Volvo Penta DPX 500 Instruction Book
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Volvo Penta DPX 500 Instruction Book

Volvo Penta DPX 500 Instruction Book

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INSTRUCTION BOOK
DPX 500, DPX 600

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Summary of Contents for Volvo Penta DPX 500

  • Page 1 INSTRUCTION BOOK DPX 500, DPX 600...
  • Page 2 California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproduc- tive harm.
  • Page 3 Check page 9 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.

  • Page 5: Table Of Contents

    DPX 500 / 600 engine — top view (shown with DPX 500 exhaust manifolds)..........13 DPX 500 / 600 engine — front view (shown with DPX 600 exhaust manifolds) ..........14 DPX 500 / 600 engine — back view (shown with DPX 600 exhaust manifolds) ..........14 DPX 500 / 600 engine —...
  • Page 6 OPERATION................................23 Engine break-in period..........................23 First service inspection (Dealer 20-hour check) .................... 24 Operating after break-in period........................25 Before starting ............................. 25 Starting the engine, cold start........................25 Starting the engine (warm start) ........................26 Stopping the engine ............................. 26 Steering system operation ...........................
  • Page 7 Marine gasoline engine and power package limited warranty ............... 58 Replacement parts and accessories limited warranty ................... 60 General pre-delivery inspection: all gasoline I/O drive systems..............62 First service inspection: all gasoline I/O drive systems ................. 63 SPECIFICATIONS ..............................65 DPX 500 ..............................65 DPX 600 ..............................66...

  • Page 9: Introduction

    Volvo Penta product. As owner of a Volvo Penta marine engine, we would also like to welcome you to a worldwide network of dealers and service workshops to assist you with technical advice, service requirements and replacement parts.

  • 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: Planning Your Trip

    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.) •...

  • Page 13: Safety

    If you are not the original owner of this engine and drive, please notify us at our address listed on page 55, 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 2. Always turn the engine off before starting service procedures. Avoid hot surfaces and liquids in supply lines and hoses when the engine has just been turned off and is still hot. 3. To prevent a possible explosion, operate the blower as recommended by the boat manufacturer before starting the engine.
  • 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.

  • Page 17: General Information

    All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of printing. Volvo Penta of the Americas, Inc. reserves the right to make changes at any time, without notice, in specifications and models;...

  • 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 Some areas may have other warranty conditions, depending on national legislation and regulations. Information about these conditions can be obtained from Volvo Penta importers and dealers in those areas. Contact your local Volvo Penta representative for a copy. Warranty Registration Form The Warranty Registration Form should always be filled out and sent in by the dealer.

  • Page 21: Features

    Your Volvo Penta product consists of three components: the engine, transom shield, 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.

  • Page 22: Dpx 500 / 600 Engine - Front View (Shown With Dpx 600 Exhaust Manifolds)

    DPX 500 / 600 engine — front view (shown with DPX 600 exhaust manifolds) ____________ ____________ DPX 500 / 600 engine — back view (shown with DPX 600 exhaust manifolds)

  • Page 23: Dpx 500 / 600 Engine - Port View (Shown With Dpx 600 Exhaust Manifolds)

    DPX 500 / 600 engine — port view (shown with DPX 600 exhaust manifolds)_____________ ________ DPX 500 / 600 engine — starboard view (shown with DPX 600 exhaust manifolds)

  • Page 24: Dpx Drive - Port View

    DPX DRIVE — port view ________________________________________________________ _____________________________________________________DPX drive — starboard view...

  • Page 25: Anodes ("Sacrificial")

    To protect your investment, Volvo Penta sterndrive units are equipped with zinc anodes to provide protection against galvanic (electrochemical) corrosion. These anodes are “sacrificial,” or designed to erode away faster than the metal on the transom shield and sterndrive.

  • Page 26: Lubrication System

    Once a month, check the switch for proper operation. With the engine running at idle in NEUTRAL, pull the lanyard. If the engine does not stop, have your Volvo Penta dealer repair your emergency stop switch. Engine protection mode ________________________________________________________ In a low oil pressure or engine overheat situation, the EFI system enters an engine protection mode.

  • Page 27: Instruments

    To reset the engine protection mode after the problem is corrected, shut off the engine, then restart it. Note: 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.

  • Page 28: Power Trim/Tilt

    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 29: Propeller Rotation

    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.

  • Page 30: Using The Remote Diagnostic Uplink System

    8. Switch off auxiliary power to the diagnostic uplink system. Steering system_______________________________________________________________ The DPX drive unit features the Volvo Penta Xact™ control steering. This system features an integrated, external hydraulic power steering system as standard equipment. The external steering cylinders connect directly to the sterndrive(s) without intermediate steering arms or joints.

  • Page 31: Operation

    Never run an engine at a constant engine speed for long periods 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 32: First Service Inspection (Dealer 20-Hour Check)

    First service inspection (Dealer 20-hour check)_____________________________________ To ensure your continued boating enjoyment, we recommend that you return your Volvo Penta product to your Volvo Penta dealer for a 20-hour check. This 20-hour check will prevent a minor problem from getting worse, and helps ensure a trouble-free boating season.

  • Page 33: 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 34: Starting The Engine (Warm Start)

    If the power steering system cannot be corrected on board, proceed at a reduced speed. (You will be able to steer the boat, but with increased effort.) See your Volvo Penta dealer as soon as possible to correct your power steering system.

  • Page 35: Power Trim And Tilt Operation

    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 the steering wheel. A slightly higher throttle and trim setting may also lessen the wander tendency.

  • Page 36: Power Tilt Operation

    Check in front and behind boat for people or obstructions before shifting. 2. Do not shift if engine speed is above 750 for DPX 500, or 850 RPM for DPX 600. 3. To go FORWARD - Actuate the NEUTRAL lock mechanism and move the shift handle forward. Throttle move- ment will begin after the FORWARD gear engages.

  • Page 37: Checking Instruments

    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 of shift and throttle control that could result in personal injury.

  • Page 38: Special Boating Circumstances

    To leave the Engine Protection Mode after the problem is corrected, turn engine off then START again. Note: If the problem continues, contact your nearest Volvo Penta dealer and have the engine checked. Shallow water operation You may tilt the drive unit to reduce the draft for shallow water running as long as you do not exceed 1000 RPM.

  • Page 39: Trailering Your Boat

    If maneuvering with an engine that has the power steering pump which stops, the power steering assist is lost. Failure to follow the above maneuvering procedure could result in a collision and personal injury. Both engines must be running during close maneuvering or at slow speeds. If only one engine is running, water may be forced back through the underwater exhaust outlet and cause serious engine damage.

  • Page 41: 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 42 Tighten/ Function Adjust Check Lubricate Fill Replace Torque Once per season * • • Bellows and clamps, drive unit ** • Exhaust manifold and risers • Distributor cap and rotors • Fuel filter, engine • Fuel system (leakage) • Impeller, water pump ** •...

  • Page 43: Preparing For Boating After Storage ("Summerization")

    15. 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 44: Drive Unit Bellows

    Premium fuel contains injector cleaners and other additives that protect the fuel system and provide optimum performance. Volvo Penta strongly recommends the use of premium grade fuels. Gasoline will degrade over time. Always buy your gasoline from a reputable dealer.

  • Page 45: 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 46: Electric Fuel Pumps

    Both pumps are protected by a single 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 47: Electrical System

    Note: 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 48: Batteries And Connections

    Batteries and connections Note: Whenever you replace your battery, read and understand the information supplied with it before you begin installation. 1. The engine start battery must be a heavy duty, 12-volt, 650 CCA battery constructed for marine use. 2. All other 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 INCA rating.

  • Page 49: Engine Start Battery

    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.

  • Page 50: 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 51: Spark Plugs

    Engine Model Spark plugs Spark plug gap installation torque Firing Order DPX 500 NGK R-5674-7 0.045 in. (1.14 mm) 1 – 8 – 4 – 3 – 6 – 5 – 7 – 2 20 ft. lb. (27 N•m) DPX 600 NGK R-5674-7 0.045 in.

  • Page 52: Belt Tension

    2. Belt tension should be checked after 10 hours of service and every 5 hours thereafter. Cooling system _______________________________________________________________ Volvo Penta engines have a thermostat-controlled, recirculating type cooling system. 1. Cool water is drawn in through a water intake located on the lower gear case by a raw water pump mounted on the front of the engine.

  • Page 53: 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 54: Power Trim/Tilt Fluid Level

    If you lubricate the sterndrive yourself, instructions for drive unit lubrication are located on page 47. If you have your Volvo Penta dealer lubricate the sterndrive, make sure to take it to your dealer at the required intervals, as outlined in the Maintenance Schedule on page 33.

  • Page 55: Checking Engine Oil Level

    Drive components _____________________________________________________________ Drive unit lubrication Lubricating the drive unit 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. Adding lubricant Each week, check the oil level in the drive unit (if possible, without removing the boat from the water).

  • Page 56: Anodes ("Sacrificial" Anodes)

    — No metal flakes should appear in the oil. If moisture or metal flakes appear in the drive unit oil, take the boat to your Volvo Penta dealer. If the oil level is low, add only enough lubricant to bring the oil level within the full range of the dipstick. Improper oil level may cause serious damage to the drive unit.

  • Page 57: Active Corrosion Protection System

    When you need to replace the anodes, see your Volvo Penta dealer. The material composition of Volvo Penta anodes meets U.S. Military Specification 18001-H. If you use other anodes, make sure they have equivalent specifications or galvanic corrosion protection will be lost.

  • Page 58: Propeller Care

    A rubber hub in the propeller is the shock absorber that minimizes damage to drive unit and engine. If the rubber hub should begin to slip, it can be easily replaced at an authorized Volvo Penta dealer or propeller service station.

  • Page 59: Boat Bottom

    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 60: Bottom Painting

    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 61: Troubleshooting Checklist

    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.

  • Page 63: 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 65: Warranty Information

    WARRANTY INFORMATION The information presented on the following pages shows Volvo Penta’s warranty for engines and power packages, and replacement parts and accessories. Along with these you will find examples of these documents: — General pre-delivery inspection checklist — First service inspection checklist...

  • Page 66: Marine Gasoline Engine And Power Package Limited Warranty

    This warranty does not cover first service inspection labor and any parts expense. “ Pleasure use” is defined by Volvo Penta as engines or power packages exclusively intended for pleasure craft application and used only for the owner’s personal recreation.
  • Page 67 OR EXCLUSION MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS THAT VARY FROM STATE TO STATE. This warranty applies to all products delivered from Volvo Penta of the Americas after the revised effective date of January 1, 1999.

  • Page 68: Replacement Parts And Accessories Limited Warranty

    Any Volvo Penta part or accessory that is covered by this warranty and that is found in the reasonable judgment of Volvo Penta to be defective in materials or workmanship will be repaired or replaced at Volvo Penta's option. If a problem occurs, the owner must bring the part or accessory to an authorized Volvo Penta Dealer or Distributor in a timely manner.
  • Page 69 OR EXCLUSION MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS THAT VARY FROM STATE TO STATE. This warranty applies to all products delivered from Volvo Penta of the Americas after the revised effective date of January 1, 1999.

  • Page 70: General Pre-Delivery Inspection: All Gasoline I/O Drive Systems

    General pre-delivery inspection: all gasoline I/O drive systems________________________ To insure the highest level of product satisfaction and reliability, Volvo Penta requires that the delivering dealer complete the following pre-delivery inspection checklist. IM PO R TA NT Pre-delivery Inspection labor and any parts expense are not covered by the VPA Warranty for gasoline products.

  • Page 71: First Service Inspection: All Gasoline I/O Drive Systems

    First service inspection: all gasoline I/O drive systems ______________________________ Volvo Penta recommends that an authorized Volvo Penta dealer perform the following first service inspection. It is recommended that this service be performed after 20 to 50 hours or 60 days of operation, whichever occurs first.

  • Page 73: 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. DPX 500 ____________________________________________________________________ Battery size 12 volt with 650 Cold Cranking Amp (CCA) rating Bore and stroke 4.50 x 4.00 inches (114.53 x 101.80 mm)

  • Page 74: Dpx 600

    Outside the U.S.: 90 octane (RON) unleaded gasoline Full throttle operating range 4800 – 5200 RPM 850 RPM Idle RPM (fixed) 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)

This manual is also suitable for:

Dpx 600

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