Volvo Penta V8-225 User manual

OPERATOR’S MANUAL
V8-225, V8-270, V8-300, V8-320

Content
Foreword ...................................................................................................... 2
Safety Information ...................................................................................... 5
Introduction ............................................................................................... 14
Instruments and Controls ........................................................................ 16
Optional ..................................................................................................... 22
Starting ...................................................................................................... 24
Operation ................................................................................................... 28
Engine Shutdown ...................................................................................... 44
In Case of Emergency .............................................................................. 49
Troubleshooting ........................................................................................ 52
Maintenance Schedule ............................................................................. 68
Maintenance .............................................................................................. 73
Storage ....................................................................................................... 98
Technical Data ......................................................................................... 101
Operator's Manual Order ........................................................................ 110
Alphabetical index .................................................................................. 111
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Foreword
Welcome Aboard
Congratulations on choosing a new boat equipped
with a Volvo Penta marine engine. Volvo Penta has
been building marine engines since 1907. Quality,
operating reliability, and innovation have made Volvo
Penta a world leader in the marine engine industry.
From engineering design and manufacturing to sup-
port activities in Parts, Service, and Sales, high
standards have been set to ensure your pride and
satisfaction as the owner of a Volvo Penta product.
As an owner of a Volvo Penta marine engine, we
would also like to welcome you to a worldwide net-
work of dealers and service workshops to assist you
with technical advice, service requirements and
replacement parts. Please contact your nearest
authorized Volvo Penta dealer for assistance.
Safety will always be our most distinguishing core
value. Volvo has a long history of safety innovations
in all areas of our business. Concern for the safety of
our customers is embedded in all Volvo products.
Environmental Care in all operations is an integral
part of the Volvo commitment towards customers,
employees, and the community. By embracing care
of the environment as a core value, Volvo demon-
strates its understanding of the environmental impact
its products have upon nature and the shared urban
and rural surroundings.
Volvo Penta continually commits a considerable part
of its development resources toward minimizing the
environmental impact of its products. Examples of
areas where we are always looking for improvements
are exhaust emissions, noise levels, and fuel con-
sumption.
Regardless of whether your Volvo Penta engine is
installed in a boat used for pleasure or commercial
operation, incorrect operation or improper mainte-
nance of the engine will result in disturbance or dam-
age to the environment.
Our Core Values: Quality, Safety,
Environmental Care
Volvo Penta’s core values of quality, safety, and care
for the environment are central to our operations and
activities. They express what we believe in as a com-
pany.
Quality is a value that historically referred just to
product quality, but now encompasses all aspects of
our products and services. Volvo Penta’s quality
commitment extends beyond industrial craftsman-
ship and engineering ingenuity to embrace care for
the customer throughout the life of the product.
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Models
This operator’s manual covers the following models;
V8–225–C
V8–270–C
V8–300–C
V8–320–C
These engines have catalytic converter exhaust sys-
tems.
Engines with traditional iron manifold exhaust systems
and/or Electronic Vessel Control are covered by other
manuals.
A suffix follows the —C. Example; V8-300–C-A. The
letter in the suffix is for version control.
Forward Drive
All drives mated to the engines listed above are cov-
ered by this manual, including the Forward Drive.
Illustrations throughout the manual show the traditional
SX or DPS sterndrive. The information in each of these
sections also applies to the Forward Drive (FWD),
unless noted in the text.
About this Manual
Our quality processes ensure that the correct opera-
tor’s manual is delivered with your power package.
However if you are unsure whether you have the cor-
rect manual, or would like to purchase a new manual,
please visit the publication section of our website, (vol-
vopenta.com). Use your serial number at the publica-
tion search, the site will provide you with the correct
manual.
The publication search will also provide you with all of
the other publications that are available for your power
package. These publications, such as workshop man-
uals and parts catalogs can be purchased for a small
fee.
When seeking assistance from your dealer regarding
your power package, always provide the serial number
for your engine.
This manual contains the information you need to oper-
ate and maintain your power package. Topics such as
service, troubleshooting, and storage are also cov-
ered, however at a less detailed level. For more
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Foreword
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detailed information see your authorized Volvo Penta
dealer, or the service manuals for your package.
Foreword
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Safety Information
Safety Alert Symbol and Safety
Messages
This section explains the way safety information is presented in this manual.
Safety Alert Symbol
This is a symbol that indicates a potential personal injury hazard. When you see this symbol
carefully read and follow the instructions that follow. Personal injury is possible if the instructions
are not followed.
Safety Messages
US and international standards exist and are followed in this manual to alert you of hazards as you are
operating or working on your boat. As you read the procedures be aware of the following signal words and
their definitions:
DANGER!
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING!
Indicates a hazardous situation which, if not avoided, could result in death or serious personal injury.
CAUTION!
Indicates a hazardous situation which, if not avoided, could result in minor or moderate personal injury.
Look for the safety alert symbol and Danger, Warning, and Caution messages in this manual. They alert
you to possible safety issues or important safety information. They also provide instructions on how to avoid
the safety issue.
IMPORTANT!
NOTICE!
These messages are used to provide information that will prevent damage to the product (engine, drive) or
other property. Failure to comply with a Notice or Important message may result in equipment failure or
damage.
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Safety Precautions While Operating
the Boat
Thoroughly read this operator’s manuals and other
information supplied with your new boat. Learn to oper-
ate the engine, controls and other equipment safely
and correctly.
If this is your first boat or it is a boat type with which
you are unfamiliar, we recommend that you practice
operating the boat away from other vessels, docks,
shallow areas, and other obstacles.
Remember that the person driving a boat is legally
required to know and follow the current navigation and
safety laws. Make sure you know the laws that apply
to you and the waters in which you are boating. Contact
the relevant authorities for specifics.
We strongly recommend you take a course in safe
boating. Contact your local boating organization to find
available courses.
Always observe the following minimum precau-
tions while boating:
Insist on the use of personal flotation devices (life pre-
servers) by all passengers at all times.
Never operate a boat if you are under the influence of
alcohol or drugs.
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Use extreme care when refueling the boat. Follow the
safety messages below, and any found in the boat’s
manual or posted at the refueling station.
DANGER!
Gasoline is extremely flammable and highly explosive.
Always turn off the engine before refueling. Do not
smoke or allow open flames or sparks near the boat
when adding fuel. When filling the gas tank, ground the
tank to the source of gasoline by holding the hose noz-
zle firmly against the side of the deck filler plate, or
ground it in some other manner. This action prevents
static electricity buildup that could cause sparks and
ignite fuel vapors.
DANGER!
Fuel and vapors will be present during procedure,
which can result in an explosion; provide ventilation
and eliminate all sources of spark or flame.
Never overfill the tank. Completely close the fuel filler
cap when finished.
DANGER!
To prevent a possible explosion hazard, operate the
engine compartment bilge blower as recommended by
the boat manufacturer before starting the engine. Do
not operate the engine without a fully functioning bilge
blower.
Safety messages covering gasoline and fuel vapors
encountered while working on your boat or engine are
provided in the appropraite locations throughout the
manual. Look for the saftey alert symbol (triangle).
DANGER!
A rotating propeller can cause serious injury.
Never boat near people who are swimming or where
there is a risk that there are people in the water. The
engine must be off if there is anyone in the water near
the boat.
Check that nobody is in the water before shifting the
drive in to gear.
Never swim or board at the rear of the boat when the
engine is running, even if the drive is in neutral.
Never use the drive unit as a ladder or as a lift to board
the boat.
No one should be in the water at the transom or swim
platform if the engine is running. This is also a carbon
monoxide poisoning hazard, see Carbon Monoxide.
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Safety Information
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Personal injury is possible when performing the main-
tenance or service work described in this manual. This
work can involve rotating belts and parts, pinch points,
hot surfaces, fuels that are explosive and chemicals
that are fire hazards. These hazards are covered in the
procedures, look for the safety alert symbol (triangle).
A key component of safety on a boat is the condition
of the boat and its systems, including the power pack-
age. A boat that has not been regularly maintained or
that has neglected mechanical problems is more likely
to break down, potentially leaving its passengers in
dangerous situations.
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Carbon Monoxide
DANGER!
Do not run the engine while there are people located on or near the swim platform and transom.
DANGER!
Do not tow anyone using water sports equipment (such as skis and inner tubes) closer than twenty feet (6 meters)
from the boat. Do not, under any circumstances, allow people to “body surf” using the swim platform as a means
of being pulled along.
22770
For your safety, we recommend that you install a good quality marine carbon monoxide detector aboard
your boat, in accordance with ABYC recommended practices.
The remainder of this chapter (information regarding carbon monoxide and respective illustrations) are provided
courtesy of the American Boat and Yacht Council.
Properties and Characteristics of Carbon Monoxide
Carbon monoxide (CO) is a colorless, odorless, and tasteless gas that weighs about the same as air. It cannot
be expected to rise or fall like some other gases because it will distribute itself throughout the space. Do not rely
on the sense of smell or sight of other gases to detect CO as it diffuses in the air much more rapidly than easily
detectable vapors, (i.e., visible and aromatic vapors).
What Makes Carbon Monoxide?
Carbon monoxide is produced any time a material containing carbon burns. Examples include, but are not limited
to, gasoline, natural gas, oil, propane, coal, or wood. Some common sources of CO are internal combustion
engines and open flame appliances such as:
● Gas propulsion engines ● Space heaters
● Auxiliary gas engines (gensets) ● Water heaters
● Cooking ranges ● Fireplaces
● Central heating plants ● Charcoal grills
The carbon monoxide component of diesel exhaust is extremely low relative to the carbon monoxide level found
in gasoline engine exhaust.
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How is a Person Affected by Carbon Monoxide?
Carbon monoxide is absorbed by the lungs and reacts with blood hemoglobin to form carboxyhemoglobin, which
reduces the oxygen carrying capacity of the blood. The result is a lack of oxygen for the tissues, with subsequent
tissue death and, if exposure is prolonged, death of the individual.
Carbon monoxide in high concentrations can be fatal in a matter of minutes. Lower concentrations must not be
ignored because the effects of exposure to CO are cumulative and can be just as lethal.
Symptoms of CO Poisoning – The sequence of symptoms listed generally reflects the order of occurrence in
most people; however, there are many variables that affect this order of symptom manifestation. One or more of
the following symptoms can signal the adverse effect of CO accumulation:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Watering and itchy eyes
Flushed appearance
Throbbing temples
Inattentiveness
Inability to think coherently
Loss of physical coordination
Ringing in the ears
Tightness across the chest
Headache
10.
11.
12.
13.
14.
15.
16.
17.
18.
Drowsiness
Incoherence
Slurred speech
Nausea
Dizziness
Fatigue
Vomiting
Collapse
Convulsions
Emergency Treatment for CO Poisoning – CO toxicity is a life-threatening emergency that requires immediate
attention. Following is a list of actions that should be carried out if CO poisoning is suspected. Proceed with
caution. Keep in mind that the victim may be in an area of high CO concentration and take care when entering.
● Evaluate the situation and ventilate the area
if possible.
● Contact medical help. If the victim is not breathing,
perform rescue breathing or approved cardiopul-
monary resuscitation (CPR), as appropriate, until
medical help arrives. Prompt action can make the
difference between life and death.
● Evacuate the area and move affected per-
son(s) to a fresh air environment.
● Observe the victim(s).
● Administer oxygen, if available. ● Investigate the source of CO and take corrective
action.
Marine CO Detection Systems
Even with the best of boat design and construction, and scrupulous attention to inspection, operation, and main-
tenance of boat systems, hazardous levels of CO may, under certain conditions, be present in interior spaces
and exterior areas. Vigilant observation of passengers for CO sickness symptoms should be supplemented by
marine CO detection devices in any enclosed accommodation spaces. Detection devices should be marked with
“Marine Carbon Monoxide Detector” or “A-24.”
What to do When the Alarm Sounds
Actuation of a CO alarm indicates the presence of Carbon Monoxide (CO) which can kill you. If alarm sounds,
take the following actions as appropriate:
● Shut off sources of CO such as engines (if
safe to do so), generators, and open flame
stoves.
● Provide fresh air through actions such as opening
port lights, hatches, and doors.
● Look for sources of CO that may be from
other boats and take appropriate steps,
which may include moving your boat to a safe
area.
● If anyone is exhibiting signs of CO poisoning, move
them to fresh air and seek medical assistance.
Boat Operation
Don’t run engine(s) or auxiliary generator(s) on boats with enclosed accommodation compartments unless the
boat is equipped with a functioning marine carbon monoxide detector that complies with 2ABYC A-24, Carbon
Monoxide Detection Systems on Boats.
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Stationary Operation
A boat operator should be aware that dangerous con-
centrations of CO can accumulate when propulsion
engines and/or an auxiliary generator is operated while
the boat is stationary. This is especially true when
rafted or moored in a confined area such as boat-
houses, or when in close proximity to seawalls or other
boats.
The risk from CO is greatly increased when there
is little or no wind present.
Keep engine room hatches and doors closed when
operating engine(s) and/or generator set(s).
Pay attention to prevailing conditions and provide for
ventilation to induce fresh air and minimize exhaust re-
entry.
When the propulsion engine or generator is running,
CO is produced and may remain in the vicinity of the
exhaust outlet. CO accumulation may remain entrap-
ped for some time after the engine or generator is
turned off.
● Do not occupy aft lounging area(s) or swim plat-
form,
● Do not swim under or around swim platform,
● Do not swim in the vicinity of exhaust outlet(s).
Since carbon monoxide production is greater when
engines are cold versus when they are warm, a boat
operator should minimize the time spent on getting
underway. In order to minimize CO buildup, do not
warm up or run propulsion engine(s) for extended peri-
ods while the vessel is stationary.
A boat operator should be aware that carbon monoxide
is emitted from any boat’s exhaust. Boats moored
close together can affect each other. Operation, moor-
ing, and anchoring in an area where other boats'
engines or generators are running may put your boat
in an atmosphere containing CO, even if your boat’s
engine(s) is(are) not running. Boat operators need to
be aware of the effect of their boat on other boats in
the area. Of prime concern is the operation of an aux-
iliary generator where boats are moored alongside
each other. Be aware of the effect your exhaust may
have on other boats and be aware that the operation
of other boats’ equipment may affect the carbon mon-
oxide concentration on your boat.
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Underway Operation
Do not sit on, occupy or hang on any stern appendages
(e.g., swim platforms, boarding ladders, etc.) while
underway. Do not body surf, commonly known as “teak
surfing” or “platform dragging,” in the wake of the boat.
Do not tow persons in close proximity to the stern of
the boat.
Backdrafting (Station Wagon Effect)
Backdrafting is caused by air movement over or
around a boat creating a low pressure or suction area
around the stern that can increase CO level on the
boat. Backdrafting can be affected by relative wind
direction, boat speed, and boat trim angle. At certain
speeds and under certain operating conditions the low
pressure area may form in other regions and permit
carbon monoxide to enter the hull through openings
that are not at the back of the boat.
Other factors during boat operation which may affect
carbon monoxide concentration include:
● Adding or removing canvas may raise or lower
CO levels. Image #51618 illustrates desired air-
flow through the boat. As shown in image
#51619, certain canvas configurations, such as
side curtains and position of hatches, can
increase backdrafting.
● Intentional or unintentional excessive trim angle
(e.g., high bow angle or excessively unequal dis-
tribution of weight) may raise the CO level and
should be avoided (see image #51620).
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● Opening and closing ports, hatches, doors, and
windows may raise or lower CO levels on board
a boat. When airflow is moving forward inside the
boat, CO may be entering the boat.
● Operating a boat at slow speeds with a following
wind should be avoided. Consider changing
direction, adjusting speed, or both
(see image #51621).
● Be aware that cockpit and deck drains can be a
source of CO ingress into boats, especially boats
with cockpits or decks enclosed with canvas or
permanent boat structures.
● Altitude and Sea Conditions – Operation at alti-
tudes greater than 5,000 ft (1500m) contributes
to inefficient engine performance and may
require adjustments to ignition systems, fuel sys-
tems, or changing the propeller’s size or gear
ratio. Failure to make adjustments to ignition sys-
tems and/or fuel systems for altitude conditions
may cause an increase in CO. Reduced power
resulting from increased altitude may require
adjustments to propeller size. Heavy seas or out
of trim conditions tend to load engines, resulting
in reduced performance and increased CO pro-
duction.
● Portable Generator Sets – Do not use this equip-
ment on boats. Gasoline powered portable gen-
erator sets produce CO. These sets discharge
their exhaust products in locations which can lead
to an increase in the accumulation of carbon
monoxide in enclosed accommodation spaces.
Maintenance
Engine Performance – Efficient engine performance is
vital to minimizing CO production. Efficient engine per-
formance can be ensured through regular mainte-
nance. Refer to the Maintenance Schedule and Main-
tenance sections of this manual for instructions on
keeping your engine in good condition.
NOTICE! Be sure to see your Volvo Penta dealer for
regular inspections.
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Introduction
Warranty Information
Volvo Penta’s warranty information can be found on
the CD that accompanies this manual. One warranty
manual on the CD applies to the North American mar-
ket while the second applies to all other markets.
Please contact your Volvo Penta dealer if you have not
received your warranty booklet CD or a customer copy
of the warranty card.
Owner’s Identification Card
When you purchased your boat, the dealer was
required to register your power package with Volvo
Penta. Your dealer should provide you with proof of
ownership in the form of an Owner's Registration Card
or a print-out of the Volvo Penta computer on-line reg-
istration screen. This provides proof of ownership and
is required to validate warranty, should warranty serv-
ice become necessary.
Warranty coverage may be delayed until the warranty
and registration form is on file at Volvo Penta. Please
refer to your warranty manual for additional informa-
tion.
Keep your owner’s identification card with you at all
times; this will facilitate finding parts and providing
service when you visit any Volvo Penta authorized
dealer.
Volvo Action Service (VAS)
Volvo Action Service (VAS) is a consumer breakdown
service available 24 hours each day, 365 days per
year. If your engine breaks down, the VAS coordinator
will quickly locate your nearest dealer. If you need a
tow, parts, or mechanic, the VAS coordinator will make
all arrangements necessary to get you back underway
as soon as possible. A service charge may apply in
some situations.
Membership to Volvo Action Service is provided auto-
matically to all Volvo Penta engine owners. As long as
your Volvo Penta engine is under factory warranty, this
service covers Volvo Penta-related repairs. Refer to
the accompanying warranty literature for detailed infor-
mation regarding coverage.
In the US contact Volvo Action Service via phone at
1.877.33.PENTA (1.877.337.3682, toll-free).
Customers outside the US can find the phone number
for Volvo Action Service on our website, there is a link
to VAS on the homepage for each market unit.
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Volvo Penta Dealer Network
The Volvo Penta worldwide network of authorized
dealers is at your service. Volvo Penta strongly rec-
ommends that you take your product to an authorized
Volvo Penta dealer for service or repair. They are spe-
cialists in Volvo Penta products and have the acces-
sories, genuine Volvo Penta parts, test equipment, and
tools necessary for high quality service and repair
work.
Toll-free Dealer Locator Service
If you are away from your home waters and need
assistance, take your Volvo Penta product to the near-
est Volvo Penta servicing dealer. For the name and
location of the nearest Volvo Penta dealers, search the
dealer locator on the Volvo Penta’s web site, or call
1-800-522-1959 (US only).
Volvo Penta on the Internet
Whether you’re trying to replace a lost operator’s man-
ual, searching for updated service information about
your engine, looking for parts information, or simply
attempting to locate the nearest authorized Volvo
Penta dealer, Volvo Penta on the Internet is the web
site to visit. Additionally, you will find a wealth of infor-
mation related to our company and all the new and
innovative products we have to offer.
The URL address for Volvo Penta of the Americas is:
http://www.volvopenta.com
Customer Relations
For customers in the United States.
The Volvo Penta Customer Relations Department may
be contacted at the following address;
Volvo Penta of the Americas
attn: Customer Relations
1300 Volvo Penta Drive
Chesapeake, Virginia 23320, USA
You may also call;
Phone: [phone]
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Introduction
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Instruments and Controls
This section describes Volvo Penta instrumentation
(gauges) and controls and their functions.
Note that the instruments, gauges and controls are
installed by the boat builder and may not be Volvo
Penta parts. The layout and gauges used are also
determined by the boatbuilder.
If your boat is equipped with instruments not described
here, or you are not sure about their functionality,
please refer to the manual for your boat, or contact
your Volvo Penta dealer.
Ignition Lock
Ignition switch
Usually located at the helm, near the gauges.
Key positions control power to accessories, power to
the electrical system, and starting the engine;
A
Power is provided to run accessories.
Ignition is OFF and engine is OFF.
Not present on all ignition switches.
O
Off position, the key can be inserted or removed.
I
Ignition is ON and engine is OFF. System energized.
S
START position (momentary). The starter motor is
engaged and starting the engine.
See Starting page 24.
Volvo Penta ignition keys are marked with a code for
use when ordering extra keys. Record the code so that
replacement keys can be ordered.
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Gauges
This section provides the general description and func-
tion of the gauges found on a boat.
1Tachometer
Gives the engine speed in RPM (revolutions per
minute).
2Speedometer
Provides boat speed.
3Temperature Gauge
Shows engine temperature, measured in the cool-
ing water or coolant.
4Oil Pressure Gauge
Indicates the engine oil pressure. Look for trends or
changes in the oil pressure reading. Lower oil pres-
sure is normal and should be expected at idle after
a sustained cruise.
5Voltmeter
Shows the voltage in the electrical system. When
the engine is running, alternator charge voltage is
shown, normal reading is approximately 14 volts.
When the engine is off (key on), battery voltage is
shown, normal voltage is approximately 12 volts.
6Fuel Gauge
Provides fill level of fuel tank(s).
7Trim Gauge
Position of the drive relative to vertical, explained in
more detail at Trim Gauge page 19 .
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Engine Status Panel
The engine status panel, located on the boat’s dash-
board, will provide you with visual and audible indica-
tions of any faults that may be occurring in the engine
or emission control system.
Volvo Penta provides an engine status panel with
every engine, its installation is determined by the man-
ufacturer of your boat. If your boat does not have an
engine status panel available, we strongly recommend
that you contact your dealer to have one installed.
See Engine Status Panel Function page 63 for an
explanantion of how the panel functions.
NOTICE! All malfunctions should be investigated as
soon as possible. Engine damage is possible if alarms
and indicator lights are ignored.
Power Trim
Your Volvo Penta drive is equipped with a power trim
system as standard equipment. The power trim allows
the operator to raise and lower the drive from the helm.
This changes the angle of the drive (and its thrust) in
relation to the boat bottom. This is called trimming, and
provides the following benefits:
•Improves acceleration to planing.
•Keeps the boat on plane at reduced throttle settings.
•Improves fuel economy.
•Provides smoother and/or drier ride in choppy water
conditions.
•Increases maximum speed.
WARNING!
Risk of personal injury. Read the procedures and
safety messages in Operation before operating these
controls.
Trim system controls and gauges are shown in this
section. Use of the trim system during boating and
related safety messages are covered in Power Trim/
Tilt page 32 in Operation. Do not operate the trim
system until you have read that chapter.
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