Volvo Penta PENTA User manual

WELCOME ABOARD
Pleasestudy this manualto completelyunderstandhow
your Volvo Pentamanneengineoperates andto enable
youto takefull advantageof its manybuilt=in features.
Boating Responsibilities
Mostcountries havereguJationscontrolling boatingAl-
waysmakesure youfollow theseregulationsI Asa boat
owner,youhavecattamresponsibilities to others. Be
surethat all operatorsreadthis manual.
Youare legally responsiblefor all occupantsof your
boatInstruct at least oneof your passengersin the be-
sic fundamentalsof handhngyourboat~n caseof an
emergencyShowall handsthe location of emergency
equipmentandhowto use it In the U.S.you are re-
quired by law to have oneUSCost Guardapproved
hie jacket for eachpersonaboard,plus oneapproved
throwable device for manoverboardprotecbonOther
countriesmayhaveregulationsthat differ, contact Boat
foundationsin your countryfor detadedmformahon
Learnthewaterwayrules of thelocality in whichyou
are going to operateyour boat Navigablewaterways
arecontrolledby Federal(national) regulationswhilein-
landlakesare controlledbylocal jurisdictions. Obey
theseregulabonsto protect yourself, yourpassengers
andfellow boatingenthusiasts.
Thoroughlyfamiliarize yourself with weatherbureau
warningsystemsagnalsandwaterwaytraffic signs
in the U.S.contact yourlocal US. CoastGuardstabon
andtake advantageof their seasonalboat mspecbens
andtrain=ng coursesFor other countries, contact Boat
foundationsfor inforrnabon.
Our Joint ResponsibUity
VolvoPentacontinualIy invests considerabledevelop-
mentresourcesto minimizetheeffects onthe env=ron-
mentcausedby our productsExamplesof this continu-
ousworkare the improvementsin exhaustemassions,
soundlevels andfuel consumption
Whetheryour Volvo Pentaengineis usedto powera
pleasureboator is usedin acommercialapplicationit
can,if usedincorrectlyor maintainedinsufficiently, dis-
turb or damagethe environment
This Owner’sMarque{cove~several servtca checks
that, if not performedcorrectly, cancausea deteriora-
tion of theenginea~ectlngthe environment,Its service
life andoperatingeconomyAlwaysfollow the recom-
mendedservice intervals andmakeit a hab{t to check
for anything abnormaleacht{meyouuse the engine
Anexampleof this is excess=veexhaustsmokeCon-
tact anAuthorizedVolvoPentaServtcaDealerif you
cannotremedythe causeyourself.
Rememberthat mostchemicalproductsusedto main-
tain yourboat andengineare harmfulto the enwron-
merit, if usedincorrectly. VolvoPentarecommendsthe
useof biodegradabledegreasingagentsduring all
cleaning. Alwaysdisposecorrectly of usedengineand
transmissioneel, paint, degreasingagentsandwashing
fluids etc., so that they cannotharmthe environment.
Whenusingyour boat, alwaysadjust the speedand
d~stancato preventthe wakeor soundlevel fromdis-
turbing wildlife, mooredboats, pontoons,etc. Leavethe
watersandnatural harborsIn the conditionyouyourself
wouldlike to find them.
Wethank youfor yourchoice of VolvoPentamarine
engineandwewishto continueto supplyyouwith
maintenanceandadweeto help youget the best possi-
ble performancefrom your engine.Contactyournear-
est AuthonzedVolvoPentaServmeDealer for assis-
tance.
Wewishyoupleasanttrips with yourboat.
AB VOLVOPENTA
Identification Numbers
Recordyourengineandreversegear modelandsenalnumbersimmediatelyafter purchase.This w~ll enableyouto
havethemavailablefor quickreferencewhenorderingparts or literature.
EngineModelNo.........................................
ReverseGearModel.......................................
ignitionKeyNo............................................
BoatModelNo...............................................
Serial No............................................
Serial No...........................................
RecommendedPropellerSize..............................
Hull Identification No.CHIN).............................
Toll Free Dee|or Locater Service for U.S.A.
Tolocate the anauthorizedVolvoPentaservicing
dealer, consult the YellowPagesunder"BoatDealers"
or call ’1-8(}0-522-’1$59
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Owner’s Manual
Introduction
Features74 Gi
Features7 4 GL,82 GL
Instruments
Controlumts
Operation
Starting 6
After use .. 7
Measureswhenfreezmgts imminent 7
Marineengines
7.4 GL, 7.4 Gi,
8,2 GL
Contents
RegularMaintenance
2 Eng[nemaintenance
3 TransmissionHS1
4 Boatmaintenance
5 Troubleshootingchart
Maintenanceschedule
Layingup
Laytngup& Off seasonstorage
Pre-Eunch&launching
10
t£
19
2o
21
COrn
24
Technicaldata
Models74 G[ 25
Models7 4 GL,8 2 GL 27
Z~ important information
Stopthe enginebeforeopenmgthe hatch
to the eng!necompartmentTherearero-
tahngparts onanenginewhtcharedanger-
ousto approachwhenthe engineis run-
ning
Bear~nmndthe nskof fire All enginefuel
ts tnfiammableAlcohol,e~thermethanolor
ethanolts somettmesaddedto fuel, espe-
cially to unleadedgasohneTheseadd[hves
shortenthehfe of rubberandplastic com-
ponentsmthe fuel systemInspectregulaPj
for leaksandcracks
Theengine~sflu=d°cooledDra~nthecool~ngsys-
temwhenthe enginehasbeenstoppedif there
is ansko~freez.ngNotethat siphoningachon
canoccurwtthcertarnworkonthe coolmgsys-
temCloseall dratnagepointswhenthe boat,s
not underconstantsupervJstonIncorrectlyper-
formeddrainagemaycausethe boatto become
filled withwaterandsink, in additionto damaged
engineparts
Readthis Owne,’sManualcarefully beforeput-
tmgyourengineinto operationTheenginescov-
eredmths manualhaveasstandardequ=pment
the VolvoPentaHS1 hydrauhcreversegearbox
Asanopttonthe enginescanbeequrppedw[th
reversegearsfromother manufacturersPlease
consultthemanufacturerof thereversegearfor
ownerandserv=ceinforrnat~on
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Features,Model7.4 Gi
1Ot[filler, engine
2Oil filler, reversegear
3 Dipst~ck,engine
4DEpstick,reversegear
5Oil withdrawaltube
6Oil filter, reversegear
7 Watercooledexhaustelbow
8Odfilter engrne
9Fuelfilter
10
\
2, 4
11
10 Fuel pumps
11 ECM
12 Backfireflamearrestor
13 Seawaterpump
14 Circuitbreakers
15 Alternator
16 Oil cooler,reversegear
17 Serralnumber,reversegear
18 Thermostathousing
14 18 3
13
15
12
17
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Features,Model7.4 GLI 8.2 GL
1Ollfiller, engine
:20=Efiller, reversegear
3 D~pstlck,eng+ne
,4 Dipstick,reversegear
5 Oil withdrawaltube
O~[filter, reversegear
7 Watercooledexhaustelbow
Oilfilter engine
9 Fuelfilter
10 Fuelpump
11 Carburetor
12 Backfireflamearrestor
13 Seawaterpump
14 CIrcmtbreakers
15 Alternator
16 Otl cooler,reversegear
17 Senalnumber,reversegear
18 Thermostathousing
7 14 3
2, 4
15
12
\1 7
11
13
6
17
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instruments, Main paneg
Revcounter
Thisshowsthe enginespeed=nrevolut=onspermrnutex I00
Speed
It is importantthat the enginereachesthe maximumspeed
w=tha normalload Thefull throttle RPMrange=s4000-4400
rpmforthe74GL For models74G[and82GLthefull
throttle rangeis 4200-4600RPMArecommendedmaxtmum
crutsmgspeedis around300-500rpmbelowthe maximum
speedachteved
NOTEIGrowthonthe hull reducesthe speed
Temperaturegauge
Dunngnormaluse,the temperaturegaugeshoulddtsplay 158-
195°F(70-90°C)Yourboatmaybeequtppedw~thanaudtble
alarmto alert theoperatorto anenginecoohngoverheat
Aif the engineoverheats,reducethe speedandshift
intoneutral. Findoutwhatis blockingthe watersup-
plyto the engineif the temperaturedoesnotdrop.
Stoptheengineif necessaryandrectify thefault.
Oil pressuregauge
Theoil pressuregaugeshouldnormallyshowabout40-45psi
(275-300kPa)whenthe enginets runnmgIt [s normalfor the
gaugeto showalower readingat lowspeedsYourboatmay
beequippedwtthanaudiblealarmto alert the operatorto low
engmeo~l pressure
,~ If theoil pressureis toolow, stoptheengineimme-
diately anddeterminethe cause,
Voltmeter
Thevoltmetershowsthe systemvoltageWhenthe engineis
runningit shouldbe140-144 V Thevoltageis 12Vwhenthe
enginets switchedoff
Mainpanelfuses
Theinstrumentpanelhastworeplaceable8 AmpfusesThe
fuseprotectedcircuits areSystemvoltageandStartingc~rcu~t
AWARNING!Always keep spare onfuses board
Pushbutton,instrumentlighting
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Controlunits.
Ignition switch
@Thetgnitionswitchhasthreepositions.
6 = Stopposition. Everythingconnectedacrossthe keyts
switchedoff. Thekeycanbewithdrawnfromthe lock
I = Driveposition.Sytemvoltage connected
II =Start position. Starter motoracttvated
AWARNING!Thetgmtlonkeymustonly bein the drive po-
stt=onwhentheenginets to bestartedandwhenthe en-
gineISrunmngCarryoutthe starting procedurein one
operation
Singlelevercontrol TheVolvoPentacontrolis designedto operatethe speed,
forwardandreversegearsby movingthe lever in the
desireddirection,Theenginespeedcanbecontroledwrthout
selectingforwardor reversebypressingthe buttonmthe center
of thecontrolhubandmovingtheleverslightly forward
Releasethe buttonandonly the enginespeedcanbe
controlledWhenthelever ~sreturnedto the neutralposlt~on,it
comesout of neutral automaticallyandthe speed,forwardand
reversecannowberegulated
F = FORWARD.Simultaneouscontrol of speedand movement
R= REVERSESrmultaneouscontrol of speedand movement
Highperformanceboatdriving
F-hghperformancers notonlydefinedbyenginesize, but bya combmatronof theenginepower,hull des=gn,
andthe stzeandwaightof the boatYournewengine(s)producea htghpoweroutputDependingonthe
boattype. the top speedmaybemuchhigherthat whatyouareusedto
F-hghspeedoperationrequ=resanexpenenceddriver whohasmasteredhandlingof highperformanceboats
It is advisablethat youlearnthe boat’sbehaviorbeforetakmgpassengersonboardInformyourpassengers
aboutthe boat’s charactenstlcsandthe maneuvresyouIntendto doUsethe boat’sperformancewith due
considerationandcare~
Whenoperatingat high speedsrememberthat other boatersmaynot reahzethe speedyouare travelling at,
especiallywhenyouclosein onanotherboatfromasternor fromahead.Alwayskeepagooddistanceto al-
13wfor the unexpected1Alwaysbepreparedfor whatother boatersmaydounexpectedlyHighspeeddnvmg
requiresthe driverto gtveahighdegreeof attentionto boatoperatton
Aboattravehngat aspeedof 70mph(60knots)covers101feet (30meters) durmg1 secondThefaster
yougo, the qutckerthmgswt]l happenHighspeeddrivingrequiresa lot of waterandgooddistanceto
possiblehazards.Alwaysallow a 3- 4 secondreactionhme
Whendnwng,makesurethat all passengersaresafelyseated.Emphasizethis espectallyi[ youhavealarg-
er cabincruiser whereonenormallymovesaboutdunngoperationReducethe speedconsiderably,or stop
completelyif someoneneedsto moveaboutmthe boat
Thedrivershouldalwaysusethesafety kill switch!Thesw~tch,whchis connectedto the driver,
immediatetyshutsoff the engine(s)shouldthednverbethrownfromthe drivingpositionEvenff the risk
falling overboardts practicallynonexistenttn yourtypeof boat,therisk of thedriverfalling andbeLngdazed
~nroughseascanbeevengreater
Remember,evenwhenthe engine(s)is stoppedin ahighperformanceboatthat is p~aning,it will
travel about325ft (100meters)beforedroppingthroughthe planingthresholdandstopping.
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Safety equipment and personal gear.
Equipyourboatwithall safetyitemsrequiredbylaw, US. CoastGuardregulationsor othernationalregula-
tions Addedto this, followtngsafetyequ=pment=swtal in a highperformanceboat
Life Jacketsof anapprovedmakefor all thoseonboardNote:Thelife jacketshouldbedesignedfor
the speedthe boat canreach.
Helmef_Ahelmetshoutdbewornfor all advancedboatdriving at h~ghspeeds.Useanapprovedtypefor use
in boats
WetSuit. WhenoperatingIn coldwaters
EyeProtection.If the boat~snot equJppedwJthanadequatewindshield,the drrverqeedseyeprotechonof
approvedshatterprooftype
Oninboard engine installations.
AWARNING!VolvoPentarecommendsuseof a properlyinstalled seastrainer or rawfilter to provide
engineandreversegearwith anunrestrictedflow of filtered coolingwaterRegularinspectionand
cleantngof this straineris requiredOperation=nareaswhereseaweed,seagrass,sandetcor other
foreignmatterm=ghtblockintakeof filter requiremorefrequentmaintenance.
Driving
Starting
I Checkthe o~1leve~Jnthe engine
NOTE!Highperformanceenginesnormally have
ahighero=l consumpttop,whencomparedw~tha
standardmarineengEneof the similar displace-
mentApartfromlubncattonthe mostimportant
taskof theoil is to coollubncatedengtneparts
Htghperformanceenginesdevelopmoreheat
comparedwith standardmarineengines.There-
fore,tt is veryimportantneverto fall belowthe
mcnimumrequiredodlevel morderto haveanop-
hmalenginehfe Checkthe oil leveBdaily!
If equlpedwithanopttonalclosedcoohngsystem,
checkthefresh waterlevel mthe coolingsystem
Thelevel shouldbeupto theloweredgeof the
filler pipeFIll withantifreezemixtureto thecor-
rectlevel Alwaysuseantifreezeevenif thereis
nonskof low temperaturesTheanttfreezeen-
suresthecoolingsystemcorrosionprotection
andrunningwith freshwateronlycanresult ~n
severecorrosiondamageto the componentparts
of the coohngsystemReferto "EngineMam-
tence"for coolantmExture
3Turnon the mainswitch
Start theengineroomtan(blower)Let it runfor
four minutesOpenall seawatercocksfor the
enginecoohngwaterintake
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5 Releasethe controllever. Idhngposition
6Start theengine(See"Ignitionswitch") If theengine
is cold,runat highidle (900-1200rpm)for 1-2min-
utesuntil engineIs at operatingtemp
NOTE!7 4 GiThefuet rejectionsystemis controlling
the enginespeedduringwarm-upphaseandthusthe
enginespeedcontrol shouldremamset onJdle
7Reducethe enginespeedto idle andreadthe instru-
ments.If the readingsareabnormal,stoptheengine
anddetermtnethe cause
8 Checkfor obstructionsin front of andbehindtheboat
beforeselecting"Forward"or "Reverse"
Themaximumcruising speed~s300-500rpmbelow
maximumspeedGoodoperating economyrs
achievedif full throttle;s avoided
7.4 Gi, 8.2 GLmodels
AWARNING!Yourengine(s) developsa considera-
ble outputevenat idlrng Dependingonthe hull
designyourengine(s)canpushyourboatat idle
andwtth the gearengagedat a speedof 6-9mph
(5-8 knots)Therefore,youmightneedto adjust
yourspeedbyshifting into neutralandreverse
morefrequentlythat whatyouareusedto when
operatingthe boatin harbors,shallowwaters,and
whenmoonng,etc If youarenot operatingthe
gearshft frequentlywhenrunmngthe boatat en-
gine idle speedyoumrghtexceedthe maximum
allowedspeed~nharborsand~nnarrowpassages
Running in shallow waters
9 If youareuncertainof the waterdepthor whenoper-
ating in shallowwaterswerecommendthat youde-
creasespeedto ~dle
AWARNLNG!Inboardpropulsion systemsnormally
havenocollisionprotectlonfor thepropeller(s)and
propellershaftIn caseof groundingor hitting an
obstaclein thewater,checkcarefullythatnothing
ts damagedandthereis nowaterleakagento the
boatCheckthat the propellersarenot damaged
andthat therearenovibrationsIf operationis ab-
normal,returnto port at reducedspeedandhave
thevesselhauledontolandfor acloserinspec-
tion
After use
10 Afteruseandwhentheboatis tied up,it is important
for theenginetoidle for at least1minutebeforeshut
downto avoidboiling of the coolant
11 Stoptheengineusingthe ignition switch
Switcf"off thema=nbatteryswitchCloseall
seawatercocks
~WARNING!Neversw=tchoff the mare
batteryswitchbeforestoppingthe en-
gine Thiscoulddamagethe alternator
Onthe 7 4 Gi modelelectronic compo-
nents~nthe fuel injectionsystemmaybe
damaged
Before Ieaving the boat
12 Checkfor leaksaroundthe engineandthat
everythingelse fn the enginecompartment
appearsnormalIf leakageoccurs,fred the
causeandcorrect it tmmedlately
NOTE!Whenusrngthe bilge pumpbe ob-
servantthat thebilge warerdoesnotcontain
oil or otherchemicalsthat canbeharmfulto
~e environment
WARNING!Beobservantof the water
depthUndernoconditions, suchas low
wateretcshalltheret:,e anyriskthat the
hull hits thebottomwhentheboatis tted
up
CoKdweather precautions
13Beforeleavtngthe boat,the coohn9water
(rawwater)mustbedrainedfromthe engine
to preventfreezedamage
,~ WARNNNG!Beobsen/antfor anywater
leakageinto the boatCloseall seawater
cocksbeforedrainingthe coolingsystem
Incorrectly performeddrainagemay
causethe boatto becomefilled with wa-
ter andsink
Drainthe coolingsystemin thefollowingse-
quenceReversegearHSI: Closethe bot-
tomcockandremovethe hoseono~1coolers
portside
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All models:Loosenandslide clampsback{2)
Removehosesfrom the rear of waterpumpand
dram
3,~ ~~
Seawatercooledmodels:Disconnectlong
hoseat thermostathousmg(3) Loweraiongstde
blockanddraincompletelyDisconnectanddrain
large hoseat waterpumphousing(4).
Freshwatercooledmodels:Removethe ex-
pansiontankfill capandcheckthefreezmgpoint
of thecoolantmixtureIf it is notsufftclent,then
drainthe freshwatersystemandreplacewJth50/
50coolantm=xtureCloseall drampointsandfit
the cooling waterhosesUsethe bilge pumpto
pumpoutanywaterbeforeleavingthe boat.
AWARNING!If thereis arisk of freezingwhile
theboatis moored,it mustnotbeleft in the
waterw=thoutfirst takingsomespec=alprecau-
tionseg watercirculationaroundthehull us-
mgair bubblesBeobservantfor anyfloating
~cedueto currentsandwindsContactwtth
floating ice cancauseextensivedamageto
the hull andpropellers
Seawatercooledmodels:Removethe plugs
ontheport andstarboardsidesof the cylinder
block(5) andremovemanifoldhoses(6)
CbosedcooBedmodels:drammanifold hoses
(6) andmakesure the seawaterhasbeen
draJnedfromthe expansiontank
Closeall drampointsandfit the coohngwater
hoses. Usethe biJgepumpto pumpeut any
waterbeforeleavingthe boat.
Donot forgetto openall seawatercocksbefore
starting the engineaga[nRetightenall hose
clampsanddramplugs
Idle engine
14 In orderto preventenginecorrosiondamage,the
engineshouldberunwarmat least onceevery
monthas longasthe boatis ~nthe waterAllow
engTneto reachoperatingtemperaturewhenrun-
nmg
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Corrosion Protection
15 Yourboatis protectedagainstgalvaniccorrosion
bysacrificial zincanodesThefollowingis gener-
al informationaboutcorrosionprotectionConsult
yourboatmanualor boatdealerfor detailedinfor-
mationconcerningyourboatmodel
Thezrnc anodesmustbe replacedwhen50%
erodedWhenreplacinganodes,scrapethe sur-
facecEeansothat goodmetallic contactis made
betweenthe anodeandthe surface
Toremoveanyoxide coatingfromthe anodes
surfacecleanw~thcoarseemeryor sandpaper;
just beforelaunchingAlsonewanodesshou[d
becleanedCleaningshouldbedonefrequently
onboatsthat arestoredonlandwhennot used
Note!Steelbrushesor othersteeltools mustnot
beusedfor cleamngof the zinc anodesasthey
candeterioratethegalvanicprotection
Thegalvamccorrosionprotecboncanmalfunc-
tion if straycurrentsfromtheelectricalsystem
occurThis canhappenif the wrongtypeof
equipmentis usedor the connectionof electrical
equipmentto the negativepoleis incorrectThe
following shouldalwaysbeobserved
Themainswitchfor the engineshouldbecon-
nectedto thepositive(+) poleof thebatteryThe
mainswitchshoulddisconnectall circuits. Electn-
cal cablesshouldberoutedandclampedsothat
theyarenotexposedto dampnessor the rtsk of
exposureto watermbtlge
If severalbattenesareused,thereshouldbe
separateswitchesfor extra equipmentThere
shouldalsobea maresw~tchbetweenthe post-
tlve (+) poleof theextrabatteryandthefuse
panelfor the boarselectrical equipmentThe
mareswitchfor the extrabatteryshoulddiscon-
nectall circuits connectedto it andshouldbe
switchedoff whenthereis nolongeraneedfor
electricity Themainswitchfor theengineshould
bedtsconnectedwhenthe engine~snot muse
Theengineanddrivetrammustnot beelecthcal-
ly connectedwith otherequipmentsuchastrim
tabs, laddersetc Theengineandreversegear
mustnotbeusedasgroundfor radioor naviga-
tion equipmentor otherelectrical equipment
whereseparategroundcablesare usedAll such
separategroundconnectJonsshouldbegathered
to a commongroundpoint separatedfromthe
eng~ne/dnve
If shorepoweris connected,noprotecbveAC
groundmustbeconnectedto the engineor any
otherDCgroundpointsmthe boatunlessan~so-
iationdeviceis installed
Thetransformerfor shorepowershouldhavethe
protectiveACgroundonthe input side(120/
220V) andthe negative
(-) connectionontheoutputstale(12/24V)with-
outanyconnectionto eachot!,~er
AWARNING!E[ectrolyt~ccorrosiondueto stray
currentscanin a shortt~mecausesevereand
expensivedamageto the boat’s s equipment
All workinvolvingtheboat’ss lowvoltagec~r-
cult shoutdonlybedonebytrainedor knowl-
edgeablepersonnelInstallation or workwith
shorepowerequipmentmustonly be done
byaquahfiedmanneelectNc~an,authorized
for highvoltageinstallation
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Regular maintenance
Thefollowingtext is describingthe regularmaintenanceproceduresTheReferenceNumbersrefer to the
MaintenanceScheduleon pages21& 22
Z~ WARNING!ToavoLdinJury, alwaysmakesurethat the engine~sswitchedoff beforestarting work
on~t. Anenginewhich~srunninghasrotating andmovingpartswhicharedangerousto touch
IEngine maintenance i
1. Engineoil levelcheck.Thelevel shouldbebe-
tweenthe "Add"and"Full" marksonthe d[pstlck
Referto "Technicaldata"for thecorrecttypeof ot[
CAUTIONIDonot fill abovethe ’Fuil" markNever
allowthelevel to gobelowthe "Add"mark
Drainingandfilling the EngineCrankcase.
Changethe0~1=na newor recondLt~onedengineaf-
ter thefirst 20hoursof operationandthenafter
every100hoursof operationRunthe engineuntil =t
is hot Removedipstick andwithdrawoil from
crankcasetroughthe dipsticktube(A)
AWARNING!Hot oil can causeburns Be
carefulnottospill 011
WithdrawoTIwith a suctionpumpor usea special
oil v~thdrawalpump.Aspecialfitting ~sprovidedfor
the oil withdrawalpumpReplenishwLthoil to the
correctlevel Referto "TechmcalData"for thecor-
rectchoiceofoil
NOTE:Theodfilter mustbechangedbeforenewo=1
is added
2.Oil FHter.Theoil filter is changedfor thefirst
tEmeafter 20hoursof operationandthenafter every
I 100hoursof operation(everyoil change)Unscrew
I theoldfilter. If theoldfilter is (J~fficulttoremove,use
J
an0~1filter wrench
AWARNING!Hotoil cancauseburnsBecare-
fulnottospilloil
Coatthe rubbersealonthenewfilter witho~1Check
thecontactsurfaceontheengineto seethat the
oldsealis notstuckto theodfilter adapterand
screwonthe filter byhandunhlit makescontact
withthefaceof theadapterThentJghtenthe filter a
further half turn - nomore.
CAUTION!Useonly genuineVolvoPentaoil fU-
tersor filters withthesamecapacity,flowrateand
fittings
AWARNINGtFdterswhichdo not complywith
the requirementscancausesevereengine
damageandvoid VolvoPenta’sWarranty
Starttheengine,let It runat idling speedandcheck
to ensurethereis nooil leakagearoundthefilter or
eli hoses
Note!Theoldfilter containsoil Disposeof usedill=
ter ~naccorancew~thanyapphcabLeenvironmental
regulations
10
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3. Checkthebelt tension.Excessivebelt tension
will damagethe bearingsin the waterpumpandal-
ternatorInsufficienttensionwill causeslipping
Replacewornbelts
Belt Tensionis determinedbybelt deflectionWith
enginestopped,the belt shouldbet=ghtenoughso
thatit will deflect1/4to 1/2in (6-13mm)when
pressedwith the finger at thepointsGandI shown
If thebeltis tootight, excessivebelt andbearing
wearcanoccur.If thebelt is tooloose,slippagecan
occur,resulting~nbelt wearandpooroperationof
lhe watercirculatingpumpandalternator
,AlternatorBelt. Withengineoff, checkalternator
belt deflectionmidwayGbetweenthe circulating
pumppulleyandthe alternatorpulley
Loosenalternator mountingscrewsandnuts, and
pivotalternatorawayfromengineto ~ncreasebolt
lenslonWhilemamtalnlngpressureona{ternator,
ret~ghtentop screwandbottomscrewandnut Re-
checkbelt tension
WaterPumpBelt. Withengineoff, checkwater
pumpbelt deflection midwayI betweenthe water
pumppulley andthe clrculabngpumppulley
Loosenmountingbracketto waterpumpscrews,
andpry waterpumpawayfromengineto increase
belt tensionWhlemaintalnEngpressureonwater
pump,retighten top andbottomscrews.Recheck
belttension.
DriveBelt. Withthe engineoff, checkthedrivebelt
deflecbonmidwayHbetweenthe waterpumppuIley
andthetensionerpulley.
Loosenthe tensionerbracketscrewsandpry
tensionerawayfromthe engineto increasebelt
tensionWhilemaintainingpressureonthe
tensroner,ret~ghtenthe bracketscrews.Recheck
belttension
Checkingthe cooling system.Thetemperature
gaugefor the coolantshouldshowbetween148--
160°F/ 64--71°C(seawatercooled),160--185°F
.tl--85°0 (closedcooled)Thisis thenormalcool-
ant temperaturewhenthe engineIs warmIf the
coohngwatertemperatureis abnormal,the cooling
systemmustbeexaminedimmedJately
Excesswetemperaturemaybedueto a cloggedwa-
ter retake,defectiveimpellerin the seawaterpump,
blockagein the engine’scoolingwaterchannels,
cloggedreversegearOlt cooler,engineOll cooleron
74/82 models,faulty thermostator inaccurate
gauge.LowwatertemperatureJs usually causedby
a faulty thermostator thegaugereadingIS incorrect
Operationin areaswhereseaweed,seagrass,sand
etc or otherforeignmattermightcauserestricted
coohngwaterflow or damageto the waterpumpIm-
peller requirestheuseof properlyinstalled seawa-
ter filter or strainerIn theseareasa frequentmain-
tenanoeof thefilter is needed
4. Checkthe coolantlevel (closedcooledmod-
els)
,~ WARNING!Closedfresh watersystemrs un-
derpressureIf pressurecapis removed
whenengineis at operatingtemperature,turn
capto first stopandallowpressureto escape
beforecompletelyremovingcap
Removepressurecapandfill the enginecoolant
systemuntil thecoolantlevel reachesthelower
edgeof thefiller pipeFIil withanti-freezemixtureto
the correctlevel Topupusingonly50/50m~xof wa-
ter andantJ-freeze.Donot exceedthis mixtureratio
NOTE!A~waysuseanti-freezeevenif thereis no
risk of lowtemperatures.Theanbqreezeensures
the coolingsystemcorrosionprotectionandrunmng
w~thfreshwateronlycanresultIn severecorrosion
damageto the componentparts of the coolingsys-
temDrain,flush andreplacethe coolanteveryother
season
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DrainingandFilling EngineCoolant(closed
cooledmodels).
Removethe bottomcoverp[ateof the heatex-
changerto dramseawaterfromheatexchanger
core. Loosenhoseclampsandremovehosesfrom
rear of seawaterpump.Besureto allowhosesto
dramcompletelyDrainexhaustmanifoldsbyre-
movingthe cooltnghoseonthe forwardendof the
manifoldor byremovingthe hoseclampandcapon
the rearof manifold
NOTE!Marineinboardenginescanbeinstalled at
variousinstallation anglesBesureto dramexhaust
manifoldsfromthelowestpoint (front or rear)
Removethe hosefromthe heatexchangerto the
expansiontank Th~swd[drain thecoolantmtxture
fromthe expansiontank andheatexchangerDis-
connectanddramthelarge hosefromthectrcula-
tion pumpTheengineblockis drainedby opening
the petcocksonbothsidesof the engineblock
Note[If engineblockdoesnot drain, probepetcock
with a pieceof wireto remeveanysediment.
Beforefilling thesystem,closea[I petcocksand
checkthe tightnessof all hoseclamps.Preparea
50/50mixtureof fresh waterandantt-freezeRefer
to "TechnicalData"for coolingwatercapacityFill
thecoolingsystemuntil thecoolantlevelis equalto
the "Minimum"markonthe expanstontank Start
the engineto purethe coohngsystemof trappedair
Note!Donot runenginewithoutwatersupplyto sea
waterpumpl
Checkcoolingsystemfor leaks. Whenengine
reachesoperatingtemperatureshutoff the engine
andcheckthe coolantlevel Coolantlevel shou[dbe
betweenthe "Maximum"and"Minimum"marks.Add
coolantas required
Z~, WARNING!Closedfresh watersystemis un-
derpressureTurnfill capto first stoptore*
Ileve pressureThenfully removecapfor
servicing
12
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6. ElectricalSystem.Theengine’selectrical sys-
temis equippedwith analternatorwith anintegrated
transistorizedvoltageregulatorThealternatorout-
put at idle speed=sapproximately20amperesand
raprdlyincreasesto the maximumoutputat 2000
RPM(alternator speed)
Neverdisconnectthe batterycabiesor othercables
in thechargingcircuit whenthe engineis running
sincethis candestroythealternatoror sensitive
electroniccomponentsin the fuel injection systemof
the 7 4 Gi moderThebatteryterminals’ polarities
mustneverbe reversedsince this canimmedi=
ateiy damagesensitive electroniccomponents.
ThenegatLvebatterycablemustbeattachedto the
negativeterminal(-) onthe batteryandthe posltve
cablemustbeattachedto the posltveterminal(+)
onthe battery
Thecableterm=netsmustbeproperlyttghtenedand
greased
7. Battery.Usea 12volt battery with a mmlmum
650amperescoldcrankingrating at 0° F(- 18"C)
and115minutesreservecapacityrating at 80
° F
(27° C)( 70ampere- hourreference)
~. !.~kWARNING!Thebattery mustnot beexposed
to a openflameor anelectncsparkDonot
smokein the vicimtyof the batteryThebat-
tery produceshydrogenwhichts easdyignited
andexplosiveDonot usejumpercablesand
aboosterbatteryto start en!;llne, Removebat-
tery fromboatandrecharge
Thebattery containssulphuncacidDonot allow
thebatteryacidto comein contactwith youreyes,
skin or paintedsurfacesIf th~sshouldhappen,wash
the areaaffectedwith waterimmedtatelyObtain
medtcalaidas soonaspossible
Checkingthe battery. Checkthe chargestate of
the batteryandtheelectrolyteregularlyThecorrect
levelis 1/4"--1/2"(6-13mm)abovetheceil plates
Thebattery connectionsshall beclean, greasedand
tight
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Circuit BreakersandFuses7.4 Gi. Theengineis
protectedfromoverloadbycircuit breakers.If a
circuit breakeris tripped,it mayberesetIf it
continuesto tr~p, seeyourVolvoPentadealerThe
mainwlnngharnessts protectedbya 60ampcircuit
breakerB Asecond50ampcircu=t breakerA is
installedbut~snotusedonthemodelscovered~n
this manualThefuel tn]ectlon systemhasa 125
ampcircuit breakerCto protectthe ECMunit from
over[oadThesecircuit breakersarelocatedonthe
starboardsideof the engineThefuel pumpsare
protectedby 20ampcircuit breaker(seepage17)
Theinstrumentsareprotectedbytworeplaceable8
ampfuses(seepage4)
NOTE!Theinstallationof anyadditionalelectrical
accessoriesrequiresthe useof indMdualprotected
circuits Powertakeoff shouldbemadeat thebat-
tery. Boatswith VolvoPentainstrumentpanelshave
twosplicesfor powertakeoff Oneallowingmaxi-
mum5 amp(fuseprotected)take off, oneallowing
maximum20 amp(not fuse protected) Seeyour
VolvoFentadealerfor assistence
C
, /
Circuit BreakersandFuses7.4 GL1 8.2 GL
Theengineis protectedfromoverloadbycircuit
breakersIf a ctrcult breakeris tripped,it maybere-
set.If it continuestotrip, seeyourVolvoPentadeal-
er Thema=nwrongharnessJs protectedbya 50
ampc~rcuit breakerB Asecond50ampc~rcuJt
breakerAIs installed butis notusedonthemodels
coveredmthis manualThefuel pumpis protected
bya125 ampcircuit breaker(seepage17)These
c~rcuJtbreakersarelocatedonthestarboards~deof
the engine
Theinstrumentsareprotectedbytworeplaceable8
ampfuses(seepage4)
NOTE!Theinstallation of anyaddttionalelectrical
accessoriesrequirestheuseof =ndEv~dualprotected
c=rcutsPowertakeoff shouldbemadeat the bat-
tery Boatswith VolvoPentainstrumentpanelshave
twosphcesfor powertakeoff Oneallowingmaxi-
mum5 amp(fuseprotected)takeoff. oneatlowmg
maximum20amp(not fuse protected) Seeyour
VolvoPentadealerfor ass[stence
14
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Fuel injection System(7.4 Gi)
Thefuel injection systemItself doesnothaveany
serviceablepontsTherefore,anyrepairs, should
beperformedbyanauthorizedVolvoPentaService
Workshop,whichhasat its disposalthe necessary
testing equipmentandtrainedservicepersonnel
Checkonceayearthat the systemwrongharness=s
cleanandwCthoutdamage.Usea pieceof cloth
andamild solventto cleanNeverflush with
wateror with anykind of degreasingagent.The
contactterminalsof the systemaremoisture-proof
andfelled withaspecialtypeof greaseto prevent
corrosionThecontactterminalsandthe systemas
a wholeshouldbecheckedeverysecondyearbyan
authonzedVolvo PentaServiceWorkshop
AWARNING!Neverremovethe contact ter-
minalsof the wire harnessfromthe sen-
sots or from the EngineControl Module
(ECMunit). Partof theelectronicsystem
operabngonverylowvoltageof 4-5vo[ts The
electnccomponentscanbedestroyedby a
static dischargeaslowas100volts1Asa
comparison,the humanbodycanonlyfee[
statEcdischargesabove4000volts Emergency program I RPMreduction
(7.4 Gi)
Thisengine’selectronicfuel mjecbonsystemis de-
velopedspecifically for marineu~,eTheECM
moduleof thesystemis controlhngtheignition, idling
speedandfuel consumptionTheoperatorshould
beawareof the following: Thesystemis designed
with a built-in "emergencyprogram"Thisprogramis
automaticallyengaged,whenthe ECMmodulerecog-
nizeswrongor abnormalvaluesfromanyof the sen-
sorsor in caseof afault in theECMunit itself Inor-
derto avoidenginedamages,the enginespeedis
limited to 2500rpm
~IMPORTANT!Should the engine speed
only reach2501} rpmas a maximum,you
mustcontactthe nearestVolvoPenta
ServiceWorkshopin order to checkthe
fuel injection system.
7788827 - Ladattu osoitteesta www.volvopenta.com 17.11.2010 12:21:31

General Information about the ECM
7.4 Gi models
Thefuncbonof thefuel meteringsystemis to deliver
thecorrectamountof fuel to theengineunderall op-
eratingcondtlonsFuelis dehveredbyeight fuet
injectorscontrolledbythe EngineControlModule
(ECM)
TheECMlooksat voltagefromseveralsensorsto
determinehowmuchfuel to givethe engine.
Oneof the sensorsis the MamfoldAbsolutePres-
sureSensor(MAP)that measuresthe pressurein the
intake manifold.TheMAPsensorallowsthe ECMto
automaticallyadjustford~fferentaEtitudes.No
highaltitudeadjustmentis necessary.
TheKnockSensordetectsabnormalenginewbra-
tions (spark knock)TheECMusesthe knocksen=
sorvoltageto calculatethetgnitlontlmng
AWARNING!It Is extremelyimportantthat the
correct KnockSensoris usedTheKnock
sensor~sun=qefor th~smarineengineNever
subsbtutewrth automot[veor othersensors
asthis canresult in enginedamageIf the
KnockSensorhasbeenremoved~t mustbe
installedcorrectly.Besurethethreadsare
cleanandbghtento 11-16lb ft. (15-22Nm)
the KnockSensoris overor undertorquedit
will givefalsesignalsConsultyourVolvo
Pentadealerfor asststence.
Theelectronics mthe ECMare protectedmsever
at waysfor false signalsandinterferenceThefol-
lowingshouldbeobserved;Nevermountradl-
otransmRterantennasnearthe ECMunit, or
groundanywiring to the engineDonot wtresend-
er antennacablesnearthe ECMas electromag-
neticfields candzsturbtheECMelectronics
If the enginefloodsit canbeclearedby opening
the throttle to 75%of its travel TheECMthen
shutsdownthefuel rejectorssonofuel is delivered
aslongthethrottle staysat 75%andtheengine
speedspeedis below400rpm(crankingspeed)
throttle poslbonbecomesgreateror less than75%
the ECMreturnsto the starting mode
8. HighTensionLeadRouting.
~WARNING!Damagedhigh tension leads or
sparkplugbootscanemitexternalsparks,
witchcouldtgnite anyfuel vapors~ntheen-
gine compartment.Donot operateengine
with damagedleads
Whensparkplug leadsareremoved,besurethey
arereplacedin correctorder
Fmngorder1-8-4-3-6-5=7-2
Distributor CapandRotor. Removeandrespect
distnbutorcapandrotor Checkthat cap~sclean
andthat it hasnocracksReplacethe components
if wornor damagedwith genuineVolvoPentaParts
Nootherdlstnbutorpartsrequireserv{caor replace-
ment
AWARNING!Topreventfire andexplosion,
VolvoPentaigmtJoncomponentsmeet
U.SC.Gandothernationalsafety requtre-
mentsfor externalEgnltlonproofparts.Donot
substitutewith automottveor othernon-ap-
provedparts
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9. SparkPlugsAlwayscleanareaaroundspark
plug beforeremovingsparkplug Removespark
plugfor inspectionCleanandcheckgapwith feeler
gauge;replaceif electrodesareroundedor the
sparkplughascrackedceramEcbody
AWARNING!Incorrect type of sparkplugs can
causeoperationaldlfftculttes anddamageto
the engine.Donotoperateengineif spark
plug hasa crackedceramicbodyDamaged
sparkplugscanemitexternalsparkswhich
couldignite anyfuel vaporsin engine
compartment.
For recommendedsparkplugs, plug gapandinstal-
lation torque,referto TechnicalData
11. Fuelsystem.
~WARNING7Topreventfire andexplosion,
serviceproceduresarealwaysperformedwith
the enginestoppedAfter completingservice
procedures,checkentire fuel systemfor pos-
sible leaksbothbeforeandafter starting en-
gmeFailureto inspectyourworkcouldallow
fuel leakageto goundetectedThiscouldbe-
comea fire or explosionhazard
Topreventfire andexplosion,VolvoPenta
fuel systemcomponentsmeetUSCGand
other nationalsafety requirementsOonot
substitutewith automotrveor othernon-ap-
provedparts
FuelPumps7.4 Gi. Theengineis equippedwith
twoelectncfuel pumps,onelowpressurepumpto
bringfuel fromtheboattankto theengineanda
highpressurepumpto supplythe fuel [njectors Both
pumpsareprotectedby a s=ngle20ampc~rcu~t
breakerF. Theelectrical fuel pumpsareactivated
onlywhenengineis running
Fuel Pumps7.4/8.2 GL.Theeng[nesare equipped
witha efectr[c fuel pumpprotectedbya single20
ampcCrcultbreakerG.Theelectrical fuel pumpis
actEvatedonlywhenengineis running
NOTE!Aloudwh[ningnorseat tdle maybedueto a
restrictedfuel filter causinga noisyfuel pumpOper-
atingenginewith a restrictedfilter maydamage
pressureregulatoror fuel pumpsSeeyourVolvo
Pentadealer if pumpsmakeabnormalno=se
Donotrunengineoutof fuel Theelectric fuel
pumpswill bedamaged
NOTE!Donot runfuel pumpsout of fuel The
electncfuel pumpswill bedamaged
If theenginehasstopped,or will notstart andyou
suspectthat thefuel pumpsare not activated,check
thec~rcuitbreakerReferto C=rcuitBreakersand
FusesSeeyourVolvoPentadealerCffurther serv-
icets required
10. ExhaustSystem.Penodlcallyrespectengine
exhaustsystemCheckfor deterioratedor burned
hoses,looseclamps,andewdenceof waterleaks
~WARNING!Replacedamaged/defective
components,andsecurelytighten all clamps
Exhaustleaksreleasefunqesthat cancreate
hazardousconditionsfor operatorandpas-
sengers
G
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B
CarburetorFuelFilter (7.4GL,8.2GL).
Thecarburetoris equippedwithafuel filter mthe
fuel line connect=onnextto thecarburetor.
AWARNING!Exercise extremecare whenre-
placingthefuel filter or cleaningthecarbure-
tor’s filter Gasolineis highlyflammableand
canbeextremelyexplosiveundercertain con-
ditions
Tocleanor replacecarburetorfue)filter D~sconnect
fuel line at carburetorRemovefuel inlet nutC, gas-
kets D, filter ERemovealso the spnngonmodels
74GL,8 2GLReplacefilter, or cleanwmthsolvent
andblowdryInstall filter, gasketsandfuel inlet nut
Tightennut securelyConnectfuel line andtighten
securelyCleanupanysp=lledfuel Runthe engine
compartmentfan(blower)
~4min, start the engine
andinspectthoroughlyfor anyleakage.
12.EngineFuelFHter.Thefuel filter Bis locatedin
the fuel line beforethefuel pump
NOTE!Thefuel injectedenginerequiresa special
marinefilter w~tha5-10m~cronfiltering capabilty.
Donotsubstituteanyothertypeof filter
AWARNING!Accumulationof waterandother
fuel contaminantsmayformcorrosivecom-
poundswhichcandamagethe fuel filter and
otherfuel systemcomponents,resultingin
fuel leakage.Forth~sreason,annualreplace-
mentofthefuelfilter is requiredto avoidrisk
of explosionor fire
Unscrewfuel filter byturningcounterclockwise,re-
moveanddiscardNote~Theold filter contains
flammablefuel Pleased~sposeof old filter properly
Lightlylubricatethegasketonnewfuel filter Screw
onfuel filter byturningclockwiseandhandbghten,
followinginstrucbonsonfilter Cleanupanyspilled
fuel
Runthe enginecompartmentfan (blower)for 4 mln,
start the engineandcheckfor leakage
E
D
13. BackfireFlameArrestor. Removethe backfire
arrrestorAeachyearfor cleantng.CleanIn solvent,
air dry, andrespectfor damageReplaceif dam-
agedReinstallflamearrestormakingsureumtis
securelyfastened.
z~WARNmNG!Topreventfire or explosionin
the enginecompartment,the backfireflame
arrestormustalwaysbein place,properlyse-
cured, andundamaged
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