Volvo Penta 3.0GS/SX User manual

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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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.
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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
design, coupled with revolutionary new ideas and concern for the environment,
where traditional Volvo Penta qualities such as first class performance, reliability
and durability have been upheld. We believe that this also reflects what you require
and expect from your new marine engine.
To help you fulfill your expectations, we want you to read through this instruction
manual carefully, and take our advice about operating and maintaining the engine,
before you cast off on your maiden voyage.
Best regards
AB VOLVO PENTA
© 1997 AB VOLVO PENTA
All rights to changes or modifications reserved
Printed on environmentally-friendly paper
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Safety Precautions ................................................ 4
Safety precautions to be taken when operating
the boat ................................................................... 5
Safety precautions for maintenance and service .... 7
Introduction ........................................................... 9
Responsibility for the environment .......................... 9
Running-in............................................................... 9
Fuel and oils............................................................ 9
Service and replacement parts ............................... 9
Certificated engines ................................................ 9
Warranty................................................................ 10
Identification numbers ........................................... 11
Presentation ........................................................ 13
Instrumentation ................................................... 16
Emergency stop switch ......................................... 18
Controls ............................................................... 19
Power Trim........................................................... 21
Trim controls ......................................................... 21
Trim instruments ................................................... 23
Impact protection................................................... 25
Starting the Engine ............................................. 26
Preparations.......................................................... 26
Starting.................................................................. 27
If engine floods...................................................... 28
Operation ............................................................. 29
Checking instruments............................................ 29
Engine protection mode ........................................ 30
How to shift and control speed .............................. 31
Twin unit maneuvering .......................................... 31
Cruising speed ...................................................... 32
Power Trim............................................................ 32
After Use .............................................................. 35
Stopping the engine .............................................. 35
Salt water operation .............................................. 36
Cold weather precautions ..................................... 36
Laying up............................................................... 36
Transporting on a trailer ........................................ 37
Laying up on land.................................................. 37
Other Product Information ................................. 38
Fuel requirements ................................................. 38
Electronic engine control....................................... 39
Maintenance and Care ........................................ 40
Engine ................................................................... 40
Lubrication system ................................................ 43
Cooling system...................................................... 45
Fuel system........................................................... 50
Ignition system ...................................................... 54
Electrical systems ................................................. 56
Drive. SX and DP-S............................................... 62
Steering................................................................. 69
Propellers .............................................................. 70
Propeller replacement, SX drive............................ 72
Propeller replacement, DP-S drive........................ 73
Maintenance Schedule........................................ 74
Laying up/Launching .......................................... 75
Inhibiting................................................................ 75
Bringing out of storage .......................................... 76
Painting the drive and keel .................................... 77
Troubleshooting .................................................. 78
Technical Data ..................................................... 79
Contents
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Safety Precautions
Read this chapter carefully. It concerns your safety. This section describes how safety information is presented
in the Instruction Manual and on the engine. It also gives a general account of basic safety precautions to be
taken when operating the boat and maintaining the engine.
Check that you have the correct Instruction Manual before you read on. If this is not the case please
contact your Volvo Penta dealer.
If operations are performed incorrectly it could result in personal injury, or damage to property
or the engine. 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.
Always read these safety precautions very carefully.
In the Instruction Manual warning texts have the following priority:
WARNING! If these instructions are not followed there is a danger of personal injury, exten-
sive damage to the product or serious mechanical malfunction.
IMPORTANT! Used to draw your attention to something that can cause damage, product
malfunction or damage to property.
NOTE! Used to draw your attention to important information that will facilitate work or opera-
tions.
This symbol is used in certain cases on our products and refers to important information in
the Instruction Manual. Ensure that warning and information symbols on the engine and trans-
mission are always visible and legible. Replace symbols that have been damaged or painted
over.
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Safety precautions to be taken when operating the boat
Your new boat
Read Instruction Manuals and other information
supplied with your new boat. Learn to operate the
engine, controls and other equipment safely and cor-
rectly.
If this is your first boat, or is a boat type with which
you are not familiar, we recommend that you practice
controlling the boat in peace and quiet. Learn how
the boat behaves at different speeds, weather condi-
tions and loads before casting off for your “real” mai-
den voyage.
Remember that the person driving a boat is legally
required to know and follow the current rules regar-
ding traffic and safety at sea. Make sure you know
the rules that apply to you and the waters you are
sailing in by contacting the relevant authorities or or-
ganization.
A good piece of advice is to take a course in sea-
manship. We recommend that you contact your local
boating organization to find a suitable course.
Accidents
Statistics show that poor maintenance of boats and
engines and a lack of safety equipment are often the
cause of accidents at sea.
Ensure that your boat is maintained in accordance
with the relevant Instruction Manual and that the ne-
cessary safety equipment is on-board and is service-
able.
Daily checklist
Make a habit of checking the engine and engine
compartment visually before operating the boat (be-
fore the engine is started) and after operating the
boat (after the engine has been stopped). This will
help you to quickly detect fuel, coolant and oil leaks
and spot anything else unusual that has or is about
to happen.
Maneuvering
Avoid violent and unexpected changes in course and
gear engagement. There is a risk that someone
aboard will fall down or overboard.
A rotating propeller can cause serious injury. Check
that nobody is in the water before engaging ahead or
astern. Never drive near bathers or in areas where
people could be in the water.
Avoid trimming an outboard drive too much, as steer-
ing will be severely reduced.
Refueling
When refueling there is always a danger of fire and
explosion. Smoking is forbidden and the engine must
be switched off.
Never overfill the tank. Close the fuel tank filler cap
properly.
Only use the fuel recommended in the Instruction
Manual. The wrong grade of fuel can cause opera-
ting problems or cause the engine to stop. On a die-
sel engine poor quality fuel can cause the control rod
to seize and the engine to overrev with a resultant
risk of damage to the engine and personal injury.
Safety breaker
We recommend that you install and use a safety
breaker (accessory), especially if you boat can travel
at high speeds. The safety breaker stops the engine
if the driver falls down and loses control over the
boat.
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Remember
●Safety equipment: Life jackets for everybody on board, communication equipment, distress
flares, approved fire extinguishers, life-buoys, anchors, paddles, torches etc.
●Replacement parts and tools: impeller, fuel filter, fuses, tape, hose clamps, engine oil, propeller
and the tools for jobs that may be necessary.
●Get out up-to-date charts for the planned route. Calculate distance and fuel consumption. Listen
to weather reports.
●Tell friends or relatives about your planned route when undertaking longer journeys. Remember
to tell people about changes to your plans.
●Teach those on-board the location of safety equipment and how to use it. Ensure that there is
more than one person on-board who can start and drive the boat safely.
This list should be added to if the type of boat requires extra safety equipment. We recommend that
you contact your local boating organization to find a suitable course.
Carbon monoxide poisoning
When a boat moves forward through the water a va-
cuum is created behind it to a greater or lesser ex-
tent. In some circumstances this vacuum effect can
be so great that the boat’s own exhaust gases are
sucked into its cockpit or cabin. This poses a risk of
carbon monoxide poisoning to those on-board.
This problem is greatest for high, wide beamed boats
with a vertical stern. However, it can be a problem for
other types of boat in certain conditions (running with
the cover up for example). Other factors that exacer-
bate the problem are wind conditions, load distribu-
tion, sea conditions, trim, open hatches and ventil-
ators etc.
Most modern boats are designed so that vacuum ef-
fect problems are very rare. If a vacuum forms be-
hind the boat do not open ventilators or hatches at
the front of the boat. Strangely enough this leads to
an increase in the vacuum effect. Instead, try chang-
ing speed, trim or load distribution. Try also to take
down, open or in some other way change the confi-
guration of the cover. Contact your boat dealer to
find a solution for your particular boat.
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Safety precautions for maintenance and service
Preparations
Knowledge base
The Instruction Manual contains instructions on how
to carry out the commonest maintenance and service
operations safely and correctly. Read them carefully
before starting work.
Service literature for more extensive work can be ob-
tained from your Volvo Penta dealer.
Never undertake an operation if you are not com-
pletely sure how to do it. Contact your Volvo Penta
dealer for assistance instead.
Stopping the engine
Stop the engine before the engine compartment co-
ver is opened or removed. Unless otherwise speci-
fied all maintenance and service must be carried out
with the engine stopped.
Immobilize the engine by removing the ignition key,
turning off the power supply with the main switch and
locking it in the OFF position. Fix a warning that
work is being undertaken to the control position.
Approaching a running engine is dangerous. Loose
clothing, long hair, fingers or tools can get caught in
rotating parts and cause serious personal injury.
Volvo Penta recommend that all servicing with the
engine running be undertaken by an authorized
Volvo Penta workshop.
Lifting out the engine
Use the lifting eyes mounted on the engine/reverse
gear when lifting the drive unit. Always check that
lifting equipment is in good condition and has suffi-
cient load capacity to lift the engine (engine weight
including reverse gear and any extra equipment in-
stalled). For safety reasons the engine should be lif-
ted with an adjustable lifting beam. All chains and
cables should run parallel to each other and as per-
pendicular as possible to the top of the engine. Note
that extra equipment mounted on the engine can
change its center of gravity. Special hoists may be
necessary to balance the engine and make handling
it safe. Never carry out work on an engine suspen-
ded on a hoist.
Before starting the engine
Reinstall all protective components that have been
removed before starting the engine. Check that no
tools or other objects have been left on the engine.
Fire and explosion
Fuel and lubricating oil
All fuels, most lubricating oils and many chemicals
pose a fire hazard. Read and follow the instructions
on packaging.
Work on the fuel injection system must be carried out
on a cold engine. A fuel leak or spill onto a hot surfa-
ce or an electrical component can cause a fire.
Store oil and fuel soaked rags and other flammable
material in fireproof conditions. In certain circumstan-
ces oil soaked rags can spontaneously combust.
Never smoke when refueling, changing the oil or clo-
se to filling stations or in the engine compartment.
Non-original components
The components in the fuel injection system, ignition
system and electrical system in Volvo Penta pro-
ducts are designed and manufactured to minimize
the risk of fire and explosion.
Using non-original Volvo Penta parts which do not
meet the above standards, can result in fire or explo-
sion on board.
Batteries
Batteries contain and produce oxyhydrogen, especi-
ally when they are being charged. This gas is easily
ignited and highly volatile.
Never allow a naked flame or sparks near the bat-
teries or battery compartment.
Incorrect connection of a battery lead or jump lead
can cause a spark which is sufficient to cause the
battery to explode.
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Hot surfaces and liquids
When the engine is at operating temperature there is
always a danger of burns. Avoid hot surfaces. For
example: exhaust manifold, oil sump, hot coolant and
hot lubricating oil in pipes and hoses.
Carbon monoxide poisoning
Only start the engine in a well-ventilated area. If ope-
rating the engine in an enclosed space, ensure that
exhaust gases and crankcase emissions are ventila-
ted out of the working area.
Chemicals
Most chemicals such as glycol, rustproofing agents,
inhibiting oils and degreasing agents are hazardous
to health. Read and follow the instructions on packa-
ging.
Certain chemicals such as inhibiting oils are inflam-
mable and also hazardous to health if inhaled. Ensu-
re that ventilation in the workplace is good and use a
protective mask when spraying. Read and follow the
instructions on packaging.
Store chemicals and other hazardous material away
from children. Deposit excess or used chemicals at a
properly designated disposal site.
Cooling system
There is a risk of water penetration when working on
the seawater system. Turn off the engine and close
the sea cock before starting work on the system.
Avoid opening the coolant filler cap when the engine
is hot. Steam or hot coolant can spray out and cause
burns.
If work must be carried out with the engine at opera-
ting temperature and the coolant filler cap or a cock
open or a coolant hose disconnected, open the coo-
lant filler cap carefully and slowly to release pressure
before removing the cap completely. Note that the
coolant may still be hot and can cause burns.
Lubrication system
Hot oil can cause burns. Avoid skin contact with hot
oil. Ensure that the lubrication system is not under
pressure before commencing work on it. Never start
or operate the engine with the oil filler cap removed,
otherwise oil could be ejected.
Fuel system
Always use protective gloves when tracing leaks.
Liquids ejected under pressure can penetrate body
tissue and cause serious injury. There is a danger of
blood poisoning.
Always cover the generator if it is located under the
fuel filter. The generator can be damaged by spilled
fuel.
Electrical system
Cutting off power
Always stop the engine and break the current using
the main switches before working on the electrical
system. Isolate shore current to the engine block
heater, battery charger, or accessories mounted on
the engine.
Batteries
The batteries contain an extremely corrosive electro-
lyte. Protect your skin and clothes when charging or
handling batteries. Always use protective goggles
and gloves.
If battery electrolyte comes into contact with unpro-
tected skin wash off immediately using plenty of wa-
ter and soap. If battery acid comes into contact with
the eyes, flush immediately with plenty of water and
obtain medical assistance without delay.
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