Volvo Penta 5.7 Gil-B, Operator'S Manual

Page 1: ...OPERATOR S MANUAL 5 7 GiI B 5 7 GiI C 5 7 GXiI C 5 7 GXiI D 8 1 GiI B 8 1 GiI C 8 1 GXiI B 8 1 GXiI C ...

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Page 3: ...ucts it also encompasses personal family business and environmental values Environmental Care in all operations from design to production distribution service and recycling is an integral part of the Volvo quality commitment towards customers employees and the community By embrac ing the environment as a core value Volvo demonstrates its understanding of the environmental impact its products have ...

Page 4: ...9 Engine Protection Mode 40 Master Slave Installation 40 High Altitude Operation 40 How to Shift and Control Speed 41 Twin Unit Maneuvering 41 Cruising Speed 42 After use 43 Stopping the Engine 43 Safety Measures 43 Salt Water Operation 44 Cold Weather Precautions 44 Laying up in Water 44 Laying up on Land 44 Maintenance Schedule 45 Maintenance and Care 46 Engine 46 Belt Adjustment 46 OilLevel Che...

Page 5: ...damaged or painted over Safety Precautions 2 Always turn off the engine before starting service procedures Avoid hot surfaces and liquids in supply lines and hoses when the engine has just been turned off and is still hot 3 To prevent a possible explosion operate the blower as recommended by the boat manufacturer before starting the engine If the engine compartment is not equipped with a blower op...

Page 6: ...erpendicular as pos sible in relation to the top of the engine Always check that lifting equipment is in good condition and has suf ficient load capacity to lift the engine and any extra equipment installed 18 If extra equipment is installed on the engine which al ters its center of gravity a special lifting device is re quired to achieve the correct balance for safe handling 19 Never work on an e...

Page 7: ...lowatts KW or horsepower HP for a given engine speed usually at maximum revolutions per minute RPM How Load Conditions Affect the Speed of a Planing Hull The overall weight of the boat is another important factor in performance Any increase in boat weight will slow down the boat speed particularly on boats with planing and semiplaning hulls For example a new boat tested with fuel and water tanks o...

Page 8: ...t for the first time We strongly recommend that you install an emergency stop switch regardless of the type of boat If your boat does not have an emergency stop switch contact your Volvo Penta dealer who can assist you in selecting one Boater s Responsibilities The operation maintenance and care of the Volvo Penta engine and power package as outlined in the owner s manual are the owner s responsib...

Page 9: ...he boat type the top speed may be much higher than what you are accustomed to High speed operation requires an experienced operator who has mastered handling of high performance boats It is advisable that you learn the boat s behavior before you take passengers on board Inform your passengers about your boat s characteristics and the maneuvers you intend to do Use the boat s performance with due c...

Page 10: ... must always be carried out by an authorized Volvo Penta workshop The engine must not be modified in any way except with accessories and service kits approved by Volvo Penta No modifications to the exhaust pipes and air supply ducts for the engine may be undertaken Seals may only be broken by authorized personnel Otherwise the general instructions contained in the Instruction Manual concerning ope...

Page 11: ... so that you have a copy should the boat be stolen The appearance of identification plates is shown below The letters in brackets refer to the location of the identification numbers on the identification plate Note that some variation may occur in the location of numbers Engine decal Hurth Transmission plate Engine plate Borg Warner Transmission plate Owner s Identification Card When you purchased...

Page 12: ... additional information call toll free 1 877 33 PENTA Doing Your Own Maintenance and Repairs If you plan to do your own maintenance and repairs on your Volvo Penta products you should purchase a set of service manuals that pertain to your particular engine and drive Keep in mind however that there are certain tasks that should only be performed by your Volvo Penta dealer The dealer has the tools e...

Page 13: ... Ideally take your product back to your selling dealer he also knows you and your equipment For the name and location of your nearest Volvo Penta dealer consult the Yellow Pages under Boat Dealers or call 1 800 522 1959 Volvo Penta on the Internet The URL address for Volvo Penta of the Americas is http www volvopenta com Warranty Information Volvo Penta s warranty package can be found in the accom...

Page 14: ...9 Idler Pulley 10 Oil Filter 5 7 GiI B HSW630A 5 7 GiI C HSW630A 5 7 GXiI C HSW630A 5 7 GXiI D HSW630A 1 2 9 10 12 13 16 9 11 Oil Siphon Tube 12 Raw Water Drain Engine 13 Raw Water Pump 14 Serpentine Belt 15 Starter 16 Belt Tensioner 17 Water Drain Manifold 18 Heat Exchanger Optional 19 Transmission Fluid 20 Running Engine Raw Water Flush 14 3590874 F ...

Page 15: ...13 Features 3 11 17 6 7 15 6 7 8 10 3 11 3 11 18 20 5 4 19 3590874 S 3590874 S ...

Page 16: ...ipstick Engine 4 Water Coolant Fill Optional 5 Flame Arrestor 6 Fuel Filter 7 Fuel Pump 8 Fuses 9 Idler Pulley 10 Oil Filter 11 Oil Siphon Tube 12 Raw Water Drain Engine 13 Raw Water Pump 14 Serpentine Belt 15 Starter 16 Belt Tensioner 17 Water Drain Manifold 18 Heat Exchanger Optional 19 Transmission Fluid 20 Running Engine Raw Water Flush 14 3590875 F ...

Page 17: ...15 Features 3 11 17 6 7 15 6 7 8 10 3 11 3 11 18 20 3 11 5 4 3590875 S 3590875 T 19 ...

Page 18: ...uel Filter 7 Fuel Pump 8 Fuses 9 Idler Pulley 10 Oil Filter 11 Oil Siphon Tube 12 Raw Water Drain Engine 13 Raw Water Pump 14 Serpentine Belt 15 Starter 16 Belt Tensioner 17 Water Drain Manifold 18 Heat Exchanger Optional 19 Transmission Fluid 20 Running Engine Raw Water Flush 5 7 GiI B HSW630V 5 7 GiI C HSW630V 5 7 GXiI C HSW630V 5 7 GXiI D HSW630V 14 ...

Page 19: ...17 Features 3 11 17 6 7 15 6 7 8 10 3 11 3 11 4 18 20 3590873 S 5 19 3590873 T ...

Page 20: ...ngine 4 Water Coolant Fill Optional 5 Flame Arrestor 6 Fuel Filter 7 Fuel Pump 8 Fuses 9 Idler Pulley 10 Oil Filter 11 Oil Siphon Tube 12 Raw Water Drain Engine 13 Raw Water Pump 14 Serpentine Belt 15 Starter 16 Belt Tensioner 17 Water Drain Manifold 18 Heat Exchanger Optional 19 Transmission Fluid 20 Running Engine Raw Water Flush 14 3590877 F ...

Page 21: ...19 Features 3 11 17 6 7 15 18 6 7 8 10 3 11 3 11 19 20 3590877 S 3590877 T 5 4 ...

Page 22: ...4 Water Coolant Fill Optional 5 Flame Arrestor 6 Fuel Filter 7 Fuel Pump 8 Fuses 9 Idler Pulley 10 Oil Filter 11 Oil Siphon Tube 12a Raw Water In 12b Raw Water Out 13 Raw Water Pump 14 Serpentine Belt 15 Starter 16 Belt Tensioner 17 Water Drain Manifold 18 Heat Exchanger Optional 19 Transmission Fluid 20 Running Engine Raw Water Flush 3590879 F 9 14 5 12b ...

Page 23: ...21 Features 17 6 7 15 6 7 8 3 11 10 3590879 T 3590879 S 3 11 5 4 19 18 3 11 5 20 ...

Page 24: ...Fill Optional 5 Flame Arrestor 6 Fuel Filter 7 Fuel Pump 8 Fuses 9 Idler Pulley 10 Oil Filter 11 Oil Siphon Tube 12a Raw Water In 12b Raw Water Out 13 Raw Water Pump 14 Serpentine Belt 15 Starter 16 Belt Tensioner 17 Water Drain Manifold 18 Heat Exchanger Optional 19 Transmission Fluid 20 Running Engine Raw Water Flush 1 2 9 12a 13 16 3590880 F 9 14 5 12b ...

Page 25: ...23 Features 17 6 7 15 6 7 8 3 11 10 3590880 T 3590880 S 3 11 5 4 19 18 3 11 5 20 ...

Page 26: ...Fill Optional 5 Flame Arrestor 6 Fuel Filter 7 Fuel Pump 8 Fuses 9 Idler Pulley 10 Oil Filter 11 Oil Siphon Tube 12a Raw Water In 12b Raw Water Out 13 Raw Water Pump 14 Serpentine Belt 15 Starter 16 Belt Tensioner 17 Water Drain Manifold 18 Heat Exchanger Optional 19 Transmission Fluid 20 Running Engine Raw Water Flush 1 2 9 12a 13 16 3590883 F 9 14 5 12b ...

Page 27: ...25 Features 17 6 7 15 6 7 8 3 11 10 3590883 T 3590883 S 3 11 5 4 19 18 3 11 5 20 ...

Page 28: ... Pulley 10 Oil Filter 11 Oil Siphon Tube 12a Raw Water In 12b Raw Water Out 13 Raw Water Pump 14 Serpentine Belt 15 Starter 16 Belt Tensioner 17 Water Drain Manifold 18 Heat Exchanger Optional 19 Transmission Fluid 20 Running Engine Raw Water Flush 1 2 9 12a 13 16 3590881 F 9 14 5 12b 8 1GiI B HSW800A2 8 1GiI C HSW800A2 8 1GXiI B HSW800A2 8 1GXiI C HSW800A2 ...

Page 29: ...27 Features 17 6 7 15 6 7 8 3 11 10 3590881 T 3590881 S 3 11 5 4 19 18 3 11 5 20 ...

Page 30: ...ipstick Engine 4 Water Coolant Fill Optional 5 Flame Arrestor 6 Fuel Filter 7 Fuel Pump 8 Fuses 9 Idler Pulley 10 Oil Filter 11 Oil Siphon Tube 12a Raw Water In 12b Raw Water Out 13 Raw Water Pump 14 Serpentine Belt 15 Starter 16 Belt Tensioner 17 Water Drain Manifold 18 Heat Exchanger Optional 19 Transmission Fluid 20 Running Engine Raw Water Flush ...

Page 31: ...29 Features 3 11 17 6 7 15 6 7 8 10 3 11 18 5 5 19 3 11 4 20 3590884 T 3590884 S ...

Page 32: ... 8 1 GXiI B Transmissions Shift Lever Transmission Identification Plate Neutral Switch Dipstick Oil Fill Shift Lever Transmission Identification Plate Neutral Switch Dipstick Oil Fill Hurth HSW630V Applies to the following engines 5 7GiI C 5 7GXiI D 8 1GiI C 8 1 GXiI B 630A 2 630A 1 630V1 630V2 ...

Page 33: ...ll Breather Shift Lever Transmission Identification Plate Neutral Switch Dipstick Oil Fill Breather Shift Lever Borg Warner BW72C Applies to the following engines 5 7GiI C 5 7GXiI D Borg Warner BW72VD Applies to the following engines 5 7GiI C 5 7GXiI D 8 1GiI C 8 1 GXiI B 72C1 72C2 72VD1 72VD2 ...

Page 34: ...instrument displays the engine s operating time in hours and tenths of an hour 2 Temperature Gauge Indicates the engine coolant temperature Normal operat ing temperature is 70 73 C 157 163 F for 5 7 liter engines and 59 61 C 138 142 F for the 8 1 Liter engines 3 Oil pressure Gauge Indicates the engine oil pressure Normal operating oil pressure should be approximately 150 500 kPa 21 71 psi Lower oi...

Page 35: ...nition ON engine running System voltage connected II Start position momentary The starter motor is engaged and starting the engine Caution Read the starting instructions in the chapter Starting the engine The ignition keys are marked with a key code for use when ordering extra keys Make a note of this key code so that keys can be ordered if the old keys get lost Keep the code in a safe place where...

Page 36: ... pressing in and holding the emergency stop switch button followed by normal starting procedures When the button is released the engine will stop Note The emergency stop switch can only be effective when in good working order Observe the following Lanyard must always be free of entanglements that could hinder its operation Once a month check the switch for proper operation With engine running pull...

Page 37: ...mote control used in your boat since operation and function may differ from Volvo Penta remote controls 21187 21183 Controls Maneuvering Shifting and engine speed are controlled with the same lever 1 N Neutral position Drive reverse gear disengaged F Drive reverse gear engaged for forward movement ahead R Drive reverse gear engaged for backward movement astern T Engine speed control Disengaging th...

Page 38: ...e lever in the throttle half open position forward reverse Remove the cover over the control For side mounted controls the lever must first be removed Adjust the friction brake by turning the screw at the arrow see figure Turn clockwise for more friction and counter clockwise for less friction Reinstall the cover and lever ...

Page 39: ...uel cock Check that there are no fuel engine coolant or oil leaks Check the engine oil level See section on Mainte nance Switch on the main switches Caution Never break the circuit with the main switches while the engine is running The generator and engine electronics injection engines may be damaged Insert the key in the ignition switch Turn the key one step to the right operating position I This...

Page 40: ...ow engine coolant is high or exhaust temperature is high This alarm will sound briefly when the ignition is turned on Never rev a cold engine above 2000 RPM If the engine is cold idle it while casting off for example It is not necessary to idle engine for long periods before getting underway The engine will warm up faster while idling in gear Allow engine to warm while manoeuvreing before going to...

Page 41: ...0 500 kPa 21 71psi At engine idle this is normally lower Your engine is equipped with a low oil pressure acoustic alarm Caution If oil pressure is too low Stop the engine immedi ately and investigate Operating the engine with oil pressure too low will damage the engine Engine Coolant Temperature The temperature gauge should read between 70 90 C 158 194 F normally Your engine is equipped with an en...

Page 42: ...ontinue with normal operation NOTE Should the problem continue contact your nearest Volvo Penta dealer and have the engine checked Master Slave Installation For twin unit installations both engine ECMs can be tied together electronically One engine will then be the mas ter engine and the other will be the slave engine The starboard engine or the engine with the power steering pump is always connec...

Page 43: ...ine systems before leaving the dock Move control handle to the neutral detent idle position Check in front and behind boat for people or obstructions before shifting To go forward Move the shift handle forward Throttle movement will begin after forward gear engagement To go in reverse Move the shift handle rearward Throttle movement will begin after reverse gear engagement Caution Do not shift if ...

Page 44: ...ds a cruising speed in the range 300 500 rpm lower than maximum rpm at WOT Depending on hull type choice of propeller load and conditions etc the maximum engine speed at top speed can vary but it should be within the WOT range Wide Open Throttle WOT range 5 7Gi 4600 5000 RPM 5 7GXi 4600 5000 RPM 8 1Gi 4200 4600 RPM 8 1GXi 4600 5000 RPM 21198 Operation ...

Page 45: ... not forget to open the cock before the engine is started again Switch off the main battery switches if the boat is not to be used for some time Caution Never break the circuit with the main battery switches while the engine is running The generator and engine electronics may be damaged After use To counteract boiling and heat stress the engine should be run for a few minutes at idle in neutral be...

Page 46: ...ed battery may burst as a result of freezing Laying up in Water If the boat is not going to be used for some time but will be left in the water the engine must be run hot at least once every 14 days This prevents corrosion in the engine If the boat is not going to be used for longer than two months then inhibiting procedures must be applied See chapter Laying up and inhibiting Laying up on Land Wh...

Page 47: ...l level see transmission manual AFTER THE FIRST 20 50 OPERATING HOURS First Service inspection1 not shown EVERY 50 HOURS OR AT LEAST ONCE A YEAR Seawater pump Check impeller page 49 Flame arrestor mounting Tighten page 52 EVERY 100 OPERATING HOURS OR AT LEAST ONCE A YEAR Engine oil and oil filter Replace2 page 47 Fuel filter Replace page 53 Transmission Oil replace see transmission manual EVERY 20...

Page 48: ...ce schedule which shows when maintenance operations must be carried out Caution When replacement parts are required always use genuine Volvo Penta parts or parts with equivalent characteristics including type strength and material Failure to do so may result in product malfunction and possible injury to the operator or passengers WARNING To prevent personal injury the engine must be turned off bef...

Page 49: ...ch more heat at full load than lower powered engines So it is important that the correct oil level is always maintained Check oil level daily Caution Fill to the Max mark and no higher The level must not drop below the MIN mark Engine damage may result Oil and Oil Filters Replacement The oil should be changed when the engine is at normal operating temperature Start the engine and allow it to idle ...

Page 50: ...th freshwater so that deposits do not dry and also to prevent the buildup of salt crystals Draining Cooling System Raw Water System Draining the cooling system before the air temperature drops below freezing will prevent damage to its components Perform this procedure with the boat out of water When draining the engine raise or lower the bow of the boat in order to level the engine This will provi...

Page 51: ...ller Checking Replacing WARNING If the engine is installed so that the seawater pump is located under the water line there is a risk of water penetration Close the seacock IMPORTANT Always carry a spare impeller on board Remove the hose clamps and hoses from pump Remove the stationary bracket 1 Remove the four screws and remove the housing 2 Inspect the impeller 3 If there are cracks or other defe...

Page 52: ...osion in the coolant water ducts these should be filled with either a 50 50 mixture of freshwater and glycol or emulsifying oil Fill a bucket with either the 50 50 mixture or the oil If possible fix up an overflow return to the bucket or another bucket Start the engine and let it idle Stop the engine if the bucket starts to empty and needs filling Caution The pump must never run dry When the engin...

Page 53: ...amount of antiknock quality The amount of antiknock quality is defined as Octane If a fuel is used that does not have enough octane the engine will emit a high pitched metallic rapping noise This knocking sound while annoying also cases real damage to the engine and decreases engine life and performance The fuel injection system on Volvo Penta engines have a device know as a knock sensor which det...

Page 54: ... of low fuel demand such as idle the fuel recirculates between the injection system and the vapor separator fuel cooler tank to help prevent vapor lock in the fuel system Caution Do not run the fuel pumps dry This will damage the fuel pumps 1 2 3 4 5 Fuel Injection The function of this fuel metering system is to deliver the correct amount of fuel to the engine under all operating conditions Fuel i...

Page 55: ...el Dispose of safely Lightly lubricate the gasket and inner seal on new fuel filter using clean engine oil Screw on fuel filter and hand tighten following instructions on filter Clean up any spilled fuel Run the bilge blower for at least five minutes to vent engine compartment Smell for fuel in the bilge If you detect a fuel odor explosion and fire are an extreme possibility Clean up the bilge unt...

Page 56: ... fire and explosion Volvo Penta ignition components meet safety standards The use of components that do not meet safety standards automobile components for example can cause a fire or explosion on board If ignition cables are removed ensure that they are rein stalled in the correct order The figure shows the typical layout for the ignition cables Electronic Engine Control Your engine features an E...

Page 57: ...so contains relays for the starting and fuel injection circuits DANGER Explosion hazard Never allow an open flame or sparks near the battery area Always use eye protection when working with the batteries The battery electrolyte contains extremely corrosive sulfuric acid If electrolyte comes into contact with the skin wash it off with soap and plenty of water If battery acid comes in contact with t...

Page 58: ...ower consuming equipment as soon as the engine is stopped If an extra battery has been installed then there must be separate switches for extra equipment There should also be a main switch between the auxiliary battery positive terminal and the electrical equipment fuse strip The main switch for the auxiliary battery must cut off all power consuming equipment connected to that battery and be turne...

Page 59: ...tenance DANGER Risk of fire and explosion Never allow an open flame or electric sparks near the battery or batteries Never mix up battery positive and negative terminals This may cause sparks and an explo sion WARNING The battery electrolyte contains extremely corrosive sulfuric acid Protect your skin and clothes when charging or handling batteries Always use protective goggles and gloves If batte...

Page 60: ...ave special instructions which must be followed Caution Never mix up battery positive and negative terminals Battery Charging DANGER Explosion Hazard The batteries give off hydrogen gas during charging which when mixed with air can form an explosive gas oxyhydrogen A short circuit naked flame or spark can cause a large explosion Ensure that the area in which you are working is well ventilated WARN...

Page 61: ...atteries are being charged in an enclosed area WARNING Always switch off the charging circuit before removing the battery charger connectors Never mix up battery positive and negative terminals This may cause sparks and an explosion Special instructions apply when boost charging the batteries Follow the battery manufacturers instructions for boost charging Engine Alignment Engine alignment require...

Page 62: ...th the boat OUT of the water q Any fouling on the hull is easier to remove directly after hauling the boat before it has had time to dry q Clean and inhibit the raw water system q Remove the impeller from the raw water pump Store the impeller in a sealed plastic bag in a cool place Caution When the cooling system has been prepared for winter storage using a mixture of water glycol the impeller mus...

Page 63: ...elt Small cracks in the multi groove portion of the belt are normal Replace the belt if there are signs of delamination or belt separation q Check the condition of rubber hoses and check hoses to ensure they are securely clamped in place q Connect the batteries q Paint the hull See the following section q Immediately before launching any sacrificial anodes must be cleaned off with emery paper If a...

Page 64: ...nge This will allow the thermostat to open and ensure the fresh water circulates throughout the engine After engine is flushed shut engine down Disconnect water hose and reinstall the cap Drain the engine if freezing temperatures are expected Flushing Port General Most countries have introduced legislation controlling the use of antifouling agents In some cases these agents are completely forbidde...

Page 65: ...gine runs erratically 3 9 10 Engine vibrates 11 Performance Loss 12 13 14 15 High shift effort 16 1 No fuel in tank or gasoline shut off valve closed 2 Water in fuel supply or gasoline is old 3 Fuel system problem 4 Emergency stop switch 5 Battery 6 Cable connections loose or corroded 7 Ignition system problem 8 Remote control is not in NEUTRAL position 9 Fuel filters 10 Electrical system problem ...

Page 66: ...tick liters 1 0 0 26 US gal Oil grade in accordance with the API system Synthetic Service SG Viscosity at 0 C 32 F SAE 30 Viscosity at 5 50 C 23 122 F SAE 20W 50 SAE 15W 50 Oil Filter Volvo Penta part no 3850559 SAE 30 Volvo Penta DuraPlus Synthetic Motor Oil part no 3851230 7 U S and Canada Only If not available multi viscosity oils such as 20W 50 or 15W 50 are acceptable Ignition System Firing o...

Page 67: ...rs 1 0 qt US 9 liter Oil grade in accordance with the API system Synthetic Service SG Viscosity at 0 C 32 F SAE 30 Viscosity at 5 50 C 23 122 F SAE 20W 50 SAE 15W 50 Oil Filter Volvo Penta part no 3850559 SAE 30 Volvo Penta DuraPlus Synthetic Motor Oil part no 3851230 7 U S and Canada Only If not available multi viscosity oils such as 20W 50 or 15W 50 are acceptable Ignition System Firing order 1 ...

Page 68: ... unavailable SAV certification will not apply if leaded fuel is used WARNING Fuel is extremely flammable and highly explosive under certain conditions Always stop the engine and do not smoke or allow open flames or sparks near the boat when refuelling When filling the fuel tanks ground the tanks to the source of fuel by holding the hose nozzle firmly against the side of the deck filler plate or gr...

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