and running against a choppy wave condition In the fully bow down position the boat may tend to self steer You may have to...

Page 35: ... extended periods engine damage may occur This type of damage is not covered by warranty See the section entitled Techni cal Data for full throttle operating ranges The engine should not be operated at RPMs above the WOT range see Technical Data If the engine is rou tinely exceeding the WOT maximum RPM or is fre quently at limited RPM range controlled by engine computer the boat should be taken to...

Page 36: ...ck Button P0016255 The neutral interlock button which is only available on side mount controls prevents accidental movement of the control lever out of the neutral position This button must be depressed to shift the lever out of neutral To move the control lever away from neutral 1 With the control lever in NEUTRAL depress the neutral interlock button 2 While keeping the button pressed move contro...

Page 37: ...ear engaged for forward move ment ahead R Drive reverse gear engaged for backward move ment astern T Throttle engine speed control 1 Trim tilt switch port 2 Trim tilt switch starboard Shifting from Neutral To move the remote control lever from the neutral detent position simply move the control lever in the desired direction Operation 47702842 04 2012 35 47702842 Downloaded from www volvopenta com...

Page 38: ...k 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 To go forward Move the control han...

Page 39: ...n neutral N on standby and use the star board engine The use of one control is very effective and more convenient In the event that the starboard engine which is being used for maneuvering stops you can immediately go to the port engine which has been on standby NOTICE Both engines must be running during close maneuvering or at slow speeds If only one engine is running water may be forced back thr...

Page 40: ...e 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 any occupant of the boat may attempt to resta...

Page 41: ... 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 power steering system is on the starboard engine therefore when operating on a single engine use the starboard engine Using a port engine that does not have a functional power steering ...

Page 42: ... you do not exceed 1000 RPM Exceeding 1000 RPM at high trim tilt is not nec essary It will only increase the boat wake and will not increase boat speed appreciably NOTICE Exceeding 1000 RPM with the drive unit tilted could damage drive train components This type of damage is not covered by warranty Never attempt to plane the boat or exceed 1000 rpm with the drive unit in a partially tilted positio...

Page 43: ...ared for what other boaters may do unexpectedly High speed driving requires the driver to give a high degree of attention to boat operation and surrounding conditions A boat travelling at a speed of approximately 70 M P H 60 knots covers about 101 feet 30 meters in 1 second The faster you go the quicker things will happen High speed driving requires a lot of water and a good distance from possible...

Page 44: ...anges in boat movement Allow the engine to run at low idle in neutral for a few minutes after operations are completed This allows engine temperatures to equalize This is especially important when the engine has been run at high rpm or under heavy load just prior to shutdown Turn the key switch to the off position O Stop the Engine Allow the engine to run at low idle in neutral for a few minutes a...

Page 45: ...ng shut it down 2 Remove the blue plastic cap from the hose that is clamped to the port side of the engine It is marked with the running engine flush symbol 3 Connect a water hose from a fresh water source to the female flush connector 4 Turn water on full and start the engine 5 Let engine idle until engine temperature stabilizes at its normal operating range This will allow the thermostat to open...

Page 46: ...ld be all the way up and secured whenever the trailer and boat are being moved During transport be aware of high spots or dips in the roadway such as railroad crossings low street gutters large potholes or other uneven road surfa ces Be careful when backing The drives could strike the road or ground causing damage When you have reached your destination if the boat will be stored on the trailer the...

Page 47: ...drain 2 Loosen 9 16 nut A on the stud holding the end cap on the bottom of the heat exchanger Do not remove the nut from the stud 3 Make sure the cap completely separates from the heat exchanger NOTICE Risk of freeze damage to heat exchanger The raw water portion of the heat exchanger has mul tiple compartments to insure that all compartments drain the cap must completely separate from the gas ket...

Page 48: ...ke an object or run aground NOTICE If there are problems at any of the following steps call for assistance to move the boat to a location where it can be removed from the water for inspection Oper ating with damaged equipment especially at speed could worsen the damage Steering and control could also be affected Throttle back to idle if possible maneuver to a safe place out of high traffic areas P...

Page 49: ...ain To prevent galvanic corrosion any paint damage on the drive and propeller should be repaired before launching the boat again Tie Rod Applies to twin engine boats with mechanical not elec tric steering The tie rod connects the tiller arms of the two drives It is mounted inside the boat at the rear of the engines Check the tie rod if you have hit an obstacle If the tie rod is bent loose or damag...

Page 50: ...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 the discharged battery e g the sta...

Page 51: ...n 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 m...

Page 52: ...e 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 Troubleshooting 50 47702842 04 2012 47702842 Downloaded from www volvopenta com 10 27 2012 8 15 23 P...

Page 53: ...eration 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 Hard Starting Hot Engine Is this a New Condition Check Quality of fu...

Page 54: ...ler Mountings Check Loose broken or worn engine mounts Loose lag screws holding mounts to stringer Call for assistance or see Volvo Penta authorized dealer Alternator Check Loose pulley see dealer Noise from bearings see dealer Call for assistance or see Volvo Penta authorized dealer Sterndrive Check Failed U joints or gimbal bearing see dealer Damaged internal drive components see dealer Worn ben...

Page 55: ...ition Check Spark plug wires Ignition switch wires Circuit breakers and relays Wiring between engine and dash Call for assistance or see Volvo Penta authorized dealer Engine Stops Or Dies Out Due To Seizure Check Call for assistance or see Volvo Penta authorized dealer Engine Won t Reach Operating RPM Refer to the section entitled Engine Protection Mode Check Boat overloaded or load improperly pla...

Page 56: ...ged battery to jump start the engine Refer to Starting Using Auxilliary Batteries in section entitled In Case of Emergency Recharge starter battery Check battery condition replace if necessary To Prevent All electrical accessories including ignition circuit are turned off Turn battery switch off and disconnect main battery negative cable from battery If problem persists call for assistance or see ...

Page 57: ... 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 designed to give maximum speed w...

Page 58: ...larm stops sounding the malfunction has been cleared and the engine may now be operated normally Use the oil pressure and water temperature gauges to verify a problem exists then inspect the engine crank case for proper oil level and check the water inlets for obstructions The low oil pressure engine overheat problem must be corrected before the engine will return to normal operation To reset the ...

Page 59: ... 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 unable to add oil to the engine make ...

Page 60: ...ich 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 contact your dealer for repairs as soon as possible W...

Page 61: ...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 dealer if the pump makes an unusual noise Circuit Breakers and Fuses The engine s electrical system is protected against cir cuit overload by fuses and circuit breakers Engine electrical circuits may also be rou...

Page 62: ...ine Several spare fuses and relays are located on the inside of the fuse box cover In case of malfunctioning or faulty fuses and relays use the spares provided Remember to replace any spares that are used NOTICE Circuit breakers or fuses that repeatedly fail indicate a problem that requires immediate attention See your Volvo Penta dealer P0016589 Troubleshooting 60 47702842 04 2012 47702842 Downlo...

Page 63: ...chnician soonB ON A ON YES Engine operates at reduced throttle providing maneuvering speed only operate boat accord inglyD Engine and or emission system should be inspected by authorized service technician as soon as possibleE 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...

Page 64: ...ease the switch and wait for the motor to cool and then reset Resume trimming Drive Physically Blocked from Moving Check to see if anything has become entangled in the drive or the trim cylinders Clear the obstruction before proceeding with trimming Steering 51836 If you experience difficulty steering the boat check for the following Check the fluid level in the power steering pump reservoir The f...

Page 65: ...or your emission control system if failure results from abuse neglect improper mainte nance or unapproved modifications If emission control system repair is required during the warranty period you are responsible for presenting your sterndrive engine to a Volvo Penta authorized dealer as soon as the problem exists The warranty repairs will be completed using genuine Volvo Penta parts in a reasonab...

Page 66: ...emote 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 Exhaust Check for wear leaks and loose...

Page 67: ...lems 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 servicing your engine See Technical Dat...

Page 68: ...ery 100 Hours Check Correct Fill Lube Adjust Tighten Clean Change Replace Engine Check for Campaigns or Recalls Dealer to check serial number on Partner Network Serpentine Belt Wear tension Oil and Filter 1 2 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 Ch...

Page 69: ...nnections 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 Joystick Only Dealer to replace fluid...

Page 70: ...ta 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 general hardware parts ...

Page 71: ...ning sign in the con trol position that work on the engine is being carried out Approaching or working on an engine that is running is dangerous Loose clothing hair fingers or a dropped tool can be caught in the rotating parts of the engine and cause serious personal injury We recommend that all servicing with the engine running be undertaken by an authorized Volvo Penta workshop Starting the Engi...

Page 72: ...t 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 authorized per sonnel Otherwise the ge...

Page 73: ...f 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 missing chunks Dry rot Exposed cords or excessive fraying Oil or grease If the belt needs to be replaced refer to the Workshop Manual for the procedure or t...

Page 74: ... the oil level on the dipstick could be above the actual level If the oil level is checked directly after shutting the engine off the oil level on the dipstick will be low To get an accu rate oil level reading on the dipstick 1 Run the engine to normal operating temperature then shut it off and wait at least 5 minutes 2 Remove the dipstick and check the oil level NOTICE Gas engines require a preci...

Page 75: ...rter Approved SAE 10W 40 for make up oil see Engine Oil Specifications Adding Oil After Break in Period Check the oil level frequently see Maintenance Schedule for minimum intervals Frequent oil level checks are a good strategy to ensure long engine life Oil level checks help identify engine service issues such as leaks and excessive oil consumption before they become serious Maintain oil level be...

Page 76: ... or explosion Frequently inspect fuel system parts and replace if fuel leakage or parts deterioration are found DANGER To prevent fire and explosion perform all service procedures with the engine turned OFF DANGER Failure to inspect your work may allow fuel leakage to go undetected This could become a fire or explosion hazard WARNING Risk of fire When carrying out work on the fuel system make sure...

Page 77: ...ay 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 main battery switch 9 Run the bilge b...

Page 78: ...h fuel enough to run engine 15 minutes Two cycle motor oil 50 1 ratio gas to oil Fuel stabilizer per manufacturer s instructions DANGER Fuel and vapors will be present during procedure which can result in an explosion provide ventilation and eliminate all sources of spark or flame CAUTION Engine must be run to complete process Take pre cautions to ensure safety and prevent engine damage Run engine...

Page 79: ...l inlet fitting and check for fuel leaks Do not start engine DANGER Failure to inspect your work may allow fuel leakage to go undetected This could become a fire or explosion hazard Electronic Fuel Injection The electronic fuel injection EFI fuel metering system delivers the correct amount of fuel to the engine under all operating conditions The EFI system is controlled by a microprocessor and req...

Page 80: ...he impeller must be replaced Inspect the O rings 5 for nicks cuts and wear Replace as necessary O rings 6 are for retaining cover screws in the cover and are not critical 4 Lubricate the pump housing with non petroleum based lubricant suitable for rubber such as glyc erine If you have purchased the Volvo Penta impeller kit a packet of glycerine is included 5 Reinstall the impeller and O rings Rein...

Page 81: ...This engine uses Volvo Penta VCS coolant only yellow color Do not use other coolant types mixing other cool ants may damage the cooling system Sacrificial Anode These engines have a sacrificial anode A located in the heat exchanger as shown in the illustration Anodes are slowly eroded away by galvanic action and require inspection Additionally anodes that are sub jected to frequent wetting and dry...

Page 82: ...an open flame or electric sparks near the battery or batteries Never smoke in proximity to the batteries The batteries give off hydrogen gas during charging which when mixed with air can form an explosive gas This gas is easily ignited and highly volatile WARNING Battery electrolyte is a corrosive acid and should be handled with care If you spill or splash electrolyte on any part of the body immed...

Page 83: ...if they were supplied with the battery use a lock nut instead NOTICE Some maintenance free batteries have spe cial care instructions Make sure to follow the battery manufacturers instructions carefully NOTICE When replacing your battery read and understand the information supplied with it before you begin installation The service life of your battery depends largely on how it is maintained Keep ba...

Page 84: ...el If level is too high remove until oil is at proper level See Do 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 o...

Page 85: ...ully enough to cause an injury NOTICE Do not exceed 116 PSI 800 kPa as this may damage the drive 1 The pitot tube hose A is attached 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...

Page 86: ...tion 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 manufacturers rec ommendations Anode Replacem...

Page 87: ...following Copper paints must not be used Use paints specifically designed for aluminum sterndrives Procedure should be carried out by a qualified technician at an authorized Volvo Penta dealer ship due to environmental concerns NOTICE If you do use copper 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...

Page 88: ...sure 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 the key into the ignition switch O Turn the key one step to the right I to switch on engine ...

Page 89: ...r hands from the sharp edges of the pro peller blades Wear gloves whenever you remove or replace a propeller Do not attempt to hold propellers by hand when you remove or install propellers and propeller nuts Serious injury could result NOTICE Never continuously run with a damaged pro peller Running with a damaged propeller can result in drive unit and engine damage NOTICE Propellers must be remove...

Page 90: ...roceed slowly and check for bending blades If propellers appear to bend refer to the Do It Yourself manual for an alternate procedure or contact your dealer 5 Remove rear propeller 3 6 Use propeller tool P N 3862797 and ratchet to remove front propeller nut 2 7 Remove front propeller 1 NOTICE Propeller may be stuck to shaft Tap the forward edge of the propeller blades LIGHTLY with a NON METALLIC h...

Page 91: ... lb 60 Nm NOTICE Be sure the chamfered edges of the propeller nuts are facing forward Failure to install the propeller nuts correctly could result in propel lers coming loose and damage to the lower unit and or propellers 5 Install the rear propeller 3 6 Install the rear propeller nut 4 chamfered edge forward Use a 30 mm socket and torque wrench to torque the nut to 75 ft lb 100 Nm 7 With the remo...

Page 92: ...when checked If needed add Volvo Penta Power Trim Tilt and Steering Fluid Do not overfill the pump reservoir NOTICE Never fill the steering system with oil of unknown quality Non recommended oil may cause steering operation impairment or component damage Do not allow contaminants to enter the reservoir when checking or filling the oil level 51836 Maintenance 90 47702842 04 2012 47702842 Downloaded...

Page 93: ...ock See information on draining the engine in the section entitled Engine Shutdown Draining the Engine Store battery as recommended by manufacturer Add fuel stabilizer please refer to Ethanol Blended Fuels E10 in the chapter entitled Tech nical Data P0016600 47702842 04 2012 91 47702842 Downloaded from www volvopenta com 10 27 2012 8 15 23 PM ...

Page 94: ... Fuel Sys tem in the chapter entitled Maintenance Please be sure to read the entire procedure in Fuel System and Fuel Storage Mixture before con tinuing Check coolant for proper fill level and freeze pro tection level Drain water from raw water side of engine See information on draining the engine in the section entitled Engine Shutdown Draining the Engine Close the valve in the fuel line between ...

Page 95: ...lugs Reconnect any hoses removed for storage Check battery for correct charge Reinstall if removed Open the fuel shut off valve and check fuel system for leaks Check all oil and fluid levels and fill as nec essary Check drive transom shield and heat exchanger anodes Clean or replace as nec essary Storage 47702842 04 2012 93 47702842 Downloaded from www volvopenta com 10 27 2012 8 15 23 PM ...

Page 96: ...ck 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 fill as nec essary Check drive transom shield and heat exchanger anodes Clean or r...

Page 97: ... plug installation torque 11 ft lb 15 Nm COOLING SYSTEM Thermostat 160 F 71 C closed cooling heat exchanger mounted on engine Coolant type See Maintenance Freshwater System OIL FILTER Engine oil filter Volvo Penta replaceable paper element OIL CAPACITY NOTICE Overfilling the oil can cause engine and or sterndrive damage We urge you to use the dipstick to check the oil level whenever you are changi...

Page 98: ...erter Approved SAE 10W 40 These oils are engineered to meet all of the requirements of your V8 380 and are formulated spe cifically for marine engines These oils are available at Volvo Penta dealers If the Volvo Penta oil is not available use an oil that meets NMMA FC W Catalyst Compatible specifica tions Viscosity should be SAE 10W 40 or higher example 15W 40 20W 40 25W 40 15W 50 Do not use 0W40 ...

Page 99: ...l and that meets the mini mum octane specification 10 ethanol blended fuel is also commonly referred to as E10 Because of the high content of alcohol in the blend users of ethanol blended fuels must take additional care in the maintenance of their fuel systems The effects vary depending on the fuel tank material Most boats have fuel tanks constructed of aluminum stain less steel or composites Sinc...

Page 100: ... recommended when storing ethanol blended fuels for more than 2 weeks Avoid extended storage of ethanol blended fuels whenever possible Other Ethanol Blended Fuels NOTICE Do not use ethanol blends greater than 10 especially E85 85 ethanol Volvo Penta engines are not designed to run on high percentages of etha nol Loss of performance will occur Engine damage may also occur damage caused by fuel wit...

Page 101: ... possible during freezing temperatures if coolant mix is not correct If the boat engine will be stored or used in an area with freezing temperatures the coolant mixture must be checked to insure it has adequate temperature protec tion properties As part of winterization Volvo Penta highly recommends that the coolant be checked for correct freeze protection Use a coolant test kit hydro meter to che...

Page 102: ... starting and electrical component damage Battery Battery Requirements Replace the battery with one that has the same or more cold cranking amps and reserve capacity as the battery installed in your boat by the boat builder See Technical Data for your engine for minimum battery requirements If you are unsure of the battery to be used consult your dealer NOTICE Failure to use a battery of recommend...

Page 103: ...ic gearcase lubricant NOTICE Whenever you are changing or topping up the oil always check the oil level using the dipstick Sterndrive Oil Capacity DPS Models 2 6 quarts 2 5 liters NOTICE If your drive is equipped with a Drive Spacer you will need to add more oil than the recommended amount P0016608 P0016609 Technical Data 47702842 04 2012 101 47702842 Downloaded from www volvopenta com 10 27 2012 ...

Page 104: ...m assembly drive unit stickers should be located on the engine decal Your Volvo Penta dealer will have attached these stickers at the time that the transom assembly and drive unit were mounted on your boat and attached to the engine 51802 The engine plate is typically located on the port rear side of the engine block 3863274 The label depicting the serpentine belt configuration is typically mounte...

Page 105: ... IMPELLER 21700445 2 ea 21772268 ENGINE WATER POWER STEERING FLUID MODEL Qt 1141679 L 3809443 DPS A 2 6 US Qts 2 45L OIL FILTER 8692305 DRIVE GEAR LUBE PS FLUID 3851039 FUEL FILTER 3847644 Max WOT RPM 5600 6000 COOLANT Volvo Penta VCS P0015661 The tune up and color code decal is located on the engine cover Technical Data 47702842 04 2012 103 47702842 Downloaded from www volvopenta com 10 27 2012 8...

Page 106: ...nd store the information so that it is available in the event of the boat being stolen NOTICE The identification plates depicted in the illustrations below are samples only The numbers on your identification plates will be different than those shown below Engine Plate 51802 SERIAL NUMBER SALES NUMBER EMISSION MODEL NUMBER Transom Shield Plate 51804 SERIAL NUMBER PRODUCT NUMBER TYPE Drive Unit Plat...

Page 107: ...nnex 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 Operator s manual ISO 10240 2004 Annex I C 2 EMC Directive 89 336 EEC This declaration of ...

Page 108: ...eb page type in the publication number found in the bottom of this page 7 8 digits http vppneuapps volvo com manual coupon If internet access isn t possible please contact your Volvo Penta dealer All order information is stored internally at AB Volvo Penta and will not be shared with third parties 106 47702842 04 2012 47702842 Downloaded from www volvopenta com 10 27 2012 8 15 23 PM ...

Page 109: ...4 H High Altitude Operation 40 High Performance Boat Operation 41 Hour Meter 65 Hull Weight 55 I Identification Numbers 102 104 Impeller Checking Replacing 78 Informational Decals and Identification Plates 102 Inlet and Exhaust System 80 L Less than Optimal Performance 55 Long Term Storage 92 Low Oil Pressure 57 Lubrication System 72 96 M Maneuvering 31 Models 2 O Oil Sensor Reset 86 Operating in ...

Page 110: ...riking an Underwater Object 46 T Trailering Your Boat 44 Trim Tilt Motor Protection 33 Twin Unit Maneuvering 37 Twin Unit Steering 39 V V8 380 95 Volvo Action Service VAS 12 Volvo Penta Dealer Network 13 Volvo Penta on the Internet 13 W Warranty Information 12 Washing the Engine 70 Water in Bellows 58 Water in Oil and Oil Level 58 108 47702842 Downloaded from www volvopenta com 10 27 2012 8 15 23 ...

Page 111: ...47702842 Downloaded from www volvopenta com 10 27 2012 8 15 23 PM ...

Page 112: ...VPA 47702842 English 05 2012 47702842 AB Volvo Penta SE 405 08 Göteborg Sweden www volvopenta com ...

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