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Related Manuals for Volvo Penta 3.0 GS
Summary of Contents for Volvo Penta 3.0 GS
- Page 1 OPERATOR’S MANUAL 3.0 GS, 4.3 GL/Gi, 5.0 GL/Gi, 5.7 GS/GSi, 7.4 Gi/GSi, 8.2 GSi, DPX 385/415...
- Page 3 Check page 17 for the location of product serial number plates. © 1999, Volvo Penta of the Americas, Inc. Volvo, Volvo Penta, DP Duoprop, and (Aquamatic) are ® of AB Volvo. DPX and QL are ® of AB Volvo Penta. DuraPlus, 2PLUS4, Speed Rails, and Xact are trademarks of Volvo Penta of the Americas, Inc.
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Page 5: Table Of Contents
Product references, illustrations, and specifications ....................17 Volvo Action Service (VAS)............................. 17 Doing your own maintenance and repairs ......................18 Parts and accessories ............................18 Volvo Penta dealer network ............................ 18 Warranty information .............................. 18 2 PLUS 4™ Extended Protection ........................... 19 FEATURES .................................. 21 Anodes (“sacrificial”) .............................. - Page 6 Operating trim controls ............................ 40 Remote diagnostic uplink system ........................... 41 Setting up the diagnostic uplink system cell phone ..................41 Using the remote diagnostic uplink system ...................... 41 OPERATION ................................43 Engine break-in period ............................43 Operating after break-in period ..........................45 Before starting ................................
- Page 7 Boat bottom ................................80 Engine alignment ..............................80 Replacement parts ..............................81 Bottom painting ..............................81 Engine submersion ..............................82 PROBLEM RESOLUTION ............................85 SPECIFICATIONS ................................ 87 3.0 GS ..................................87 4.3 GL/Gi ................................88 5.0 GL/Gi ................................89 5.7 GS/GSi ................................90...
- Page 8 7.4 Gi/GSi; 8.2 GSi ..............................91 DPX 385; DPX 415 ..............................92 APPENDIX A: CERTIFIED ENGINES AND BSO NUMBERS ..................93 Certified engines ..............................93 Bodensee Shiffahrts Ordnung (BSO) number ......................93...
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Page 9: Introduction
Volvo Penta corporate identity, brand position and legal status have been founded. Today’s core values of quality, safety, and care for the environment remain central to Volvo Penta. They express what we believe in as a company and will ultimately help us to survive. -
Page 10: Factors That Affect Engine Performance
In September 1989, all major marine engine manufacturers agreed to quote engine power output according to a common set of conditions. These conditions are referred to as ISO 8665. All Volvo Penta engines meet the ISO 8665 standard. This ISO standard outlines the following fixed values or common conditions for determining the rating of the engine. -
Page 11: Your New Boat
We strongly recommend that you install an emergency stop switch (see page 33), regardless of the type of boat. If your boat does not have with an emergency stop switch, contact your Volvo Penta dealer, who can assist you in selecting one. - Page 12 Keep your boat and equipment neat and in top operating condition. Carry a selection of spare parts for the engine. (Volvo Penta’s on-board kit contains a selection of essential items that a boat owner should carry at all times. See your Volvo Penta dealer.) •...
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Page 13: Safety
If you are not the original owner of this engine and drive, please notify us at our address listed on page 85, or through an authorized Volvo Penta dealer about the change in ownership. This is the only way we will be able to contact you if necessary. - Page 14 Below is a summary of the risks and safety precautions you should always observe or carry out when operating or servicing the engine: Check that the warning or information decals on the engine are always clearly visible. Replace decals that have been damaged or painted over. Always turn the engine off before starting service procedures.
- Page 15 22. Always use protective gloves when tracing leaks. Liquids ejected under pressure can penetrate body tissue and cause serious injury. 23. Always use fuel recommended by Volvo Penta. The use of lower quality fuels can damage the engine. Poor fuel quality can also lead to higher maintenance costs.
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Page 17: General Information
Service is provided automatically to all Volvo Penta engine owners. As long as your Volvo Penta engine is under factory warranty, this service is absolutely free for Volvo Penta-related repairs. Towing is not covered by the Volvo Penta warranty. Once your warranty period has expired, there is a charge of $50.00 U.S. -
Page 18: Doing Your Own Maintenance And Repairs
Doing your own maintenance and repairs ________________________________________ If you plan to do your own maintenance and repairs on your Volvo Penta products, you should purchase a set of service manuals that pertain to your particular engine and drive. Keep in mind, however, that there are certain tasks that should only be performed by your Volvo Penta dealer. -
Page 19: Plus 4™ Extended Protection
4™ Extended Protection ________________________________________________ PLUS In addition to our factory warranty, owners may purchase Volvo Penta’s exclusive 2 PLUS 4 Extended Protection plan, which provides additional service benefits for a total of six years of coverage. -
Page 21: Features
Your Volvo Penta product consists of two components: the engine and the drive. There are certain parts on each component that you, the owner, must take care of to make sure that your Volvo Penta product stays in optimum running condition. The important parts of each component are shown in the photographs on pages 22 through 31. - Page 22 3.0 GS Alarm and Fuse Detail 3.0 GS (front view)
- Page 23 3.0 GS (starboard view) 3.0 GS (port view)
- Page 24 Fuses and circuit Fuses and circuit breakers breakers (port view) (starboard view) 4.3 GL, 5.0 GL, 5.7 GS (front view)
- Page 25 4.3 GL, 5.0 GL, 5.7 GS (starboard view) 4.3 GL, 5.0 GL, 5.7 GS (port view)
- Page 26 Fuses and circuit breakers Fuses and circuit (starboard view) breakers (port view) 4.3 Gi, 5.0 Gi, 5.7 GSi (front view)
- Page 27 4.3 Gi, 5.0 Gi, 5.7 GSi (starboard view) 4.3 Gi, 5.0 Gi, 5.7 GSi (port view)
- Page 28 Fuses and circuit breakers Fuses and circuit (starboard view) breakers (port view) 7.4 Gi, 7.4 GSi, 8.2 GSi (front view)
- Page 29 7.4 Gi, 7.4 GSi, 8.2 GSi (starboard view) 7.4 Gi, 7.4 GSi, 8.2 GSi (port view)
- Page 30 Fuses and circuit breakers Fuses and circuit (starboard view) breakers (port view) DPX 385, 415 (front view)
- Page 31 DPX 385, 415 (starboard view) DPX 385, 415 (port view)
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Page 32: Anodes ("Sacrificial")
If you have a stainless steel propeller, you may need additional sacrificial anodes or a Volvo Penta active corro- sion protection system to handle the added corrosion potential. Your Volvo Penta dealer will help you to decide which is more appropriate for your boat. -
Page 33: Exhaust System
3. Distributor cap and rotors 4. Spark plugs Gi, GSi only Your Volvo Penta engine features an Electronic Fuel Injection (EFI) system that uses a microprocessor (ECM) to control idle air flow, fuel, and ignition. Note: The electronics in the ECM require protection from false signals and interference. Never mount radio transmitter antennas or sender cables near the ECM and never ground any wiring to the engine. -
Page 34: Engine Protection Mode (Efi Systems)
If the problem continues, contact your nearest Volvo Penta dealer and have the engine checked. Instruments _________________________________________________________________ Before operating your Volvo Penta product, familiarize yourself with the instruments supplied with your boat. (Some boats may not have Volvo Penta instruments. Read the boat’s owner’s manual to become familiar with the instruments used.) Engine instruments... -
Page 35: Trim Instruments
Trim instruments The trim instrument indicates the current trim position. Your boat may be equipped with an analog or a digital trim instrument, as shown. The SX drive has an analog trim instrument only. The DP-S drive may have either an analog or a digital trim instrument. -
Page 36: Trim/Tilt Motor Protection
Check the engine compartment for water leakage. If there is obvious or suspected damage, operate the boat at low RPM and take it to a Volvo Penta dealer for inspec- tion. Have necessary repairs made immediately. Only operate your boat if absolutely necessary. Operating a damaged unit could cause additional damage and could become very costly to repair. -
Page 37: Propellers
Many factors influence the way a propeller performs, including hull shape, onboard weight, engine horsepower, power trim, and the way the boat is used. Ask your Volvo Penta dealer to assist you in choosing a propeller that is right for your needs. -
Page 38: Drive Unit, Rotation, And Propellers
Twin engine installation Your Volvo Penta drive unit can be set up to rotate in either direction. The propeller, propeller shaft, and vertical drive shaft are the only parts that counter- rotate. The engine always has standard rotation. - Page 39 To provide your boat with the best engine life, fuel economy, and performance, select the correct propeller to allow the engine to run at full throttle in the recommended operating range. Your Volvo Penta dealer will help you to choose the correct propeller(s) for your application.
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Page 40: Trim Controls
Use only a remote control unit with start-in-neutral-only feature. This feature can prevent injury resulting from the propeller turning unexpectedly, or the boat moving suddenly. The shift mechanism on all Volvo Penta controls can be disengaged to allow for easier starting and engine warm-up. Control panel... -
Page 41: Remote Diagnostic Uplink System
boat’s bow. • The catch buttons disconnect a “catch” so that the drive can be trimmed into the BEACH position. Remote diagnostic uplink system _______________________________________________ Your boat may be equipped with a diagnostic uplink system, which allows you to use a cellular phone to access remote communication IMPORTANT with Volvo Action Service, a 24-hour per day customer assistance service. -
Page 43: Operation
Do not run engine at a constant RPM for prolonged periods of time during the break-in period. All Volvo Penta engines have been run for a short time during a final test at the factory. You must follow the engine break-in procedure during the first 20 hours of operation to ensure maximum performance and longest engine life. - Page 44 Check the oil dipstick. If required add oil, but do not overfill. If the oil level is correct and the condition persists, ask your Volvo Penta dealer to check for possible gauge or oil pump malfunc- tion.
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Page 45: Operating After Break-In Period
20 hours of operation and establish a routine preventive maintenance schedule. In the US, Canada, and Mexico, the 20-hour check is paid for by the boat owner and performed by your Volvo Penta dealer at local rates. In other markets, warranty inspection is paid for according to the warranty policy for Importers. -
Page 46: Starting The Engine, Cold Start
6. Switch on the main switches (if so equipped). 7. Insert the key into the ignition switch. Turn the key one step to the right to switch on engine system voltage and instrumentation. 8. Make sure that you have enough gasoline. 9. -
Page 47: Starting The Engine (Warm Start)
If you do not move the remote control handle to IDLE as soon as the engine starts, the engine will overspeed and could be damaged. When you start your engine for the first time after off-season storage, always run the engine in IDLE for one minute to allow the water pump to prime. -
Page 48: Operating Remote Controls
NEUTRAL. Steering system operation _____________________________________________________ The steering system for your Volvo Penta sterndrive is operated by a steering cable connected to the helm. Restricting movement of the steering cable will limit or stop the steering system’s hydraulic assist. -
Page 49: Power Trim And Tilt Operation
“bow-up” or “bow-down” positions. Boat stability and steering torque can also vary due to changing water conditions. If you experience boat instability and/or high steering torque, see your Volvo Penta dealer to correct these conditions. -
Page 50: Power Tilt Operation
Personal injury could result from contact with rotating engine parts and propeller. Any malfunction of the trim/tilt system could result in a loss of impact protection. Malfunction can also result in loss of reverse thrust capability. If malfunction occurs, see your authorized Volvo Penta dealer. Power trim/tilt switch operation... -
Page 51: Power Trim/Tilt Switch And Gauge Location
Inform passengers of potential problems and take all precautions necessary to ensure their safety. If you suspect there is a problem, see your Volvo Penta dealer as soon as possible for proper diagnosis and required service or adjustment. Continued operation could result in damage to the shift mechanism and loss... -
Page 52: Checking Instruments
High altitude operation Volvo Penta EFI engines have programmed altitude compensation; however, there may be a slight performance loss at altitudes above 5000 feet due to lower air density. If you are boating above 5000 feet for a short time, a lower pitch propeller will restore some of the lost performance. -
Page 53: Operating Procedure For Freezing Temperatures
We recommend that you use fresh water to flush out the engine and drive after you use it in polluted or salt water. This will prolong the service life of the manifolds and risers. Contact your authorized Volvo Penta dealer for an engine flushing kit that allows you to flush out the engine whether it is in or out of the water. - Page 54 43 MPH (35 knots). F-series stainless steel propeller sets should be used in these applications. If you use D-series aluminum propeller sets, you must also use an in-trim limiter kit. See your Volvo Penta dealer.
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Page 55: Maintenance
Maintenance schedule ________________________________________________________ The operation, maintenance, and care of the Volvo Penta engine and power package as outlined in the owner’s manual are the owner’s responsibility. The owner must keep records of all maintenance services performed. This record of proper maintenance may be required to determine warranty coverage on certain repairs and should be transferred to each subsequent owner. - Page 56 • Spark plug wires/boots (deterioration) • Steering system cable (operation) Throttle cable (damage and operation) • • Dealer only Belt: serpentine (3.0 GS; all fuel-injected • models) • Carburetor adjustment (as needed) • Engine alignment and mounting screws • Exhaust manifold & risers (corrosion; blockage) •...
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Page 57: Preparing For Boating After Storage ("Summerization")
16.Check drive and transom shield anodes. Clean or replace as necessary. Off-season storage preparations (“winterization”) _________________________________ Be sure to properly winterize your Volvo Penta equipment. Engine or drive damage can result from ignoring simple preventive maintenance steps during autumn. Winterizing gives you the assurance that your engine will run more reliably and economically in the springtime. -
Page 58: Drive Unit Bellows
Premium fuel contains injector cleaners and other additives that protect the fuel system and provide optimum perfor- mance. Volvo Penta strongly recommends the use of premium grade fuels. Gasoline will degrade over time. Always buy your gasoline from a reputable dealer. -
Page 59: Detonation (Spark Knock)
After completing service procedures, start engine and check entire fuel system for possible leaks. To prevent fire and explosion, Volvo Penta fuel system components meet U.S. Coast Guard requirements for fuel and fuel vapor containment. Do not substitute automotive or other non-approved parts. -
Page 60: Flame Arrestor
Both pumps are protected by a single 20-amp fuse. The pumps will operate 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. -
Page 61: Carburetor Fuel Filter Replacement
A loud whining noise at idle may be due to a restricted fuel filter causing a noisy fuel pump. Operating 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. -
Page 62: Battery Cables
If electrical connections are reversed, or wires are disconnected when the key switch is ON or the engine is running, sensitive electrical components may be immediately damaged. Do not turn off the main battery switch until the engine has stopped. Battery cables The following are the minimum specifications for stranded copper cables from the motor to the battery for all models. - Page 63 3. Make sure the ignition switch is OFF before removing or installing electrical equipment, checking any electrical connections, or installing battery cables. See your Volvo Penta dealer for recommendations on installing multiple batteries. Note: When replacing your battery, read and understand the information supplied with it before you begin installation.
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Page 64: Engine Start Battery
1. Batteries must be heavy-duty and constructed for marine use. They can be either vented/refillable, maintenance-free, or deep-cycle with a CCA or MICA rating. Refer to Specifications on pages 95 through 100 for the correct battery sizes. 2. Use bolts and nuts to secure battery cables to the battery terminals. Do not use wing nuts to secure battery cables, even if they were supplied with the battery. -
Page 65: Multiple Batteries And Selector Switch
Make sure the ignition switch is OFF before removing or installing electrical equipment, checking any electrical connections, or installing battery cables. See your Volvo Penta dealer for recommendations on installing multiple batteries. Multiple batteries and selector switch If your boat is equipped with multiple batteries and a selector switch, the engine should be operated with the selector switch set to the ALL position. -
Page 66: Checking And Changing Spark Plugs
Do not operate engine if spark plug boots or high-tension leads are torn or cracked. This condition could allow external sparks which could ignite 3.0 GS any fuel vapors in the engine compartment, and result in fire or explo- sion. -
Page 67: Belt Adjustments
This single belt replaces three separate belts (alternator, circulation, and power steering). At least once per year, have your Volvo Penta dealer check the serpentine belt for wear. An ideal time to have this check performed is when you have the gimbal bearings and universal joints lubricated. -
Page 68: Alternator Belt
3. While maintaining pressure on the bracket, tighten the screw closest to the tab, then tighten the other screws. 4. Recheck belt tension. Cooling system ______________________________________________________________ Volvo Penta engines have a thermostat-controlled, recirculating type cooling system. 1. Cool water is drawn in through water intakes located on both sides of the lower gear case by a raw water pump mounted on the front of the engine. -
Page 69: Draining The Cooling System
The following steps are very important in protecting your engine from damage in freezing conditions. If you are unsure of how to perform any of the following steps, see your Volvo Penta dealer for a complete end-of-season/winterization service. Freeze damage to the engine package is not covered by your Volvo Penta limited warranty. -
Page 70: Raw Water Pump
Whenever you check the engine oil, also remove the steering reservoir dipstick and check the fluid level. Wipe the dipstick and note the “hot” and “cold” fluid levels. If needed, add Volvo Penta DuraPlus Power Trim/Tilt and Steering Fluid. Do not overfill the pump reservoir. -
Page 71: Primary Shaft Spline And Bearing Lubrication
Instructions for DPX drive unit lubrication are located on page 75. If you have your Volvo Penta dealer lubricate the sterndrive, make sure to take it to your dealer at the required inter- vals, as outlined in your maintenance schedule on page 55. -
Page 72: Checking Engine Oil Level
5. Dispose of used oil according to any applicable federal, state, and local environmental regulations. 6. Replace the oil filter. 7. Remove the oil fill cap and fill the crankcase to the specified capacity with Volvo Penta DuraPlus premium engine oil. -
Page 73: Changing The Oil Filter
4. Run engine and check for leaks. (Do not run engine out of water.) Drive components ____________________________________________________________ The drive unit is filled at the factory with Volvo Penta DuraPlus™ GL 5 Synthetic Gear Lube. Drive unit lubrication Lubricating the drive unit (SX) - Page 74 Leave the dipstick loose during the waiting period. This will help ensure all air is purged from the oil cavity. Lubricating the drive unit (DP-S) The drive unit is filled at the factory with Volvo Penta DuraPlus GL5 Synthetic gearcase lubricant. This lubricant must be used when adding lubricant or refilling the drive unit.
- Page 75 Leave the dipstick loose during the waiting period. Lubricating the drive unit (DPX) The drive unit is filled at the factory with Volvo Penta DuraPlus GL5 Synthetic gearcase lubricant. This lubricant must be used when adding lubricant or refilling the drive unit.
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Page 76: External Lubrication Points
The gimbal bearing and universal joints must be lubricated each year. This procedure requires the removal of the drive unit; therefore, your Volvo Penta dealer should do it. An ideal time to have this done is during the winterization process. -
Page 77: Active Corrosion Protection System
If additional electronic or electrical equipment is installed, each item should have an individual anode or grounding device and all grounding devices must be interconnected. Follow equipment manufacturer’s recommendations. Note: When your boating is done mostly in fresh water, Volvo Penta recommends replacing zinc anodes with magne- sium anodes. Active corrosion protection system... -
Page 78: Propeller Replacement - Sx
1. Ignition switch must be OFF. 2. Make sure the remote control is in NEUTRAL. 3. Coat the full length of the propeller shaft with Volvo Penta propeller shaft grease. (Removal of the propeller will be difficult if this is not done.) 4. -
Page 79: Propeller Replacement - Dp-S
1. Ignition switch must be OFF. 2. Make sure the remote control is in FORWARD. 3. Coat the full length of the propeller shaft with Volvo Penta propeller shaft grease. (Removal of the propeller will be difficult later if this precaution is not done.) 4. -
Page 80: Propeller Replacement - Dpx
1. Ignition switch must be OFF. 2. Coat the full length of both propeller shafts with Volvo Penta propeller shaft grease. (It will be difficult to remove propellers later if this precaution is not done.) 3. Make sure the remote control is in FORWARD to lock the propeller shaft. -
Page 81: Replacement Parts
Substituting automotive or generally supplied parts and hardware may result in product malfunction and possible injury to the operator and/or passengers. Never use parts of unknown quality. See your Volvo Penta dealer. You can depend on him to furnish expert service and Volvo Penta parts. -
Page 82: Engine Submersion
Engine submersion ___________________________________________________________ 1. Remove the engine from the water as quickly as possible. 2. Contact your local Volvo Penta dealer for service. • Your dealer will need to drain all water from the engine and immediately relubricate all internal parts. - Page 83 The following troubleshooting checklist gives some of the most common problems and their solutions. If your problem does not appear on this checklist, please contact your Volvo Penta dealer. After following the “Action” described in the chart, and before cranking the engine, make sure there are no loose electrical connections that could spark.
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Page 85: Problem Resolution
If you have questions about service or your product’s performance, your Volvo Penta dealer will be happy to answer them. There may be times, though, that, in spite of the best intentions, differences develop between a boat owner and a dealer. If this happens to you, Volvo Penta and your dealer will work together to pursue a reasonable resolution. -
Page 87: Specifications
SPECIFICATIONS Note: Volvo Penta of the Americas, Inc., reserves the right to make changes in weight, construction, materials, or specifications without notice or obligation. 3.0 GS ______________________________________________________________________ Battery size 12 volt with 360 Cold Cranking Amp (CCA) rating Bore and stroke 4.00 x 3.60 inches (101.60 x 91.44 mm) -
Page 88: 4.3 Gl/Gi
4200 – 4600 RPM Idle RPM GL: 550 – 650 RPM in forward gear Gi: 600 RPM Ignition timing Authorized Volvo Penta dealer service only Oil capacity Engine Without filter: 4 quarts (3.8 liters) With filter: 4.5 quarts (4.3 liters) Drive unit SX: approximately 2.2 quarts (2.1 liters) -
Page 89: Gl/Gi
Gi: 4600 – 5000 RPM Idle RPM (fixed) GL: 4400 – 4800 RPM Gi: 600 RPM Ignition timing Authorized Volvo Penta dealer service only Oil capacity Engine Without filter: 5 quarts (4.7 liters) With filter: 6 quarts (5.7 liters) Drive unit SX: approximately 2.2 quarts (2.1 liters) -
Page 90: 5.7 Gs/Gsi
GSi: 4600 – 5000 RPM Idle RPM (fixed GS: 550 – 650 RPM in forward gear GSi: 600 RPM Ignition timing Authorized Volvo Penta dealer service only Oil capacity Engine Without filter: 5 quarts (4.7 liters) With filter: 6 quarts (5.7 liters) Drive unit SX: approximately 2.2 quarts (2.1 liters) -
Page 91: 7.4 Gi/Gsi; 8.2 Gsi
DuraPlus GL 5 synthetic gear lube Power steering fluid DuraPlus power steering fluid Spark plugs 7.4 Gi — Volvo Penta P/N 3854399 7.4, 8.2 GSi — Volvo Penta P/N 3854400 Spark plug gap 0.045 inches (1.14 mm) • Spark plug installation torque... -
Page 92: Dpx 385; Dpx 415
DPX 385: 4800 – 5200 RPM DPX 415: 4600 – 5000 RPM Idle RPM (fixed) 600 RPM Ignition timing Authorized Volvo Penta dealer service only Oil capacity Engine Without filter: 8 quarts (7.5 liters) With filter: 9 quarts (8.5 liters) Drive unit Approximately 2.06 quarts (2.0 liters) -
Page 93: Appendix A: Certified Engines And Bso Numbers
The following information concerns engines certified for European use on Lake Constance and in Switzerland. All Volvo Penta engines and products have been developed on the basis that they should have as little an impact on the environment as possible. However, national and regional environmental legislation is different for all the markets where Volvo Penta sells its products. - Page 96 AB Volvo Penta SE-405 08 Göteborg, Sweden www.volvopenta.com...
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Questions and answers
quali sono i valori ottimali della compressione cilindri?
Optimal cylinder compression for the Volvo Penta 3.0 GS engine is typically around 12 bar (174 psi). A difference of up to 10% between cylinders is generally considered acceptable. Therefore, compression values between approximately 10.8 bar (157 psi) and 12 bar (174 psi) are within tolerance.
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