Related Manuals for Volvo Penta 3.0GS/SX
Summary of Contents for Volvo Penta 3.0GS/SX
- Page 1 OWNER’S MANUAL 3.0GS/SX, 4.3GL/SX/DP-S, 4.3GS/SX/DP-S, 4.3Gi/SX/DP-S 5.0GL/SX/DP-S, 5.0Gi/SX/DP-S , 5.7GS/SX/DP-S, 5.7GSi/DP-S...
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Page 3: Marine Engines
Owner’s Manual Marine engines 3.0GS/SX 4.3GL/SX, DP-S • 4.3GS/SX, DP-S • 4.3Gi/SX, DP-S 5.0GL/SX, DP-S • 5.0Gi/SX, DP-S 5.7GS/SX, DP-S • 5.7GSi/SX, DP-S This Owner´s Manual is intended for markets outside North America only. - Page 4 Welcome aboard Congratulations on your new boat and your choice of a Volvo Penta marine engine. A choice that will give you many years of boating pleasure. Your new marine engine is the result of 90 years experience in marine engine...
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Page 5: Table Of Contents
Contents Safety Precautions ..........4 After Use .............. 35 Safety precautions to be taken when operating Stopping the engine ..........35 the boat ..............5 Salt water operation ..........36 Safety precautions for maintenance and service ..7 Cold weather precautions ........36 Laying up ............... -
Page 6: Safety Precautions
Read the Instruction Manual carefully before operating or servicing the engine. If anything is unclear please contact your Volvo Penta dealer for assistance. This symbol is used in the book and on the engine to make you aware of safety information. -
Page 7: Safety Precautions To Be Taken When Operating The Boat
Safety precautions to be taken when operating the boat Your new boat Maneuvering Read Instruction Manuals and other information Avoid violent and unexpected changes in course and supplied with your new boat. Learn to operate the gear engagement. There is a risk that someone engine, controls and other equipment safely and cor- aboard will fall down or overboard. - Page 8 bate the problem are wind conditions, load distribu- Carbon monoxide poisoning tion, sea conditions, trim, open hatches and ventil- When a boat moves forward through the water a va- ators etc. cuum is created behind it to a greater or lesser ex- Most modern boats are designed so that vacuum ef- tent.
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Page 9: Safety Precautions For Maintenance And Service
Never undertake an operation if you are not com- Store oil and fuel soaked rags and other flammable pletely sure how to do it. Contact your Volvo Penta material in fireproof conditions. In certain circumstan- dealer for assistance instead. - Page 10 Hot surfaces and liquids Lubrication system When the engine is at operating temperature there is Hot oil can cause burns. Avoid skin contact with hot always a danger of burns. Avoid hot surfaces. For oil. Ensure that the lubrication system is not under example: exhaust manifold, oil sump, hot coolant and pressure before commencing work on it.
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Page 11: Introduction
Introduction This Instruction Manual has been compiled to help you get the most from your Volvo Penta engine. It contains all the information you need in order to operate and maintain your engine safely and correctly. Please read the Instruction Manual carefully and learn how to operate the engine, controls and other equipment safely. -
Page 12: Warranty
Warranty and Service book. Note that AB Volvo Penta’s liability is limited to that contained in the Warranty and Service Book. Read this book as soon as you take delivery of the engine. It contains important information about warranty cards, service and maintenance which you, the owner, must be aware of, check and carry out. -
Page 13: Identification Numbers
This information is necessary when you contact your Volvo Penta or boat dealer for service and spare parts. Take a copy of the information and keep it in a safe place so it is available should the boat be stolen. - Page 14 Location of type approval plate, engine type The engine type approval plate is located on the left- hand valve cover of the engine (3.0 models) and on the inside of the port valve cover (4.3, 5.0 and 5.7 models). 4.3, 5.0, 5.7 Location of drive/shield type plate SX/DP-S The drive type plate is located on the drive unit behind the port trim/tilt cylinder.
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Page 15: Parts View
Presentation Please note! The photos below do not show all engine/transmission combinations. If your engine does not have the drive shown, refer to another engine with the relevant drive for an introduction to the transmission. Engine 3.0GS 1. Starter Motor 2. - Page 16 Engine 4.3GL, 4.3GS, 4.3Gi 1. Starter Motor 2. Oil Withdrawal Tube 3. Oil Filter 4. Fuel Pump 5. Oil Level Dipstick 6. Circuit Breakers 7. Type Plate (engine). See page 12 8. Water-Cooled Exhaust Pipe 9. Type Plate (shield). See page 12 10.
- Page 17 Engine 5.0GL, 5.0Gi, 5.7GS, 5.7GSi 1. Starter Motor 12,14 2. Oil Withdrawal Tube 3. Oil Filter 4. Fuel Pump 5. Oil Level Dipstick 6. Circuit Breakers 7. Type Plate (engine). See page 12 8. Water-Cooled Exhaust Pipe 9. Type Plate (shield). See page 12 10.
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Page 18: Instrumentation
Instrumentation The instrument panel for Volvo Penta petrol engines is equipped with a tachometer, temperature gauge, oil pressure gauge, voltmeter, 2 fuses, instrument lighting switch and an ignition switch. Instruments, fuses and ignition switch can also be installed separately without an instrument panel. The boat builder’s instrumentation can also be supplemented with extra Volvo Penta instruments, such as: synchronization tachometers, fuel gauge, fresh water gauge, clock, speed log or rudder indicator. - Page 19 6. Fuses, 8 A Fuses for the starter function and system voltage. To change fuses: Press the button and turn anti- clockwise. IMPORTANT Always carry extra fuses on board. 7. Ignition switch The ignition switch has three positions (these positions are not marked): 0 = The key can be inserted and taken out.
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Page 20: Emergency Stop Switch
High performance sport boats Small runabouts Boats with sensitive steering Boats where the distance from the top of the gunwale down to the driver’s seat is less than 30 cm. See your Volvo Penta dealer for installation of an emergency stop switch. -
Page 21: Controls
The shift function and engine speed control are combined in one lever. The shift function can be simply disengaged so that only engine speed is affected. The Volvo Penta controls are available for top or side mounting. The control levers have an adjustable friction brake. A neutral position switch is available as an accessory, this will only permit the engine to be started with the drive disengaged. - Page 22 Adjustment of friction brake The friction brake only affects engine speed adjust- ment. Adjust with the lever in the throttle half open position (forward/reverse). Remove the cover over the control. For side- mounted controls the lever must first be removed. Adjust the friction brake by turning the screw at the arrow (see figure).
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Page 23: Power Trim
Power Trim Your Volvo Penta drive has a Power Trim system as standard equipment. The purpose of Power Trim is to al- low the helmsman to change the angle at which the drive is set, without leaving the cockpit. Changing this angle relative to the bottom of the boat is referred to as trimming. - Page 24 Control lever Control button (2) in the control lever is used to raise the bow, by pressing the top half, and to lower the bow by pressing the lower half of the button. To put the drive in the “Beach” position, you have to press a separate switch to bypass the catch which prevents entry to the “Beach”...
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Page 25: Trim Instruments
Trim instruments The SX drive only has an analogue trim instrument. The DP-S drive can either have an analogue or digi- tal trim instrument. Analogue trim instrument (SX, DP-S) The trim instrument indicates the current trim position. It has a scale with five segments and three main ranges: 1. - Page 26 TRIM = Drive position at all speeds. Max trim up to 5. BEACH = Used for operation at in shallow water where water depth is uncertain. Speed should always be low, max. 1000 rpm. 5 - 40. LIFT = Flashing red warning lamp. Drive up completely 41 - 51.
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Page 27: Impact Protection
Check engine compartment for water leakage. If there is obvious or suspected damage, operate boat at low RPM and take your boat to a Volvo Penta dealer for inspection. Have necessary repairs made immediately. Operating a damaged drive unit could cause additional damage and could become very costly to repair. -
Page 28: Starting The Engine
Starting the Engine Familiarize yourself with the operation of the remote control supplied with your boat, then proceed as follows. IMPORTANT! Pumping bilge: Frequently check bilge for leaking engine, power steering, or trim system oil. Find the cause and correct it immediately. Regulations prohibit the pumping of oil into any navigable wa- ters. -
Page 29: Starting
Starting NOTE! Do not start engine out of water unless using a flushing adapter. WARNING! When using a flushing adaptor, re- move the propellers befor starting engine to prevent accidental contact with moving propel- lers. If propellers are not removed, personal injury could result. -
Page 30: If Engine Floods
If engine floods Gi, GSi models: A flooded engine can be cleared by advancing the control handle to a position of 3/4 throttle. In this th- rottle position and the engine speed below 400 RPM (cranking speed) the ECM turns off the fuel injectors so no fuel is delivered. -
Page 31: Operation
Operation All shifting between forward/reverse must be done at engine idle speed. Shifting at higher speeds may damage the drive/reverse gear and will also be uncomfortable for those on board. If the boat has two or three engines, it is important that they are all running during maneuvers astern (rearward movement), otherwise water might get into the exhaust of the engine which is not running when the backwash catches up with the boat. -
Page 32: Engine Protection Mode
To reset the Engine Protection Mode after the problem is corrected, allow the engine to cool and then continue with normal operation. NOTE: Should the problem continue, contact your nearest Volvo Penta dealer and have the engine checked. Master/slave installation Gi, GSi For twin unit installations both engine EMCs can be tied together electronically. -
Page 33: How To Shift And Control Speed
How to shift and control speed Twin unit maneuvering NOTE! If your boat is equipped with a non-Volvo When leaving or approaching the dock, or for any clo- Penta remote control system, ask your dealer how to se maneuvering at slow speed, place the starboard properly operate it. -
Page 34: Cruising Speed
Operating the engine at wide open throttle (WOT) should be avoided since it is both uneconomical and uncomfortable. Volvo Penta recommends a cruising speed in the range 300 - 500 rpm lower than maxi- mum rpm at WOT. Depending on hull type, choice of propeller, load and conditions etc. - Page 35 When starting Trim the drive. The bow will be pressed down and the boat accelerates faster. This gives improved running and steering characteristics at speeds below the pla- ning threshold. At planing speed Trim the drive out to the running position which feels comfortable and the boat feels stable and smooth.
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Page 36: Running Aground
If this is the case or if other damage has occurred to the drive it must be inspected at an authorized Volvo Penta workshop. If a propeller has been damaged it must be replaced. -
Page 37: After Use
After use To counteract boiling and heat stress the engine should be run for a few minutes at idle (in neutral) before turning it off. This is especially important if the engine has been operated at high engine speeds (rpm). Before stopping the engine: The drive must be trimmed in to its maximum to protect the trim cylinders untreated surfaces from fouling. -
Page 38: Salt Water Operation
Salt water operation Your Volvo Penta sterndrive is built for operation in either fresh or salt water. If boat is moored for long periods, tilt drive unit out of the water (except during freezing temperatures). When removing the boat from the water, lower drive... -
Page 39: Transporting On A Trailer
NOTE! Do not use a wire brush or other steel tools when cleaning, as these may damage the galvanic protection. IMPORTANT! After use in polluted or salt water the entire Volvo Penta sterndrive’s exterior should be rinsed with fresh water. -
Page 40: Other Product Information
Other Product Information Fuel requirements WARNING! Fuel is extremely flammable and highly explosive under certain conditions. Al- ways stop the engine and do not smoke or allow open flames or sparks near the boat when re- fuelling. When filling the fuel tanks, ground the tanks to the source of fuel by holding the hose nozzle firmly against the side of the deck filler plate or ground it in some other manner. -
Page 41: Electronic Engine Control
It has a memory that stores diagnostic infor- mation in the form of service codes to aid your Volvo Penta dealer when diagnosing performance pro- blems. Contact your Volvo Penta dealer if service is required. NOTE! The electronics in the EEC require protection from false signals and interference. -
Page 42: Maintenance And Care
The following chapter has a maintenance schedule which shows when maintenance operations must be carried out. NOTE! Always use Volvo Penta Original Spare Parts, otherwise you run the risk of losing the original quality of the product, quite literally bit by bit. - Page 43 Alternator belt With engine off, check alternator belt deflection mid- way (A) between the circulating pump pulley (1) and the alternator pulley (2). To increase belt tension: Loosen alternator mounting screws and nuts, and pivot alternator away from engine to increase belt tension.
- Page 44 To increase belt tension: Loosen pump mounting screws. Insert a 1/2 in. breaker bar into the square hole (D) in the pump mounting bracket, and pivot pump away from engine as shown. Never pry against the pump reservoir or pull filler neck. While maintaining pressure on pump, retighten all mounting screws.
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Page 45: Lubrication System
The oil is cooled in the oil cooler (not all models) and cleaned in the oil filter. Al- ways use Volvo Penta original oil filters, they have an integral relief valve that allows the oil to by-pass the filter even if the filter is completely clogged. - Page 46 Oil and oil filters. Replacement The oil should be changed when the engine is hot. Stop the engine. Suck out oil through the oil scaveng- ing/bilge pipe. WARNING! Hot oil can cause burns. Unscrew the old filter. NOTE! Avoid oil spillage. Check the mating surface of the engine is clean.
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Page 47: Cooling System
If overheating still occurs, return to port at low RPM to prevent excessive overheating and engi- ne damage. See your Volvo Penta dealer for service assistance. If there is a risk of frost the cooling system must be drained. - Page 48 Starboard Remove one cylinder block drain (C) and clear hole with a wire. Loosen clamp (D) and remove manifold hose. Port Remove one cylinder block drain (E) and clear hole with a wire. Loosen clamp (F) and remove manifold hose. Water pump Loosen and slide clamps back.
- Page 49 3.0 models Remove the longer cooling hose (1) from the thermo- stat housing, then bend the hose down so that it emp- ties completely. Remove and empty the thicker coo- ling hose (2) from the circulation pump. Remove the drain plug (3) at the exhaust pipe, then clear the hole of any impurities using steel wire so that the water can run out freely.
- Page 50 Pivot housing (SX, DP-S) To drain cavity in pivot housing, tilt drive unit to the full tilt (up) position and remove the water drain plug (G) from the port side of the pivot housing. Tilt the drive unit to the full tilt down position. Allow unit to drain.
- Page 51 Cooling system. Inhibiting When laying up the boat for the winter it is important that the cooling system be flushed with freshwater so that deposits do not dry and to prevent the build-up of salt crystals. Seawater in the system causes corrosi- on when air is introduced and can cause the build-up of salt crystals that could block the system.
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Page 52: Fuel System
Check both before and after starting the engine. Run the engi- ne compartment fan for at least 4 minutes before starting the engine. To prevent fire and explosion, Volvo Penta fuel system components meet requirements for fuel and fuel vapour containment. Do not substitute automotive or other non-approved parts. - Page 53 The fuel injectors are controlled by the ECM. It requires no periodic maintenance or adjustment. If operational problems occur, see your Volvo Penta dealer. Flame trap The flame trap (B) should be cleaned annually. Rem- ove flame trap and clean in kerosene or other solvent.
- Page 54 4.3, 5.0 and 5.7 models All models have a fuel filter (C) in the fuel line before the fuel pump. IMPORTANT! Volvo Penta EFI engines require a special marine filter with a 5-10 micron filtering capability. Do not substitute any other type of fil- ter.
- Page 55 Clean up any spilled fuel. Run bilge blower for at least five minutes to vent engine compartment, then start engine and check for leakage. Smell for fuel in the bilge’s, if you can smell fuel, explosion and fire are an extreme danger. Clean up the bilge’s until fuel cannot be detected by smell.
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Page 56: Ignition System
Replace if damaged. Other distributor components are maintenance free. WARNING! To minimize the risk of fire and ex- plosion Volvo Penta ignition components meet national and marine safety standards. The use of components that do not meet safety stan- dards (automobile components for example) can cause a fire or explosion on board. - Page 57 Firing orders: 3.0 engines 4.3 engines 5.0 and 5.7 engines 1-3-4-2 1-6-5-4-3-2 1-8-4-3-6-5-7-2...
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Page 58: Electrical Systems
Electrical systems The electrical system has a voltage of 12 V. The generator has a charging regulator to make it more effective. The engine also has semi-automatic and normal fuses which cut off the current if there is an overload. There are also fuses for the trim pump and the Power Trim controls. - Page 59 For the same reason charging circuits must never be switched over while the engine is running. To simul- taneously charge two independent battery circuits, fit a Volvo Penta charge distributor (accessory) to the regular generator. IMPORTANT Turn the engine off and switch off power at the main switches before carrying out work on the electrical system.
- Page 60 Charging Avoid boost charging the batteries. If boost charging is necessary then both battery leads must be remo- ved from the battery. Never use a boost charger unit to jump start an engine. When charging, unscrew filler plugs but leave them in their holes.
- Page 61 Also check that all other electrical connections are dry and free of oxidation and that there are no loose connections. If necessary, spray these connec- tions with a water-repellent spray (Volvo Penta Uni- versal oil). WARNING! Never mix up battery positive and...
- Page 62 Power should be taken from the battery (or from a contact unit intended for this purpose). Boats with Volvo Penta instrumentation also have two power take off terminals for accessories under the instrument panel. One fused for up to 5 A and one not fused for up to 20 A.
- Page 63 4.3 , 5.0 and 5.7 models Automatic fuse (A)* is 50 A and protects the Power Trim pump circuit. Automatic fuse (B)* is 60 A and protects the main engine cabling. Automatic fuse (C)* is 12.5 A and protects the engine control module (EEC) (Gi, GSi models only).
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Page 64: Drive. Sx And Dp-S
Drive. SX and DP-S Corrosion protection Anodes Sacrificial anodes are attached to the bottom of the gimbal housing (A), at the front (B) of the gearcase above the anti-ventilation plate. SX-C models also have anodes in the exhaust passage (C). Anodes are slowly eroded away by galvanic action and require in- spection. - Page 65 Active Corrosion-Protection Most boats are equipped with a Volvo Penta Active Corrosion Protection System as standard equip- ment. The system greatly improves the protection and life of the drive unit from corrosion. If your boat does not have this system as standard you can buy it as an accessory.
- Page 66 Oil level. Check Trim the drive to it's normal running position. Remove the dipstick (A) and check the oil level covers the en- tire marked area. Add oil if required through the dip- stick hole. If oil level is low, add only enough lubricant to bring the oil level within the full range of dipstick.
- Page 67 Oil. Replacement DP-S drive Place drive unit in the run (down) position. Remove propellers and mounting hardware. See chapter Pro- pellers. NOTE! Removing DuoProp propellers require the use of special tools. Remove the oil drain plug (B) (below propeller shaft) and the oil level dipstick (A).
- Page 68 WARNING! Removal of the drive requires spe- cial knowledge and tools. A falling drive can cause serious personalinjury. Please contact your nearest authorized Volvo Penta dealer for assistance. IMPORTANT! Failure to lubricate the gimbal bearing and universal joints each year will result in damage to the pivot housing and drive unit.
- Page 69 Power Trim pump . Oil level SX-C and DP-S drives Trim up the drive completely and then remove the le- vel/filling plug (A). WARNING! The hydraulic system is under pres- sure. Before removing the filler plug the drive must be trimmed up completely so that the sys- tem is not under pressure.
- Page 70 Trim fin. Adjusting, SX drive NOTE! The DP-S drive has no trim fin. No adjustment is required if the boat has power stee- ring. If there is no power steering the trim fin must be adjusted depending on propeller rotation. With a left- rotating propeller the measurement (A) is 83 mm (3.3 in)(B= 5 °...
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Page 71: Steering
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 72: Propellers
See your Volvo Penta dealer for help in determining the correct propeller(s) for your application. - Page 73 Under these conditions stop the engine and check the propeller for damage. If the propeller appears damaged, have it checked by your local Volvo Penta dealer. Always carry a spa- re propeller and replace the damaged propeller as soon as possible.
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Page 74: Propeller Replacement, Sx Drive
Propeller replacement, SX drive Removal Installation Set the control lever in the NEUTRAL position. WARNING! Make sure the ignition switch is Grease the propeller shaft using water repellant OFF. grease. Set the control lever in the NEUTRAL position. Install the bushing (F) with the inner cone turned Remove the split pin (A) and the locking tab was- toward the propeller shaft cone. -
Page 75: Propeller Replacement, Dp-S Drive
Installation Coat the full length of both propeller shafts with WARNING! Ignition switch must be OFF. Volvo Penta propeller shaft grease. Place remote control in the FORWARD position to Place remote control in the FORWARD position to lock propeller shafts. -
Page 76: Maintenance Schedule
Read the chapter Maintenance carefully before starting work. If there is any item you are not sure of, please contact your Volvo Penta dealer for more information. IMPORTANT! These service operations must be carried out by an authorized Volvo Penta Service work- shop. Daily before starting first time: Engine. -
Page 77: Laying Up/Launching
Maintenance carefully. There you will find the instructions on how to carry out the points recom- mended in the checklist. If there is any item you are not sure of, please contact your Volvo Penta dealer for more information. -
Page 78: Bringing Out Of Storage
Bringing out of storage Immediately before launching the drive’s sacrificial Check oil level in the engine and drive/reverse anodes must be cleaned off with emery paper. If gear. Top up if required. For oil quality: See an anode is 2/3 its original size (1/3 eroded), it chapter Technical Data. -
Page 79: Painting The Drive And Keel
If the boat is easy to take up on land at least two coats of Volvo Penta anti-fouling primer. then we recommend only teflon treatment combined Let them dry. A further two coats of Volvo Penta anti- with mechanical cleaning several times during the fouling should then be applied. -
Page 80: Troubleshooting
Performance Excessive water in bilge Drain bilge. loss Boat hull condition Clean boat hull. See your Volvo Penta dealer. Incorrect fuel octane Fill tank with proper fuel. Remote control box, or shift High shift See your Volvo Penta dealer. -
Page 81: Technical Data
1-6-5-4-3-2 Ignition timing ............0 ° ° (GL, GS) ° (Gi) Spark plugs P/N: Volvo Penta ....... 3851831 38511831 AC ..........MR43LTS MR43LTS Champion ........RS12YC RS12YC Spark plug gap, mm ..........1.1 Tightening torques, spark plugs ....... 27 Nm... - Page 82 Firing order ............... 1-8-4-3-6-5-7-2 1-8-4-3-6-5-7-2 Ignition timing ............10 ° BTDC ° BTDC Spark plugs P/N: Volvo Penta ....... 3851831 3851831 AC ..........MR43LTS MR43LTS Champion ........RS12YC RS12YC Spark plug gap, mm ..........1.1 Tightening torques, spark plugs ......27 Nm...
- Page 83 Firing order ............... 1-8-4-3-6-5-7-2 1-8-4-3-6-5-7-2 ° ° Ignition timing ............8 BTDC BTDC Spark plugs P/N: Volvo Penta ....... 3851831 3851831 AC ..........MR43LTS MR43LTS Champion ........RS12YC RS12YC Spark plug gap, mm ..........1.1 Tightening torques, spark plugs ......27 Nm...
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Page 84: Fuel Specification
Fuel specification. See chapter Other product information for more information. 3.0GS ..............93 Octane (RON) unleaded fuel** 4.3GL, 4.3GS ............93 Octane (RON) unleaded fuel** 4.3Gi ..............93* Octane (RON) unleaded fuel** 5.0GL ..............93 Octane (RON) unleaded fuel** 5.0Gi ..............93* Octane (RON) unleaded fuel** 5.7GS .............. - Page 85 Notes ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________...
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Page 88: Ab Volvo Penta
AB Volvo Penta SE-405 08 Göteborg, Sweden www.volvopenta.com...