Volvo Penta 3.0 GS, 4.3GL Gi, 5.0GL Gi, 5.7 GS GSi, 7.4 GI GSi, 8.2 GSi, DPX 385415 Operators Manual_344181372 – PDF DOWNLOAD

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Volvo Penta 3.0 GS, 4.3GL Gi, 5.0GL Gi, 5.7 GS GSi, 7.4 GI GSi, 8.2 GSi, DPX 385415 Operators Manual_344181372 – PDF DOWNLOAD

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Volvo Penta 3.0 GS, 4.3GL Gi, 5.0GL Gi, 5.7 GS GSi, 7.4 GI GSi, 8.2 GSi, DPX 385-415 Operators Manual_344181372 – PDF DOWNLOAD

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Volvo Penta 3.0 GS, 4.3GL Gi, 5.0GL Gi, 5.7 GS GSi, 7.4 GI GSi, 8.2 GSi, DPX 385415 Operators Manual_344181372 – PDF DOWNLOAD

INTRODUCTION:

• Quality, operating reliability, and innovation have made Volvo Penta a world leader in the marine engine industry. From engineering design and manufacturing to support 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 owner of a Volvo Penta marine engine, we would also like to welcome you to a worldwide
  network of dealers and service workshops to assist you with technical advice, service requirements
  and replacement parts. Please contact your nearest authorized Volvo Penta dealer for
  assistance.
• The values and qualities that Volvo Penta expresses are what make the company unique. From the very beginning,
  safety and quality have stood at the heart of the development of all of our products, processes, and services. It is on
  these values and qualities that the Volvo Penta corporate identity, brand position and legal status have been founded.
  Today’s core values of quality, safety, and care for the environment remain central to Volvo Penta. They express what
  we believe in as a company and will ultimately help us to survive.

TABLE OF CONTENTS:

Volvo Penta 3.0 GS, 4.3GL Gi, 5.0GL Gi, 5.7 GS GSi, 7.4 GI GSi, 8.2 GSi, DPX 385415 Operators Manual_344181372 – PDF DOWNLOAD

CONTENTS ……………………………………………………………………………………………………………………………………………….5
INTRODUCTION…………………………………………………………………………………………………………………………………………9
Our core values: Quality, Safety, Environmental Care ………………………………………………………………………………….9
Factors that affect engine performance ……………………………………………………………………………………………………10
Power ratings …………………………………………………………………………………………………………………………………10
How load conditions affect the speed of a planing hull …………………………………………………………………………. 10
“Wagon-back” effect ………………………………………………………………………………………………………………………. 10
Your new boat …………………………………………………………………………………………………………………………………….. 11
Boater’s responsibilities ……………………………………………………………………………………………………………………….. 11
Planning your trip …………………………………………………………………………………………………………………………… 11
Safety equipment …………………………………………………………………………………………………………………………… 11
Basic safety rules of boating ……………………………………………………………………………………………………………. 11
SAFETY …………………………………………………………………………………………………………………………………………………..13
GENERAL INFORMATION …………………………………………………………………………………………………………………………17
Identification numbers …………………………………………………………………………………………………………………………..17
Owner’s identification card ………………………………………………………………………………………………………………. 17
Product references, illustrations, and specifications …………………………………………………………………………………..17
Volvo Action Service (VAS)……………………………………………………………………………………………………………………. 17
Doing your own maintenance and repairs ………………………………………………………………………………………………..18
Parts and accessories …………………………………………………………………………………………………………………………..18
Volvo Penta dealer network ……………………………………………………………………………………………………………………18
Warranty information ……………………………………………………………………………………………………………………………. 18
2 PLUS 4™ Extended Protection ……………………………………………………………………………………………………………19
FEATURES ………………………………………………………………………………………………………………………………………………21
Anodes (“sacrificial”) ……………………………………………………………………………………………………………………………. 32
Audible alarm ………………………………………………………………………………………………………………………………………32
Engine systems ……………………………………………………………………………………………………………………………………32
Cooling system ………………………………………………………………………………………………………………………………32
Fuel system …………………………………………………………………………………………………………………………………..32
Exhaust system ……………………………………………………………………………………………………………………………..33
Electrical system ……………………………………………………………………………………………………………………………. 33
Lubrication system …………………………………………………………………………………………………………………………. 33
Steering system ……………………………………………………………………………………………………………………………..33
Drive components ………………………………………………………………………………………………………………………………..33
Emergency stop switch …………………………………………………………………………………………………………………………33
Engine protection mode (EFI systems) ……………………………………………………………………………………………………34
Instruments …………………………………………………………………………………………………………………………………………34
Engine instruments …………………………………………………………………………………………………………………………34
Trim instruments ……………………………………………………………………………………………………………………………. 35
Trim/tilt motor protection …………………………………………………………………………………………………………………. 36
Impact protection ……………………………………………………………………………………………………………………………36
Power trim/tilt ………………………………………………………………………………………………………………………………………36
Propellers ……………………………………………………………………………………………………………………………………………37
Drive unit, rotation, and propellers ……………………………………………………………………………………………………. 38
Trim controls …………………………………………………………………………………………………………………………………. 40
6
Operating trim controls ……………………………………………………………………………………………………………………40
Remote diagnostic uplink system ……………………………………………………………………………………………………………41
Setting up the diagnostic uplink system cell phone ………………………………………………………………………………41
Using the remote diagnostic uplink system …………………………………………………………………………………………41
OPERATION ……………………………………………………………………………………………………………………………………………. 43
Engine break-in period …………………………………………………………………………………………………………………………. 43
Operating after break-in period ………………………………………………………………………………………………………………45
Before starting ……………………………………………………………………………………………………………………………………..45
Starting the engine, cold start …………………………………………………………………………………………………………………46
Starting the engine (warm start) ……………………………………………………………………………………………………………..47
Stopping the engine ……………………………………………………………………………………………………………………………..47
Operating remote controls ……………………………………………………………………………………………………………………..48
Side mount control …………………………………………………………………………………………………………………………. 48
Top mount control …………………………………………………………………………………………………………………………..48
Steering system operation ……………………………………………………………………………………………………………………..48
Twin unit steering ……………………………………………………………………………………………………………………………48
Power trim and tilt operation …………………………………………………………………………………………………………………..49
Power trim operation ………………………………………………………………………………………………………………………. 49
Determining the proper trim ……………………………………………………………………………………………………………..49
Operating in “bow-up” position …………………………………………………………………………………………………………. 49
Operating in “bow-down” position ……………………………………………………………………………………………………..49
Power tilt operation …………………………………………………………………………………………………………………………50
Power trim/tilt switch operation …………………………………………………………………………………………………………50
Power trim/tilt switch and gauge location ……………………………………………………………………………………………51
Shifting and controlling speed ………………………………………………………………………………………………………………..51
Checking instruments……………………………………………………………………………………………………………………………52
Special boating circumstances ………………………………………………………………………………………………………………. 52
Engine protection mode operation (fuel injection systems) ……………………………………………………………………52
Shallow water operation …………………………………………………………………………………………………………………..52
High altitude operation ……………………………………………………………………………………………………………………. 52
Operating procedure for freezing temperatures …………………………………………………………………………………..53
Salt water operation ………………………………………………………………………………………………………………………..53
Twin unit operation …………………………………………………………………………………………………………………………. 53
Trailering your boat ………………………………………………………………………………………………………………………………53
Propeller selection ………………………………………………………………………………………………………………………………..53
MAINTENANCE ………………………………………………………………………………………………………………………………………..55
Maintenance schedule …………………………………………………………………………………………………………………………. 55
Preparing for boating after storage (“summerization”) ………………………………………………………………………………..57
Off-season storage preparations (“winterization”) ………………………………………………………………………………………57
Exhaust system ……………………………………………………………………………………………………………………………………57
Engine exhaust system ……………………………………………………………………………………………………………………57
Drive unit bellows ……………………………………………………………………………………………………………………………58
Fuel system …………………………………………………………………………………………………………………………………………58
Gasoline recommendations ……………………………………………………………………………………………………………..58
Gasoline containing alcohol ……………………………………………………………………………………………………………..58
Detonation (spark knock) …………………………………………………………………………………………………………………59
Preventing gum formation and corrosion in the fuel system…………………………………………………………………..59
Carburetor (GL, GS only) …………………………………………………………………………………………………………………59
Electronic fuel injection (Gi, GSi only) ………………………………………………………………………………………………..59
Flame arrestor ………………………………………………………………………………………………………………………………. 60
Electric fuel pumps …………………………………………………………………………………………………………………………60
Fuel filter ………………………………………………………………………………………………………………………………………. 60
7
Engine fuel filter replacement …………………………………………………………………………………………………………..60
Carburetor fuel filter replacement ……………………………………………………………………………………………………..61
Electrical system …………………………………………………………………………………………………………………………………. 61
Battery cables ………………………………………………………………………………………………………………………………..62
Batteries and connections ………………………………………………………………………………………………………………. 62
Engine start battery …………………………………………………………………………………………………………………………64
Multiple batteries and selector switch ………………………………………………………………………………………………..65
Distributor cap and rotor …………………………………………………………………………………………………………………. 65
Circuit breakers and fuses ………………………………………………………………………………………………………………. 65
Spark plugs ……………………………………………………………………………………………………………………………………65
Checking and changing spark plugs …………………………………………………………………………………………………. 66
Belt adjustments ……………………………………………………………………………………………………………………………. 67
Belt tension ……………………………………………………………………………………………………………………………………67
Alternator belt ………………………………………………………………………………………………………………………………..68
Idler belt ………………………………………………………………………………………………………………………………………..68
Cooling system ……………………………………………………………………………………………………………………………………68
Draining the cooling system ……………………………………………………………………………………………………………..69
Engine — raw water cooled ……………………………………………………………………………………………………………. 69
Engine — fresh water cooled (if equipped) …………………………………………………………………………………………69
Raw water pump……………………………………………………………………………………………………………………………. 70
Oil cooler ………………………………………………………………………………………………………………………………………70
Steering system …………………………………………………………………………………………………………………………………..70
Power trim/tilt fluid level …………………………………………………………………………………………………………………..70
Steering reservoir fluid level ……………………………………………………………………………………………………………..70
Primary shaft spline and bearing lubrication ………………………………………………………………………………………. 71
Tie rod (twin installations only) …………………………………………………………………………………………………………. 71
Engine and drive service ………………………………………………………………………………………………………………………. 71
Lubrication system ………………………………………………………………………………………………………………………………. 71
Engine/crankcase oil………………………………………………………………………………………………………………………. 71
Checking engine oil level …………………………………………………………………………………………………………………72
Changing engine oil ………………………………………………………………………………………………………………………..72
Changing the oil filter ………………………………………………………………………………………………………………………73
Drive components ………………………………………………………………………………………………………………………………..73
Drive unit lubrication ………………………………………………………………………………………………………………………. 73
External lubrication points ………………………………………………………………………………………………………………..76
Anodes (“sacrificial” anodes) ……………………………………………………………………………………………………………76
Active corrosion protection system ……………………………………………………………………………………………………77
Propeller care ………………………………………………………………………………………………………………………………………77
Propeller replacement — SX ……………………………………………………………………………………………………………78
Propeller replacement — DP-S…………………………………………………………………………………………………………79
Propeller replacement — DPX…………………………………………………………………………………………………………. 80
Boat bottom…………………………………………………………………………………………………………………………………………80
Engine alignment …………………………………………………………………………………………………………………………………80
Replacement parts ………………………………………………………………………………………………………………………………. 81
Bottom painting ……………………………………………………………………………………………………………………………………81
Engine submersion ………………………………………………………………………………………………………………………………82
PROBLEM RESOLUTION ………………………………………………………………………………………………………………………….. 85
SPECIFICATIONS …………………………………………………………………………………………………………………………………….. 87
3.0 GS ……………………………………………………………………………………………………………………………………………….. 87
4.3 GL/Gi ……………………………………………………………………………………………………………………………………………. 88
5.0 GL/Gi ……………………………………………………………………………………………………………………………………………. 89
5.7 GS/GSi …………………………………………………………………………………………………………………………………………. 90
8
7.4 Gi/GSi; 8.2 GSi ……………………………………………………………………………………………………………………………… 91
DPX 385; DPX 415 ……………………………………………………………………………………………………………………………….. 92
APPENDIX A: CERTIFIED ENGINES AND BSO NUMBERS ……………………………………………………………………………. 93
Certified engines ………………………………………………………………………………………………………………………………….. 93
Bodensee Shiffahrts Ordnung (BSO) number ……………………………………………………………………………………………. 93

Questions? Email us: [email protected]

https://vimeo.com/799777814

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

S.V