Workshop Manual Electrical, Ignition, Fuel
C 2(0)
Contents General General Informa Information......................................................... tion.........................................................
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Crankin Cranking g Sys System tem ................................... .............................................................. ...........................
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Charging Charging System System ...................................... ............................................................. .......................
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Trim/Tilt Electrical System ...............................................
4
Ignition System
.............................................. .......... Delco EST ....................................
5
Ignition System
B.I.D. ................................... ................................... Prestolite® B.I.D.
6
Fuel System - Carbureted Models ...................................
7
Safet Sa fety y ...................................................................... ................................................................................ ..........
S
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Model Identification M
All stern drive system components must be matched for either single or dual engine installations. Failure to properly match engine, transom bracket and vertical drive will result in poor boat performance, and risk damage to engine and drive because of incorrect drive gear ratio. Model identification is located on the engine valve cover, cover, and MUST correspond with the transom bracket and vertical drive numbers as listed in this document.
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1 DR1145
3
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Engine Mo Model Nu Number
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Trans ransom om Brac Bracke kett Mod Model el Num Numbe berr 4
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Verti ertica call Dri Drive ve Mo Mode dell Numb Number er 5
2 DR4282
3 DR6815
4 DR2058
5 DR4957 Elect/eng
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Section 1 General Information Table of Contents Battery and Cables ................................ ................................................. ................................. ............................ ............1-8 1-8 Circuit Protection ................................ ................................................ ................................. .............................1-12 ............1-12 Circuit Protectors and Locations ........................... ......................................... ......................... ...........1-13 1-13 Connector Service Amphenol ............................... ............................................... ................................ ................................. ....................... ...... 1-19 Packard ................................ ................................................. ................................. ................................. ......................... ........ 1-21 Conversion Charts Drill ................................. ................................................. ................................. ................................. ...............................1-31 ...............1-31 Metric ................................. ................................................. ................................. ................................. ........................... ........... 1-30 Gasoline Requirements Requirements ............................... ................................................ ................................. ..................... ..... 1-6 Gasolines Containing Containing Alcohol ............................ ......................................... ........................... ................. ... 1-7 Ignition Switch ................................. .................................................. ................................. ................................1-18 ................1-18 Introduction Introduction ............................... ................................................ ................................. ................................. ........................ ....... 1-3 Oil and Water Sending Sending Units ............................... ............................................... ............................ ............1-14 1-14 Periodic Maintenance Maintenance Chart ................................. ................................................. ........................... ........... 1-33 Relays ............................... ................................................ ................................. ................................ ................................ ................ 1-11 Sealants, Lubricants Lubricants and Adhesives ........................... ......................................... ..................... ....... 1-2 Solenoids ................................. ................................................. ................................. ................................. ........................ ........ 1-10 Spark Plugs and Leads .......................... ........................................ ........................... ........................... ................ 1-16 Special Tools ................................. .................................................. ................................. ................................ .................... .... 1-2 Symbols ................................. .................................................. ................................. ................................ .......................... ..........1-32 1-32 Torque Specifications, General .......................... ....................................... ........................... ................ .. 1-34 Troubleshooting Engine Troubleshooting Troubleshooting Guides ........................... ......................................... ....................... .........1-23 1-23 System Isolation.......................... Isolation........................................... ................................. ................................ .................. 1-22 Tachometer ............................... ............................................... ................................. ................................. ....................... ....... 1-18 Tuning the Engine ................................. ................................................. ................................ ............................. .............1-5 1-5
Safety Warnings Before working on any part of the electrical system, read the section called Safety at the end of this manual. The original mounting, support and routing of electrical system parts conform with U.S. Coast Guard requirements. It is important to maintain the original mounting, support and routing after servicing the electrical system to prevent possible fire and explosion in boat’s engine compartment. Do not substitute automotive parts. Volvo Penta marine components meet U.S. Coast Guard regulations for external ignition proof operation and marine use. Volvo Penta marine components are specially designed not to cause ignition of fuel vapors in the bilge or engine compartment. The use of automotive parts can result in fire and explosion.
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Special Tools Tool Name Crimping Pliers Insert Tool Pin Remover Socket Remover
Part No. 3854349-2 3854350-0
Panel Location B B B B
Sealants, Lubricants and Adhesives DuraPlus TM Marine Fuel Conditioner Black neoprene dip Isopropyl alcohol Terminal grease
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Introduction This service manual is divided into sections concerning various systems and assemblies. Refer to the Contents to locate the section covering the system or assembly requiring service. Each section title page has an additional listing that will describe the section’s contents in more detail. Be sure to read the Safety Section at the end of this manual, and pay special attention to all safety warnings as they appear throughout the text. Since models are subject to change at any time, some photos may not depict actual product.
Good Service Practice Service required for stern drives is generally one of three kinds:
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Norm Normal al care care and and main mainte tena nanc nce e - which includes putting a new stern drive into operation, storing engines, lubrication, and care under special operating conditions such as salt water and cold weather.
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Oper Operat atin ing g malf malfun unct ctio ions ns - due to improper engine or drive mounting, propeller condition or size, boat condition, or the malfunction of some part of the engine. This includes engine servicing procedures to keep the engine in prime operating condition.
•
Comp Comple lete te disas disassem sembl bly y and over overha haul ul - such as major service or rebuilding a unit.
It is important to determine before disassembly just what the trouble is and how to correct it quickly, with minimum expense to the owner. When repairing an assembly, the most reliable way to ensure a good job is to do a complete overhaul on that assembly, rather than just to replace the bad part. Wear not readily apparent on other parts could cause malfunction soon after the repair job. Repair kits and seal kits contain all the parts needed to ensure a complete repair, to eliminate guesswork, and to save time. Repair time can also be minimized by the use of special tools. Volvo Penta special tools are designed to perform service procedures unique to the product that cannot be completed using tools from other sources. They also speed repair work to help achieve service flat rate times. In some cases, the use of substitute tools can damage the part.
Do not operate engine out of water even momentarily. If operated in test tank, use proper test wheel. Failure to do so can damage water pump, overheat engine, or allow excessive engine RPM.
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Preparation for Service Proper preparation is extremely helpful for efficient service work. A clean work area at the start of each job will minimize tools and parts becoming misplaced. Clean an engine that is excessively dirty before work starts. Cleaning will occasionally uncover trouble sources. Obtain tools, instruments and parts needed for the job before work is started. Interrupting a job to locate specia l tools or repair kits is a needless delay. Use proper lifting and handling equipment. Working on stern drives without proper equipment can cause damage a nd personal injury. Always use clean fresh fuel when testing engines. Troubles Troubles can often be traced to the use of old or dirty fuel.
Service Policy It is a policy of Volvo Penta to provide dealers with service knowledge so they can give professional service demanded by today’s consumer. The Volvo Penta Penta Training Centers, Centers, frequent mailing of Service Service Bulletins, Letters and Promotions, Special Tools and this Service Manual represent our continuing efforts to assist dealers in giving consumers the best and most prompt service possible. If a service question does not appear to be answered in this manual, you are invited to write to the Volvo Penta Service Department for additional help. Always be sure to give complete information, including engine model number and serial number. When a brand-name product or specific tool is called for, another item may be used. However, the substitute must have equivalent characteristics, including type, strength, and material. You must determine if incorrect substitution could result in product malfunction and personal injury to anyone. To avoid hazards, equivalent products whi ch are used must meet all current U.S. Coast Guard Safety Regulations and ABYC standards.
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Replacement Parts 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 ma y result in product malfunction and possible injury to the operator and/or pass engers. Parts Catalogs Parts catalogs contain exploded views showing the correct assembly of all parts, as well as a complete listing of the parts for replacement. These catalogs are helpful as a reference during disassembly and reassembly, and are available from Volvo Penta parts order.
Special Service Tools Volvo Penta has specially designed tools to simplify some of the disassembly and assembly operations. These tools are illustrated in this Service Manual, in many cases in actual use. All Volvo Penta special tools can be ordered from Volvo Penta parts order. Individu al purchasers of Service Manuals mu st order Special Tools through an authorized deal er.
Product References, Illustrations & Specifications Volvo Penta reserves the right to make changes at anytime, without notice, in specifications and models and also to discontinue models. The right is also reserved to change any specifications or parts at any time without incurring any obligation to equip same on models manufactured prior to date of such change. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of printing. The right is reserved to make changes at anytime without notice. All photographs and illustrations used in this manual may not depict actual models or equipment, but are intended as representative representative views for reference only. The continuing accuracy of this manual cannot be guaranteed.
Tuning The Engine The purpose of an engine tune-up is to restore power and performance that has been lost through wear, corrosion or deterioration of one or more parts or components. In the normal operation of an engine, these changes can take place gradually at a number of points, so that it is seldom advisable to attempt an improvement in performance by correction of one or two items only. Time will be saved and more lasting results will be obtained by following a definite and thorough procedure of analysis and correction of all items affecting power and performance. Refer to the Engine Service Manual for all tune-up specifications.
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Gasoline Requirements Stern drive models in this manual are designed for maximum performance with the use of gasoline with the following minimum or higher octane specification: •
Anti-K Anti-Knoc nock k Inde Index x Numb Number er (AKI (AKI)) - 89 89
•
Resea Researc rch h Octa Octane ne Num Number ber (RON) (RON) - 93 93
EFI Models Only: Some marinas sell fuel with lead additives. Do not use such fuel as it may plug the fuel injectors. Premium grade fuels contain injector cleaners and other additives that protect the fuel system and provide optimum performance. The use of premium grade fuels is strongly recommended. Carbureted Models Only: Use of lead-free or leaded gasoline is acceptable. If fuels with 89 AKI (93 RON) octane or higher are not available, lower octane fuels, with a minimum of 86 AKI (90 RON) octane, can be used. Some engines may require timing adjustments if fuels lower than 89 AKI (93 RON) octane are used. See the General Information section of the Engine Service Manual. When lower octane fuels are used, a slight decrease in power can be expected. Engine damage resulting from the use of gasoline with octane lower than 86 AKI (90 RON) is considered misuse of the engine and will void the engine warranty. Volvo Penta suggests Penta suggests the use of 89 AKI or higher fuels. These fuels have additives that are beneficial to maximum engine performance and long life of service components. To prevent gum formation and corrosion in the fuel system, use DuraPlusTM Marine Fuel conditioner in the gasoline. DuraPlus TM Marine Fuel conditioner is available from your authorized dealer. dealer.
Gasoline is extremely flammable and highly explosive under certain conditions. Always stop engine and do not smoke or allow open flames or sparks near the boat when refueling gas tanks. When filling the gas tank, ground the tank to the source of gasoline by holding the hose nozzle firmly agains t the side of the deck filler plate, or ground it in some other manner. This action prevents static electric ity build-up which could cause sparks and ignite fuel vapors.
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Gasolines Containing Alcohol Many gasolines being sold today contain alcohol. Two commonly used alcohol additives are Ethanol (ethyl alcohol) and Methanol (methyl alcohol). See the Owner’s Manual for your boat to determine if the boat’s fuel system is compatible with alcohol blended fuels. If it is compatible, your engine may be operated using gasolines blended with no more than 10% Ethanol (ethyl alcohol) meeting the minimum octane specification. Do not use any gasoline which contains METHANOL (methyl alcohol). Serious damage to the boat or engine fuel systems will result from the continued use of fuel containing METHANOL (methyl alcohol). If you use gasoline containing alcohol, be aware of the following: •
The engin engine e will operate operate leane leanerr with with alcohol alcohol blended blended fuel. fuel. This may cause engine problems such as vapor lock, low speed stall, or hard starting.
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Alcohol Alcohol blende blended d fuels fuels attract attract and and hold hold moistur moisture. e. Moistu Moisture re inside fuel tanks can cause corrosion of the tank material. Inspect fuel tanks at least annually. Replace fuel tanks if inspection indicates leakage or corrosion.
•
Inspect Inspect non-m non-metal etallic lic parts parts of of fuel fuel system system freque frequently ntly and replace if excessive stiffness, deterioration or fuel leakage is found.
Fuel leakage can contribute to a fire and/or explosion.
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Battery and Cables Special Tools Required: Battery Hydrometer The primary function of the battery is to provide power to operate the starter motor. The battery also supplies power to operate the lights and other electrical equipment which may be used when the engine is not running. On battery ignition systems, the battery must supply the ignition current during the starting period and during the time that the alternator is not producing a sufficient charge to meet operating requirements.
Battery Requirements 3.0 GS, 4.3 GL & GS MODELS ONLY •
Use a 12 volt volt batte battery ry havin having g a minim minimum um rating rating of 360 360 Cold Cranking Amps at 0° F (-18° C), and a 115 minute reserve reser ve capacity capa city rating ra ting at 80° 8 0° F (27° C).
ALL OTHER MODELS •
Use a 12 volt volt batte battery ry havin having g a minim minimum um rating rating of 650 650 Cold Cranking Crank ing Amps at 0° F (-18° C), and a 165 minute reserve reser ve capacity capa city rating ra ting at 80° 8 0° F (27° C).
Battery Maintenance There are two things which must be done periodically in order to obtain long life from a battery. 1. The electrolyte must be kept above the plates and separators at all times. The liquid level should be brought up to the level specified by the battery manufacturer. manufacturer. Acid should never be added except when it is definitely known that some has been lost by spilling, and then only by an experienced battery man.
Battery electroly te is a corrosive acid and should be handled with care. If electrolyte is spilled or splashed on any part of the body, body, immediately flush the e xposed area with liberal a mounts of water and obtain medical aid as soon as possible.
1 2. Be sure that the battery is kept nearly at full charge at all times. The state of charge should be checked at frequent intervals by making specific gravity readings with a battery hydrometer. It is suggested that gravity readings and replacement of evaporated water be made every two weeks. Should the gravity fall more than 0.040 specific gravity below a fully charged gravity reading, remove the battery and have it charged.
1 DR3201
Full c harge spec ific gra vity is 1.260 at 80° F (27° C).
Do not use a jumper cable and a booster battery to start engine. Remove battery from boat and recharge. Fumes v ented during charging battery can lead to an explosion.
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Good Battery Servicing Includes the Following Nine Points: a. b. c. d. e. f. g. h.
Protect Protect boat boat against against acid acid damage damage.. Clean Clean batt battery ery.. Inspec Inspectt cables cables.. Clean Clean termi terminal nals. s. Inspec Inspectt hold-do hold-downs wns.. Inspe Inspect ct casing casing for leaks. leaks. Make hydromet hydrometer er test. test. Remove battery battery from boat for tests. Recharge Recharge battery battery if less than 3/4 charged. Make load test. i. Add wa water.
If battery is not in a good state of charge or if it uses an excessive amount of water, check the charging system. Clean the battery and terminals with a solution of baking soda and water. This will neutralize the acid on the battery. After washing with this solution, flush top of battery with clear water. water. Care must be taken when washing the battery so that the baking soda and water solution does not enter the battery cells.
Cable Requirements The battery should be mounted as close to the engine as practical to cut down on battery cable lengths. Follow the recommendations below. •
0-10 Feet 0 G Ga auge
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10-1 10-15 5 Fee Feett 2/0 2/0 Gaug Gauge e
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15-2 15-20 0 Fee Feett 4/0 4/0 Gaug Gauge e
These specifications do not apply to aluminum battery cables. Volvo Penta does not recommend the use of aluminum battery cables.
To prevent possible explosion or fire, do not substitute automotive parts for the following marine components: star ter, alternator, distributor and related ignition parts, spark plug leads, solenoids, carburetor (and related parts ), fuel pump or fuel filter canister. These components have been specifically designed not to emit fuel vapors or to cause ignition of fuel vapors in the bilge.
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Solenoids Special Service Tools Required: Test Light or Continuity Meter and Carbon Pile The purpose of the solenoid assembly is to perform mechanical jobs electromagnetically. In the case of the solenoid used with the starter, this job consists of completing the heavy electrical circuit between the battery and the motor.
1 The solenoid is a completely sealed unit which consists of a plunger A and contact disk assembly B , a coil winding C , a contact disk return spring D , and four terminals which protrude from the solenoid body. The two larger terminals E are the battery and motor terminals, while the smaller ones F are the switch control terminal, and terminal for sending battery voltage to the ignition system during engine cranking. Grounding is by an external ground wire in the engine harness, and internally (through bracket). Coat all electrical connections after reassembly wi th black neoprene dip or equivalent. In operation, when the ignition switch is closed, an electric current flows through the coil winding, causing the plunger and contact disk to be drawn inward. When drawn inward, the contact disk completes the circuit between the battery, battery, motor and ignition terminals, allowing the battery current to flow.
1 DR3196
A return spring is located just below the contact disk. When the electrical circuit as described above is completed, the spring is compressed by the magnetic pull on the plunger and contact disk. When the electrical circuit is broken (ignition switch released), the magnetic pull on the plunger and contact disk drops to zero. At this time, the compressed return spring breaks the circuit by pushing the contact disk away from the motor and battery studs of the solenoid.
Inspection Procedure The solenoid used with the starter motor has proven to be trouble free under normal operating conditions. No periodic service is required other than a check to ensure that all connections are clean and tight.
Test Procedure Being a completely sealed unit, repai r or troubleshooting of detail parts is impractical. If a solenoid is suspected of being inoperative, it should be tested as follows. Ensure solenoid has a good ground.Grounding is done by a ground wire in the engine wiring harness and through the base.
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1. Connect a continuity light or ohmmeter the two large terminals H of the solenoid.
G
, set to high ohms, to
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2. Connect a carbon pile I in series with a battery J and reduce the voltage to less than six volts. Connect battery leads to the one small terminal of the solenoid and the base. 3. Increase the voltage until the continuity meter or test light shows a completed circuit. Stop and note the voltage reading - it should be between six and eight volts. If the solenoid requires more than eight volts to complete the circuit it should be replaced since, in actual use, it may not perform satisfactorily.
Service and Repair Procedure None - replace a malfunctioning unit.
Relays Special Service Tools Required: Ohmmeter or Test Light The purpose of the relay assembly is to use a low amperage electrical electrical circuit to control a high amperage circuit. In the case of a relay used in a starting circuit, the low amperage circuit from the key switch will control the high amperage circuit from the battery to the starter motor.
2 DR3202
Inspection Procedure The relays used in stern drive electrical circuits h ave proven to be trouble free under normal operating conditions. No periodic service is required. To prevent corrosion, all terminals of the relay and socket should be covered with terminal grease.
Relay Ohmmeter Tests Throughout this section two symbols are used to interpret electrical troubleshooting results.
3 DR2065
3 This symbol indicates continuity or very low resistance. 4 This symbol indicates no continuity or very high resistance ( ). ¥
To avoid damaging components or troubleshooting equipment, disconnect the battery cables from the battery and remove the relays before proceeding. 1. Use a continuity light or ohmmeter calibrated on appropriate scale to test continuity.
4 DR2066
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1 2. Connect meter leads to relay terminals 87a and 30. • 2
The The met meter er mu must st show show continuity.
3. Connect meter leads to relay terminals 87 and 30. •
The The met meter er mu must st show show no continuity.
3 4. Calibrate an ohmmeter on appropriate scale and connect the leads to relay terminals 85 and 86. •
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The me meter ter mu must st show show 70 - 100 100 ohms ohms..
DR2149
4 5. Connect meter leads to relay terminals 87 and 30. Connect a 12 volt source to relay terminals 85 and 86. •
The The met meter er mu must st show show continuity.
5 6. Connect meter leads to relay terminals 87a and 30. Connect a 12 volt source to relay terminals 85 and 86. • The The met meter er mu must st show show no continuity. 7. Replace relay if your test results vary.
Circuit Protection
2 DR2149A
Do not attempt to connect or disconnect any part of the electrical circuit while the engine is running. When installing additional electrical accessories always use individual fused circuits. Power takeoff should be made at a terminal strip powered by auxiliary accessory wire and protected by a 30 amp (maximum) fuse.
3 DR2149B
4 DR2149C
5 DR2149D
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Circuit Protectors and Locations 10 Amp Fuse * Protects trim switch. Located on trim/tilt pump.
SFE 20 Amp Fuse * Protects ignition switch. Located under dash.
6 Amp Circuit Breaker ê Protects fuel pump. Located at starboard front of engine on fuel pump bracket.
15 Amp Fuse Protects ignition/injector relay and ECM. Located at front of starboard high-rise exhaust elbow
20 Amp Fuse Protects fuel pumps. Located at port front of engine.
50 Amp Circuit Breaker * Protects trim/tilt motor. Located at front of starboard high-rise exhaust elbow.
40 Amp fuse * Protects main harness. Located at front of starboard high-rise exhaust elbow.
* All Models ê 4.3 GL, 5.0 GL, and 5.7 GS Models Only
All Gi and GSi Models Only
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Oil and Water Sending Units Special Tools Required: Ohmmeter Inspection Procedure Check wiring and connections between senders and gauges. Check to see that senders are operating properly. properly. Inspect orifice in oil pressure sender for blockage.
Test Procedure - Gauge Sending Units Oil Pressure Sender: To check oil gauge senders, start engine and run up from slow to fast. Observe gauge. If reading is unsatisfactory, check sender with an ohmmeter: •
0P PSI SI ... ... 227 227-2 -257 57 ohms ohms
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40 PSI PSI ... ... 92-1 92-114 14 ohms ohms
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80 PSI PSI ... ... 21.5 21.5-4 -49. 9.5 5 ohm ohms s
Replace sender with a new one if it fails the ohmmeter checks. Retest; Retest; if reading is still unsatisfactory unsatisfactory, problem may be in gauge, engine lubrication system or excessive bearing wear. Refer to appropriate Engine Section, paragraph Oil Pump Service. To check gauge, disconnect wire at sender, turn ignition switch on, and momentarily ground sender wire. Gauge needle will peg at high side of scale if gauge is operating properly. properly.
Water Temperature Sender: To check water temperature senders, remove sender from engine. Connect sender to a digital ohmmeter. Immerse sender in a container of oil with a cooking thermometer. thermometer. Heat oil over a flameless source. Observe meter and thermometer. Meter should indicate: •
448 ohms ohms ± 10% at 100° 100° F (38° (38° C)
•
128 ohms ohms ± 7.5 7.5% % at 160° 160°F (71° (71° C)
•
46.6 46. 6 ohms ohms ± 5% at 220° 220° F (105° (105° C)
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Test Procedures - Audible Warning Switches (if equipped) Oil Pressure Switch: The oil pressure audible warning switch is calibrated to make or break contact at 4 ± 2 PSI (27,6 ± 13,8 kPa). Use an ohmmeter to make the following continuity checks. Replace the switch if it fails either of these tests. 1. With the engine off and the switch wire disconnected, there should be a full continuity (zero) reading between the switch terminal and engine block. 2. With the engine running and switch wire disconnected, there should be no continuity (infinity) reading between the switch terminal and engine block.
Water Ternperature Switch: The water temperature audible warning switch is cal ibrated to make or break contact at 200° ± 5° F (93° ± 5° C). Attach an ohmmeter to the switch and make the following check. Replace the switch if it fails this test. 1. Immerse switch in a container of oil. Heat oil over a flameless source and check temperature with a cooking thermometer. thermometer. 2. Below the make/break temperature, temperature, the ohmmeter should show a no continuity (infinity) reading. Above the make/break temperature, the ohmmeter should show a full continuity (zero) reading.
Test Procedure - Audible Warning Horn (if equipped) Under normal conditions, horn will sound when ignition is turned on. Horn will continue to sound until engine is started and oil pressure exceeds 4 ± 2 PSI (27,6 ± 13,8 kPa). The dash mounted audible warning horn can be tested as follows. Replace the horn if it fails this test. 1. Turn ignition switch to the ON position. Do not start engine. 2. If horn does not sound, disconnect the lead at the water temperature audible warning switch, and momentarily touch lead terminal to engine block. If audible warning horn does not sound, horn is defective, or wiring of switch-horn-ignition switch-horn-ignition switch circuit has lost continuity. continuity. 3. Disconnect the lead at the oil pressure audible warning switch, and momentarily momentarily touch lead terminal to engine block. If audible warning horn does not sound, horn is defective, or wiring of switch-horn-igniti on switch circuit has lost continuity.
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Spark Plugs and Leads Removal and Inspection 1. To To disconnect wires, twist and pull only on boot because pulling on wire may cause separati on of the core of the wire. Remove spark plugs using a 5/8 in. spark plug socket or a 5/8 in. box wrench. Use care to avoid cracking the spark plug insulators. 2. Carefully inspect the insulators and electrodes of all spark plugs. Replace any spark plug which has a cracked or broken insulator or which has loose electrodes. If the insulator is worn away around the center electrode, or the electrodes are burned or worn, the spark plug is worn out and should be discarded. Spark plugs which are in good condition, except for carbon or oxide deposits, should be thoroughly cleaned and gapped. 3. The spark plug wires are a special resistance type. The core is carbon impregnated linen. This type wire is superior to copper core wire in its resistance to cross-fire; however, however, it i s more easily damaged than copper core. For this reason, care must be taken so that the spark plug wires are removed by pulling on the spark plug boots rather than on the wire insulation. If the wire is stretched, the core may be broken with no evidence of damage on the outer insulation. If the core is broken, it will cause misfiring. In the case of wire damage, it is necessary to replace the complete wire assembly since a satisfactory repair cannot be made. 4. Use an ohmmeter to test ignition leads for excessive high resistance or an open circuit. Proper resistance is 3,000-7,000 ohms per foot. 5. Clean ignition wires with a cloth moistened in kerosene, and wipe dry. Bend wires to check for brittle, cracked or loose insulation. Defective insulation will permit misfir ing, cross-firing, or spark to ground, therefore defective wires must be replaced. 6. If the wires are in good condition, clean any terminals that are corroded and replace any that are broken or distorted. Replace any wires with broken or deteriorated cable nipples or spark plug boots.
Spark Plug Cleaning Spark plugs which have carbon or oxide deposits should be cleaned in a blast type spark plug cleaner. Scraping with a pointed tool will not properly remove the deposits and may damage the insulator. If spark plugs have a wet or oily deposit, dip them in a degreasing solvent and dry thoroughly with compressed air. air. Oily plugs will cause the cleaning compound to pack in the shell.
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Carefully follow the instructions of the manufacturer of the cleaner being used. Clean each plug until the interior of shell and entire insulator is cleaned. Avoid excessive blasting. 1. Examine interior of plug in good light. Remove any cleaning compound with compressed air. If traces of carbon or oxide remain in plug, finish the cleaning with a light blasting operation. Clean firing surfaces of center and side electrodes with several strokes of a fine cut file. 2. When spark plugs have been thoroughly cleaned, carefully inspect them for cracks or other defects which may not have been visible before cleaning.
1 DR2451
Adjust Spark Plug Gap Use a round wire feeler gauge to check the gap between the spark plug electrodes. Flat feeler gauges will not give a correct measurement if the electrodes are worn. Adjust gap by bending the side electrode only. Bending the center electrode will crack the insulator. Setting the spark plug gap to any other specification in an attempt to improve idle or affect engine performance is not recommended.
2
Installation of Spark Plugs and Wires
DR2448
• 3.0 GS Models 1 •
All V6 Models
2
•
All V8 Models
3
For proper engine performance it is very important that the correct spark plugs be used. When installing spark plugs, make sure that the threads in the cylinder head and all surfaces on plugs and in cylinder heads are clean. Tighten spark plugs the specified amount. All engines use tapered seat plugs without gaskets.
Do not operate engine if spark plug boots or high tension leads are torn or cracked. This condition can allow external sparks which could ignite any fuel vapors in the engine compartment. Spark plug wires must be arranged between the distributor cap and spark plugs in the order of firing sequence. If spark plug wires are not correctly installed, misfiring or cross-firing will result.
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3 DR2453
Ignition Switch Special Tools Required: Continuity Light or Meter Inspection Procedure Check for loose connections, loose or corroded terminals. Check for correct wiring.
Test Procedure
1 Disconnect battery leads at battery and leads at switch. •
Connect continuit Connect continuity y light light or or ohmmet ohmmeter er leads leads betw between een switch battery (B) terminal and ignition (A) terminal. Turn switch to ON position. Light or meter should indicate continuity.
•
Connect continuit Connect continuity y light light or or ohmmet ohmmeter er leads leads betw between een switch battery (B) terminal and starter (S) terminal. Turn switch to START position. Light or meter should indicate continuity.
In the OFF position, there should be no continuity between the battery (B) terminal and either the ignition (A) or start (S) terminal. The (M) terminals and (C) terminal are not used in stern drive applications.
S
C A M M B
1 DR3206
Service and Repair Procedure Clean terminals, correct wiring (see appropriate wiring diagram at end of this section) or replace unit. Tighten connections and coat with black neoprene dip or equivalent.
Tachometer Special Tools Required: None
2
Inspection Procedure
DR3197
1. Check for loose or corroded terminals and connectors. 2 2. Check tachometer for tight connections, and trace leads for proper routing. Determine if tachometer is programmed correctly for each engine: A
B C
Four-cylinder engine - arrow goes to Number 2 Six-cylinder engine - arrow goes to Number 3 Eight-cylinder engine - arrow goes to Number 4
1-18
Elect/eng
Amphenol Connector Service Terminal Removal Use the recommended luricant for terminal removal. Substitutes may cause high resistance connections or short circuits between terminals, or adversely affect the connector material. 1. To remove a terminal from the plug or receptacle, lubricate it by applying isopropyl alcohol to both ends of the cavity. cavity.
3 2. Select the proper removal tool for the terminal: D
E
3 DR4164
Pin Remover Socket Remover, P/N 3854350-0
3. Place the plug or receptacle against the edge of a flat surface and allow clearance for the terminal to be removed.
4 4. Insert the removal tool into the terminal and push the terminal from the connector.
5 5. Pin
and socket G terminals may be replaced if damaged. Crimp new terminals onto the wire at point H . 6
F
4 30386
6. Use crimping pliers when attaching amphenol terminals.
5 DR4541
6 30387
Elect/eng
1-19
Terminal Installation 1. Connect the plug and receptacle before installing the terminals. Apply isopropyl alcohol to the plug and receptacle. receptacle. Align arrows and carefully insert the plug into the receptacle. 2. Apply isopropyl alcohol to the terminal cavity.
1
Use only insert tool, Volvo Volvo Penta P/N 3854349-2, to install terminals. To avoid injury, securely hold insert tool against shoulder of terminal while inserting terminals. 2
3. Position the insert tool
A
against the shoulder
B
1 30388
of the termi-
nal.
3 4. Rest the connector against a solid surface. With the insert tool firmly against its shoulder, insert the leading tip of the terminal into its cavity. cavity. Push the terminal in until the step C of the insert tool reaches the connector body, seating the terminal.
4 5. Check your work. Separate the connector and look at the terminal you just installed. If it is properly seated, apply isopropyl alcohol to both connector halves and reconnect them. If the terminal did not seat, remove it and repeat the procedure.
2 30389
5 6. Secure the connector with wire retainer.
3 30390
4 30391
5 30392
Safety Related
1-20
Elect/eng
Packard Connector Service Terminal Removal To remove a terminal, its holding tab must first be compressed enough to clear the body of the connector when sliding out. 6
Insert a thin wire, such as a paper clip, about 1/4 in. (6 mm) into the slot next to the terminal to be removed. As the wire seats, it will compress the tab. Gently pull the wire and slide its terminal out of the connector body.
6 23541
Terminal Installation 7
The tab on the terminal must extend out enough to lock the terminal in place inside the connector body. body. If the tab isn’t extended, use a thin tool and bend it outward slightly. Insert the terminal into the connector body until the tab locks into place.
7 23540
Elect/eng
1-21
Troubleshooting - System Isolation The following is to help you isolate a malfunction of one or possibly several systems. After After determining which systems are related to the malfunction, refer to the individual system troubleshooting charts to isolate the specific cause.
Engine should crank at specified RPM. If not, check for:
Cranking System
1. Discharged or dead battery 2. Loose or corroded connections 3. Cranking System Troubleshooting Troubleshooting Chart Must have good spark at spark plugs. If not, check the:
Engine Does Not Run
Ignition System
1. Distributor cap and rotor 2. Coil and spark plug leads 3. Ignition timing 4. Automatic spark advance 5. Ignition Troubleshooting Chart 6. EFI Models: refer to GM Diagnostic Manual
EFI Models: refer to GM Diagnostic Manual Non-EFI Models: Carburetor accelerator pump should squirt fuel into venturi when throttle is advanced. If not, check the: Fuel System
1. Fuel tank, valves, and lines 2. Fuel pumps and filter 3. Carburetor and filter 4. Boat Fuel System Troubleshooting Troubleshooting Chart 5. Carburetor Troubleshooting Chart 6. Engine Fuel System Troubleshooting Troubleshooting Chart Check the following:
Engine Runs Improperly
1. Compression 2. Ignition system 3. Fuel system 4. Lubrication system 5. Cooling system 6. Vertical drive and propeller 7. Vertical drive gear ratio and installation 8. PCV Valve 9. Engine Troubleshooting Guides
1-22
Elect/eng
Engine Troubleshooting Guides EFI Engines: Refer to GM EFI Diagnostic Manual. These guides were written to help you trace the symptoms of the trouble to the source, without having to read through and prove every possibility. Much of the information here will be familiar to well informed mechanics. Also, many factors will seem insignificant but when you think of it, usually the toughest problem to troubleshoot is caused by the smallest error. ror. The greatest aid to solving a service problem is information. Start gathering information from from the boat operator and write it on his job card or work ticket. Find out pertinent facts, such as: •
When When did did thi this s trou troubl ble e star start? t?
•
How Ho w was was the the boa boatt loa loade ded? d?
•
Did th the e trouble trouble occu occurr suddenly suddenly,, or start start grad graduall ually? y?
Analyze this information and try to match it to similar situations you have experienced in the past. Keep i n mind the fundamental rules: 1. COMPRESSION - Mixture inducted into cylinder and compressed. 2. SPARK - Proper intensity at the proper time. 3. FUEL - Proper mixture of air and fuel. There are very old rules, but necessary for the engine to run. Use these charts and the service information they refer to. Do not try to remember tolerances, settings, measurements, measurements, etc., as they are written in the service manual. Leave your mind free to analyze the problem. Following is a list of the troubleshooting guides which may be found on the pages indicated.
Title ............................... ............................................... ................................. ................................. ................................. ................... Page 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Engine Will Not Crank ......... .............. .......... ......... ......... .......... .......... ......... ......... .......... .......... ......... ...... .. 1-24 Engine Cranks, But Will Not Start....... Start.......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 1-24 Hard Starting - Cold Engine ..... .......... ......... ......... .......... .......... ......... ......... .......... .......... ......... ...... .. 1-25 Hard Starting - Hot Engine ......... .............. ......... ......... .......... .......... ......... ......... .......... .......... ......... .... 1-25 Engine Runs Rough ......... .............. .......... ......... ......... .......... ......... ......... .......... .......... ......... ......... .......... ..... 1-26 Engine Noises and Vibrations ..... .......... .......... ......... ......... .......... ......... ......... .......... .......... ........ ... 1-26 Engine Overheat s ..... ......... ......... .......... ......... ......... .......... .......... ......... ......... .......... .......... ......... ......... ......... .... 1-27 Engine Dies Out ......... .............. .......... ......... ......... .......... ......... ......... .......... .......... ......... ......... .......... .......... ....... .. 1-28 Engine Won’t Reach Operating RPM ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... 1-28 Defective Engine Lubricating System ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 1-29 Low Battery Voltage After After Short Storage ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ... 1-29
Elect/eng
1-23
Engine Will Not Crank Starter Circuit - Check: • • • • • • • •
Battery Battery condi condition tion:: weak, weak, dead, dead, sulfate sulfated, d, bad bad cells cells Battery Battery cables cables ffor or loose loose or corr corroded oded connecti connections ons Short Shorted ed or open open ignit ignition ion switc switch h Starter Starter moto motorr and solen solenoid oid for for shorts shorts,, grounds grounds or open open circuits Star Starter ter assist assist solen solenoid oid/r /rela elay y Circ ircuit uit brea break kers ers Wirin Wiring g from from batt batter ery y to ignit ignition ion swit switch ch See Cranking System section
Engine Cranks, But Will Not Start Ignition Circuit - Check: • • • • •
Primary Primary circu circuit it wiring wiring from from ignitio ignition n switch switch to igniti ignition on coil/ coil/ ignition module Secondar Secondary y circui circuitt wiring wiring from coil to s spark park plug Spark Spark plugs plugs for for proper proper gap, gap, foulin fouling, g, burne burned d electro electrodes, des, cracked or dirty insulator See respect ective Ignition System section Low Low Bat Batte tery ry Volta oltage ge
Fuel System - Check: • • • • • • • • • • •
Quantit Quantity y and and condit condition ion of fuel in boat boat tan tank k Operatio Operation n and flow flow capaci capacity ty of boat anti-si anti-siphon phon valve valve Fuel Fuel tan tank k vent vent is unres unrestr trict icted ed Fuel Fuel tank tank pick-u pick-up p scr screen een is clea clean n Correct Correct diamete diameter/u r/unres nrestric tricted ted boat fuel lines lines Fuel shutof shutofff and multiple multiple tank valves valves are are open open and operoperating properly Fuel pump pump vent vent hos hose e for signs signs of fuel fuel or or oil that that w would ould indicate a fuel pump failure Fuel pump/r pump/relay elay/cir /circuit cuit breaker breaker operati operation on Externa Externall fuel fuel filter filter caniste canisterr and carburet carburetor or filter filter Carburet Carburetor or accel accelerat erator or pump pump for fuel dischar discharge ge See Fuel System section
Cylinder Compression - Check: •
See Engine Service Manual
1-24
Elect/eng
Hard Starting - Cold Engine Ask these questions first:
Has Engine Always Done This? Check: • • • •
Carburet Carburetor or choke choke opera operation tion and adjustm adjustment ent Fuel Fuel lin lines es for for obs obstr truc ucti tion ons s For For deb debri ris s insi inside de fue fuell tank tank See Fuel System section
Was Engine Used For A Long Time? Check: • • • • •
For clean clean exte external rnal canis canister ter and and carbur carburetor etor fuel filte filters rs Empty Empty carbu carburet retor or ffloat loat bowl due to evapo evaporati ration on Wate Waterr in fue fuell due due to to cond condens ensat ation ion Fuel Fuel qua quali lity ty det deter erio iora rati tion on See Fuel System section
Is This A New Condition? Check: • • • • • •
Carburet Carburetor or choke choke opera operation tion and adjustm adjustment ent Carbur Carbureto etorr accele accelera rato torr pump pump Fuel system system for leaks, leaks, dirt, dirt, or obst obstruct ructions ions Engine Engine timing timing and igniti ignition on syst system em See General Information, Ignition System, Fuel System sections See Engine Service Manual
Hard Starting - Hot Engine Ask these questions first:
Has Engine Always Done This? Check: • •
Carburet Carburetor or choke choke opera operation tion and adjustm adjustment ent See Fuel System section
Is This A New Condition? Check: • • • • •
Brand, Brand, type type or or oct octane ane of fue fuell Spark plugs Water in fuel Condit Con dition ion of bat batter tery y and and cable cables s Start Starter er mot motor or ffor or ove overhe rheat at dam damage age
Did Engine Refuse To Start After Being Run? Check: • • • • • •
Elect/eng
Ignit Ignition ion syst system em prima primary ry circui circuitt Ignit Ignition ion coil/ coil/ign igniti ition on mo modul dule e Engine titiming Carburet Carburetor or choke choke opera operation tion and adjustm adjustment ent See General Information, Ignition System, Fuel System sections See Engine Service Manual
1-25
Engine Runs Rough If At Slow Speed - Check: • • • • • • • •
Idle Idle spe speed ed and and idl idle e mixt mixtur ure e Engine Engine timin timing g and and spark spark plugs plugs Fuel Fuel pump pump pres pressu sure re Wate Waterr or or cont contami aminan nants ts in fuel fuel Carbur Carburet etor or or or manif manifold old vacuu vacuum m leak leak Inter Interna nall car carbur buret etor or fuel fuel leak leak See General Information, Ignition System, Fuel System sections See Engine Service Manual
If At High Speed - Check: • • • • • • • • • • • •
Air leak leak on s suct uction ion side side of fue fuell syste system m Too low low oct octan ane e fue fuell Igniti Ign ition on s sys yste tem m seco seconda ndary ry circ circuit uit Engine titiming Wrong Wrong model model or size size carbur carbureto etorr, imprope improperr main jets jets or or power valve, defective secondary fuel circuit, secondary vacuum diaphragm failure External External caniste canisterr and and carbur carbureto etorr fuel fuel filte filters rs Fuel Fuel pump pump pres pressu sure re Engi Engine ne comp comprressi ession on Water Water or contam contaminan inants ts in fuel, fuel, water water in cylinder cylinders s See General Information, Ignition System, Fuel System sections See Engine Service Manual Engi Engine ne oper operat atin ing g in in S.L.O.W.
Engine Noises and Vibrations Valves - Hydraulic Lifters • • • • • •
Rapping only Rapping only when when starti starting ng (oil (oil too heavy heavy for preva prevailin iling g weather, varnish on lifter, oil needs to be changed) Intermi Inte rmitte ttent nt rappin rapping g (leakag (leakage e at lift lifter er check check ball) ball) Idle noise noise (exce (excessiv ssive e leak down down rate, rate, fau faulty lty check check ball ball seat) Generall Generally y noisy noisy (exces (excessive sive oil oil in crankc crankcase, ase, stuck stuck lifter lifter plunger) Loud noise noise at at ope operati rating ng temper temperatur ature e (scored (scored lifte lifterr plunger plunger,, fast leak down rate, oil viscosity too light for prevailing weather or operating temperatures) See Engine Service Manual
1-26
Elect/eng
Engine Noises and Vibrations, Cont. Ignition System (Ping or Knock) • • • • •
Improper per tun tunin ing g Incor Incorre rect ct spa spark rk plug plug wire wire routi routing ng Poor Poor quali quality ty or or cont contam amina inate ted d fuel fuel See General Information, Ignition System sections See Engine Service Manual
Cooling System • • •
Supply pump Loos Loose e bel belts ts,, pul pulle leys ys See Cooling System section of Engine Service Manual
Mountings • •
Loose, broke Loose, broken n or wor worn n engin engine e moun mounts ts Loose Loose lag lag screws screws holding holding mounts mounts tto o st string ringer er
Crankshaft Balancer or Flywheel •
Loose b bo olt(s)
• •
Loose Loo se pulle pulley y, wor worn n bear bearing ings s Loos Loose e mou mount ntin ing g bol bolts ts
Alternator
Vertical Drive • • • •
Failed Failed U-join U-joints ts or or gimb gimbal al bear bearing ing Damag Dam aged ed int intern ernal al dri drive ve comp compone onent nts s Worn, Worn, bent bent or brok broken en prop propelle ellerr hub hub or blades blades Loose, Loo se, worn worn or or dama damage ged d engine engine couple couplerr
Engine Overheats - Check: • • • • • • • • • • • •
Elect/eng
Actual Actual engine engine tempe temperat rature ure by by verify verifying ing with with an accur accurate ate thermometer Gauge Gauge oper operat ation ion and wiring wiring circui circuitt Sending Sending unit operatio operation n and and wirin wiring g circ circuit uit Supply Supply pum pump, p, cir circul culat ating ing pum pump p and belt belt Wate Waterr inta intake ke scr scree eens ns ffor or bloc blocka kage ge Thermostat Water ater supp supply ly hose hoses s Engine titiming Water Water leaks leaks on pres pressure sure side of s suppl upply y pump pump Air leaks leaks on on suct suction ion side side of of supp supply ly pump pump Engi Engine ne comp compre ress ssio ion n See Engine Service Manual.
1-27
Engine Dies Out Loss Of, Or Out Of, Fuel - Check: • • • • • • • • • • • • •
Fuel Fuel gau gauge ge oper operat ation ion and and wir wiring ing Fuel uel le level in in ta tank Water ater or debr debris is in fuel fuel Fuel Fuel p pick ickup up ttube ube and and scre screen en b bloc lockag kage e Fuel Fuel tank tank vent vent bloc blocka kage ge Plugged Plugged exter external nal canis canister ter or or carbure carburetor tor fuel filters filters Air leak leak on suc suctio tion n side side o off fuel fuel syst system em Fuel Fuel leak leak on pre press ssure ure side side of fuel fuel sys system tem Inoper Ino perativ ative, e, restric restricted ted or incorre incorrectl ctly y sized anti-s anti-siph iphon on valve Boat Boat fuel fuel line lines s too too small small in d diam iamet eter er Fuel Fuel pum pump p pre pressu ssure re and sucti suction on Carbu Carburet retor or clean cleanlin liness ess and and op oper erat ation ion See Fuel System section
Loss Of Ignition - Check: • • • • • •
Prima Primary ry and and second secondar ary y ignitio ignition n circui circuits ts Igniti ition swit witch Circ ircuit uit brea break kers ers Wirin Wiring g bet betwee ween n engi engine ne and dash dash Main Ma in eng engin ine e harn harnes ess s wiri wiring ng See Gene Genera rall Infor Informa matio tion n and appr appropr opriat iate e Ignition System sections
Engine Stops Or Dies Out Due To To Seizure - Check: • • • •
Vertic ertical al drive drive for for inter internal nal dam damag age e Oil pre pressu ssure re gaug gauge e and cra crankc nkcase ase oil oil level level Temperat emperature ure gauge gauge and cooli cooling ng syste system m operat operation ion Inte Intern rnal al engin engine e compo componen nents ts as requ require ired d
Engine Won’t Reach Operating RPM - Check: • • • • • • • • • • • • • • • •
Fuel Fuel type type or octa octane ne Propeller Propeller pitch or diamet diameter er,, damaged damaged blades, blades, slippin slipping g hub Cran Crankc kcas ase e oil oil volu volume me Marin Ma rine e gro growth wth on hull hull and and drive drive Wrong Wrong verti vertical cal drive drive gear gear ratio ratio Oper Operat atin ing g at high high alt altit itud ude e Restr Restrict icted ed car carbur buret etor or air air int intake ake Restrict Restricted ed exhaust exhaust outle outlets ts in engine engine,, transom transom bracket bracket or drive Poor Poor cyl cylin inde derr comp compre ress ssio ion n Carburet Carburetor or size size and type type corre correct ct ffor or engin engine e Fuel Fuel pum pump p pre press ssur ure e and and vacuu vacuum m Boat overload overloaded, ed, or load imprope improperly rly placed placed Engi Engine ne over overhe heat atin ing g Engine Engine timing timing and ignition ignition system system operatio operation n Remote Rem ote contr control ol cables cables and and linkage linkage for for prope properr attach attachment ment and travel Engi Engine ne oper operat atin ing g in in S.L.O.W.
1-28
Elect/eng
Defective Engine Lubricating System Engine Components - Check: • • • • • • • • • • •
Clogg Clogged ed or incor incorrec rectt oil oil filt filter er Worn Worn oil oil pum pump p gear gears, s, cov cover er or or shaf shaftt Worn Worn or collaps collapsed ed oil pump pump relie relieff valve valve spring, spring, or or foreign foreign material caught on valve seat Oil pump pump relief relief v valve alve plunger plunger loose loose in cover cover Damag Dam aged ed filte filterr bypa bypass ss grom gromme mett Clogged Clogged oil oil pickup pickup screen, screen, broken broken ttube ube or or housin housing g Plugg Plugged ed cran cranksh kshaf aftt or bloc block k oil gall galleys eys Dirty Dirty or defec defective tive hydr hydraulic aulic lifters, lifters, clogged clogged push push rod rod passages Poor quality quality,, incorr incorrect ect visco viscosity sity or quanti quantity ty of oil Incorre Incorrect ct hose hose routin routing g on remot remote e filter filter syst systems ems Water Water in crankc crankcase ase oil oil from conde condensat nsation, ion, defe defectiv ctive e head gasket, oil cooler, or cracked manifold/block water passages
Oil Pressure Warning System - Check: • • •
Oil gauge/w gauge/warni arning ng horn operatio operation na and nd wiring wiring Engi Engine ne temp temper erat atur ure e Oil press pressure ure gauge gauge and warning warning horn horn sender sender operat operation ion and wiring
Low Battery Voltage After Short Storage Engine/Boat Components - Check: • • •
All electr electrical ical acces accessori sories es includin including g ignition ignition circuit circuit off off Disconne Disconnect ct main main batte battery ry negati negative ve cable cable from from batt battery ery Connect Conn ect amme ammeter ter or or voltmet voltmeter er in serie series s between between n negat egative ive battery cable and negative battery post: 1. Meter reading reading of “0” “0” indicates no draw, draw, test battery battery and charging system 2. Meter movement no matter matter how slight indicates indicates draw draw from battery
•
Disconne Disconnect ct main main engine engine harne harness ss 10-Pi 10-Pin n Connec Connector tor:: 1. Meter drops back to “0”, problem problem caused by boat system, continue to isolate each boat electrical accessory until problem is found 2. Meter Meter does not not drop drop back to to “0”, probl problem em caused caused by engine electrical system, continue to isolate each engine electrical accessory until problem is found
•
Elect/eng
Repair Repa ir or replace replace componen components ts as necessar necessary y
1-29
METRIC CONVERSION CHART LINEAR i n c he s fe e t y a rd s mi l es i n c he s
ENERGY OR WORK X X X X X
2 5 .4 0 .3 04 8 0 .9 14 4 1. 60 9 3 2 .5 4
= = = = =
mi l l i me tre s ( mm) met re s ( m) me tr e s (m) k i l o me tre s (k m) c e nt i me tre s (c m)
f oo t- po u n ds c a l o ri e s Btu w a tt -h ou rs k i l o w a tt - hr s
AREA 2
inches inches 2 feet2 yards2 a cr es miles2
X X X X X
1 .3 5 5 8 4 .1 87 1055 3500 3 .6 0 0
= joules (j) = j ou l e s (j ) = j o u l es ( j ) = j o ul es ( j ) = me g a j o ul e s (MJ )
FUEL ECONOMY AND FUEL CONSUMPTION X X X X X X
64 645.16 6. 45 2 0 .0 9 29 0 .83 6 1 0 .4 0 47 2.5 9 0
= = = = = =
2
2
mill imetres (mm ) centimetres 2 (mm 2) metres 2 (m 2) metres 2 (m 2) hectares (10 4 m 2) (ha) kilometres 2 (km 2)
mi l es /g al X0 0..42514 = ki kil ometres/litre ((k km/ l ) Note: 235.2/(mi/gal) 235.2/(mi/gal) = litres/100 km 235.2/(Iitres/100 235.2/(Iitres/100 km) = mi/gal
LIGHT VOLUME inches 3 inches 3 inches 3 q u art s g a l l on s feet3 feet3 fl u i d o z yards3
f oo tc a nd l e s X X X X X X X X X
1 6 38 7 16 16.387 0. 0.0163 01639 9 0.9 4 63 5 3 .7 8 54 2 8.3 1 7 0. 0.02832 2 9 .57 0 .76 4 6
= millimetres 3 (mm 3) = centimetres 3 (cm 3) = lit litrres (l) = l i tre s (l ) = l i tr es ( l ) = l i tre s (l ) = m me etres 3 (m 3) = mi l l i l i tr es ( ml ) = metres 3 (m 3)
X 1 0 .7 6
= lumens/metre 2 (lm/m2)
PRESSURE OR STRESS inch inches es HG (60° 60°F) p o un d s/s q i n inches H 2O (60° (60°F) b a rs p o un d s/s q ft
X X X X X
3 3..377 377 6 .8 9 5 0.24 0.2488 88 100 4 7.8 8
= = = = =
kil kilo opas pascals cals (kPa) Pa) ki k i l op a sc al s ( kP a ) kilo kilopa pasc scal als s (kPa (kPa)) ki l o pa s ca l s (k P a) pa p a sc al s (P a )
POWER MASS o u nc e s (a v ) p o un d s (a v) tons (2 (2000 lb lb ) tons tons (200 (2000 0 lb) lb)
X X X X
28 .3 5 0. 45 3 6 9 90 0 7. 18 0.9 0.907 0718 18
= = = =
h o rs e po w e r f t-l b f/ mi n
g ra ms (g ) k i l o gr ams (k g) ki kilograms (k (kg) m met etri ric c tton ons s (t) (t)
X 0. 74 6 = k i l o w a tts ( kW ) X 0 .0 22 6 = w a tts ( W)
TEMPERATURE °Celsius = 0.556 X (°F -32) °Fahrenheit = (1.8 X °C) +32
FORCE o u nc es - f (a v ) X 0 .2 7 8 pounds - f (av) X 4. 4.448 k i l o gra ms - f X 9 .8 0 7
= ne w to ns (N ) = n e w ton s (N ) = ne w to ns (N )
TORQUE poun poundd-in inch ches es X 0.1 0.112 1299 99 p o u nd -f ee t X 1. 1.3558
= n new ewto tonn-me metr tres es (N m) = newton-metres (N m) •
•
ACCELERATION feet/sec2 inches/sec2
X 0 .3 04 8 X 0 .0 25 4
VELOCITY
= metres/sec 2 (m/S 2) = metres/sec 2 (m/S 2)
mi l es /h ou r f ee t/s ec kilo kilome metr tres es/h /hrr mi l es /h ou r
1-30
X X X X
1 1..6093 0 .3 04 8 0.27 0.2777 778 8 0.4 4 70
= ki kilometres/hour (k (km/h) = me tre s/ se c (m/s ) = me metr tres es/s /sec ec (m/s (m/s)) = me tr es /se c ( m/s)
Elect/eng
Drill Size Conversion Chart SHOWING MILLIMETER SIZES, FRACTIONAL AND DECIMAL INCH SIZES AND NUMBER DRILL SIZES MilliDec. Fract- Num- MilliDec. Fract- Num- MilliDec. Fract- Num- MilliDec. Fract- Num- MilliDec. FractMeter Equiv. ional ber Meter Equiv. ional ber Meter Equiv. ional ber Meter Equiv. ional ber Meter Equiv. ional .1 .15 .2 .25 .3 ... .35 ... .39 .4 ... .45 ... .5 ... ... .55 ... .6 ... ... .65 ... ... .7 ... .75 ... .79 .8 ... ... .85 ... .9 ... ... .95 ... ... 1.0 ... ... 1.05 ... ... 1.1 1.15 ... 1.19 1.2 1.25 1.3 ... 1.35 ... 1.4 1.45 1.5 ... 1.55 1.59 1.6 ... 1.65 1.7 ...
.0039 .0059 .0079 .0098 .0118 .0135 .0138 .0415 .0156 .0157 .0160 .0177 .0180 .0197 .0200 .0210 .0217 .0225 .0236 .0240 .0250 .0256 .0260 .0280 .0276 .0292 .0295 .0310 .0312 .0315 .0320 .0330 .0335 .0350 .0354 .0360 .0370 .0374 .0380 .0390 .0394 .0400 .0410 .0413 .0420 .0430 .0433 .0452 .0465 .0469 .0472 .0492 .0512 .0520 .0513 .0550 .0551 .0570 .0591 .0595 .0610 .0625 .0629 .0635 .0649 .0669 .0670
80
1 / 64
79 ... 78 77 76 75 74 73 72 71 70 69
1 / 32
68 ... 67 66 65 64 63 62 61 60 59 58 57
3 / 64
56 ...
55 54
53 1 / 16
... 52
51
1.75 ... 1.8 1.85 ... 1.9 ... 1.95 1.98 ... 2.0 2.05 ... ... 2.1 2.15 ... 2.2 2.25 ... 2.3 2.35 ... 2.38 2.4 ... 2.45 ... 2.5 ... ... 2.6 ... 2.7 ... 2.75 2.78 ... 2.8 ... ... 2.9 ... 3.0 ... 3.1 3.18 3.2 3.25 ... 3.3 3.4 ... 3.5 ... 3.57 3.6 ... 3.7 ... 3.75 ... 3.8 ... 3.9 ... 3.97
.0689 .0700 .0709 .0728 .0730 .0748 .0760 .0767 .0781 .0785 .0787 .0807 .0810 .0820 .0827 .0846 .0860 .0866 .0855 .0890 .0905 .0925 .0935 .0937 .0945 .0960 .0964 .0980 .0984 .0995 .1015 .1024 .1040 .1063 .1065 .1082 .1094 .1100 .1102 .1110 .1130 .1141 .1160 .1181 .1200 .1220 .1250 .1260 .1279 .1285 .1299 .1338 .1360 .1378 .1405 .1406 .1417 .1440 .1457 .1470 .1476 .1495 .1496 .1520 .1535 .1540 .1562
50
49 48 5 / 64
... 47
46 45
44
43
3 / 32
42 ... 41 40 39 38 37 36
7 / 64
... 35 34 33 32 31
1 / 8
...
30
29
9 / 64
28 ... 27 26 25 24
5 / 32
23 ...
... 4.0 ... ... 4.1 4.2 ... 4.25 4.3 ... 4.37 ... 4.4 ... 4.5 ... 4.6 ... 4.7 4.75 4.76 4.8 ... 4.9 ... ... 5.0 ... 5.1 ... 5.16 ... 5.2 ... 5.25 5.3 ... 5.4 ... 5.5 5.56 5.6 ... 5.7 5.75 ... 5.8 5.9 ... 5.95 6.0 ... 6.1 ... 6.2 6.25 6.3 6.35 6.4 6.5 ... 6.6 ... 6.7 6.75 6.75 ...
.1570 .1575 .1590 .1610 .1614 .1654 .1660 .1673 .1693 .1695 .1719 .1730 .1732 .1770 .1771 .1800 .1811 .1820 .1850 .1870 .1875 .1890 .1910 .1929 .1935 .1960 .1968 .1990 .2008 .2010 .2031 .2040 .2047 .2055 .2067 .2086 .2090 .2126 .2130 .2165 .2187 .2205 .2210 .2244 .2263 .2280 .2283 .2323 .2340 .2344 .2362 .2380 .2401 .2420 .2441 .2460 .2480 .2500 .2520 .2559 .2570 .2598 .2610 .2638 .2657 .2657 .2660
22 21 20
19
11 / 64
18 ... 17 16 15 14 13
3 / 16
... 12 11 10 9 8
13 / 64
7 ... 6 5
4 3 7 / 32
... 2
1
15 / 64
A ... B C D
1 / 4
E
F G 17 / 64
... H
6.8 6.9 ... 7.0 ... 7.1 ... 7.14 7.2 7.25 7.3 ... 7.4 ... 7.5 7.54 7.6 ... 7.7 7.75 7.8 7.9 7.94 8.0 ... 8.1 8.2 ... 8.25 8.3 8.33 8.4 ... 8.5 8.6 ... 8.7 8.73 8.75 8.8 ... 8.9 9.0 ... 9.1 9.13 9.2 9.25 9.3 ... 9.4 9.5 9.53 ... 9.6 9.7 9.75 9.8 ... 9.9 9.92 10.0 ... ... 10.32 ... 10.5
.2677 .2716 .2720 .2756 .2770 .2795 .2811 .2812 .2835 .2854 .2874 .2900 .2913 .2950 .2953 .2968 .2992 .3020 .3031 .3051 .3071 .3110 .3125 .3150 .3160 .3189 .3228 .3230 .3248 .3268 .3281 .3307 .3320 .3346 .3386 .3390 .3425 .3437 .3445 .3465 .3480 .3504 .3543 .3580 .3583 .3594 .3622 .3641 .3661 .3680 .3701 .3740 .3750 .3770 .3780 .3819 .3838 .3858 .3860 .3839 .3906 .3937 .3970 .4040 .4062 .4130 .4134
I J
9 / 32
K ...
L M 19 / 64
... N
5 / 16
... O
P
21 / 64
... Q
R 11 / 32
...
S
T 23 / 64
...
U
3 / 8
... V
W 25 / 64
13 / 32
... X Y ... Z
10.72 11.0 11.11 11.5 11.51 11.91 12.0 12.30 12.5 12.7 13.0 13.10 13.49 13.5 13.89 14.0 14.29 14.5 14.68 15.0 15.08 15.48 15.5 15.88 16.0 16.27 16.5 16.67 17.0 17.06 17.46 17.5 17.86 18.0 18.26 18.5 18.65 19.0 19.05 19.45 19.5 19.84 20.0 20.24 20.5 20.64 21.0 21.04 21.43 21.5 21.83 22.0 22.23 22.5 22.62 23.0 23.02 23.42 23.5 23.81 24.0 24.21 24.5 24.61 25.0 25.03 25.4
.4219 .4330 .4375 .4528 .4531 .4687 .4724 .4843 .4921 .5000 .5118 .5156 .5312 .5315 .5469 .5512 .5624 .5709 .5781 .5906 .5937 .6094 .6102 .6250 .6299 .6406 .6496 .6562 .6693 .6719 .6875 .6890 .7031 .7087 .7187 .7283 .7344 .7480 .7500 .7656 .7677 .7812 .7874 .7969 .8071 .8125 .8268 .8218 .8437 .8465 .8594 .8661 .8750 .8858 .8906 .9055 .9062 .9219 .9252 .9375 .9449 .9531 .9646 .9687 .9843 .9844 1.0000
27 / 64 7 / 16 29 / 64 15 / 32 31 / 64 1 / 2 33 / 64 17 / 32 35 / 64 9 / 16 37 / 64 19 / 32 39 / 64 5 / 8 41 / 64 21 / 32 43 / 64 11 / 16 45 / 64 23 / 32 47 / 64 3 / 4 49 / 64 25 / 32 51 / 64 13 / 16 53 / 64 27 / 32 55 / 64 7 / 8 57 / 64 29 / 32 59 / 64 15 / 16 61 / 64 31 / 32 63 / 64 1 DR2949
Elect/eng
1-31
SYMBOLS
Certain symbols or combinations of symbols may appear on your stern drive or on their accessories. It is very important that you understand their meaning or purpose. If any symbol is not clearly understood, see your dealer. dealer.
“Safety Warning” Symbols
Risk of serious injury Be Careful Follow instructions
Poisonous Fire Hazard
Contents Under Pressure
“Position Indicator” Symbols Shift Positions
NEUTRAL Raise
Lower
FORWARD
REVERSE
“Condition” Symbols Voltmeter Ammeter
Hour Meter
-
+
Battery
Water Temperature
r/min
Tachometer
Oil Filter
Fuel Filter
Emergency Stop
Oil Pressure
“Instructional” Symbols Use unleaded gasoline Gasoline is present
Read Operator's Manural before operating product
Oil Fill DR3847
1-32
Elect/eng
Periodic Maintenance Chart Items marked Safety Warning are safety related service points to prevent mechanical failures, fire and explosion. Make sure the safety related service is performed at these points and at the intervals specified.
Electrical Ser v i c e Po i n t
Ev er y 25 Ho u r s o r as Sp ec i f i ed
Ev er y 50 Ho u r s o r as Sp ec i f i ed
R ec o m m en d at i o n s
Battery
Check electrolyte level monthly
Tighten connections
Recharge battery if specific gravity reads below 1.220 temperature corrected.
Electrical System
Check connections and insulation.
Tighten loose connections, and replace deteriorated wiring.
High Tension Leads and / or Distributor Cap
Check for corrosion, deterioration or arcing. Boots must fit snugly on terminals.
If damaged, replace with specifiedVolvo Penta parts. Maintain original routing and support.
Ignition Coil
Check for arcing or cracks in plastic portion of coil.
Replace with specifiedVolvo Penta parts.
Spark Plugs
Annually check ceramic for cracks. Replace, or clean and gap.
If damaged, replace with specified Volvo Penta parts. Maintain original routing and support.
Fuel Ser v i c e Po i n t
Ev er y 25 Ho u r s o r as Sp ec i f i ed
Ev er y 50 Ho u r s o r as Sp ec i f i ed
Rec o m m en d at i o n s
Annually or as needed.
Ad just idle mixture and idle RPM. Clean linkage.
Flame Arrestor-Mounting
Clean and check annually.
Tighten nut. Replace if damaged.
Fuel Filter
Annually
Replace fuel filter.
Carburetor
Elect/eng
Mechanical Fuel Pump
Check transparent vent tube for presence of fuel or oil.
Replace leaking fuel pump. Check for leaks after starting engine.
Fuel System
Check for leakage daily.
Tighten connections. Replace with specified Volvo Penta components.
Fuel Tank
Check for water in fuel tank.
Keep tank filled with recommended fuel.
Non-Metallic Fuel Hoses
Check for excessive stiffness, deterioration and / or leakage every 50 hours or monthly, whichever comes first.
Replace as necessary with A.B.Y.C. approved components.
Safety Related
1-33
General Torque Specifications The following specifications are for nut and screw sizes not having specific torque recommendations. recommendations.
U.S. Sc r ew Si zes No. 6 No. 8 No. 10 No. 12 1 / 4-20 5 / 16-18 3 / 8-16 7 / 16-14
Ft . L b s .
Nm
... ... 2-3,5 3-4 5-7 12-14 20-25 32-40
1,1-1,6 2,2-2,8 2,7-4,7 4,1-5,4 6,8-9,5 16-19 27-34 43-54
1-34
Met r i c Th r ead Si zes
Ft . L b s .
Nm
M-6 M-8 M-10 M-12 M-14
6-9 14-21 28-40 50-71 80-114
8-12 19-28 38-54 68-96 108-155
Elect/eng
Section 2 Cranking System Table of Contents Cranking System Operation ................................. ................................................. .............................2-2 .............2-2 Cranking System Problems................ Problems ................................ ................................. ............................... ..............2-9 2-9 Starter Motor Bench Test ................................. ................................................. ................................ ................................. ...................... ..... 2-5 Replacement ................................ ................................................. ................................. ................................ ................... ... 2-6 Specifications................. Specifications ................................. ................................ ................................. ............................... ..............2-10 2-10 Test Procedures ............................... ............................................... ................................ ...............................2 ...............2-2 -2 Wiring Diagrams, Cranking Circuit Circuit ........................... ........................................ ........................ ...........2-7 2-7
Safety Warnings Before working on any part of the electrical system, read the Safety section at the end of this manual. The original mounting, support and routing of electrical system parts conform with U.S. Coast Guard requirements. It is import ant to maintain the original mounting, support and routing after servicing the electrical system to prevent possible fire and explosion in boat’s engine compartment. Do not substitute automotive parts. Volvo Penta marine components meet U.S. Coast Guard regulations for external ignition proof operation and marine use. Volvo Penta marine components are specially designed not to cause ignition of fuel vapors in the bilge or engine compartment. The use of automotive parts can result in fire and explosion.
Sealants, Lubricants and Adhesives Black neoprene dip
Elect/eng
2-1
2
Cranking System Operation The cranking system consists of a 12 volt starter motor, solenoid(s), ignition switch, neutral start switch, 50 amp circuit breaker, 20 amp fuse and wiring to complete the circuit with the battery.
Any remote control box used with the stern drives covered in this manual must have a neutral start switch which prevents operation of the starter if the control handle is not in the neutral position. All Volvo Penta remote controls meet this requirement. Stern drive starters employ a solenoid and lever to close the battery circuit and engage the starter pinion with the flywheel ring gear. When the key switch is turned to START position, an assist solenoid energizes the starter solenoid which closes the battery circuit and through leverage engages the starter pinion with the flywheel ring gear. When the key switch is released, the solenoids are de-energized, springs open the battery circuit, and the over-running clutch disengages the starter pinion.
Starter Motor Test Procedures Batter y Hydrometer, Hydro meter, Voltmeter, Ammeter, TaTaSpecial Tools Required: Battery chometer, Jumper Wire
Do not substitute an automotive type starter. The Volvo Penta starter motor meets U.S. Coast Guard regulations for external ignition proof operation and marine us e. The Volvo Penta starter is specially designed not to cause ignition of fuel vapors in the bilge or engine compartment. The use of automotive type starters can result in fire and explosion. Inspection Procedure No periodic lubrication of the starter motor or solenoid is required. Starter motor action is indicative, to some extent, of the starter motor condition. A starter motor which responds readily and cranks the engine at normal speed when the control circuit is closed is usually in good condition. Check the starter motor and solenoid switch attaching bolts to make sure these units are solidly mounted; both the starter and solenoid use their mounting for a ground path. Inspect and manually check all wiring connections in the starter motor circuit. Make sure these connections in the starter motor and control circuits are clean and tight. It is advisable to test the cranking circuit to ensure that excessive resistance does not exist. See Test Procedure.
Safety Related
2-2
Elect/eng
Test Procedure With Starter Installed The voltage across the starting motor and switch, while cranking the engine, gives a good indication of any excessive resistance.
All remote control boxes used with Volvo Penta stern drives must have a neutral start switch to prevent operation of the starter if the shift lever is not in the neutral position. Engine must be at normal operating temperature when test is made. 1. Inspect the battery and cables to make sure that battery has ample capacity for cranking and ignition. Battery must be fully charged. 2. To crank the engine without firing:
Ensure ignition switch is off when disconnecting primary wires. Failure to do so may result in sparking that can ignite fuel vapors in engine compartment or bilge, and may result in fire or explosion. •
All All Mode Models ls Exce Except pt 5.0 5.0 GL GL and and 5.7 5.7 GS: GS: Turn off ignition switch, and disconnect both 2-wire connectors at ignition coil.
•
5.0 5.0 G GL L and and 5. 5.7 G GS S: Turn off ignition switch, disconnect purple leads from ignition coil.
1 3. Connect the voltmeter POSITIVE (+) lead to the motor terminal on the solenoid switch; connect the voltmeter NEGATIVE (-) lead to ground B on starter. A
4. Turn the ignition switch on, crank engine and take voltmeter reading as quickly as possible. If starter motor turns engine at normal cranking speed with voltmeter reading nine or more volts, the motor and switch are satisfactory. If the cranking speed is below normal and the voltmeter reading is lower than 9 volts, check for defective battery, corroded battery terminals, or corroded solenoid. Do not operate starter motor for more than 10 second s at a time without pausing to allow motor to cool for at least two minutes; otherwise, overheating and damage to the motor may result.
Elect/eng
Safety Related
2-3
1 DR3199
Solenoid Contacts Test If the starter motor turns the engine at a low rate of speed and the voltmeter reads less than 9 volts, test the solenoid switch contacts as follows:
1 1. With the voltmeter switch turned to any scale above 12 volts, connect the voltmeter NEGATIVE (-) lead to the motor terminal A of the solenoid switch and connect the POSITIVE (+) lead to the battery terminal B of the solenoid switch. 2. Turn the ignition switch on and crank the engine. Immediately turn voltmeter switch to low scale and take reading as quickly as possible, then turn switch back to higher scale and stop the motor. motor.
1 DR3203
The voltmeter will read 1/10 volt or less if solenoid switch contacts are satisfactory. If voltmeter reads more than 1/10 volt, solenoid switch should be repaired or replaced.
Solenoid Amperage Test An amperage test of the solenoid switch will determine two things: •
Curren Currentt draw draw of bot both h windin windings gs in para paralle llel. l.
•
Curren Currentt draw draw of of holdhold-in in wind winding ing alone. alone.
2
1. Remove screw from solenoid motor terminal C and bend field leads slightly until clear of terminal. Ground motor terminal of solenoid with a heavy jumper wire D . 2
2. Connect a 12 volt battery, a variable resistance E (such as a carbon pile), and an ammeter F of 100 amperes capacity in series with the solenoid “S” terminal G . Connect a heavy jumper wire H from starter to ground post of battery. 2
3. Connect a voltmeter I between the base of the solenoid and the small solenoid “S” terminal.
2 DR3195
4. Slowly adjust resistance until voltmeter reads 10 volts and note ammeter reading. This shows current draw of both windings in parallel, and should be 47 to 55 amperes at 10 volts, with solenoid at room temperature. 5. Remove the jumper wire from the solenoid motor terminal and read just resistance until voltmeter reads 10 volts, then note ammeter reading. This shows current draw of hold-in winding alone and should be 15 to 20 amperes at 10 volts with solenoid at room temperature.
2-4
Elect/eng
6. If the solenoid windings do not test within the specifications given, the solenoid switch assembly should be replaced.
Starter Motor Bench Test 3 To obtain full performance data on a starter motor, or to determine the cause of abnormal operation, the motor should be removed from the engine and submitted to a no-load test with equipment designed for such tests. In a no-load test the starter motor is connected in series with a 12 volt battery J and an ammeter K capable of reading several hundred amperes. A variable resistor L is connected between the ammeter and the solenoid battery terminal. Attach a voltmeter M between the solenoid BAT terminal and motor ground N . Activate the motor by attaching a jumper wire O between the solenoid’s BAT and S (starter) terminals. A tachometer or RPM indicator is used to indicate armature RPM. Starter motor specifications will be found at the end of this section.
3 DR3200
Compare the results of the test with the chart below. This will indicate what should be looked for when the motor is overhauled.
Test Result
Probable Cause
1. Current draw and no-load speed within specifications
Normal condition for starting motor.
2. Low free speed and high current draw
Too much friction - namely tight, dirty or worn bearings, bent armature shaft, or loose pole shoe screws allowing armature to drag. Shorted armature. Check after disassembly on growler. Grounded armature or fields. Check further after disassembly. disassembly.
3. Fails to operate with high current draw
Direct ground in terminal or fields. "Frozen" bearings. Should be noticed by turning armature by hand.
4. Fails to operate with no current draw
Open field circuit. Check after disassembly by inspectig internal connections and tracing circuit with a test lamp. Open armature coils. Inspect for badly burned bars after disassembly. disassembly. Broken brush spring, worn brushes or high insulation between commutator bars thus preventing preventing good brush to commutator contact.
5. Low no-load speed and low current draw
High internal resistance due to poor connections, defective leads or dirty commutator. (Also, causes listed under 4, above.)
6. High free speed and high current draw
Shorted field coils. If shorted field coils are suspected, replace with new coils and check for improved performance.
Elect/eng
2-5
Starter Motor Replacement
A
Removal Do not substitute an automotive type starter. The Volvo Penta starter motor meets U.S. Coast Guard regulations for external ignition proof operation and marine us e. The Volvo Penta starter is specially designed not to cause ignition of fuel vapors in the bilge or engine compartment. The use of automotive type starters can result in fire and explosion.
1 14704
1. Disconnect the battery ground cable at battery and disconnect all wires at solenoid terminals to prevent sparks in engine compartment.
1
2
2. Cut the strap A holding bell housing drain hose, if equipped, to solenoid. Remove nut from starter support bracket. Remove ring gear guard B from front of flywheel housing. Take Take out starter mounting screws and remove the starter assembly.
Installation 1. To reinstall, position the starter assembly on the engine and start the mounting hardware.
2 6715
2. Snug hardware while holding the starter squarely against its mounting surface. Tighten Tighten the screws to 30-36 ft. lb. (41-49 N m). Install ring gear guard and tighten screws to 5-7 ft. lb. (7-9 N m). •
•
3. Connect wires to solenoid and apply black neoprene dip to terminals to prevent corrosion. 4. Connect battery ground cable at battery. Attach bell housing drain hose, if equipped, to solenoid with a tie strap.
2-6
Elect/eng
7
6
4
7 R
40
DRC7513
3.0 GS Models 4.3 GL Models 5.0 GL Models 5.7 GS Models Cranking Circuit 1 2 3 4 5 6 7
Elect/eng
Black Red Yellow/Red Starter Relay Red/Purple 20 Amp Fuse 40 Amp Fuse
2-7
7 6
4
7 R
40
DRC7518
Cranking Circuit 4.3 Gi Models 5.0 Gi 5.7 GSi 7.4 Gi & GSi Models 8.2 GSi Models 1 2 3 4 5 6
7
Black Red Yellow/Red Starter Relay Red/Purple 20 Amp Fuse 40 Amp Fuse
2-8
Elect/eng
Cranking System Problems
Starter turns engine slowly. Check: • • • •
battery batter y water water level level and and speci specific fic grav gravity ity for loose loose and and corr corrode oded d conn connect ection ions s engine eng ine and drive drive unit unit for for bindin binding g starter starter armature armature,, brushe brushes, s, field field coils, coils, or bearings bearings
Starter turns intermittently. Check: • • •
start starter er mot motor or - comple complete te tear tear-do -down wn conn connec ecti tion on at at igni igniti tion on swi switc tch h star startter solen olenoi oid d
Starter doesn’t turn - solenoid clicks. Check: • • • •
batt batter ery y and and conn connec ecti tion ons s star startter solen olenoi oid d engine, engine, trans transom om bracket bracket and verti vertical cal drive drive for seizure, seizure, or debris start starter er armat armature ure,, brush brushes, es, or or field field coils coils
Starter doesn’t turn - solenoid doesn’t click. Check: • • • • •
remote remote contr control ol in start start positio position, n, shift shift into neutral neutral batt batter ery y and and conn connec ecti tion ons s star startter solen olenoi oid d key switch switch and wiring wiring circui circuitt 20 am amp p fuse fuse 50 am amp pc cir ircu cuit it brea breake kerr
Starter remains engaged and runs with engine. Check: • • •
Elect/eng
shor shorte ted d igni igniti tion on swit switch ch start starter er mot motor or - comple complete te tear tear-do -down wn defective defective electric electric fuel fuel pump pump “Oran “Orange” ge” lead lead diode diode - 4.3 4.3 GL, GS, 5.0 GL and 5.7 GS models only
2-9
Starter Motor Specifications Do not substitute automotive parts. Volvo Penta marine components meet U.S. Coast Guard regulations for external ignition proof operation and marine use. Volvo Penta marine components are specially designed not to cause ignition of fuel vapors in the bilge or engine compartment. The use of automotive parts can result in fire and explosion.
Motor Free Speed At 11.5 Volts (between 3-5 seconds) Current - 64-95 amps Speed - 2825-3275 RPM
Safety Related
2-10
Elect/eng
Section 3 Charging System Table of Contents Alternator Service Assembly ............................ ......................................... ........................... ........................... ........................... ................... ..... 3-15 Belt Tension ........................... ......................................... ........................... ........................... ............................ ................. ... 3-4 Disassembly .......................... ........................................ ........................... ........................... ............................ ................ 3-10 Internal Diagram .......................... ........................................ ........................... ........................... ....................... ......... 3-20 Replacement ........................... ......................................... ............................ ........................... ........................... ................ .. 3-3 Specifications Specifications ............................ ......................................... ........................... ........................... ......................... ............ 3-21 Testing Rectifier ........................... ......................................... ............................ ........................... ..................... ........ 3-13 Charging System Problems .......................... ....................................... ........................... ...................... ........ 3-19 Circuit Diagrams ........................... ........................................ ........................... ........................... ......................... ............ 3-17 Description....................................... Description......................... ........................... ........................... ............................ ........................ ..........3-2 3-2 Troubleshooting Alternator ........................... ......................................... ............................ ........................... ........................... ..................... ....... 3-5 Chart ............................... ............................................... ................................. ................................. ................................ .................. 3-8 Wire Harness Tests ........................... ........................................ ........................... ............................ .................... ...... 3-6
Safety Warnings Before working on any part of the electrical sy stem, read the Safety section at the end of this manual. The original mounting, support and routing of electrical system parts conform with U.S. Coast Guard requirements. It is important to maintain the original mounting, support and routing after s ervicing the electrical system to prevent possible fire and explosion in boat’s engine compartment. Do not substitute automotive parts. Volvo Penta marine c components omponents meet U.S. Coast Guard regulations for external ignition proof operation and marine use. Volvo Penta marine components are s pecially designed not to cause ignition of fuel vapors in the bilge or engine compartment. The use of automotive parts can result in fire and explosion.
Sealants, Lubricants and Adhesives Black neoprene dip
Elect/eng
3-1
3
Description Stator
1 There are three independent windings connected together in the stator, in which three-phase alternating current is produced. There are two types of stator windings used in the alternator: the “Delta” - connection A and the “Y” - connection B .
Rotor
1
2
DRC6720
The rotor core and coil assembly includes; a rotor shaft, two slip rings, two rotor poles and a coil ass embly. The rotor shaft is supported at each end by bearings. The slip rings, core and coil assembly are press fitted to the shaft with a rotor pole enveloping each end of the coil. Protected slip-type field wi ndings are bonded with epoxy resin and anchored to resist damage by vibration from sharp acceleration. The rotor assembly is balanced to provide smooth, efficient operation throughout normal speed range. The slip ring s are made of copper, and thus rustproof, keeping good electrical contact. The rotor core and coil assembly turns inside the stator core and coil assembly with a very narrow air gap between the two assemblies. This narrow clearance permits maximum magnetic power.
2 45453
Rectifier
3 The rectifier, rectifier, with six silicon diodes, is located between the stator and the inside surface of the rear bracket.
4 Three of the six diodes are positive, and are located in an insulated heat sink. The current induced in the stator coil flows into the positive diodes and comes out the “B” terminal. Three other negative diodes are located in the negative heat sink that is grounded. The six diodes act together to change the alternating current produced produced in the alternator into direct current.
3 45438
Regulator
5 The voltage regulator assembly contains the voltage regulator, brush holder and the brushes.
4 45439
5 45448
3-2
Elect/eng
Alternator Replacement Carbureted Models Only Removal To ensure proper operation operati on and to protect the alternator alternat or and regulator, the following steps should be observed during removal and installatio n.
Do not substitute automotive parts. Volvo Penta marine components meet U.S. Coast Guard regulations for ex ternal ignition proof operation and marine use. Volvo Penta marine components are specially designed not to cause ignition of fuel vapors in the bilge or engine compartment. The use of automotive parts c an result in fire and explosion.
6 49475
1. Disconnect the battery ground cable at battery. 6
2. Remove alternator adjusting bolt and nut D .
C
from brace. Loosen pivot bolt
3. Push alternator towards engine and remove alternator belt. 7
4. Disconnect all leads from the alternator.
8
5. Remove alternator pivot bolt and nut
D
7 49480
. Remove the alternato r.
Installation 8
1. Position alternator in bracket and loosely install the pivot bolt and nut D .
9 2. Connect purple lead
to “EXC” terminal. Connect black lead F to “E” terminal. Tighten nuts securely and coat both terminals with blac k neoprene dip. E
10
3. Connect heavy gauge orange lead G to “B” terminal and orange jumper lead H to “S” terminal. Tighten nuts secu rely. Slide rubber boot up lead and cover terminal.
8 49483
10
4. Carbureted Models Only: Connect purple/white lead to “P” terminal. Tighten nu t securely. Slide rubber boot up lead and cover terminal.
9 49481
10 49482 Elect/eng
Safety Related
3-3
2
1
3
49480
45373
45382
1 5. 4.3 GL, 5.0 GL, 5.7 GS and DPX models only: Connect the electric fuel pump lead to the “L2” terminal. Coat the ground terminal with black neoprene dip. 2
5. Pivot alternator towards the engine and place the belt onto the pulley. Attach the alternator brace to the alternator with screw A . Follow the procedure for “Alternator Bel t Tension” Tension” in this section. Correctl y tension the belt and tighten all mounting bolts B to 26-30 ft. lb. (35-41 N m). •
7. Connect battery cables.
4 DRC7451
Alternator Belt Tension • 1 2 3 4
Carb Ca rbur uret eted ed V6 and and V8 Mo Mode dels ls 4 Crankshaft Pulley Circulating Pump Pulley Alternator Pulley Belt Tension Tension Chec k Point
With engine stopped, check belt tension half way between the crankshaft and the alternator using one of the following methods:
5 47507
5 Use belt tension gauge to s et tension to 75 ± 10 lb. (33.6 ± 44.5 N). 6 Use light thumb pressure and check for 1/4 in. (6.4 mm) belt deflection.
If belt is too tight, excessive belt and bearing wear can occur. If it’s too loose, slippage can occur, resulting in belt wear; and poor circulating pump, alternator, or power steering operation. Tension of a new belt should be checked after 10 hours of service and every 50 hours thereafter.
6 47508
3.0GS and Fuel Injected Models except DPX. 7 The serpentine belt tension is set automaticlly by the belt tensioner. No adjustment is needed.
7 3-4
Elect/eng
1. Loosen alternator mounting bolts and nuts, and pivot alternator away from engine to increase belt tension. 8
9 2. While maintaining pressure o n alternator, retighten top bolt,
bottom bolt and nut. Recheck belt tension. The belts used for the alternator, circulating circulating pump, and power steering pump are heavy-duty. Do NOT replace with automotive belts. When adjusting alternato r belt, do not overtightens The alternator may be damaged.
8
Troubleshooting the Alternator
49476
Belt Tension 6
7
Check the alternator belt for correct tension.
Alternator Output Test Before beginning charging system checks, test the alternator output to verify that a charging problem exists. 10 1. Disconnect orange lead D from “B” terminal at back of alternator and connect an ammeter E in series. 10 2. Attach a voltmeter
F
to the “B” terminal
G
9 49477
and an engine ground.
3. Connect a carbon pile or Stevens LB-85 Stevens LB-85 Load Bank across the battery. 4. Start and run the engine. The amperage and voltage output readings should be as follows when the carbon pile is adjusted to obtain maximum output: 650 RPM - 20 amps min. 1500 RPM - 53 amps min.
10
2000+ RPM - 56 amps min.
DRC7602
Regulated Voltage Range: 14.0 - 14.7 volts
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3-5
The output test results will fall i nto one of these categories; overcharging, undercharging or no charge at all. If battery overcharge is indicated by excessive water use, ammeter or voltmeter showing consistent charge, or alternator output exceeding 15.0 volts (no load) with engine idling, check orange “S” lead voltage. Low volts, or no volts, will cause overcharging. If orange “S” lead voltage is okay, voltage regulator is shorted and must be replaced. If battery undercharge (or no charge) is indicated, perform the following tests in the order shown.
Alternator Wire Wir e Harness Tests Tests For the battery to receive sufficient charging curre nt, and the alternator to supply the correct amount, three wires must carry battery voltage; the orange output (“B”) lead, orange jumper (“S”) sense lead and the purple excite (“EXC”) lead.
Check No. 1: Testing Battery Charging Circuit 1. Slide the protective rubber boot off the “B” terminal.
1 2. Connect the voltmeter positive lead to the orange lead
A
, and negative lead to an engine ground . With the key switch o ff, the voltmeter should show a reading nearly equal to battery voltage. B
Test Results: a. Circuit Okay - voltage reading is within a few tenths of battery voltage. Go on to Check No. 2. b. Excessive Resistance - one or more volts less than battery voltage (example: 10.2 volts versus 11.8 volts). c. Open Circuit - a voltmeter reading of zero. If circuit is open or resistance is excessive, disconnect orange lead at alternator. With an ohmmeter, check alternator output circuit between alternator and battery. Correct any problems, then conduct alternator output test again. If output reading is still not as specified, go on to following test.
3-6
1 DRC7601
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Check No. 2: Testing Ignition Circuit 2
1. Connect a voltmeter to the “EXC” lead and an engine ground B .
C
at back of alternator
2
2. With battery connected and key switch E on, the voltmeter reading should be within a few tenths of battery voltage.
Test Results : a. Circuit Okay - voltage reading is within a few tenths of battery voltage. Go on to Check No. 3.
2 DRC7600
b. Excessive Resistance - one or more volts less than battery voltage (example: 10.2 volts versus 11.8 volts). c. Open Circuit - a voltmeter reading of zero. d. Grounded Circuit - a reading of zero accompanied by a blown fuse or circuit breaker each time key switch is turned on.
Results were conditions “b” or “c”: disconnect the purple lead from back of alternator, then use an ohmmeter to check wire continuity back to key switch. Correct any problems, then conduct alternator output test again.
3 Results were condition “d”: disconnect the purple lead from back
3 DRC7599
of alternator and repeat voltage check, Steps 1 and 2 above. If fuse or circuit breaker no longer blows, circuit is grounding through alternator; replace alternator. alternator. Fuse or circuit breaker continues to blow, check wiring back to key switch to find cause. Correct any problems, then conduct alternator output test again. If the tests show the engine wiring, battery or accessories are not at fault, make additional running tests on the alternator, Check No. 3.
Check No. 3: Testing Excite/Sense Circuit 1. Unscrew protective cap on “L2” terminal. Retain cap for reuse.
4 2. With key switch
E
on, but engine not running, check for 1.0-2.0 D volts at the “L2” terminal . 3. If “L2” terminal voltage is not as specified, replace voltage regulator. If alternator still fails to produce the specified voltage/amperage after installation of a new regulator, the alternator will have to be disassembled in order to test internal components.
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3-7
4 DRC7598
Alternator Troubleshooting Chart Troubleshooting Troubleshooting the charging system may involve any one or more of the components in the system: the alternator (including voltage regulator), the battery, battery, key switch, and wiring connecting these components into a circuit. The following troubleshooting chart categorizes trouble and remedies.
Tr o u b l e Battery UnderCharging
Pl ac e o f Tr o u b l e
Pr o b ab l e Cau s e
Rem ed y
Fan Belt
Fan belt slipping
Read just the tension of belt
Alternator
1. Stator coil grounded or disconnected
Repair or replace stator assembly if necessary
2. Rotor coil disconnected
Replace
3. Brush and slip ring insufficient contact
Worn brushes to be renewed, (holders to be cleaned) slip ring polished
4. Diode intermittently operated Replace rectifier assembly 5. Capacitor puncture Replace capacitor Battery
1. Not enough or bad electrolyte
Supply, remeasuring specific gravity
2. Sulfated plate (short circuit)
Change battery
3. Insufficient contact due to corroded terminal
Clean and tighten
3-8
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Alternator Troubleshooting Chart (Cont.)
Tr o u b l e
Pl ac e o f Tr o u b l e
Pr o b ab l e Cau s e
Rem ed y
Battery UnderCharging
Wiring
Disconnection or insufficient contact between key-switch and regulator "Exc" terminal
Repair
Ammeter Needle Unstable
F a n Be l t
Loose fan belt
Read just belt tension
Key Switch
Key switch insufficient contact
Change key switch
Wiring
Connection point loose, almost disconnected wires
Tighten, repair
Alternator
1. Inferior bearings
Change bearings
2. Diode puncture
Replace rectifier assembly
3. Stator coil groounded or layer shorted
Replace stator assembly
Wiring
"B" terminal shorted
Repair
Alternator
1. Positive side and negative side diode shorted
Replace rectifier assembly
Abnormal Noise from Alternator
Charging Circuit Fuse Melted
Replace capacitor 2. Capacitor puncture
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Regulator
Over charge
Replace regulator assembly
Battery
Battery misconnected
Connect properly
3-9
Alternator Disassembly To prevent possible fire and explosion, do not substitute automotive parts for this alternator or its internal components. These parts and assemblies have been specifically designed not to cause ignition of fuel vapors in the bilge. Regulator/Brush Holder Removal
1 1. Remove protective cap flange nuts move cover. 2
B
and one screw
2. Remove two screws assembly. Remove assembly.
A C
D
from “L2” terminal. Remove two securing the regulator cover. Re-
1 45383
securing the regulator/brush holder
3 3. Remove the nut holding the capacitor. capacitor. Remove capacitor. 4 4. Remove three insulators from the “L2,” “P,” and “B” terminals. 5 5. Remove the four thru-bolts securing alternator housing.
2 45384
3 45385
4 45386
5 5 45387
Safety Related
3-10
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Rotor Removal 6
1. Set alternator with pulley side down. Insert a screwdriver on each side of the housing. Pry from under the stator using any two lower slots. Do not pry on coil wires. 7
2. Remove the stator and rear housing from the rotor assembly.
8
9 3. Use a soft jaw vise to hold the rotor armature. Remove the
pulley nut E , washer rotor shaft.
F
, pulley
G
, tall spacer
H
and fan
I
from the
6
10 4. Using a plastic ha mmer, tap the top of the rotor shaft while lifting up on the front housing. Remove short spacer J and front bracket K .
45389
7 45390
8 45391
9 45392
10 45397 Elect/eng
3-11
Bearing Removal
1 Remove the three screws
A
and retainer B from front housing. Support bracket in a press on the inside mach ined surface. Press bearing out from the bracket.
Stator Removal 2
Unsolder the stator leads. Hold the rectifier lead with long nose pliers to protect rectifier from the heat. Remove the stator.
1
Rectifier Removal
45396
3 Remove the screw securing the rectifier to the back housing. Remove rectifier.
Testing Stator The stator consists of three separate windings terminating in a delta type connection. It produces alternating current for charging the battery and operating electrical accessories. accessori es. The windings must be checked for grounds and open circuits with an ohmmeter. Any stators with discolored windings should be replaced.
2
Open Circuit Check
45395
1. Resistance throu gh the stator is very low, so set an ohmmeter o n the low ohm scale.
4 2. Connect the leads to terminals
and D and check for approximately 0.2 ohm resistance. Repeat this check using terminals C and E , then terminals D and E . The resistance values of all three checks must be the same. If not, replace the stator. C
Ground Check
5 1. Set the ohmmeter on the high ohm scale. Connect the leads between one terminal and the stator frame. The meter must show no continuity (infinity).
3 45393
2. Repeat this check with the remaining two terminals. If any reading shows continuity, continuity, the stator is grounded and must be replaced.
4 45398
5 45399
3-12
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Testing Rotor Asse mbly The rotor assembly requires two tests; one for shorts and open circuits, the other for grounds. Conduct both checks checks with an ohmmeter. ohmmeter. Clean slip ring surfaces with a fine crocus cloth and wipe off dust. This will ensure accurate ohmmeter readings.
Open/Short Circuit Check 1. Set the ohmmeter to the low scale. 6
2. Touch one ohmmeter lead to each slip ring. The meter reading should be approximately 4.1 to 4.7 ohms at room temperature. A lower reading indicates shorted windings. A higher reading shows excessive resistance. An infinity reading means an open circuit. Replace the rotor if it doesn’t have the specified resistance.
6 45400
Ground Check 1. Set the ohmmeter ohmmeter to the the high scale. 7
2. Touch one meter lead to a slip ring and the other to the rotor body. The only acceptable reading rea ding is infinity. Any continuity reading means mea ns the rotor assembly is grounded and must be replaced.
7 45401
Testing Rectifier The rectifier contains nine diodes. The rectifier converts stator alternating current into direct current as it leaves the alternator. Tests must be made with an ohmmeter to check continuity of all nine diodes in both directio ns of polarity.
Checking Positive Diodes 8
1. Test Test the positive diode by touch ing the positive ohmme ter probe to the terminal of each diode and touching the negative ohmmeter probe to the heat sink. 2. All the diodes should indicate continuity. continuity. If a diode indicates no continuity, that diode is open, replace the rectifier assembly. 3. Reverse the probes to check the diode in the other direction. All the diodes should indicate no continuity. If it indicates continuity, that diode is shorted, replace the rectifier assembly.
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3-13
8 45449
Checking Negative Diodes
1 1. Test Test the negative diode by touching the positive ohmmeter probe to the heat sink and the negative ohmmeter probe to the terminal of each diode. 2. All of the diodes should indicate continuity. continuity. If a diode indicates no continuity, that diode is open, replace the rectifier assembly. 3. Reverse the ohmmeter probes to check the diode in the other direction. All of the diodes should indicate no continuity. If diode indicates continuity, that diode is shorted, replace the rectifier assembly.
1 45451
Checking The Diode Trio Test the diode by touchi ng the positive ohmme ter probe to one 2 1. Test end of the diode and the negative oh mmeter probe to the opposite side of the diode. Then reverse the probes to check the diode in the other direction. 2. The meter must show continuity only in one direction and a high resistance reading in the other. 3. Repeat this test on each of the two remaining diode terminals. Test results must show a continuity reading in the same direction for all three diodes, and a high resistance reading in the opposite direction. If any diode fails a test, replace the rectifier assembly.
2 45452
Checking Brush and Brush Holder
3 1. Check the exposed brush length
A
. Minimum Minimum exposed exposed length
should be 0.197 in. (5 mm). 2. The contact between the brush and a holder must be smooth. The insulation between the holder and bracket bracket should be checked to make sure there is no electrical conduction. 3. Spring pressure range should be between 8.8 - 12.3 oz. (250 g - 350 g) when spring length is 0.512 in. (13 mm). If tension is low, the lowering motion of the spring will be stiff and cause inadequacy of contact with the slip ring. If pressure is high, wear from friction increases.
3-14
3 45410
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4
5
6
45444
45394
45 4 1 1
Testing Capac itor
4 The capacitor is held to the alternator rear cover by a single screw. Use an appropriate capacitor tester and follow the manufacturer’s instructions. The capacitor capacity should be 0.5 - 0.1 microfarad.
Voltage Regulator There are no volt, ohm, or amperage tests for the voltage regulator because it’s a solid-state, transistorized component. If all other alternator components test okay, replace the regulator.
7 45412
Alternator Assembly Rectifier and Stator Installation
5
1. Install rectifier into the alternator back housing. Secure the rectifier with scre w. Tighten securely. 6 2. Install stator into the front housing. Solder the three leads to each diode terminal.
Front Housing Assembly
8
7
45403
1. Press bearing i nto front alternator bracket until it seats. Attach Attach retainer to the inside of the bracket with three scre ws. Tighten securely. 8
2. Place rotor in a soft jaw vise. Install front housing over rotor shaft. Place the short spacer B on the shaft.
9 3. Place fan spacer
D
C
onto the shaft with blades facing down. Place tall on the shaft.
10 4. Install pulley E , washer and pulley nut nut to 47 ft. lb. (63 N m).
F
onto the shaft. Tighten
•
9 45404
10 45405 Elect/eng
3-15
1
2
3
45406
45474
45473
Rotor Installation
1 1. Position stator with three screws
A
at the top and the pivot point at the bottom. Align the four thru-bolt holes and tighten bolts C securely. B
2 2. Install three insulators on the “L2”, “P” and “B” terminals.
3 3. Install capacitor
D
and secure with nut E . Attach capacitor wire to “B” terminal and tighten securely. Place nut on “P” terminal and tighten securely.
4 45407
Regulator/Brush Holder Installation
4
5
1. Inspect seal for wear or damage. Place the seal on the regulator/brush holder assembly.
5 2. Push in brushes on the regulator/brush holder assembly and temporarily lock in place with a pin or wire hole in the brush holder.
F
inserted through access
6
3. Place regulator/brush holder onto the back alternator housing. Secure the regulator/brush holder assembly with two screws G and tighten securely. Seat the seal around the end of the housing H . Attach conducting strap I to terminal “L2”.
5 45475
6
4. Remove the temporary holding pin F to release the brushes. Spin the alternator to be sure it moves freely. 7
5. Place cover over regulator/brush holder assembly and tighten the two flange nuts J to 51 in. lbs. (5,8 N •m) and one screw K to 30 in. lbs. (3.4 N •m).
6 45476
7 45477
3-16
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4
R 0 4
7
3 1
6 5
P B+
L2
1
E EXC
S
6
8
56
4
4 2
5
6 1
2
-
+
C S M
4
A M B
DRC7517
Charging Circuit Diagram 3.0 GS Models 4.3 GL and GS Models 5.0 GL Models 5.7 GS Models 1 2 3 4 5 6 7 8
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Black Red Purple/White Red/Purple 20 Amp Fuse Purple Carburetor Choke Coil Orange
3-17
4
R 0 4
6 5
P B+
L2
1
E EXC
S
6
8
56
4
4 2
5
6 1
2
-
+
C S M
4
A M B
DRC7520
Charging Circuit Diagram 4.3 Gi Models 5.0 Gi Models 5.7 GSi Models 7.4 Gi, GSi Models 8.2 GSi Models 1 2 3 4 5 6 7
Black Red Purple/White Red/Purple 20 Amp Fuse Purple Orange
3-18
Elect/eng
Charging System Problems Battery. Check: • Proper Proper Cold Cold Cran Crankin king g Amps Amps rati rating ng • All All wir wirin ing g and and conn connec ecti tion ons s • Spec Specif ific ic gra gravit vity • Water ater,, add add and and rec recha harg rge e • Make lo load test Overcharge. Check: • Regulator • Loos Loose e conn connec ecti tion ons s • B a tt e ry Undercharge. Check: • • • •
Belt te tension Regulator Tarni arnish shed ed slip slip ring rings s Intern Internal al altern alternato atorr compon component ents s
No charge. Check: • • • • • • •
Alte Altern rnat ator or grou ground nd Belt te tension 20 amp amp fuse fuse a and nd 50/6 50/60 0 amp amp circu circuit it brea breaker ker All All wir wirin ing g and and conn connec ecti tion ons s Regulator Tarni arnish shed ed slip slip ring rings s Intern Internal al altern alternato atorr compon component ents s
Ignition Misfire. Check: •
Alte Altern rnat ator or grou ground nd
Inoperable Electric Fuel Pump. Check: •
4.3 GL, GL, GS, GS, 5.0 5.0 GL and 5.7 5.7 GS models models only only - voltage voltage at “L2” terminal
Inoperable Electric Choke. Check: •
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All carburete carbureted d models models - voltag voltage e at “P” terminal terminal
3-19
P B
5
3
6
0.5MF (REG (REG.)
1
4
KEY
L2 EXC
L O A D
S F
E
2
DRC6719
Alternator Internal Diagram 1
2 3 4 5 6
Regulator Rotor (field) Stator Rectifier Diode Trio Capacitor
3-20
Elect/eng
Specifications Alternator - 65 Amp Mini mum Engine Engin e RPM for Alternat Alte rnator or Output ................................ ................................................ ................................ ................................. ................................. ................400 400 RPM Regulate Regu lated d voltage volt age range rang e ............................... ............................................... ................................. ................................. ................................. ................................. ............................ ............ 14.0 - 14.7 Amperage Ampe rage output outp ut ................................ ................................................ ................................. ................................. ................................. ................................. ................................ ................................ ..................... ..... 65 Regulator Regu lator ................................. ................................................. ................................. ................................. ................................. ................................. ................................ ..................... .....Inte Internal rnal , soli d state stat e Belt Bel t tension tens ion ................................. ................................................. ................................. ................................. ................................ ........................ ........ 1/4-1/2 1/4- 1/2 in. give with fing er pressure pres sure Output tests: ......... ............. ......... .......... .......... ......... ......... .......... ......... ......... .......... .......... ......... ......... .......... .......... ....... Load battery to obtain maximum alternator output At 650 engine RPM ............................... ................................................ ................................. ................................ ................................. ............................ ........... 20 amps approxim appr oximatel atel y At 1500 engine en gine RP M ................................ ................................................ ................................. ................................. ................................ ................................. .......................... ......... 53 amps min . At 2000 + engine engi ne RPM ............................... ............................................... ................................. ................................. ................................. ................................. ........................ ........ 56 amps min . “L2” termina l voltage volt age (engine runnin g) ................................ ................................................. ................................. ................................. ..............................13 .............13.0 .0 - 14.0 volts “P” termina l volt age (engin e runn ing) ............................... ............................................... ................................. ................................. ................................ ..................... ..... 6.5 - 7.5 volts Capacito Capa cito r capa city ............................... ............................................... ................................. ................................. ................................ ................................. ...................... ..... 0.5 ± 0.1 microfarads microfa rads
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3-21
Section 4 Trim/Tilt Electrical Electrical System System All Models Table of Contents Relay Ohmmeter Ohmmeter Tests ................................. ................................................. ................................. ....................... ...... 4-7 4-7 Trim Sending Unit Adjustment Procedure ........................... ......................................... ............................ ........................... .............4-6 4-6 Test Procedure ............................ ......................................... ........................... ............................ ......................... ........... 4-6 Specifications ........................... ......................................... ........................... ........................... ............................ ................. ... 4-8 Trim/Tilt Operation ................................ ................................................ ................................ ................................. ......................... ........ 4-2 Switch ................................ ................................................. ................................. ................................ ............................. ............. 4-3 Troublesh roubleshooti ooting ng ................................. .................................................. ................................. ................................ ................ 4-4 4-4 Trim/Tilt Trim/Tilt Circuit Wiring Wiring Diagram ............................... ............................................... ......................... ......... 4-9 4-9
Safety Warnings Before working on any part of the electrical s ystem, read the Safety section at the end of this manual. The original mounting, support and routing of electrical system parts conform with U.S. Coast Guard requirements. It is important to maintain the original mounting, support and routing after s ervicing the electrical system to prevent possible fire and explosion in boat’s engine compartment. Do not substitute automotive parts. Volvo Volvo Penta marine components meet U.S. Coast Guard regulations for external ex ternal ignition proof operation and marine use. Volvo Penta marine components are spec ially designed not to cause ignition of fuel vapors in the bilge or engine compartment. The use of automotive parts can result in fire and explosion.
Elect/eng
4-1
4
Trim/Tilt Operation Stern drive models covered in this manual are equipped with power trim/tilt as standard equipment. The purpose of the trim/tilt system is to enable the operator to change the angle of the vertical drive from the helm. Changing the angle of the vertical drive in relation to the boat bottom is called “trimming.” “trimming.” Trimming Trimming provides the following benefits: •
Impro Improves ves accele accelerat ration ion ont onto o plan plane e
•
Maintains Maintains boat on plane plane at at reduced reduced throttle throttle settings settings
•
Incr Increa ease ses s fuel fuel econ econom omy y
•
Provides Provides smoot smoother her and/o and/orr drier drier ride ride in choppy choppy water water conditions
•
Incr Increa ease ses s ttop op spee speed d
The trim/tilt switch is located on the remote control handle or on the boat’s dashboard. The trim/tilt switch changes the direction of movement of the boat’s bow. The trim/tilt gauge located on the dash shows the corresponding bow position.
Trimming Safety Warning: The boat trim should be adjusted to provide balanced steering as soon as possible each time you get underway. Some boat/motor/propeller boat/motor/propelle r combinations may encounter boat instability and/or high steering torque, when operated at or near the limits of the “Bow-Up” or “Bow-Down” positions. Boat stability and steering torque can also vary due to changing water conditions. If you experience boat instability and/or high steering torque, see your authorized dealer to correct these conditions. The power trim is normally used prior to accelerating onto plane, after reaching the desired RPM or boat speed, and when there is a change in water or boating condition. Locate passengers and equipment in the boat so that the weight is balanced fore and aft, and side to side. Trimming will not cancel an unbalanced load. To operate the trim, push the switch until the desired bow position is reached. The trim may be operated at any boat speed or at rest. Avoid operating the trim system when running in reverse. Observe the trim/ tilt gauge which indicates the boat’s bow position achieved by the trim angle of the vertical drive unit. “Bow-Up” corresponds to the upper portion of the trim range on the gauge while “Bow-Down” corresponds to the lower portion of the trim range on the gauge. The boat will be properly trimmed when the trim angle provides the best boat performance for your particular operating conditions. A trim position that provides a balanced steering load is desirable.
Safety Related
4-2
Elect/eng
Tilting The tilting feature of the vertical drive unit is also controlled by the trim/ tilt switch. When the switch is held in the “Bow-Up” position, the vertical drive unit tilts up until the switch is released or the drive unit reaches the maximum tilt position. The trim/tilt gauge will indicate the “Tilt” position whenever the vertical unit is in the tilt range. Tilting is normally used for raising the vertical drive unit to obtain clearance when beaching, launching from a trailer, or mooring. When tilting the vertical drive unit, the boat should be at rest or at idle speed only. Do not operate the drive unit out of water even rnomentarily, water pump may be damaged or engine may overheat. •
To avoid possible contact with the propeller, never use the vertical drive unit as a ladder or as a lift to board the boat. Never board at the rear of the boat when the engine is running, even if the engine is operating in neutral.
•
Any malfu malfunct nction ion of of the trim/ trim/tilt tilt system system could could result result in a loss of shock absorber protection if an underwater obstruction is hit. Malfunction can also result in loss of reverse thrust capability. If malfunction occurs, see your authorized dealer.
Trim/Tilt Switch Test Lig ht Special Tools Required: 12 Volt Test
Inspection Procedure: Check wiring connections, 50-amp trim/tilt circuit breaker, 10-amp circuit breaker on pump, and battery voltage. Test Proce dure When switch is operated, current flows from input terminal (red/purple) to respective output terminals. To check switch: 1. Probe red/purple red/purple terminal with test light for for voltage. If test indicates no input voltage, check 50-amp circuit breaker, 10-amp circuit breaker on trim pump, or wiring connections. 2. When pressing switch down, probe green/white terminal for voltage. 3. When pressing switch up, probe blue/white terminal for voltage. If test light indicates failure, replace trim/tilt switch.
Elect/eng
Safety Related
4-3
1
2 DRC7370
DR3950
Trim/Tilt System Troubleshooting Before beginning this procedure: •
Charge Cha rge batt battery ery and and conne connect ct batt battery ery cabl cables. es.
•
Turn Turn key key switch switch OFF OFF,, and remo remove ve key key.
All tests are made from the RELAY SIDE of the trim/tilt relay sockets. 1. Connect voltmeter black lead to a clean engine ground. 2. Check for voltage at both sides of the 50 amp trim/tilt circuit breaker. •
If no voltage voltage at ttrim/tilt rim/tilt side side of the 50 amp circuit circuit breaker, breaker, check for a tripped breaker. breaker. If okay okay check battery and wiring.
•
If voltage at at trim/tilt trim/tilt side of 50 amp circuit breaker, breaker, go to Step Step 3 (or Step Step 11, 11, if problem problem is only with with tilt down/trim in).
UP CIRCUIT
1
2
3. Mark UP and DOWN relays, and remove relays from relay sockets.
4. Connect voltmeter red lead to V1 and black lead to V2. •
If no volt voltag age e at V1 , check red/purple wire between trim/tilt side of 50 amp circuit breaker and relay sockets. If red/purple wire is okay, check black wire between relay sockets and engine ground.
•
If voltage at V1, go to Step 5.
5. Connect voltmeter black lead to a clean engine ground, and voltmeter red lead to V3 (blue). 6. Push UP trim button. •
If no volt voltag age e at V3, check trim switch and wiring, and go to Step 7.
•
If voltage at V3, go to Step 7.
4-4
Elect/eng
7. Reinstall UP relay. Push blades only halfway into UP socket. 8. Push UP trim button and check for voltage at V4 on relay blade (M terminal of relay). •
If no volt volta age at V4, go to Relay Ohmmeter Test.
•
If v vo oltage at at V4 , go to Step 9.
9. Disconnect trim motor’s blue/white and green/white power wire connector (leave relay in socket). 10. Push UP trim button. Check for voltage on blue/white wire. •
If no voltage on blue/white wire, check check blue/white blue/white wire from relay relay bracket bracket to motor connector. connector.
•
If v voltag oltage e on blue/white blue/white wire, check check motor motor and lead.
DOWN CIRCUIT
1
2
11. Mark UP and DOWN relays, and remove relays from relay sockets.
12. Connect voltmeter red lead to V5 and black lead to V6. •
If no volt oltage age at V5, check red/purple wire between trim/tilt side of 50 amp circuit breaker and relay sockets. If red/purple wire is okay, check black wire between relay sockets and engine ground.
•
If voltage at V5, go to Step 13.
13. Connect voltmeter black lead to a clean engine ground, and voltmeter red lead to V7 (green). 14. Push DOWN trim button. •
If no no v vo ol ta tage a att V7 , check trim switch and wiring, and go to Step 15.
•
If voltage at V7, go to Step 15.
15. Reinstall DOWN relay. Push blades only halfway into DOWN socket. 16. Push DOWN trim button and check for voltage at V8 on relay blade (M terminal of relay). •
If no volt volta age at V8, go to Relay Ohmmeter Test.
•
If v vo oltage at at V8, go to Step 17.
17. Disconnect trim motor’s blue/white and green/white power wire connector (leave relay in socket). 18. Push DOWN trim button. Check for voltage on green/white wire.
Elect/eng
•
If no voltage, voltage, check check green/wh green/white ite wire from from relay relay socket socket to motor motor connector connector..
•
If v voltag oltage e on green green/whit /white e wire, wire, check check motor motor and lead. lead.
4-5
Trim Sending Unit Test Procedure Procedur e Remove sender from gimbal ring. Disconnect the sender 3-pin connector inside the boat. 1. Attach an ohmmeter between the “A” terminal ribbed black lead and the terminal “C” smooth black lead of the sending unit. Slowly rotate the sending unit control nut counter cloc kwise until the ohmmeter is set at infinity or open line (OL), then slo wly rotate control nut counter clockwise and ohmmeter will jump to 0 ohms. Continue to rotate control nut for a highest ohmmeter reading of 600 ± 25 ohms.
1 19766
2. Attach an ohmmeter between the “A” terminal ribbed black lead and the terminal “B” white lead of the sen der. Slowly rotate the sending unit control nut counter clockwise until the ohmmeter is set at infinity or open line (OL), then slowly rotate control nut counter clockwise and ohmmeter will jump to a highest ohmmeter reading of 600 ± 25 ohms. Continue to rotate control nut for a lowest ohm reading of 0 ohms. 3. Attach an ohmmeter between the “C” terminal smooth black lead and the terminal “B” white lead of the sender. sender. Slowly rotate control nut counter clockwise. Ohmmeter should maintain a steady 600 ± 25 ohms.
2 19514
If sender fails one of the three previous ohmmeter tests, replace the sender.
Adjustment Procedure
1 1. Attach an ohmmeter between the “A” terminal black lead and the terminal “C” black lead of the sending unit amphanol connector A . Slowly turn the sending unit control nut until the meter reads 11 ± 1 ohm. 2
2. With the pivot housing pushed in towards the gimbal housing, install and engage the sending unit control nut into the pivot bolt head. Install two trim sender mounting screws B finger tight.
3 19765A
3 3. With the pivot housing pushed in toward the gimbal housing, check adjustment of sending unit. Rotate sending unit to obtain a 11 ± 1 ohm reading on the meter, then tighten mounting screws to a torque of 18-24 in. lb. (2.0-2.7 N m). •
47508
4-6
Elect/eng
Relay Ohmmeter Tests 4 The orientation and location of the UP and DOWN relays in the bracket will vary from model to model, but the relay terminals are always connected to the electrical system and trim motor as follows:
S
= Swit Switch ch (+ or or – –)) Wire Color = Blue/White, Green/White, or Black
olt (+) (+) Batt Batter ery y B+ = 12 Volt Wire Color = Red
4
Battery y (Groun (Ground) d) B- = 12 Volt (–) Batter Wire Color = Black
DR3950A
M = Motor Wire Color = Blue or Green To protect your test li ght or ohmmeter, remove relays from sockets before proceeding with test. 1. Use an ohmmeter calibrated calibrated on high ohms scale or a continuity light to test continuity.
5 2. Connect meter leads to relay terminals “B–” and “M”. • 6
5
The The met meter er mu must st show show continuity .
DR3950B
3. Connect meter leads to relay terminals “B+” and “M”. •
The The met meter er mu must st show show no continuity .
7
4. Calibrate ohmmeter on appropriate scale and connect the leads to the two relay “S” terminals. To avoid immediate meter damag e, never apply an ohmmeter to an electrical circuit where voltage is present. •
The me meter ter must must s show how 70-100 70-100 ohms. ohms.
6 DR3950C
7 DR3950D
Elect/eng
4-7
1 5. Connect a 12-volt source to the relay “S” terminals. Use an ohmmeter calibrated calibrated on high ohms scale or continuity light to test for continuity on relay terminals “B+” and “M”. •
The The met meter er mu must st show show continuity .
2 6. Leave the 12-volt source connected to the “S” terminals. Connect meter leads to relay terminals “B–” and “M”.
•
The The me mete terr mu must st show show no continuity .
1
7. If your results vary, replace the relay.
DR3950
2 DR3950
Specifications Trim/Tilt Motor Circuit Breaker Open ..... ......... ......... .......... .......... ......... ......... ....... .. within 20-6 0 seconds @ 80 amps Outdrive Travel Travel Time Time ...... ........ one up/down cycle @ 40 sec. max.
Trim Sending Unit Resistance ..... ......... ......... .......... .......... ......... ......... .......... .......... ......... ......... ........ ... 0-600 + 25 ohms Mounting Screw Torque Torque ...... ............ ............ ............ ...... 18-24 in. lb. (2.0-2.7 N m) •
4-8
Elect/eng
DRC7514
Trim/Tilt Circuit C ircuit 1 2 3 4 5 6 7 8
Elect/eng
9
Black Red Black (Ribbed Wire) Red/Purple 20 Amp Fuse Purple Brown/White Trim Sending Unit
White Relays 11 Green 12 Blue 13 Green/White 14 Blue/White 15 10 Amp Fuse 16 40 Amp Fuse 10
4-9
NOTES
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GMEFIDI/eng
Section 5 Ignition System Delco EST 3.0 GS Models 4.3 GL Models
Table of Contents Description................................................. Description.................................... ........................... ........................... .......................... ............. 5-3 Distributor Installation ........................... ......................................... ............................ ........................... ........................... .................. .... 5-6 Removal ........................... ......................................... ........................... ........................... ............................ ...................... ........ 5-5 Service .......................... ........................................ ........................... ........................... ............................ ........................ .......... 5-5 Ignition Circuit Diagrams .......................... ........................................ ........................... ........................ ........... 5-12 Ignition Coil Replacement Replacement ........................... ......................................... ........................... ....................... .......... 5-9 Ignition System Problems Problems ........................... ......................................... ............................ ..................... ....... 5-10 Sealants, Lubricants and Adhesives............ Adhesives .......................... ........................... ...................... ......... 5-2 Setting Initial Initial Timing ................................ ................................................ ................................. ......................... ........ 5-8 Special Tools............... ools ............................... ................................. ................................. ................................ ...................... ...... 5-2 Specifications ........................... ......................................... ........................... ........................... ............................ .............. 5-11 Troubleshoot Troubleshooting ing .......................... ........................................ ............................ ........................... .......................... ............. 5-3 12 Volt Positive (B+) Test .......................... ........................................ ............................ ....................... ......... 5-3 Ignition Coil Test Test ........................... ......................................... ........................... ........................... ...................... ........ 5-3 Ignition Module Test .......................... ........................................ ........................... ........................... .................. .... 5-5 Pickup Coil Test ................................ ................................................. ................................. ............................. ............. 5-4
Safety Warnings Before working on any part of the electrical system, read the Safety section at the end of this manual. The original mounting, support and routing of electrical system parts conform with U.S. Coast Guard requirements. It is important to maintain the original mounting, support and routing after servicing the electrical system to prevent possible fire and explosion in boat’s engine compartment. Do not substitute automotive parts. Volvo Penta marine components meet U.S. Coast Guard regulations for external ignition proof operation and marine use. Volvo Penta marine components are specially designed not to cause ignition of fuel vapors i n the bilge or engine compartment. The use of automotive parts can result in fire and explosion.
Elect/eng
5-1
5
Special Tools Tool Name Timing Test Lead
Volvo P/N
Panel Location
88 51 63 -6
*
*Component not located on a tool panel.
Sealants, Lubricants and Adhesives Silicone Grease Marine EP/Wheel Bearing Grease
5-2
Elect/eng
Description The Delco EST Delco EST (Electronic Spark Timing) system is used on non-EFI engines. The system consists of a distributor with an electronic ignition control module and pickup coil, a cap, rotor and remote coil. It does not contain breaker points, a condenser or centrifugal advance.
Troubleshooting The following tests are used to check various components of the Delco system. These These tests should be conducted as necessary to solve a particular problem, and should not be part of a normal tune-up procedure. The following equipment will be needed: • • • • • • •
O hmmete r Voltmeter Termi ermina nall Ada Adapt ptor ors s Timing Li Light Timin iming g Tes Testt Lea Lead, d, Volvo Penta P/N Penta P/N 885163-6 Tachometer Test est Pro Prope pell ller er - See See the the Propeller section of the Vertical Drive/Transom Bracket service manual.
All running tests must be conducted in water with the correct test propeller to properly load engine. Do not perform tests with a flushing adaptor.
12 Volt Positive (B+) Test Ignition Coil: 1. Disconnect the purple and gray wire connector at coil.
1 2. Connect voltmeter positive (+) lead to purple wire terminal
in connector and the negative (–) lead to engine ground B . Turn on ignition switch, meter should read a minimum of 8 volts. A
Distributor: 1. Attach purple and gray wire connector to coil. Disconnect pink and brown wire connector at distributor. 2
2. Connect voltmeter positive (+) lead to pink wire terminal C in connector and the negative (–) lead to engine ground. Turn Turn on ignition switch, meter should read a minimum of 8 volts.
Ignition Coil Test The ignition coil can be checked for open circuits and shorts with an ohmmeter. If the ignition coil fails any one of the following checks replace it. Remove both wire connectors from coil before performi ng tests.
1 34932
2 37708 Elect/eng
5-3
1
2
3
D R 3 3 02
DR3302
DR3302
1 1. To To check for short to ground , connect ohmmeter to the frame
A
and purple wire terminal B . With the ohmmeter set on the high scale, reading should be infinite ( ¥). A reading of other than infinity ( ¥) indicates a short to ground. 2
2. To check for an open or shorted primary circuit, connect ohmmeter to purple wire terminal B and gray wire terminal C . With the ohmmeter set on the low scale, reading should be .35-.45 ohms. A reading of more than .45 ohms indicates a possibl e open circuit. A reading of less than .35 ohms indicates a shorted circuit.
4 34935
3 3. To check for an open or shorted secondary circuit, connect ohmmeter to purple wire terminal B and high tension terminal D . With the ohmmeter set on the high scale, reading should be 7500-9000 ohms. A reading higher than 9000 ohms indicates a possible open circuit. A reading lower than 7500 ohms indicates a shorted circuit.
Pickup Coil Test The pickup coil can be checked for an open circuit and shorts with an ohmmeter. If the pickup coil fails either one of the following checks replace it.
5
1. Remove the flame arrestor cover (4.3 GL and GS Models Only). Remove screws securing distributor cap. Remove cap and rotor.
34936
4 2. Release locking tab E and unplug pickup coil connector. 5 3. To check for a short to ground, connect ohmmeter to the body of distributor and either terminal F or G . With the ohmmeter set on the high scale, reading should be infinite ( ¥). A reading of less than infinity ( ¥) indicates a shorted circuit. 6
4. To check for an open or shorted coil, connect ohmmeter to terminals F and G . With the ohmmeter set on the high scale, a good coil should have a constant value between 700 and 900 ohms. A reading higher than 900 ohms indicates a possible open circuit. A reading lower than 700 ohms indicated a shorted circuit.
5-4
6 34937
Elect/eng
Ignition Module Test The distributor’s ignition module has only two failure modes, “No spark” and “No spark advance”. After all other checks have been made and these conditions still exist, replace ignition module.
Distributor Removal 1. Disconnect high tension leads from distributor cap. 7
2. Lift locking tabs H and unplug both connectors from the distributor. tributor. Crank engine so number 1 cylinder is in firing position. Make a mark I on distributor base and engine, so the distributor can be replaced in its original position during installation.
7 34939
3. Remove two attaching screws and distributor cap. Note rotor tip position, and place a reference mark at this point on distributor housing so rotor/distributor rotor/distributor housing can be realigned during installation. If engine is cranked while distributor is out, complete ignition timing procedure must be followed. See Distributor Installation and Initial Timing procedure. 4. Remove distributor clamp and li ft distributor from engine. Discard gasket.
8 22817
Distributor Service Do not substitute automotive parts. Volvo Penta marine components meet U.S. Coast Guard regulations for external ignition proof operation and marine use. Volvo Penta marine components are specially designed not to cause ignition of fuel vapors in the bilge or engine compartment. The use of automotive parts can result in fire and explosion.
9
Disassembly Remove distributor from engine (if necessary) following previous procedure.
Ignition Pickup Coil: 1. Pull off rotor. 8
2. Place a mark on the gear J and the drive tang K so that the gear can be re-installed in its original location. Drive pin from gear and remove shaft assembly. 9 3. Detach leads from module. Pry off retainer coil M .
Elect/eng
Safety Related
L
, and remove pickup
5-5
22819
Ignition Module:
1 Detach leads and remove the mounting screws
. Remove module. Module may be stuck to housing and require prying off. A
Reassembly Ignition Module: 1. Clean old heat sink compound or silicone grease from mounting surfaces of module and distributor. 2
2. Apply Heat Sink Compound , or silicone grease, to mounting surface of module.
1 22818
Heat sink compound or silicone grease is necessary for proper heat dissipation.
1 3. Position module on mounting area of distributor and install the two mounting screws
A
. Tighten securely.
Ignition Pickup Coil:
3 1. Align tab
and hole C and attach pickup coil to pole piece as shown. Reattach pickup coil leads to module. B
4 2. Install retainer with locking tabs securely positioned in shaft groove
D
2 34941
.
Shaft, Gear and Rotor:
5 1. Install shaft into housing and assemble gear on shaft. Align gear
E
with tang mark
F
and secure with roll pin.
2. Align rotor with notch in shaft and press on securely. securely.
Distributor Installation Engine Not Disturbed Use this procedure if the rotor/housing/block relationship was marked, and the crankshaft has not been rotated. If ignition/valve timing relationship has been disrupted or engine has been cranked with distributor out, install distributor following Timing Out of Synch procedure.
3 23054
1. Position rotor about one-eighth turn counter-clockwise from the rotor reference mark previously placed on the distributor housing.
4 23053
5 22817
5-6
Elect/eng
2. Place a new distributor gasket on engine block. Align reference mark on distributor housing with mark on engine. Push distributor down into block until the housing is in a normal installed position. It may be necessary to move rotor slightly to engage distributor with camshaft gear and oil pump driveshaft, but rotor/housing/block rotor/housing/block reference marks should properly align when distributor is down in place. 3. Reinstall hold-down clamp and screw. Tighten Tighten screw enough so you can just turn the distributor. Attach the connector(s) to the distributor. 4. Install distributor cap. Tighten screws securely to maintain external ignition proof characteristics. Lubricate sockets in the distributor cap with EP/Wheel Bearing Grease or Grease or equivalent and install spark plug wires if they were removed. 5. Time ignition as required. See Setting Initial Timing procedure.
Timing Out of Synch Use this procedure if the rotor/housing/block rotor/housing/block relationship was not marked, or if the crankshaft has been rotated and the ignition timing is completely off. 1. Move number 1 piston to firing position (both valves for number 1 cylinder are completely closed) and alig n harmonic balancer timing mark with timing grid. Number 1 cylinder is now in position to fire. 6
2. Install distributor into engine. After distributor seats, rotor must be in position to fire number 1 cylinder as shown. If distributor does not seat in engine block, press down lightly on distributor housing while turning rotor. After distributor engages oil pump shaft, install distributor clamp and bolt, leaving bolt just loose enough to permit movement of distributor with heavy hand pressure. 3. Place cap on distributor housing. Rotate housing left or right until rotor lines up with terminal for number 1 spark plug wire. 4. Check all high tension wiring, and connect spark plugs wires to cap in proper sequence if they have been removed. 5. Attach connecto r(s) to distributor. Continue on to Setting Initial Timing procedure.
Elect/eng
Safety Related
5-7
6 34928
To prevent a possible explosion, operate the blower as recommended by the boat manufacturer before starting engine. If the boat is not equipped with bilge blower, open engine cover or hatch prior to starting and leave open until after engine is running.
Setting Initial Timing 1 The timing mark is stamped on the rim of the harmonic balancer. The timing grid is a scale attached to the timing chain cover. cover. It shows Top Dead Center (marked “0”) and degrees of advance (before) or retard (after). (after). Each division on the scale represents 2 degrees.
Preparation 1. Connect a 12-volt timing light to number 1 spark plug lead, and use the timing light following the manufacturer’s instructions. Be careful not to puncture the wire or boot as this would cause a high voltage leak. Make sure that spark plug wires are pushed all the way down into the distributor cap terminals and onto the spark plugs. Nipples must be firmly pushed over the terminals, and boots over the spark plugs. Failure to do so can result in ignition of fuel v apors in engine compartment or bilge, and may res ult in fire or explosion.
1 5159
2. Start engine and leave running until thoroughly warmed up.
Have someone at controls. Keep hands, hair and clothing away from rotating parts while making adjustments when engine is running. 3. Adjust idle speed to specified in-gear RPM, then shift into NEUTRAL. Shut off engine.
Setting Timing
2
The timing procedure for Delco EST Delco EST system requires shunting (shutting off) the electronic spark advance. Follow the steps that apply to your specific model.
34929
2
1. Install Timing Test Lead, Volvo Penta P/N 885163-6 A , into distributor and connect bare lead to a 12-volt engine B+ source. Start engine.
Safety Related
5-8
Elect/eng
5
6
7
34930
25545
34 9 3 1
2. Direct beam of timing l ight onto timing grid. Loosen distributor clamp, then turn distributor slowly by hand until timing mark is set at the appropriate timing figure. See Tune-up Specifica tions in the General Information section of the Engine Service Manual . 3. Recheck timing mark; rese t if necessary. Tighten clamp bolt. 4. Stop engine. Remove adaptor plug.
Ignition Coil Replacement
8
5 1. Remove ignition coil to distributor cap high tension lead
25551
, two pin connector (purple and gray wires) F , and two pin connector (pink and brown wires) G from the ignition coil. 6
2. Remove two screws move ignition coil.
H
E
securing coil to engine block and re-
7
3. Place coil in a vise. Wear eye protection. Remove two rivet heads I . Drive the rivets out of the coil. Save the bracket pieces J . 8
4. Assemble the two bracket pieces J and the coil using two screws and nuts K provided in the replacement ignition coil kit. Tighten screws securely.
9 34942
9 5. Mount the coil coil assembly to the engine engine block. Secure with two bolts
H.
Tighten to 20-25 ft. lbs. (27-34 N m). •
10 6. Attach Attach two pin connector (pink and brown wires) G to the coil as shown. Attach Attach two pin connector (purple and gray wires) F to the coil as shown.
11 7. Apply marine EP/wheel bearing grease or equivalent to the high tension lead terminal
E
and attach it to the ignition coil.
10 34943
11 34944 Elect/eng
Safety Related
5-9
Ignition System Problems Engine runs sluggish, overheats. Check: • timing • for proper fuel • compression and for carbon buildup
Engine pings. Check: • timing • for proper fuel • compression and for carbon buildup • spark plugs for proper heat range
Engine starts hard. Check: • for spark • spark plugs • compression • battery • distributor cap
Engine misfires. Check: • spark plugs and leads • rotor and distributor cap • coil • engine firing order and plug wire routing • engine timing • engine operating in S.L.O.W.
Engine cranks but doesn’t start. Check: • for spark • coil primary and secondary circuit wiring • tachometer and wiring • primary circuit wiring to ignition coil • primary circuit wiring to distributor • ignition pickup coil • ignition module
5-10
Elect/eng
Specifications
Total Spark Advance 3.0 GS Models
600 1000 1500 2000 2500 3000 3500 4000 4600
RPM RPM RPM RPM RPM RPM RPM RPM RPM
................................. .................................................. ................................. ........................ ........ 8° ................................. .................................................. ................................. ...................... ...... 13° ................................. .................................................. ................................. ...................... ...... 15° ................................. .................................................. ................................. ...................... ...... 17° ................................. .................................................. ................................. ...................... ...... 18° ................................. .................................................. ................................. ...................... ...... 19° ................................. .................................................. ................................. ...................... ...... 20° ................................. .................................................. ................................. ...................... ...... 20° ................................. .................................................. ................................. ...................... ...... 21°
4.3 GL Models 86 AKI Fuel
E n g i ne R P M
18 ° 21° 23° 24° 25° 25° 25° 25° 25°
60 0 10 0 0 15 0 0 20 0 0 25 0 0 30 0 0 35 0 0 40 0 0 46 0 0
8 9 A K I F ue l 23° 26° 28° 29° 30° 30° 30° 30° 30°
Ignition and Pickup Coils Ignition Coil Primary Resistan ce, in Ohms @ 75° F ..... ..........0.35-0.45 .....0.35-0.45 Secondary Resistance, Resistance, in Ohms @ 75° F 7500 - 9000
Pickup Coil Resistanc e, in Ohms @ 75° F ......... ............. ......... .......... ........ ...700-900 700-900
Elect/eng
5-11
9
10
11 PUL +12V
7
G
6
A B
7
A B C D
12
C S
B A
8
3
6 B
6
A M
MA B
4
A
4
13
1
R
40
5 14
4
2
1 6 1
2 -
+
DRC7516
Ignition Circuit 3.0 GS Models 4.3 GL Models 1
Black 2 Red 3 40 Amp Fuse 4 Red/Purple 5 20 Amp Fuse 6 Purple 7 Gray 8 High Tension Tension Le ad 9 Spark Plug Lead 10 Spark Plug 11 Tachometer 12 Pink 13 Brown 14 Inductor
5-12
Elect/eng
Section 6 Ignition System Prestolite Integral BID 5.0 GL Models 5.7 GS Models
Table of Contents Distributor Initial Timing ............................... ................................................ ................................. ................................. .................... ... 6-9 Installation .......................... ........................................ ............................ ........................... ........................... .................... ...... 6-7 Removal .......................... ........................................ ........................... ........................... ............................ ........................ .......... 6-5 Service ........................... ......................................... ............................ ........................... ........................... ......................... ........... 6-6 Ignition Coil.............. Coil ............................... ................................. ................................. ................................. ......................... ......... 6-5 Ignition System Operation ................................. ................................................. ................................. ................................. ....................... ....... 6-2 Problems .......................... ........................................ ........................... ........................... ........................... ..................... ........ 6-13 Troubleshooting roubleshooting ........................... ......................................... ............................ ........................... ..................... ........ 6-10 Specifications .......................... ........................................ ........................... ........................... ........................... ................ ... 6-15 Wiring Diagram ............................... ............................................... ................................. ................................. .................. 6-14
Safety Warnings Before working on any part of the electrical system, read the Safety section at the end of this manual. The original mounting, support and routing of electrical system parts conform with U.S. Coast Guard requirements. It is important to maintain the original mounting, support and routing after servic ing the electrical system to prevent possible fire and explosion in boat’s engine compartment. Do not substitute automotive parts. parts . Volvo Volvo Penta marine components c omponents meet U.S. Coast Guard regulations for externa l ignition proof operation and marine use. Volvo Volvo Penta marine components are specially designed not to cause ignition of fuel vapors in the bil ge or engine compartment. The use of automotive parts can result in fire and explosion.
Sealants, Lubricants and Adhesives Black neoprene dip Marine EP/wheel bearing grease Silicone grease
Elect/eng
6-1
6
Ignition System Operation To clarify operating principl es as well as to simplify the process of tracing troubles, it should be understood that the ignition system contains two separate circuits.
1 The primary circuit carries the low voltage current supplied by the battery or alternator. In addition to these sources of electrical energy, the primary circuit contains the ignition switch A , primary winding B of the ignition coil, electronic control module and sensor C located in the distributor, distributor, and all low tension wiring.
1 DR4017
2
The secondary circuit carries the high voltage surges produced by the ignition coil which results in high voltage spark between the electrodes of the spark plug in the engine cylinders. This circuit contains the secondary winding D of the coil, coil to distributor high tension lead, distributor rotor and cap E , high tension ignition leads and spark plugs.
1 The electronic ignition system is “integrated”, “integrated”, in that the electronics are housed inside the distributor. distributor. Only two connections are made to the ignition coil. The electronic control module contained in the distributor is connected to the battery via the ignition coil positive terminal, and grounded through the distributor base.
3 A sensor
2 DR4016
and trigger wheel G replace the points and condenser in the distributor, and control the precise timing needed to fire the spark plugs. The electronic module H controls timing and ignition coil saturation by accurately making and breaking the ignition coil primary circuit. F
4 This ignition system is known as a “tuned” system. It uses an oscillator as its sensor. Acting Acting as a “metal detector”, it senses the trigger wheel teeth turning with the di stributor shaft. The presence of metal (each tooth) causes a change to occur in the oscillator which in turn commands the control unit transistor switch to turn off.
3 25200
5 This “off” condition causes the primary current to stop flowing. The magnetic field, which built up during the “on” time, will collapse across the secondary coil winding causing a high voltage to fire the spark plug.
4 DR3563
5 DR3564
6-2
Elect/eng
6
7
8
25630
25192
25 6 2 9
6
The sensor F is a coil of very fine wire molded into a plastic housing. This plastic housing is mounted on the base plate and connected directly to the circuit board. The sensor is serviced as an assembly with the electronic control module. 7
The electronic control control module is a completely self-contained self-contained solid state device which is encapsulated with potting compound to provide a vibration and moisture proof barrier. It is not repairable and, if necessary, must be replaced as a complete assembly. 8
9
The distributor is of a conventional conventional design using a centrifugal centrifugal advance mechanism to control timing.
25628
9 The ignition coil used with this system has a low resistance primary winding. A low resistance primary wind ing achieves high output for starting. A resistor wire is not used as primary current is regulated in the electronics. 10
As mentioned before, this system operates as a metal detecting system. The detected detected metal is each tooth of the trigger wheel when it is in close proximity to the sensor coil. The system is not speed sensitive, that is, it is not necessary to “generate” an electric current by turning the distributor shaft, and will operate at any speed above zero RPM.
10 DR3565
11 When a tooth of the trigger wheel is near the sensor, metal is detected I , the oscillator is at a low level J , the transistor is off K , and no primary current flows. This condition can be compared to “points open” L .
12 When the trigger wheel is away from the sensor, metal is not detected M , the oscillator is at a high level N , the transistor is on O , and current flows in the primary winding. This condition can be compared to “points closed” P .
11 DR3566
12 DR3567 Elect/eng
6-3
The high voltage surge produced in the secondary winding of the ignition coil travels through the cable to the center of the distributor cap, through the rotor to the adjacent distributor cap segment from which it is conducted to the proper spark plug by the high te nsion ignition wires. The high voltage surge jumps the gap between the insulated center electrode and the grounded side electrode of the spark plug, producing the spark required to ignite the fuel-air charge in the selected combustion chamber of the engine. The sequence of action described above is repeated as each tooth of the trigger wheel moves past the sensor coil, and caus es the transistor to be turned on and off. The timing of the spark with respect to the piston position in the cylinder must vary in accordance with operating conditions if best engine performance is to be obtained. The spark advance for obtaining satisfactory idling should be as low as possible. At high speed, the spark must occur earlier in the compression stroke in order to give the fuelair mixture ample time to ignite, burn and delive r its power to the piston as it starts down on the power stroke. Control of spark timing to satisfy these constantly changing operating requirements is obtained in two ways, as follows: Initial manual setti ng of distributor is made so that a tooth of the trigg er wheel passes the sensor coil at a specified position of the piston, as indicated by the timing mark on the crankshaft pulley.
1 Centrifugal advance advance is governed by engine speed. speed. The centrifugal advance mechanism consists of an advance cam, a pair of advance weights A , two springs B and a weight base plate. At idle speeds the springs hold the advance weights so that there is no spark advance, and the spark occurs in accordance with the initial manual setting of the distributor. As speed increases, centrifugal force causes the advance weights to throw outward and push against the advance cam. This rotates the weight plate causing the teeth of the trigger wheel to pass by the sensor coil earlier in the compression stroke, so that the timing is advanced.
6-4
1 25192
Elect/eng
Ignition Coil 2
Special Tools Required: Ignition Tester
Most ignition coils that are replaced are classified as weak. Many coils rejected as weak actually test up to specifications and give normal performance. A coil that actually is weak will first affect engine performance performance when the ignition reserve is at a minimum. This may be in starting, low speed acceleration or top speed. Eventually, the engine will fail to start. High resistance connections in either the primary or secondary circuit wiring will react the same as a weak coil. Wide spark plug gaps, which require higher voltage than the coil can produce, will put the coil under suspicion. High compression and lean carburetion increase the voltage requirements, requirements, and lead to many needless coil changes. Leakage of high tension current through moisture on an unprotected coil terminal may produce carbon tracks which weaken the coil output voltage. For this reason, the nipple on the coil high tension terminal must be properly installed and in good condition. When an ignition coil is suspected of being defective it should be tested on a reliable coil tester according to instructions supplied with the instrument, before being replaced.
Distributor Removal 1. Disconnect the distributor primary wires at the ignition coil. Disconnect high tension leads from distributor cap. Remove distributor cap. 2. Crank engine so number 1 cylinder is in firing position. Note rotor tip position, and place a reference mark at this point on distributor housing so rotor/distributor housing can be realigned during installation. 3. Place a mark on the distributor base and engine, so that the distributor can be replaced in its original position during installation. If engine is cranked while distributor is out, complete ignition timing procedure must be followed. See Distributor Installation and Initial Timing procedure.
Elect/eng
6-5
2 22310
4. Remove distributor clamp and lift distributor from engine. Discard gasket.
Distributor Service Do not substitute automotiv e parts. Volvo Volvo Penta marine components meet U.S. Coast Guard regulations for external ignition proof operation and marine us e. Volvo Penta marine components are specially designed not to cause ignition of fuel vapors in the bilge or engine compartment. The use of automotive parts ca n result in fire and explosion. Disassembly and Inspection Major components can be serviced without removing the distributor from the engine. 1. Remove the cap from the distributor. Some engines may require several high tension leads be removed to allow the cap to be moved out of the way. Mark the leads and terminals they were removed from so they can be replaced in the correct firing order. 2. Wipe out distributor cap with clean cloth and inspect it for chips, cracks and carbonized paths which would allow high tension leakage. Such defects require replacement of the cap. Clean loose corrosion from surfaces of terminal segments inside the cap. Do not use emery cloth or sandpaper. If segments are deeply grooved, cap should be replaced. Pull cables from terminal sockets and inspect sockets for corrosion. Clean sockets using a stiff wire brush to loosen corrosion. Lubricate sockets with wi th mari marine ne EP/wheel bearing b earing grease grea se before reassemreas sembly of high tension leads. Check carbon contact for excessive wear.
1 3. Remove the rotor and insp ect it. If rotor is cracked or rotor tip is badly burned, rotor must be replaced. 2
4. Loosen the sensor screw A . Remove two screws and lock washers B , then lift out the sensor/igniti on module assembly. Remove the purple and black wires from the ignitio n coil if this assembly is to be replaced.
1 25140
2
5. Inspect trigger wheel for signs of contact with sensor. Check distributor shaft for excessive wear between the shaft and bushings in housing.
3 6. Inspect for excessive wear between centrifugal weights and advance cam or pivot pins. Turn advance plate plate until weights are fully extended, then release and allow weights to return. Repeat several times. Springs should return weights to stop without sticking, and there should be no excess free play.
2 25200
3 25192
Safety Related
6-6
Elect/eng
7. Distributor housing: Spark suppression screens must be tightly in place.
Reassembly 1. Apply silicone grease to the bottom edge of the sensor/ignition module. 2
2. Install sensor/ignition module assembly into the distributor housing and secure with two screws and lock washers B . 2
3. Rotate the engine until one of the trigger wheel teeth lines up with the mark on the sensor. 4
4. Adjust the the sensor air gap by sliding the sensor in or out until an 0.008 in. (0,203 mm) measurement can be taken between the sensor and the trigger wheel tooth. Tighten the sensor mounting screw A securely. 1 5. Install the rotor making sure to align the notch in the distributor shaft with the rotor. Push the rotor down until it seats.
6. Attach the purple distributor lead to the positive (+) terminal of the ignition coil. Attach the black distributor lead to the negative (-) terminal of the ignition coil. Coat the terminals with black neoprene dip. 7. Reinstall the distributor cap. Tighten screws securely to maintain external ignition proof characteristics. Replace any high tension leads that were removed. Pay close attention to high tension lead routing and firing order. 8. Check ignition timing as required. See Finish Timing procedure.
Distributor Installation If the distributor has not been removed and the engine will run, continue on to the Initial Timing procedure.
Engine Not Disturbed Use this procedure if the rotor/housing/block rotor/housing/block relationship was marked, and the crankshaft has not been rotated. If ignition/valve timing relationship has been disrupted or engine has been cranked with distributor out, install distributor following Timing Out of Synch procedure.
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Safety Related
6-7
4 25146
1. Position rotor about one-eighth one-eighth turn clockwise clockwise from the rotor referreference mark previously placed on the distributor housing. 2. Place a new distributor gasket on engine block. Align reference mark on distributor housing with mark on engine. Push distributor distributor down into block until the housing is in a normal installed installed position. It may be necessary to move rotor slightly to mesh distributor gear with camshaft gear, but rotor/housing/block reference marks should properly align when distributor is down in place. 3. Reinstall hold-d own clamp and screw. Tighten Tighten screw enough so you can just turn the distributor. Connect purple primary wire to coil positive terminal and black primary wire to coil negative terminal. Coat terminals with black neoprene dip. 4. Install distributor cap. Tighten screws securely to maintain external ignition proof characteristics. Lubricate sockets in the distributor cap with mari marine ne EP/wheel bearing g rease and install spark plug wires if they were removed. 5. Time ignition as required. See Initial Timing procedure.
Timing Out of Synch Use this procedure if the rotor/housing/block relationship was not marked, or if the crankshaft has been rotated and the ignition timing is completely off. 1. Move number 1 piston to firing position (both valves for number 1 cylinder are completely closed) and align harmonic balancer timing mark with timing grid. Number 1 cylinder is now in position to fire. 2. Install distributor in engine. After distributor seats, rotor must be in position to fire number 1 cylinder. If distributor does not seat in engine block, press down lightly on distributor housing while turning rotor. rotor. After distributor engages oil pump shaft, install distributor clamp and bolt, leaving bolt just loose enough to permit movement of distributor with heavy hand pressure. 3. Place cap on distributor distributor housing. Rotate housing housing left or right until rotor lines up with terminal for number 1 spark plug wire. 4. Check all high tension wiring, and connect spark plugs wires to cap in proper sequence if they have been removed.
Safety Related
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5. Connect black primary wire to coil negative (–) terminal. Connect purple primary wire to coil positive (+) terminal. Continue on to Initial Timing procedure.
To prevent a possible explos ion, operate the blower as rec ommended by the boat manufacturer before starting engine. If the boat is not equipped with bilge blower, open engine cover or hatch pri or to starting and leave open until after engine is running.
Initial Timing
1
1 The timing grid is stamped on the rim of the harmoni c balancer. The timing mark is cast in to the timing chain c over. It shows Top Top Dead Center (marked “O”) and degrees of advance (before) or retard (after). Each division on the scale represents 2 degrees. 1. Connect a 12-volt timing light to number 1 spark plug lead, and use the timing light following the manufacturer’s instructions. instructions. Be careful not to puncture the wire or boot as this would cause a high voltage leak. Make sure that spark plug wires are pushed all the way down into the distributor cap terminals and onto the spark plugs. Nipples must be firmly pushed over the terminals, and boots over the spark plugs. Failure to do so can result in ignition of fuel vapors in engine compartment or bilge, and may result in fire or explosion. 2. Start engine and leave running until thoroughly warmed up and choke valve is wide open.
Have someone at controls. Keep hands, hair and clothing away from rotating parts while making adjustments when engine is running. 3. Adjust idle speed to specified in-gear RPM, then shift into NEUTRAL. 4. Direct beam of timing light onto timing grid. Loosen distributor clamp, then turn distributor slowly by hand until timing mark is aligned with the correct degree on the timing grid. See Tune-up Specifications in the General Information section of the Engine Service Manual.
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Safety Related
6-9
49478
5. Recheck timing mark; reset if necessary. Tighten clamp bolt. Recheck idle speed and mixture adjustments. adjustments.
Ignition System Troubleshooting Due to design and operating characteristics of this ignition system, a high voltage discharge in the coil secondary circuit may occur when the ignition switch is turned “ON” and “OFF”. The engine does not need to be cranked for this to occur. Always ground the coil high tension lead any time it is disconnected from the distributor. distributor. Failure to do so may result in fire and explosion if gas vapors are present. Ignition systems sometimes develop more than one problem. Be sure to complete the entire troubleshooting procedure before returning the boat to service. 1. Check simple things first. Inspect the follo wing and correct any problems found before preceding. •
Check Check the coil tower for carbon carbon track tracking. ing. Check primary wires for tight connections and proper polarity. Make sure the tower is clean and dry. Check coil nipple for proper sealing and insulating qualities. If flash over occurs here, the engine will not start.
•
Check Check the distribut distributor or cap cap for carbon carbon trackin tracking g and dirt inside and outside. Moisture and dirt make a good path for flash over. It is very important that the cap be clean. Once a track has started, the cap must be replaced. Check the rotor for the same condition.
•
Check Check all high high tensi tension on leads leads for for proper proper resistan resistance; ce; 3,000-7,000 ohms per foot of lead length. Also check for poor insulation, burning, cracking and deterioration deterioration of the lead, and torn or cracked plug and distributor cap boots.
•
Check Check spark spark plugs for fouling, fouling, proper proper gap gap and cracked cracked insulators. Wipe insulators clean before installing boots.
2. Check for spark from the ignition coil to the distributor, and from the distributor to the spark plug using a kilovolt meter. Follow the meter manufacturer’s instructions when performing the tests. Do not allow open sparks to occur. Open sparks can ignite fuel and air vapors that may be present in the bilge area and cause a fire or explosion. 3. If no spark occurred, remove the distribut or cap and rotor, and align a trigger wheel tooth with the center of the sensor. Check sensor air gap, which should be.008 in (0,203 mm). Note that the sensor will operate from a very small gap to a large gap. If the gap is incorrect, reset to .008 in. (0,203 mm) and repeat the spark test. Be sure the distributor shaft turns and is not broken or bent.
Safety Related
6-10
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1
2 DR5066
DR5067
Primary Circuit Voltage Tests
If voltage is 4 to 8 volts, ground the high tension tower of the coil. Place a screwdriver in front of the sensor face. This will discharge the coil. The voltage should now read 12 to 13 volts. If not, either the coil or the sensor/ circuit board assembl y is faulty. Test Test the coil and replace if defective. Repeat the screwdriver test. If no spark, replace the sensor/circuit board assemb ly and reset the sensor air gap.
Position the trigger trigger wheel so that the the sensor is between two teeth. Turn on the key switch. Primary current should flow.
1 1. Connect a voltmeter across the battery terminals A B . The meter should read between 12 and 13 volts. Recharge the battery if the voltage is low.
1
2
2. Connect the voltmeter between the negative battery terminal A or engine ground and the coil positive terminal C . The reading should be within one volt of the battery voltage in the previous stop. Perform a voltage drop test if the voltage is more than one volt low.
1
If voltage is lower than 4 volts, remove the wire from the negative terminal D of the coil. Reconnect the voltmeter to the negative terminal.
2
3. Connect the voltmeter between the negative battery terminal A or engine ground and the coil negative terminal D . The reading should be between 4 and 8 volts.
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•
12-13 12-13 volts volts - sensor sensor/c /circ ircuit uit boar board d assem assem-bly is shorted. Replace assembly.
•
0-4 volts volts - possibl possible e open open coil coil primary primary circuit. Replace coil.
If voltage is higher than 8 volts, check for an open distributor ground circuit or shorted shorted coil primary circuit. circuit.
6-11
•
Distr Distribu ibuto torr grou ground nd bad - repa repair ir..
•
Distribu Distributor tor ground ground is is good good - replace replace sensor/circuit board assembly.
•
Shorted Shorted coil primary circuit circuit - replace replace coil.
1
2 DR5066
DR5067
1
Voltage Drop Test
2 2. Connect the positive voltmeter Iead to the sensor/circuit board assembly case D , and the negative voltmeter lead to the negative negative battery post post A . The voltmeter reading should be less than one volt. If the reading is higher than one volt, tighten the system ground connections and inspect the battery ground cable. Check that the sensor/circuit board assembly mounting screws are secure. Repeat the test. Replace the battery ground cable if necessary.
Position the trigger trigger wheel so that the sensor is between two teeth . Turn on the key switch. Primary current should flow. 1
2 1. Connect the positive positive voltmeter lead to the
positive battery post B , and the negative voltmeter lead to the coil positive terminal C . The meter should read less than one volt. Check for poor connections at all attachment points. A fluctuation fluctuation indicates a poor connection and repairs must be made before proceeding. Poor connections cause heat and get worse, worse, until there is no current flow.
3. Check the distributor advance mechanism along with basic ignition timing. Be sure to operate the engine at the correct idle speed to be sure of an accurate basic timing adjustment.
6-12
Elect/eng
Ignition System Problems
Engine runs sluggish, overheats. Check: • • •
timing timing and aut automa omatic tic spark spark advanc advance e for prop proper er fuel uel compre compressi ssion on and for carbon carbon buildu buildup p
Engine pings. Check: • • • •
timing timing and aut automa omatic tic spark spark advanc advance e for prop proper er fuel uel spark spark plugs plugs for proper proper hea heatt rang range e compre compressi ssion on and for carbon carbon buildu buildup p
Engine starts hard. Check: • • • • • •
fo r sp a rk sp a rk pl u g s co mpre ss i on bypass ci ci rc u i t ba tte ry dis distrib ributor utor cap
Engine misfires. Check: • • • • • • •
spar spark k plu plugs gs and and lea leads ds roto rotorr and and dist distri ribu buto torr cap cap co i l for loose connectio connections ns at at coil coil and and igniti ignition on switch switch engine eng ine firing firing order order and and plug plug wire wire routin routing g e ng i ne ti mi n g engi engine ne oper operat atin ing g in S.L.O.W.
Engine fires when cranked, stops when key is released. Check: • •
wiring ci ci rcu i t igniti ignition on switch switch and connec connectio tions ns
Engine cranks but doesn’t start. Check: • • • • •
Elect/eng
fo r sp a rk coil an and wi wiring bypass bypass to coil coil positi positive ve (+) (+) term termina inall engine eng ine timing timing and plug plug wire wire routin routing g tach ach and wir wiring ing
6-13
L 6 8
4 A
12
13 10
+12V
16
SIGNAL G
13
2 6 9
15
14
C
A
9
5
9
M
S
4
2
M
B
8
11 5 2
R
40
7 9 5 3 2 3
_
+ 1
DRC7515
Ignition Circuit 5.0 GL Models 5.7 GS Models 1 2 3 4 5 6 7 8 9
Battery Black Red 40 Amp Fuse Red/Purple Main Cable Connector 20 Amp Fuse Ignition Switch Purple
10 11
12 13
14 15 16
Ignition Coil Distributor Tachometer Gray High Tension Tension Le ad Spark Plug Lead Spark Plug
* Optional Equipment
6-14
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Specifications
Total Ignition Spark Advance 86 AKI Fuel
En g i n e R P M
8 9 AKI Fuel
3° 7° 11° 14° 18° 22° 25° 26° 26° 26°
600 1200 1600 2000 2400 2800 3200 3600 4000 4600
8° 12° 16° 19° 23° 27° 30° 31° 31° 31°
Ignition Coil Operating Amperage @ 75° F ......... .............. ......... ......... .......... .......... ......... ....... ... 1.0 Maximum Primary R esistance , in Ohms @ 75° F ......... ............. ......... .......... .......... ....... .. 1.26 - 1.54 Secondar y Resistance , in Ohms @ 75° F ..... ......... ......... .......... ....... .. 9400 - 11000 11000 Coil must sustain 25-30 kv for 30 seconds
Distributor Sensor Air Gap ......... ............. ......... .......... .......... ......... ......... .......... .......... .........0.00 ....0.00 8 in. (0,203 mm)
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6-15
Section 7 Fuel Systems – Carbureted Models Table of Contents Carburetor Operation ................................. ................................................. ................................. ......................... ........ 7-3 7-3 Carburetor Replacement 3.0 GS Models ................................. ................................................. ................................. ................................7-12 ...............7-12 4.3 GL Models .......................... ........................................ ............................ ........................... ...........................7-12 ..............7-12 5.0 GL Models .......................... ........................................ ............................ ........................... ...........................7-12 ..............7-12 5.7 GS Models ................................. ................................................. ................................. ................................7-12 ...............7-12 Carburetor Service and Adjustments Adjustments - 2V Models 3.0 GS Models ................................. ................................................. ................................. ................................ ............... 7-11 7-11 4.3 GL Models ............................... ............................................... ................................ ................................. ................... 7-11 7-11 5.0 GL Models ............................... ............................................... ................................ ................................. ................... 7-11 7-11 5.7 GS Models ................................. ................................................. ................................. ................................ ............... 7-11 7-11 Electric Fuel Pump - 4.3 GL, 5.0 GL, and 5.7 GS Models Filter Bracket Replacement............ Replacement .......................... ............................ ........................... ................... ...... 7-28 7-28 Operati Operation on............... ................................ ................................. ................................ ................................. ......................... ........ 7-24 7-24 Relay Ohmmeter Ohmmeter Tests ................................ ................................................. ................................. ................... ... 7-33 7-33 Replac Replacemen ementt ............................... ............................................... ................................. ................................. ................... ... 7-25 7-25 Specifica Specificatio tions ns ................................. ................................................. ................................. ................................ ............... 7-30 7-30 Troublesho roubleshootin oting g ................................. ................................................. ................................ ............................. ............. 7-29 7-29 Wiring Diagram ........................... ........................................ ........................... ............................ ......................... ........... 7-34 7-34 Fuel Filter Replacement ...................... .................................. ........................ ....................... ....................... .............. 7-6 3.0 GS Models ................................ ................................................ ................................. ................................. .................. .. 7-6 7-6 Canist Canister er ................................. ................................................. ................................. ................................. ........................... ........... 7-7 7-7 Carbu Carburet retor or ............................... ............................................... ................................. ................................. ......................... ......... 7-7 7-7 Mechanical Fuel Pump and Vent Hose 3.0 GS Models ................................. ................................................. ................................. ................................. .................. 7-4 Pressure Testing ........................... ........................................ ........................... ............................ .....................7-4 .......7-4 Replacement............ Replacement .......................... ............................ ........................... ........................... ............................ ................ 7-5 Specifications Specifications .......................... ........................................ ............................ ........................... ..........................7-5 .............7-5 Vacuum Vacuum Testing .......................... ........................................ ........................... ........................... ........................7-4 ..........7-4 Sealants, Lubricants and Adhesives .......................... ....................................... ........................7-2 ...........7-2 Specific Specificatio ations, ns, Carburet Carburetor or ................................ ................................................. ................................. ................ 7-37 7-37 Tanks, Lines, Valves, Valves, and Fittings Fittings ............................... ................................................ ........................ ....... 7-8 7-8 Tools Required ........................... ........................................ ........................... ............................ ........................... ................. .... 7-2 7-2 Torque Values - All Models .......................... ........................................ ........................... ........................ ........... 7-37 7-37 Troubleshooting Boat Fuel System ................................. ................................................. ................................. ............................7-8 ...........7-8 Carbu Carburet retor or ............................... ............................................... ................................. ................................. ....................... ....... 7-22 7-22 Engine Fuel System ................................ ................................................ ................................ ....................... ....... 7-35 7-35
Elect/eng
7-1 7-1
7
Safety Warnings Before working on any part of the fuel system, read the Safety section at the end of this manual. The original mounting, support, and routing of the fuel system syste m parts conform with U. S. Coast Guard requirements. It is important to maintain the original mounting, support, and routing after servicing the fuel system. Do not substitute automotive parts. Volvo Penta marine components meet U.S. Coast Guard regulations for external ignition proof operation and marine use. Volvo Penta marine components components are specially designed not to cause ignition ignition of of fuel vapors in the bilge or engine compartment. The use of automotive parts can result in fire and explosion. Gasoline is extremely flammable and highly explosive under certain conditions. Ensure good ventilation. Do not smoke or allow open flames or sparks near fuel system or in engine compartment while servicing. When adjusting a carburetor while the engine is running or being cranked, use extreme care to avoid getting hands, fingers, or clothing caught in the alternator and water pump belts, pulleys, and other moving parts.
Tools Required Vacuum Gauge Fuel Pressure Gauge #2 Clutch Type Screwdriver
Sealants, Lubricants and Adhesives Volvo Penta gasket sealing compound Black neoprene dip Pipe sealant with Teflon Teflon
7-2 7-2
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Carburetor Operation The carburetor is a metering de vice for mixing fuel and air. At idle speed, an engine requires a mixture of about 8 parts air to 1 part fuel. High speed mixture is about 12:1. A small chamber (fuel bowl) ho lds the fuel. A float valve admi ts fuel from the fuel tank to replace fuel as it is consumed by the engine. Metering jets in the carburetor fuel chamber control the volume of fuel entering the carburetor fuel passages.
1 The intake stroke of the pistons in the engine cylinders creates a suction that draws air through the carburetor throat. A restriction in the carburetor throat, called a venturi A , has the effect of reducing air pressure B at this point by increasing air velocity.
1 The differential in throat and chamber air pressures
causes the fuel to be pushed out of the metering jets thro ugh fuel passages and into the air stream. Here it mixes with the air to form a combustible mixture for burning in the engine cylinders. C
In order to mix air and fuel in the right proportions for all engine speeds, the carburetor design includes idle, off-idle, accelerator, main, power, choke, and where applicable, secondary fuel systems. To regulate engine speeds, a throttle valve controls the volume of air/ fuel mixture drawn into the engine. To compensate for the extra amount of fuel required to start a cold engine, a choke valve is placed above the main venturi on top of the air horn. When the choke valve is clo sed, a very rich fuel mixture is drawn int o the engine. As the engine starts and warms up, the choke is opened to restore the normal air/fuel ratio required. The carburetor throat throat is frequently called the “barrel”. “barrel”. Carburetors with four barrels (BBL.) have individual metering jets, throttle and choke plates for each barrel. For more specific information about carburetor operation, refer to literature available from the carburetor manufacturer.
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7-3 7-3
1 DR3001
Mechanical Fuel Pump and Vent Hose 3.0 GS Models Special tools required: Vacuum and fuel pressure gauge such as Snap- on ® Tools MT31IJB Tools MT31IJB or equivalent. Under normal operation, the transparent vent hose should not contain fuel or oil. Any evidence of fuel fuel in this hose is an indication of a ruptured fuel pump diaphragm. Oil in the line indicates a seal failure in the pump allowing crankcase oil to leak into the pump. If fuel or oil is visible, replace the fuel pump immediately. If fuel pump is suspected of not delivering delivering proper amount of fuel fuel to the carburetor, carburetor, it should be inspected and tested as follows:
When performing procedure below, be careful of gasoline vapor build-up in engine compartment. Gasoline is very explosive. Before starting engine, always make sure compartment is free of fuel vapors to prevent possible fire and explosion. Pressure Testing 1. Make certain that there is gasoline in fuel tank. 2. Make sure fuel filter cartridge and carburetor fuel filter are new and free from obstructions. 3. Install pressure gauge to outlet side of pump. Use vacuum gauge according to instructions of the gauge manufacturer. manufacturer. Be sure to follow all notes and safety warnings. 4. Start engine and let it run at idle speed. speed. If pressure gauge gauge readings are as specified, see Boat Fuel System Troubleshooting for additional problem areas. If pressure is too low or too high, replace fuel pump. A boat fuel system that is restricted, or has an air leak on suction side of fuel pump, can cause an erroneous fuel pump diagnosis.
Vacuum Testing 1. Disconnect boat fuel line at inlet side of fuel filter canister. Cap end of line to prevent fuel leakage. 2. Disable ignition system to prevent engine starting when it’s cranked. Remove all wires from positive (+) terminal of ignition coil, and tape them to prevent accidental accidental grounding.
Safety Related
7-4 7-4
Elect/eng
3. Install and use vacuum/pressure gauge according to instructions of the gauge manufacturer. Be sure to follow all notes and safety warnings. 4. Crank engine and read gauge. Replace fuel pump if gauge does not register specified amount of vacuum.
Fuel Pump Specifications All Mechanical Fuel Pump Models Pressure ................................... ............. ………………………………………… 5 3/4 to 7 PSI (39,6 to 48,3 kPa)* Vacuum at Cranking Speed ............................. ……………………..……… 9 to 10 in. of Mercury (30 to 34 kPa) * At pump outlet, at idle speed
Fuel Pump Replacement 3.0 GS Models Removal To prevent fire and explosion, disconnect the battery before performing the following replacement procedures.
1
1. Place a container under the fuel pump to catch fuel that may drain from pump and lines when lines are removed. Unscrew fuel filter line A at fuel pump, and remove line from elbow. Be sure fuel shutoff is closed or fuel system is plugged to prevent leakage of fuel. Be careful not to spill fuel.
1 2. Disconnect carburetor fuel line at fuel pump. 1 3. Cut tie strap and pull vent hose off pump. 4. Support the front of the engine with a sutable engine hoist capable of supporting 500 lb (226 kg). 5. Remove starboard engine mounting bolts, and the upper flex mount nut. 6. Remove the engine mount. Do not change the position of the middle flex mount nut.
If the middle flex mount nut is moved, the engine alignment must be checked and reset if necessary. See ENGINE INSTALLA- TION found elsewhere in this manual. 7. Remove two fuel pump retaining screws and lock washers. Remove fuel pump and gasket from engine; discard gasket. Note orientation of pump elbows, then unscrew and save for use on new pump. 8. Thoroughly clean fuel pump mounting surface on cylinder block.
1 37919
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Safety Related
7-5 7-5
Installation
1 1. Apply pipe sealant with Teflon Teflon or equivalent to old pump elbows. Install elbows, tighten to 48-60 i n. lb. (5.4-6.7 N m), then tighten to original position. NOTE: Elbows may be angled or different sizes; make sure elbows are installed in correct holes. •
DO NOT use Teflon tape on elbow threads. Pieces can break loose and clog fuel system components. 2. Apply Volvo Penta gasket sealing compound or equivalent to both sides of a new fuel pump gasket. Place gasket on block and install pump. Install mounting screws and lock washers, and tighten screws to 20-25 ft. lb. (27-34 N m).
1 32016
•
2
3. Connect vent hose
A
to fuel pump. Secure with a new tie
strap. 2
4. Connect carburetor fuel line nut to 15-18 ft. lb. (20-24 N m).
B
to fuel pump. Tighten line
•
2
5. Connect fuel filter line 15-18 ft. lb. (20-24 N m).
C
to fuel pump. Tighten line nut to
•
6. Install the starboard engine mount to its orginal position. Use Volvo Penta thread locking compound P/N 1161053 on the mounting bolts and tighten to 35-40 ft. lb. (47-54 N•m).
2 37919
7. Install the upper flex mount nut to 100-120 ft. lb. (135-165 N•m).
After completing replacement procedures, make sure engine compartment is free of fuel vapors, then start engine and check entire fuel system for leaks.
Fuel Filter Replacement To prevent fire and explosion, disconnec t the battery before performing the following replacement procedures. After completing replacement procedures, make sure engine compartment is free of fuel vapors, then start engine and check entire fuel system for possible leaks.
3 DR5552
3.0 GS Models Removal
3
Place a shop cloth around the filter canister to catch any fuel. Loosen the yoke screw D and move the yoke to the side far enough to allow removal of the filter canister E and element F . Remove and discard the element and gasket G . Installation
3
1. Install a new gasket G inside the bottom of the pump housing H . Center the spring I inside of the filter canister E . Place the filter element F on top of the spring. Slide the canister and filter into place on the pump and secure with yoke J . Tighten the yoke screw D securely.
Safety Related
7-6 7-6
Elect/eng
2. After completing replacement procedures, make sure engine compartment is free of fuel vapors, then start engine and check entire fuel system for leaks.
Filter Canister
4 1. Unscrew (turn counterclockwise) fuel filter
to remove and discard. Check to make sure the original gasket is not stuck on the filter housing. If so, remove and discard the gasket.
5 2. Lubricate new fuel filter gasket
L
K
4
with clean oil.
31931
3. Install new fuel filter onto fuel filter bracket. Tighten approximately one-half turn after gasket makes contact with bracket. 4. Start engine and check for leakage.
Carburetor Fuel Filter Some models do not have replaceable fuel filters. Instead, the inlet nut contains a screen that should be cleaned periodically. periodically. 1. Disconnect the fuel line at the carburetor. carburetor. 6
2. Remove fuel inlet nut M and gasket N . Take out filter element gasket O , filter element P , and spring Q (if so equipped). 7
3. Clean inlet filter screen ement.
R
5 COB5375
(non-replaceable) (non-replaceable) or replace filter el-
4. To To reassemble, insta ll spring, new filte r element and gasket, and filter nut and gasket. Tighten inlet nut sec urely. 5. Connect fuel line and tighten to 11-13 ft. lb. (14.9-17.6 N m). Start engine and check for leaks. •
6 DR2931
7 DR1504
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Safety Related
7-7 7-7
Tanks, Lines, Valves, and Fittings Fitt ings Check for water and dirt in system. Examine complete fuel system for leaks and loose connections. Check operation of all fuel shutoff valves. Make sure fuel lines are securely fastened to craft to eliminate possible damage from vibration. Check for leaks in tank pickup assembly or a plugged pickup screen. If fuel system appears to block proper flow of fuel, disconnect lines at different points and blow compressed air through suspect sections. Do not blow air through sections connected to these components - fuel pump, carburetor, tank. Check tank for open air vent and clean sediment screen.
Replace all connections which leak and cannot be tightened.
Boat Fuel System Troubleshooting Fuel systems must be checked for restrictions as part of normal troubleshooting procedure. Fuel systems can use anti-siphon valves, elbows, lines, filters, etc., that may present restrictions greater than can be tolerated by the engine fuel pump. Too great a restriction could reduce fuel flow to the engine resulting in poor performanc e and stopping at higher speed. An air leak on the suction side of the fuel pump can also cause erratic operation. 1. Disconnect fuel supply line from tank and fuel filter inlet. Blow air through it to make sure it’s clear. 2. Check fuel anti-siphon valve. The marine industry recommends permanently permanently installed fuel systems meet safety standards A.B.Y.C. H-24 and I.C.O.M.I.A. No. 17. These require such systems to have some form of anti-siphon protection. An anti-siphon valv e prevents fuel spillage in case of a break or leak in the distribution system below the level of fuel in the tank. Anti-siphon protection protection may also be afforded by keeping all parts of fuel distribution system above level of tank top when boat is in its normal, unloaded, static floating position. If it’s not possible to keep all lines above tank, then an anti-siphon valve is required and each tank pickup tube must be so equipped.
Safety Related
7-8 7-8
Elect/eng
Anti-siphon val ves must have a flow restriction pressure drop of no more than 35 in. (88.9 cm) of water at a fuel flow rate of 20 gallons (80 litres) per hour. All models covered in this manual must use a valve designed for use with 3/8 in. hose. Do not use a smaller valve.
1 If there is any question that that an anti-siphon valve is suitable, then the following test should be made using a transparent hose: •
Remove Remo ve anti anti-s -sip ipho hon nv val alve ve fittings and test hose.
from tank and install test
•
Fill test hose B with water to a vertical height of 20 in. (50.8 cm) C . Water must not run from valve. An occasional drop is acceptable. A continuous drip is not acceptable.
•
Add more more water water.. Water Water must must run run from from valve valve before before water water height is 25 in. (63.5 cm).
A
An anti-siphon valve passing this test will provide anti-siphon protection for a maximum of 28-1/2 in. (72.4 cm) fuel head and also open fully with pump suction. An anti-siphon valve that does not meet these requirements must be replaced with one which does. This test does not check ability of anti-siphon valve to meet flow requirements. 2
3. Check fuel tank pickup filter screen
D
4. Check fuel tank pickup tube
F
2 DR3004
:
Pickup tube must have an I.D. measuring 3 /8 in. (9.5 mm) for all models. Dual engines require two separate pickup tubes, one for each engine.
Elect/eng
DR3003
:
Recommendations: Use stainless steel, No. 304 wire cloth, 30 mesh, with wire size 0.010-0.012 in. (0.254-0.30 4 mm) diameter. A cylindric al screen E equal to pickup tube outside diameter and 1 in. (25.4 mm) long will provide a screen with required flow area. The screen should be horizontal and set slightly abov e bottom so that maximum amount of fuel can be used. Make sure screen is not partially restricted by solder and is not bent or kinked. 2
1
7-9 7-9
7-10
Elect/eng
Carburetor Service Service and Adjustments: 2V Models 3.0 GS Models 4.3 GL Models 5.0 GL Models 5.7 GS Models Table of Contents Adjustments Accelerator Pump Clearance ........................... ......................................... ........................... ............... 7-20 Accelerator Pump Stroke .......................... ........................................ ........................... .................... ....... 7-19 Choke Unloader ........................... ......................................... ........................... ........................... ...................... ........ 7-21 Choke Vacuum Qualification Qualification ........................... ......................................... ........................... ............... 7-20 Electric Choke Choke ........................... ......................................... ........................... ........................... ........................ .......... 7-21 Float Level - 3.0 GS Models Models .......................... ........................................ ........................... ................. .... 7-19 Float Level - 4.3 GL, 5.0 GL, GL, and 5.7 GS Models ........................ ........................ 7-19 Idle Mixture and Idle Speed ........................... ......................................... ........................... ................ ... 7-21 Carburetor Assembly ........................... ......................................... ............................ ........................... ........................... .................. .... 7-16 Disassembly .......................... ........................................ ........................... ........................... ............................ .............. 7-13 Replac Replacemen ementt ................................ ................................................ ................................ ................................. ................. 7-12 7-12 Specific Specificatio ations ns................ ................................. ................................. ................................. ................................. .................. 7-37 7-37 Torque orque Values Values ................................. ................................................. ................................. ................................. .................. 7-37 7-37 Troublesh roubleshooti ooting ng ................................. .................................................. ................................. ............................. ............. 7-22 7-22
Safety Warnings When replacement parts are required, 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 and/or passengers. After any fuel system maintenance maintenance or repairs, always check for leaks. Always ensure backfire flame arrestor fins are undamaged, and arrestor is in place and secured before starting engine. When adjusting a carburetor while the engine is running or being cranked, use extreme care to avoid getting hands, fingers, or clothing caught in the alternator and water pump belts, pulleys, and other moving parts.
Elect/eng
7-11
1
2
3
21965A
21982A
21962
Carburetor Replacement The following carburetor removal and installation procedures are similar for all models. The illustrations accompanying the text may not represent the appearance of actual components on a specific engine.
All carburetors covered in this manual are designed for marine use. Do not substitute automotive carburetors because they can emit fuel vapor into engine compartment, and create a fire and explosion hazard .
4 21956A
Removal
1 1. Remove locknut, flame arrestor cover, vent hose brackets and flame arrestor to be replaced. 2
B
. Unscrew flame arrestor stud
C
2. Cut tie strap and remove fuel pump vent hose
3 3. Remove cotter pin and washer
E
, if carburetor is
D
A
, if equipped.
, then pull throttle cable off
carburetor arm.
4 4. Disconnect purple/white stripe electrical lead
F
at choke ther-
5 21963A
mostat housing.
5
5. Disconnect fuel line to spill fuel .
G
from carburetor taking care not
6
6. Remove four carburetor mounting nuts and one flat washer. Note which stud flat washer and choke ground wire H were attached to. Lift carburetor off manifold, and discard mounting gasket. Note throttle lever bracket I position, then remove it for transferal to new carburetor.
6 21960
47508
Safety Related
7-12
Elect/eng
Installation Refer to Specifications and check carburetor model number. If wrong model carburetor is used, both high and low speed operation are affected. 1. Attach throttle lever bracket from old carburetor. Be sure it’s in its original position. Place new base gasket on mounting studs and install carburetor. 7
2. Attach flat washer and choke ground wire H to original mounting stud. Install carburetor mounting nuts and tighten to 10-14 ft. lb. (1319 N m).
7 21958
•
5
3. Connect fuel line lb. (14.9-17.6 N m).
G
to carburetor and tighten to 11-13 ft.
•
4 4. Connect purple/white stripe lead F to choke housing. 3 5. Attach throttle cable and secure it with a flat washer and cotter pin E . Spread pin ends to prevent disengagement. Readjust throttle cable preload as required. 6. Attach vent hose to carburetor fitting if equipped, and secure with tie strap . 7. Screw flame arrestor stud into carburetor (if removed), and tighten to 65-80 in. lb. (7.3-9 N m). .
8
8. Install flame arrestor B and vent hose brackets A . Tighten flame arrestor nut to 30-40 in. lb. (3.4-4.5 N m). Install flame arrestor cover and tighten nut to 30-35 in. lb . (3.4-4 N m). •
•
9. Run engine. Check for fuel leaks, and take corrective action if necessary.
Carburetor Disassembly Disassembly of Fuel Bowl and Metering Block Before beginning disa ssembly, mount carburetor on a holding fixture or a set of 5/16 in. bolts.
Elect/eng
Safety Related
7-13
8 34827
1
2
3
11606
20612
20517
1. Remove primary fuel bowl and metering block. Discard gaskets.
1 2. Remove idle adjusting needles and gaskets
A
. Discard gas-
kets.
1
3. Using a jet wrench, remove main jets pegs. 2
4. Unscrew the power valve
D
B
. Lift vent baffle
and gasket
E
C
off
. Discard the gas-
ket.
4
5. Float Removal.
3
20515A
4 3.0 GS Models: First remove the inlet valve assembly. ass embly. Loosen
lock screw F and turn hex nut sembly H . Remove two screws and bracket.
G I
counterclockwise. Remove the asholding float in place. Remove float
5 4.3 GL, 5.0 GL, and 5.7 GS Models: Using needle-nose pliers, remove float retainer E-clip J . Slide float off shaft. Remove spring from float. Pull baffle K out of fuel bowl. Lift inlet needle out of seat. Unscrew seat and discard gasket underneath. 6. Unscrew fuel inlet nut to service filtering device. Some models will have a screen inside the inlet nut (non-replaceable), while others will have a wire mesh or sintered bronze filter. Clean screen type filters (replace if necessary), and discard and replace bronze filter. Replace inlet nut gasket.
5
5 11591
6
7. Remove accelerator pump cover L , diaphragm M , and spring. Verify that the inlet check ball N has the necessary freedom of movement to allow the accelerator pump to fill properly. With the bowl inverted (check ball seated), the clearance between the ball and its retainer should be 0.011-0.013 0.011-0.013 in. (0,279-0,330 mm). Carefully bend the retainer to set the specified clearance. The accelerator pump inlet check ball is not serviced separately, and should not be removed.
6 20595
8. Use a solvent soaked cloth to remove old gasket material from metering block and float bowl.
7-14
Elect/eng
Disassembly of Main Body 7
1. Invert carburetor and remove throttle body retaining screws and lock washers O . Remove choke vacuum hose P from throttle body fitting. Remove throttle body and discard gasket. 8
9 2. Remove retainer
from lower end of choke rod R . Remove thermostatic spring housing S , its retainer T , and gasket U . Q
10 3. Unscrew choke housing and discard vacuum passage gasket.
11 4. Remove accelerator pump discharge nozzle screw
, then lift pump discharge nozzle W and gaskets X out of main body. Invert main body and let accelerator pump discharge needle Y fall into your hand. V
7 21989
5. Do not remove choke plate, choke shaft, choke rod, or nylon guide unless one of them needs to be replaced. The choke plate screws are staked and must be filed flush with choke shaft prior to removal. The choke rod must be lifted out of top of main body before nylon guide can be removed.
8 21988
9 21987
10 21986
11 22104 Elect/eng
7-15
Disassembly of Throttle Body
1 1. Remove accelerating pump operating lever 2
A
2. Unscrew and remove throttle cable bracket
and retainer C
B
.
from throttle
arm. 2
3. Note screw hole number cam E , then unscrew cam.
D
on throttle arm and accelerator
Cleaning, Inspection, and Repair
1
1. Clean carburetor in a carburetor cleaning solvent.
21999
DO NOT immerse throttle body assembly, any rubber parts, plastic parts, diaphragms, or pump plungers in carburetor cleaner. Delrin cam on throttle lever and Teflon bushings Teflon bushings on throttle shaft will not withstand soaking in carburetor cleaner. Spray with choke cleaner and blow dry. 2. Use a cloth soaked in solvent to remove old gasket material. Blow out all passages in castings with compressed air. DO NOT pass drills through jets or passages.
2
3. Inspect idle mixture needles for damage.
21998
4. Examine inlet needle and seat for wear. If worn, replace with new inlet needle and seat assembly. 5. Inspect upper and lower surfaces of carburetor castings for damage. Make sure sealing beads on castings have not been damaged. 6. Inspect holes in levers for excessive wear or out-of-round condition. condition. If worn, replace levers. 7. Check all throttle levers and valves for binding or other damage. Always use new gaskets and O-rings whenever a carburetor is disassembled or overhauled. Make sure that all holes in new gaskets are properly punched and that no foreign material adheres to gaskets. Be certain that accelerator pump diaphragm is not cut or torn.
3 21997
Carburetor Assembly Assembly of Throttle Body
3 1. Attach accelerator pump cam
. Align proper hole F in cam with specified hole D in throttle arm. See Specifications for correct position. Install screw and tighten it securely. securely. E
7-16
Elect/eng
1
2. Attach throttle cable bracket to throttle arm with two screws and elastic locknuts. The upper screw must engage middle hole G in throttle arm. Tighten both screws secure ly.
1 3. Install accelerator pump operating lever
A
and retainer
B
.
Assembly of Main Body
4 1. Drop accelerator pump discharge needle
into its well. Position accelerator pump nozzle I (with nozzles down and slots facing air vent rib) and gaskets J in main body. body. Install retaining screw K .
5 2. Insert choke rod
H
4 21996A
in choke housing shaft lever as choke housing is placed into position on main body. Be sure projection on choke rod is placed under fast idle cam M , so that cam will be lifted when choke plate is closed. Install choke housing lock washers and screws. Using needle-nose pliers, install choke rod clip N . L
6
3. Place thermostatic thermostatic housing gasket on choke choke housing. Install housing and engage thermostatic spring on choke lever. Install clamp and screws. Adjust thermostatic thermostatic spring housing by aligning index mark O on cover with specified mark P on choke housing. 7
5
4. Invert main body and install throttle throttle body gasket. Install Install throttle body to main body and secure with screws and lock washers Q . Install vacuum hose R from throttle plate to choke housing.
21995
Assembly of Fuel Bowl and Metering Block 8
1. Place accelerator pump diaphragm spring S and diaphragm T in accelerator pump chamber. The diaphragm must be positioned so that large end of lever disc will be against operating lever. lever. Install cover and retaining screws. Move pump lever to compress diaphragm spring. This will make sure diaphragm is not pinched. Tighten screws securely.
6 21994
7 21989
8 20614 Elect/eng
Safety Related
7-17
1
3
2 20613
21992A
21993
2. Float Installation.
1
2
3 3.0 GS Models: Install float assembly and retain with
two screws A . Assemble inlet needle as shown. Apply a light assembly oil or petroleum jelly to the inlet needle assembly O-ring B . Install assembly into fuel bowl using gasket C , nut D , gasket E , and screw F . For float setting, refer to Adjustments for proper procedure.
4
5 4.3 GL, 5.0 GL, and 5.7 GS Models: Install inlet needle
seat G and new gasket. Install inlet needle and pull clip assembly H . Slide baffle plate I onto ridges in fuel bowl. Install spring J on float and engage needle pull clip while sliding float onto shaft. Be sure float spring is between ridges on boss on floor of fuel bowl. Install float retainer K with needle-nose pliers. For float setting, refer to Adjustments for proper procedure.
4 11719
3. Install filtering device . Insert spring and bronze filter (open end with gasket faces inlet nut), or wire mesh filter, if applicable. Place a new gasket on inlet nut. Install and tighten to specifications to prevent fuel leakage. 6
4. Refer to Specifications for correct power valve identification number. The number L (example 6.5) is stamped on a flat on base of valve. There are two types of power val ves, and each requires a different gasket. Valves Valves having multiple drilled fuel openings require a gasket having three internal projections. Valves Valves with two rectangular fuel openings require a gasket with no internal projections. Use of the wrong gasket will cause a fuel leak around the power valve.
5 11721
7
5. Install correct power valve and gasket into metering block. Installation of wrong power valve will result in poor performance.
6 DR3061
7 20517A
Safety Related
7-18
Elect/eng
8
6. Using a jet wrench, install jets Specifications for correct jet number.
M
into metering metering block. block. Refer to to
8
7. Using new gaskets, install idle mixture needles N . Turn idle mixture needles in until they j ust touch seat. Back them off the correct number of turns for a preliminary idle adjustment. Refer to Specifications for correct idle mixture setting. 8
8. Position metering metering block gasket gasket on dowels located located on back of metering block. Push metering block and gasket onto main body. Position vent baffle O then float bowl gasket on metering block. Make sure accelerator passage P is not blocked. Place new gaskets on float bowl screws, then install float bowl on main metering block and retain with screws.
8 22385
Carburetor Adjustments If the carburetor has just been completely rebuilt, adjustments adjustments should be performed in the following sequence. This will ensure that a previous/subsequent adjustment is not affected. If a rebuild has not been done, perform only the adjustment(s) that will correct the operational problem.
9 20610
Float Level - 3.0 GS Models Only
9 1. Loosen screw
and invert fuel bowl. Turn nut adjustment. Top of float S should be level. Q
9 2. Secure float level setting by holding nut lock screw
Q
R
to get an initial
R
and then tightening
.
Float Level - 4.3 GL, 5.0 GL, and 5.7 GS Models Only Do not spill fuel. This will create a fire hazard. 10 Drain fuel from carburetor and remove fuel bowl. bo wl. Remove float baffle. With bowl inverted, carefully bend curved float arm T that contacts inlet needle to set float level (parallel to fuel bowl). Reinstall bowl using new gaskets.
10 11716
Accelerator Pump Stroke
11 The accelerator pump stroke is controlled by the pump cam position. The proper amount of fuel is delivered when attachment screw is in specified hole of both cam U and throttle arm. See Specifications for position.
11 11689
Elect/eng
Safety Related
7-19
47508
Accelerator Pump Clearance
1 Block throttle plates plates in the wide open position, position, and manually depress accelerator pump arm A . Use a feeler gauge to check fo r specified clearance between arm and pump lever screw head. Turn adjusting nut B IN to increase clearance and OUT to decrease clearance. This adjustment ensures maximum pump output, full primary throttle opening, plus prevents off-idle hesitation and over-extension of the accelerator pump diaphragm. After making this adjustment, check accelerator pump operation. The pump should start to move as soon as the throttle th rottle shaft moves. This is called “immediate pump pick-up”. Any delay in pump movement will result in an off-idle hesitation or lag. If pump fails to move immediately, check for bent or worn parts, misadjusted pump clearance, or an improperly positioned pump cam.
1 31903
Choke Vacuum Qualification 1. Remove choke housing cover. 2 2. Push choke piston against the adjustable screw stop C . Use a convenient tool or a paper clip to push with. Exercise care not to scratch the inner piston ball-link seat or the casting bore.
2 DR2999
3. With the piston held against the adjustable screw stop, apply light pressure to the choke housing lever in a closing direction, until all free play is removed from the linkage. 2
4. Check the choke opening with the correct drill size. Adjustments are made by turning the adjustment screw stop C (inward for less opening, outward for more opening). Care must be taken not to back out the adjusting screw so much that the piston will partially pass the screw and then be gouged by inward screw adjustment.
7-20
Elect/eng
Electric Choke The electric choke has an adjustment to control its opening rate. By loosening the clamp screws that retain the thermostatic spring housing, the housing can be turned to alter adjustment. Turning housing in a counterclockwise direction will richen mixture and make choke stay on longer. Turning spring housing in opposite direction (clockwise) will lean out mixture and make choke come off sooner. The electric choke cap is grounded with an external groun d wire. Make sure all ground components are clean and free of corrosion.
3
1. Set choke so that index mark on choke cover relative to index marks on choke housing E as specified.
D
3 15313
is aligned
2. If a richer or leaner mixture during warmup period is desired, it can be obtained by rotating thermostat cover one mark at a time. Never set index mark on cover more than two graduations off specified setting.
Choke Unloader
4 1. Hold throttle valves in a wide open position. Insert correct size drill between lower edge
F
of choke valve and inner wall of air horn.
2. Press finger lightly against choke control lever. A slight drag should be felt as drill is pulled out.
4 22386
5
3. To adjust, bend tab G on throttle shaft kick-down lever until correct opening has been obtained.
Idle Mixture and Idle Speed 1. Initially set idle mixture by turning idle mixture screws inward until they are lightly seated, then turn screws outward the specified turns. Do not turn screws tightly against seats. Both the screw tips and casting seats may be damaged. Replace screws with damaged tips. 2. Final adjustments are made with engine running at operating temperature. Refer to Specifications for correct idle RPM. 3. Use a tachometer to make final adjustments. Turn idle mixture screws inward until engine RPM begins to drop due to lean mixture. Back screws out evenly and alternately until the best idle RPM is reached. If RPM begins to drop (due to an overly rich mixture) before reaching the specified RPM, turn screws inward until maximum engine RPM and smoothness is achieved. 4. Readjust idle speed as necessary. Always Always adjust idle speed last.
Elect/eng
7-21
5 11714
Carburetor Troubleshooting FLOAT FLOA T ADJUSTMENT ADJUSTM ENT Determines fuel level in float bowls
High Float Levels 1. Raises fuel level 2. Speeds main and secondary system start-up start-up 3. Promotes primary and secondary flooding, stalling 4. Increases fuel consumption
Low Float Levels 1. Lowers fuel level 2. Delays main and secondary system start-up 3. Results in primary and secondary flat spots, hesitation 4. Can decrease maximum fuel flow capability
ACCELERATOR ACCELERA TOR PUMP STROKE Cam type and placement determines volume of fuel per stroke
Performance Problems 1. Lean or rich condition 2. Hesitation or acceleration lag throughout RPM range 3. Damage pump diaphragm
ACCELERATOR ACCELERA TOR PUMP P UMP CLEARANCE Provides full pump output
Performance Problems 1. Prevents overstroking pump 2. Prevents off idle hesitation
CHOKE VACUUM QUALIFICATION Determines amount of choke plate opening that occurs after starting a cold engine
Performance Problems Plate closes too far (too rich): 1. Engine loads up 2. Runs rough, may die 3. Increase fuel consumption
Plate opens too far (too lean): 1. Engine runs rough 2. Will die quickly 3. Hesitation upon acceleration (continued on next page)
7-22
Elect/eng
Carburetor Troubleshooting (cont.) CHOKE ADJUSTMENT Determines how long choke stays on
Performance Problems Choke too rich: 1. Increase fuel consumption 2. Difficult hot start
Choke too lean: 1. Poor cold engine performance 2. Difficult cold engine starting
CHOKE UNLOADER Determine amount of choke plate opening at W.O.T. on a cold engine
Performance Problems 1. Affects cold engi ne at W.O.T. W.O.T. 2. Aids starting flooded engine
IDLE MIXTURE Determines fuel/air volume exiting idle circuit
Performance Problems 1. Rough or unbalanced idle 2. Tendency Tendency to die 3. May diesel or run-on
IDLE SPEED Used in conjunction with mixture screws to set idle RPM
Performance Problems 1. Idle RPM too high, may diesel or run-on 2. Idle RPM too lo w, may die
SECONDARY THROTTLE PLATE OPENING Opens secondary throttle plates to allow secondary idle circuits to function
Performance Problems 1. Open too far - high idle RPM 2. Closed too much - hesitation during transition from primary to secondary throttle operation 3. Sticking closed - hesitation during transition from primary to secondary throttle operation 4. Hole in diaphragm - hesitation during transition from primary to secondary throttle operation
Elect/eng
7-23
Electric Fuel Pump 4.3 GL, 5.0 GL, and 5.7 GS Models Operation The electric fuel pump utilizes a 12 volt DC motor that runs continuously at 4000 RPM whenever the engine is cranked or running. The electric motor drives a metal gear pump that uses the fuel as coolant. The pump supplies fuel at variable PSI as determined by engine load and fuel consumption. Excess fuel circulates within the pump past an internal pressure regulator. When the regulator is in operation, fuel stops entering the pump. This design eliminates the need for a return line to the fuel tank. The pump has excellent dry prime characteristics, and can run without fuel for up to 30-40 seconds, although running without fuel is not recommended. The carburetor float chamber will run out of fuel before damage could occur. The fuel pump has an in-line Radio Frequency Interference (R.F.I.) suppressor built into th e motor’s pla stic connecto r. A separate circuit breaker provides circuit overload protection. When the key switch is turned to the “START” position, voltage is supplied to the fuel pump relay from the start (“S”) terminal of the assist solenoid. The relay is activated and battery voltage is applied to the pump motor and then to engine ground. The alternator supplies voltage to the relay from the “light” terminal after the engine starts and the key switch is returned to the “RUN” position. The pump relay also receives voltage direct from the battery via the assist solenoid, and this circuit is protected by a 6 amp circuit breaker. breaker. A diode in the orange lead prevents voltage feedback from the alternator to the assist solenoid. This keeps the starter motor from being energized after the engine starts. A diode in the alternator green lead prevents damage to the alternator during cranking. For specific wiring connections, see the Wiring Diagram at the end of this section. The fuel pump will not run if the key switch is in the “RUN” position and the engine is not running.
Do not substitute automotive parts. Volvo Penta marine components meet U.S. Coast Guard regulations for fuel leakage, exter nal ignition proof operation, and marine use. Volvo Penta marine components are specially designed not to cause ignition of fuel vapors in the bilge or engine compartment. The use of automotive parts can result in fire and explosion.
Safety Related
7-24
Elect/eng
Electric Fuel Pump Replacement This pump has been designed to meet U.S. Coast Guard fuel systems regulations for marine use. Do not substitute other brands or models that may be similar in appearance. Use of a substitute pump could result in leakage of fuel or fumes, and cause fire and explosion. Removal 1. Disconnect positive and negative cables at the battery.
1 49528
2. Disconnect boat fuel supply line at fuel filter and plug threaded hole.
1 3. Remove screw securing fuel pump guard
to bracket. Remove guard to allow complete access to fuel l ine and pump. A
2
4. Cut cut tie straps holding electrical leads to pump. Pull connector B off pump suppressor.
3 5. Using two wrenches, one holding lower pump fitting and other on fuel line nut, unscrew carburetor fuel line out of fitting.
C
at pump and pull line
4 6. Hold the pump end cap with an open end wrench move fitting
E
2 D
49572
, and re-
.
If pump end cap is not held when removing fitting, end cap may rotate and damage internal O-ring that seals pump against external fuel leakage.
5 7. Remove two filter bracket bolts G
. Slide pump out of grommet in upper bracket after last bolt is removed. F
Fuel filter may contain fuel; be careful not to spill it.
3 49519
4 49570
5 30628 Elect/eng
Safety Related
7-25
6 H
8. To To remove fuel filter and brac ket from pump, hold pump end cap with an open end wrench, and unscrew adapter at base of pump.
lf pump end cap is not held when removing adapter, end cap may rotate and damage internal O-ring that sea ls pump against external fuel leakage. Installation Electric fuel pumps look simila r, but have different fuel flow rates. Do not interchange these assemblies.
6 30635
7
1. Place a new O-ring I on the filter bracket adaptor and positio n it against hex. Do not nick or cut O-ring on threads.
This O-ring is made of a special fuel resistant material. Substitution of parts of unknown quality could result in a fuel leak, and the possibility of fire and explosion. 8
2. Screw filter bracket bracket assembly into pump. Hold Hold lower pump end cap H with an open end wren ch and tighten adapt or to 8-10 ft. lb. (11-14 N m). •
If pump and cap is not held when installing adapter, end cap may rotate and damage internal O-ring that sea ls pump against external fuel leakage.
5 3. Slide pump up through grommet
G
and install two bolts
F
7 30626
. Tighten
bolts to 20-25 ft. lb. (27-34 N m). •
9 4. Install a new O-ring onto the fitting. Do not nick or cut O-ring on threads.
This O-ring is made of a special fuel resistant material. Substitution of parts of unknown quality could result in a fuel leak, and the possibility of fire and explosion.
8 30634
9 49520
Safety Related
7-26
Elect/eng
1
5. Screw fitting A all the way into pump outlet. Hold pump end cap B with an open end wrench and tighten fitting to 60-84 in. lb. (6.8-9.5 N m). •
2
6. Connect fuel line C to pump fitting. Hold fitting an open end wrench. Tighten fuel line securely.
A
with
If pump end cap is not held when tightening fitting, e nd cap may rotate and damage internal O-ring that seals pump against external fuel leakage.
1
3 7. Align connector tabs and push connector onto pump suppres-
49571
sor until it clicks into place.
4 8. If the electrical leads were secured to the pump body, secure them with a tie strap.
5 9. Install pump guard
D
and secure with screw.
10. Remove plug and reconnect boat fuel line. Tighten securely. Attach positive and negative cables at the battery. Run engine and check for fuel leaks.
2 49519
3 49522
4 30641
5 49528 Elect/eng
Safety Related
7-27
Filter Bracket Replacement The electric fuel pump filter has an internal seal around the fuel exit point that prevents leakage and drain back. Do not substitute other filters that may be similar in appearance. To replace filter canister, refer to Fuel Filter Replacement elsewhere in this section. 1. Remove fuel pump and filter bracket assembl y from mounting bracket. 2. Unscrew fuel inlet elbow and save for installation on new bracket. 3. Clamp filter bracket in a vise and unscrew adaptor and pump assembly. Discard bracket. 4. Thoroughly clean adaptor adapto r threads to remove old sealer, then apply Pipe Sealant with Teflon or Teflon or equivalent to the threads. 5. Clamp new bracket in a vise. Screw in adaptor and pump assembly, and tighten to at least 10 ft. lb. (14 N m). Continue tightening adaptor to achieve proper pump/bracket pump/bracket directional alignment. Do not exceed 32 ft. lb. (43 N m) torque. •
•
6. Thoroughly clean thre ads of inlet elbow to remove old sea ler, then apply pipe sealant with Teflon Teflon or equivalent to the threads. Screw in elbow and tighten to at least 12 ft. lb. (16 N m). Continue tightening elbow to achieve proper directional alignment. Do not exceed 32 ft. lb. (43 N m) torque. •
•
7. Install fuel pump and filter bracket assembly in mounting bracket. 8. Run engine and check for fuel leaks.
Safety Related
7-28
Elect/eng
Troubleshooting Electric Pump Fuel System 1. Start by verifying the pump is receiving a minimum of 12.0 ± 1 volt. Pull connector off pump suppressor. suppressor. Disable ignition to prevent engine from running, then crank engine and check yellow/red lead with a voltmeter. Shut engine off, then check connector black lead with an ohmmeter for a good ground. If If voltage is not as specified, or ground path path is suspect, check: • • • • • •
relay elay and and br brack acket fuse oran orange ge lead lead diode iode gree green n lead lead diod diode e alternato alternatorr output output at at “Light” “Light” terminal terminal (13.9 (13.9-14. -14.7 7 volts) volts) wiring wiring relate related d to to all all of of the the abo above ve
Ensure all items are functioning correctly before proceeding. As voltage to the pump drops, so will its output capability. 2. Once it’s been established that the pump i s receiving proper voltage, separate the engine fuel system from the boat’s fuel system. Disconnect the supply line at the pump’s fuel filter, and place a pick-up hose in a vented fuel container. The pick-up hose must have a minimum I.D. of 3/8 in. Do not connect engine fuel system to any supply system having a pressure producing device such as an outboard fuel tank with primer bulb, or another electric fuel pump located elsewhere in the boat or at the fuel tank. The pump is sensitive to additional fuel pressure, and will add this to its own output. The re sult will be a continually flooding carburetor with the possibility of external fuel leaks, and the potential for fire and explosion. 3. Run engine to see if problem still exists. If problem has been eliminated, source is located somewhere in boat fuel system back to, and including, the boat fuel tank. If problem still occurs, it’s located somewhere in engine fuel system.
Checking Engine Fuel System 1. The electric fuel pump requires an unrestricted, air tight fuel supply. Unscrew the pump fuel filter and check it for debris. Also check that the filter seals tightly against its fixture and the center mounting threads. Make sure the filter is the correct one for this application. Check threads of filter inlet elbow to ensure a tight seal. If any of these conditions are in doubt, correct them before continuing. 2. Remove the carburetor fuel inlet nut and inspect the inlet screen or filter for debris. Clean or replace this item before continuing.
Elect/eng
Safety Related
7-29
3. Check fuel pump mounting position. Pump must always be located on engine in original factory position. This position is determined by U.S. Coast Guard regulations a nd must be complied with. Never relocate pump to transom, stringer, fuel tank, or any point other than its original location on the engine.
Pressure Testing Fuel System Pump performance can be verified by checking pump PSI at specific engine RPM. This test must be performed with engine under load; either running in gear on water, or in gear and connected to a dynamometer. Use a good quality fuel pressure gauge and connect it into the fuel line between the fuel pump and the carburetor. carburetor. Follow the gauge manufacturer’s instructions for installation, and ensure that connections are leak free. Refer to the chart below, and run the engine at various RPM’s to check pump operating pressure.
Specifications Pump Performance at a Minimum of 12.0 + 1 Volt P.S.I.
RPM Id l e
4 .9 - 8 .5
1 00 0
4 .8 - 8 .4
1 50 0
4 .7 - 8 .3
2 00 0
4 .6 - 8 .2
2 50 0
4 .5 - 8 .1
3 00 0
4 .4 - 8 .0
3 50 0
4 .3 - 7 .9
4 00 0
4 .0 - 7 .7
4 50 0
-
4 60 0
3 .5 - 7 .3
New pumps will generally have lower operating pressures. As the pump gears break in, contact improves and pump pressure increases slightly.
Safety Related
7-30
Elect/eng
Two other items that would require checking are the screens in each end of the fuel pump body. This This requires removal of the upper elbow and the lower fuel filter adaptor. If screens cannot be sufficiently cleaned, replace the fuel pump. The screens are not serviced separately.
Checking Boat Fuel System The most common causes of failure s in the boat fuel system are due to line restrictions or air entry. Typical restrictions are: • • • • •
kinked kinked,, bent, bent, or inter internal nally ly swolle swollen n fuel fuel lines lines fuel lines and/or and/or tank tank selecto selectorr valve valve I.D.’s I.D.’s too small small restr restrict icted ed or or wrong wrong ant anti-s i-siph iphon on valv valve e cracked cracked or or blocked blocked fuel pick-up pick-up or screen screen inside inside tank blo blocke cked tan tank k ven ventt
Air entry can occur at any point on the suction side of the fuel system. Air in the fuel system is usually indicated by a pump humming or squealing noise. Pump noise is caused by air being drawn through the fuel pump gears, but is not always an indicator tha t something is wrong . Momentary noise has several causes that are not linked to fuel system failures: •
pump may squeal squeal for a short short ttime ime upon upon start start-up -up as as air is expelled
•
if ambient ambient temperat temperatures ures are high, high, the engine engine compart compart-ment will be subjected to hot operating conditions that may create vapor in the fuel lines
•
a hot engine engine after after shutdo shutdown wn will will go into a “hot “hot soak” soak” condition that may produce fuel vapors
•
the u use se of ethano ethanoll fuel fuel will also also aggrav aggravate ate tthis his condit condition ion as it’s more susceptible to vapor formation
All of these situatio ns are temporary, but may produce vapor that would cause pump noise. Pump noise that is continuous, and/or cannot be attributed to any of these conditions, could be an indicator of fuel system problems.
Elect/eng
7-31
Vacuum Testing Testing Fuel Sy stem This test must be performed with engine under load; either running in gear on water, or in gear and connected to a dynamometer. Ensure that all fuel line connections are leak free. 1. Install Vacuum and Fuel Pressure Gauge such as Snap-on ® Tools MT311JB or equivalent, and 8 in. (20,3 cm) of clear, fuel resistant vinyl hose into the fuel line at the filter bracket inlet. 2. Start engine and allow it to reach normal operating temperature. temperature. Run engine at full throttle for at least 2 minutes; observe vacuum gauge reading and check clear hose for air or vapor bubbles. bubbles. Gauge reading must not exceed 4 in. of mercury (Hg) at any time, and there should be no bubbles visible in the clear hose. Compare obse rvations to the following:
Gauge reads 1-4 in. of mercury - air bubbles present Supply side of fuel system has an air leak. Check points of possible failure as noted under Checking Boat Fuel System . Repair or replace suspect part, then make another vacuum test to verify repair.
Gauge reading exceeds 4 in. of mercury Supply side of fuel system has a restriction. Check points of possible failure as noted under Checking Boat Fuel System. Repair or replace suspect part, then make another vacuum test to verify repair.
Relay Wiring Diode Operation and Failure Alternator (Green) Lead Diode This diode prevents current from the assist solenoid/starter relay reaching the alternator regulator during engine cranking. This diode can fail one of two ways. If the diode becomes shorted (continuity in both directions), the regulator may be damaged and the alternator might not produce the proper amount of current. If the diode becomes open (no continuity in either direction), the fuel pump will not run when the engine is running. After After a short time, the engine will starve for fuel.
Assist Solenoid/Starter Role (Orange) Lead Diode This diode prevents current from the alternator “Light” terminal reaching the assist solenoid/starter relay while the engine is running. This diode can fail one of two ways. If the diode becomes shorted (continu ity in both directions), the starter starter motor will try to engage while the engine is running. If the diode becomes open (no continuity in either direction), the fuel pump will not run when the engine is cranking and may be hard to start.
Safety Related
7-32
Elect/eng
1
2
3
D R 2 06 5
DR2149
D R 20 6 6
Relay Ohmmeter Tests Throughout this section two symbols are used to interpret electrical troubleshooting results.
1 This symbol indicates continuity or very low resistance. 2
This symbol indicates no continuity or very high resistance ( ¥).
To avoid damaging components or troubleshooti ng equipment, disconnect the battery cables from the battery and remove the relays before proceeding.
4 DR2149A
1. Use a continuity light or ohmmeter calibrated on appropriate scale to test continui ty. ty.
3 2. Connect meter leads to relay terminals 87a and 30. •
The The met meter er mu must st show show continuity .
4 3. Connect meter leads to relay terminals 87 and 30. •
The The met meter er mu must st show show no continuity .
5 4. Calibrate an ohmmeter on appropriate scale and connect the leads to relay terminals 85 and 86. •
5 DR2149B
The met meter er must must show show 70 - 100 100 ohms. ohms.
6
5. Connect meter leads to relay terminals 87 and 30. Connect a 12 volt source to relay terminals 85 and 86. •
The The met meter er mu must st show show continuity .
7
6. Connect meter leads to relay terminals 87a and 30. Connect a 12 volt source to relay terminals 85 and 86. •
The The met meter er mu must st show show no continuity .
6
7. Replace relay if your test results vary.
DR2149C
7 DR2149D Elect/eng
7-33
Engine Fuel System Troubleshooting ENGINE DOES NOT START START - I MPROPER STARTING PROCEDURE USED 1. 2. 3. 4. 5. 6. 7.
Check fuel level in tank, check fuel tank vent, check fuel in carburetor. Check choke for proper operation. Check for accelerator pump discharge. Check fuel pump for correct pressure/vacuum. Check fuel lines for blockage, tank to pump fuel line for air leaks, fuel filters for blockage. Check idle mixture and i dle speed adjustment. Remove carburetor; carburetor; check float level, inlet valve valve operation; check for dirt, dirt, water, water, varnish in passages, and worn parts.
ENGINE WILL START WHEN PRIMED - WILL NOT CONTINUE TO RUN 1. 2. 3. 4. 5. 6. 7.
Check fuel suppl y. Check idle mixture and idle speed. Check fuel lines for blockage, air leaks. Check for plugged fuel filters. Check fuel pump for correct pressure/vacuum. Remove carburetor; check for dirt, water, varnish deposits; check float level, and float inlet valve operation. Check vacuum qualification adjustment.
ENGINE HARD STARTING, COLD 1. 2. 3. 4. 5.
Check choke for proper operation. Check for accelerator pump discharge. Check fuel pump for correct pressure/vacuum. Check for blockage in fuel lines, air leaks in fuel line from tank to fuel pump. Remove carburetor; check float level, inlet valve operation; check for dirt, water, water, varnish deposits; check for worn parts, leaking gaskets.
ENGINE HARD STARTING, HOT 1. 2. 3. 4. 5.
Check carburetor for flooding (smell of raw gas). Check choke for sticking, not open fully. Remove carburetor; check float level, float inlet valve operation and condition. Check for fuel line on or near hot surfaces, causing percolating in lines. Check for correct carburetor base gasket.
ENGINE RUNS ROUGH, LOW SPEED 1. Check choke for proper operation; check idle mixture, idle speed. 2. Check for dirt or water in fuel, excessive or insufficient fuel pump pressure. 3. Remove carburetor; check for proper float level, internal blockage, defective parts, and varnish deposits in passages. 4. Check other systems; intake manifold for vacuum leaks, sticking valves, overheating, etc. 5. Check setting and operation of secondary throttle plate opening. (continued on next page)
Elect/eng
7-35
Engine Fuel System Troubleshooting (cont.) ENGINE RUNS ROUGH, HIGH SPEED 1. Check for sufficient fuel in tank, blocked tank vent, proper fuel. 2. Check choke for proper operation. pressure/vacuum; check for blockage or air leaks 3. Check for water or dirt in fuel; check for correct fuel pump pressure/vacuum; in fuel line. 4. Remove carburetor; check float level, float inlet valve operation; check for proper high speed jet, power valve, internal blockage, varnish, and worn parts. 5. Check for plugged fuel filters. ENGINE DIES (ON INITIAL ACCELERATION) OR HAS ACCELERATION FLAT FLAT SPOT 1. 2. 3. 4. 5. 6.
Check idle speed and idle mixture adjustment, check manifold for leaks. Check vacuum diaphragm for premature opening. Check fuel lines for fuel leaks or partially plugged tank vent. Check carburetor accelerator pump for output and adjustment. Check for water or dirt in fuel; check fuel pump for correct pressure/vacuum. Remove carburetor; check for dirt and water; check float level and float inlet valve for operation; check for varnish in passages, worn parts; check for proper main jet.
ENGINE WILL NOT TURN RECOMMENDED RPM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Check throttle linkage adjustments to be sure throttle opens fully. Check fuel lines for leaks; check fuel pump for correct pressure/vacuum. pressure/vacuum. Check choke for proper operation. Remove carburetor; check float level; check for proper main jet, power valve; check passages for dirt and varnish. Check boat for proper trim and propeller; check hull for marine growth. Check ignition system components. Check engine and drive unit for partial seizure. Check fuel tank for plugged vent; check pickup tube for vacuum leaks. Check for plugged fuel filters. Check for full opening of secondary throttle. Check exhaust system for restrictions. restrictions. Check for restricted air intake. Check that secondary throttle plates are free to rotate when diaphragm stem is compressed. Check that secondary diaphragm is not leaking and preventing throttle plates from opening correctly. correctly.
7-36
Elect/eng
Specifications Torque Values - All Models Inlet Needle Seat ................................. ................................................. ................................. ................................. ................................ ................................. ............................. ............ 10 in. lb. (1.1 N m) Inlet Nut Fitting Fitti ng ............................... ................................................ ................................. ................................. ................................. ................................ ................................. ...................... ..... 80 in. lb. (9 N m) Main Jets ...................................... ........................................................... ......................................... ......................................... ....................................... .................................... ...................... .... 10 in. lb. (1.1 N m) Power Valve........................................ Valve........................................................ ................................. ................................. ................................. .............................. ............................. ................ 100 in. lb. (11.3 N m) •
•
•
•
Nuts Carburetor Mounting ................................ ................................................ ................................. ................................. ................................. ................................... .................... 10-14 ft. lb. (13-19 N Flame Arrestor Arre stor Cover ................................ ................................................. ................................. ................................. ................................. ................................ .................. .. 25-35 in. lb. (2.8-4 (2.8 -4 N Screws Accel erator Pump Cover ............................... ............................................... ................................. ................................. ................................ ................................. ......................... ........ 5 in. lb. (0,6 N Choke Housing ......................................... .............................................................. .......................................... ......................................... .................................. ................................. ................... 5 in. lb. (0.6 (0 .6 N Choke Plate ............................... ............................................... ................................. ................................. ................................. ................................. .................................. ........................... ......... 6 in. Ib. (0.7 N Fuel Bowl ................................. ................................................. ................................. ................................. ................................. ................................. ................................. ......................... ........ 45 in. lb. (5.1 N Pump Discharge Dischar ge Nozzl e ................................. ................................................. ................................. ................................. ................................. ................................. .................... ....15 15 in. Ib. (1.7 N Thermostat Cover ....................................... ............................................................ ......................................... ......................................... ........................................... ............................... ......... 5 in. lb. lb . (0.6 N Throttle Thro ttle Body ................................ ................................................. ................................. ................................. ................................. ................................ ................................ ...................... ...... 50 in. lb. (5.6 N Throttle Thro ttle Plate ................................ ................................................. ................................. ................................. ................................. ................................ ................................ ...................... ...... 10 in. lb. (1.1 N
•
•
m) m)
m) m) m) m) m) m) m) m)
•
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Fuel bowl screws should be tightened once a year.
3.0 GS Models Holley List 80316
50 0 CFM Model 2 3 0 0- 2V
Pump Lever Clearance ............................... ................................................ ................................. ................................ ................................. ................. 0.010-0.015 0.010- 0.015 in. (0.254-0.381 (0.254 -0.381 mm) Choke Unloader Unloader ..... .......... .......... ......... ......... .......... .......... ......... ......... .......... .......... ......... ......... .......... ......... ......... ....... .. 0.300 in. (7.62 mm) Me asured Lower Edge of P Plate late Choke Chok e Setting Setti ng ............................... ............................................... ................................ ................................. ................................. ................................. ................................. .......................... .......... 5 Notches Notc hes Lean Initial Idle Mixture Setting ..... .......... ......... ......... .......... .......... ......... ......... .......... .......... ......... ......... .......... ......... ......... .......... ......... .... 1 Turn Starboard - 1/2 Turn Port Off Seat Main Jet ............................... ................................................ ................................. ................................ ................................. ................................. .................................. .................................. ................................ ....................... ....... 7 1 Power Valve ............................... ............................................... ................................. ................................. ................................ ................................. ................................. ................................ ................................. ................... .. 2 . 5 Floa t Setti ng ................................ ................................................ ................................ ................................. ................................. ................... ... Paralle Para llell to Fuel Bowl When Bowl Inverte d Choke Vacuum Qualification............. Qualification.................. ......... ......... .......... .......... ......... ......... .......... .......... ....... 0.365 in. (9 .3 mm) Measured At Lo wer Ed ge of Plate Pump Cam Position (ora nge cam) ..... .......... .......... ......... ......... .......... .......... ......... ......... .......... .......... ......... ......... .......... ......... ........ .... No. 2 Hole H ole of Cam C am and Th rottle Arm
4.3 GL Models Holley List R-75006A
5 0 0 CF M M o d e l 2 3 0 0 - 2 V
Pump Lever Clearance ............................... ................................................ ................................. ................................ ................................. ................. 0.010-0.015 0.010- 0.015 in. (0.254-0.381 (0.254 -0.381 mm) Choke Unloader Unloader ..... .......... .......... ......... ......... .......... .......... ......... ......... .......... .......... ......... ......... .......... ......... ......... .......... ..... 3/8 in. (9.525 mm) Measured Lower Edge of Plate Choke Chok e Setting Setti ng ............................... ............................................... ................................ ................................. ................................. ................................. ................................. .......................... .......... 5 Notches Notc hes Lean Initial Init ial Idle Mixture Setting Settin g ................................. ................................................. ................................ ................................. ................................. ................................. .................... ... 5/8 Turn Turn Off Seat Sea t Main Jet ............................... ................................................ ................................. ................................ ................................. ................................. .................................. .................................. ................................ ....................... ....... 7 0 Power Valve ............................... ............................................... ................................. ................................. ................................ ................................. ................................. ................................ ................................. ................... .. 2 . 5 Floa t Setti ng ................................ ................................................ ................................ ................................. ................................. ................... ... Paralle Para llell to Fuel Bowl When Bowl Inverte d Choke Vacuum Qualification............. Qualification.................. ......... ......... .......... .......... ......... ......... .......... ......... .... 0.250 in. (6.3 5 mm) Measured At Low er Edge of Pl ate Pump C am Pos ition (red cam) ..... .......... ......... ......... .......... .......... ......... ......... .......... ......... ......... .......... .......... ......... ......... .......... .......... ..... No. 1 Hole of Cam and T hrottle Arm
Elect/eng
7-37
Specifications
5.0 GL Models 5.7 GS Models Holley List R-75004A
5 00 CFM Model 23 00 -2 V
Pump Lever Leve r Clearan Cle arance ce ............................... ............................................... ................................. ................................. ................................ ................0.01 0.010-0. 0-0.015 015 in. (0,25 4-0,381 4-0, 381 mm) Choke Unl oader ..... .......... ......... ......... .......... ......... ......... .......... .......... ......... ......... .......... .......... ......... ......... .......... ....... 0.300 in. (7,62 mm) Me asured Lower Edge of P late Choke Chok e Setting Sett ing ................................. ................................................. ................................. ................................. ................................. ................................. ................................ ........................ ........ 5 Notch es Lean Initial Init ial Idle Mixture Mixtur e Setting Sett ing ................................ ................................................ ................................. ................................. ................................. ..............................3/4 .............3/4 to 1 Turn Off Seat Main Jet ............................... ................................................ ................................. ................................ ................................. ................................. ................................. .................................. ................................. ....................... ....... 6 9 Power Valve ................................ ................................................. ................................. ................................. ................................. ................................ ............................................... ................................................ ................... 4 . 5 Float Setting ......... .............. ......... ......... .......... .......... ......... ......... .......... ......... ......... .......... .......... ......... ......... .......... .......... ......... ......... ......... .... Parallel to Fuel Bowl When Bowl Inverted Choke Vacuum Qualifi cation ..... .......... ......... ......... .......... ......... ......... .......... .......... ......... ......... ....... 0.315 in . (8,00 m m) Measured At Lower Ed ge of P late Pump C am Pos ition (yellow cam) ......... .............. ......... ......... .......... .......... ......... ......... .......... .......... ......... ......... .......... ......... ......... ..... No. 1 Hole of Cam and Throttle Arm
7-38
Elect/eng
Safety Section
Part A
Marine Product Products s and Safety Safety of People People Who Use Use Them . . . . . . . . . S-2 Sterndrive Sterndrive Shift System System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-3 Sterndrive Sterndrive Throttle Throttle Control Control System System . . . . . . . . . . . . . . . . . . . . . . . . S-4 Sterndrive Sterndrive Steering Steering System System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-5 Sterndrive Sterndrive Fuel, Fuel, Electri Electrical cal System System . . . . . . . . . . . . . . . . . . . . . . . . . S-7 Part B
Marine Marine Produc Products ts and and Safety Safety of of People People Who Who Fix Fix Them Them . . . . . . . . S-11 S-11 Handling Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-11 Handling Handling Lead Acid Batteri Batteries es . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-12 Gasoline! Gasoline! Handle Handle with Care Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-13 Hazardous Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-14
Safety
S-1 S- 1
Part A - Marine Products and safety of People Who Use Them
Enjoyable boating is the goal of people who design and build marine products. To reach this goal, manufacturers are careful to make sure... Product User is informed. . . Products are safe and reliable. . . It's up to you, the People who. . . Install accessories. . . Service and Maintain the boat. . . Service and maintain the sterndrive. . . . . . to keep the products safe and reliable. This section talks about safe boating and how you can help keep it safe. Some things you may know . . . but others you may not.
First! A word about fasteners . . . plain . . . special . . . all screws, nuts, washers and bolts.
Do Not Substitute Fasteners
They look the same, but . . . are they? The Same Size? The Same Strength? The Same Material? The Same Type? Standard or Metric Thread?
Don't substitute unless you know they are the same in all characteristics. Second! Special locking screws and nuts are often used to attach steering, and remote control components to the sterndrive. When you remove any part from the sterndrive, keep track of special screws and nuts. Don't mix with other parts When reassembling the sterndrive, use only the special screws and nuts intended to hold steering, and control cables, plus related parts. Service with parts of known quality that meet Marine Industry (BIA/ABYC) Standard.
S-2 S- 2
Safety
Sterndrive Shift System
The Shift System starts here at the remote control contro l lever. . .
. . . and ends here at a t the propeller.
What's Most Important? When the control lever is in Forward, Neutral or Reverse position . .
. . . Shift mechanism must match control lever position.
What Could Happen? If . . . Neutral
If . . . Forward
Forward or Reverse Reverse
. . . Propeller is still powered (turning) unknown to operator, or engine will start in gear, boat will move unexpectedly. unexpected ly.
. . . boat will move opposite to direction intended by operator.
How Can Loss of Shift Control be Minimized? In pre-delivery inspection inspection and when servicing . . . Read, understand and follow manufacturers instructions. Closely follow the warnings marked with
...
Assemble parts and make adjustments carefully . . . Test your work. Don't guess. Make sure propeller does what the operator wants and nothing else. Safety
S-3 S- 3
Sterndrive Throttle Control System
The throttle Control System starts here and the remote control lever . . . . . . and ends here on the engine.
What's Most Important?
When the control lever is moved from Forward (or Reverse) to Neutral . . .
. . . engine speed must slow to idle RPM and allow operator to shift into Neutral.
Operator must be able to stop propeller. What Could Happen? If operator cannot slow the engine to idle RPM and shift shi ft into neutral, (stop propeller), operator could panic and l ose control of boat.
How Can Loss of Throttle Control be Minimized? Minimized? In pre-delivery inspection inspection and when servicing servicing . . . Read, understand, and follow manufacturers instructions. Closely follow the warnings marked with
...
Assemble parts and make adjustments carefully . . . Test your work. Don't guess. Make sure engine throttle response is smooth. Make sure full throttle operating RPM can be reached so operator won't overload engine
S-4 S- 4
Safety
Sterndrive Steering System
The Steering System starts here at the helm . . .
What's Most Important? The Steering System . . .
. . . and ends here at the propeller on the sterndrive
must be installed properly must be adjusted properly must be lubricated
What Could Happen? . . . if steering system comes apart, boat would turn suddenly and circle . . . passengers and/or operator may be thrown into water and could be hit.
. . . if steering jams, operator may not be able to avoid obstacles. Operator could panic. . . . if steering is loose, operator may not be able to maintain a true course, and could result in loss of boat control.
Safety
S-5 S- 5
How Can Loss of Steering Control be Minimized? In predelivery inspection and when servicing
use steering components which meet marine industry (BIA/ABYC) standards . . . Read, understand, and follow manufacturer's instructions. Assemble parts and make adjustments carefully . . . Clos Closel ely y fol follo low w the the wa warn rnin ings gs ma mark rked ed with with ... Keep parts moving freely . . . lubricate parts as soon as shown in manuals Use bolts, nuts, and washers supplied with steering attachment kits
When power assisted or mechanical steering systems are used, check to uncover possible trouble! Cable housing in this area must not be restricted
Steering components must not bind
Why? Unit may go to full turn without turning steering wheel (Power assist models)
Why? Possible jamming of steering system.
Engine stringer must not interfere with power steering pump and pulley
Maintain proper belt tension. Power steering parts and push/pull cable must be free to move in order to actuate power steering valve when operator turns steering wheel
Check for damaged parts . . . impacts to the sterndrive like this
or this . . . or ? ? ? can put stress on steering components. Look for . . . Cracked parts Bent parts Loose fasteners
Replace damaged damaged parts. parts. If weakened, weakened, parts could could fail later . . . on the water . . . when least expected. S-6 S- 6
Safety
Sterndrive Fuel and Electrical Systems
The electrical System begins here at the battery . . . . . . and ends here at the carburetor or fuel injectors
The fuel system starts here at the fuel tank . . .
. . . and ends here on the engine.
What's Important? Fuel leakage must be prevented. Electric sparks must not happen.
What Could Happen? Gasoline can explode and/ or burn easily: When boating, fuel leaking in the engine compartment could be ignited by a spark from a loose wire connection, or a damaged or deteriorated electrical component.
How Can Fire and Explosion Be Minimized? Read, understand and follow manufacturers instructions. Closely follow the warnings marked with
...
Do not substitute fuel or electrical parts with other parts which may look the same. These parts are designed and manufactured to meet special U. S. Coast Guard safety regulations to prevent fire and explosion. If you work on marine engines, you must must understand these U.S. Coast Guard requirements. If you don't have them, write to . . . ------------------------National Technical Information Service
. . . and ask for copies of:
Springfield, Virginia 22161
(1) Electrical System Compliance Guideline (AD/A-049-638) (2) Fuel System Compliance Guideline (AD/A-047-767) These are concise guidelines - easy to read and understand. They explain what must be done to prevent fire and explosions. Safety
S-7 S- 7
Always use replacement parts specified by the manufacturer. They meet the U.S. Coast Guard requirements. Most automotive parts do not, especially electrical components compone nts that must meet meet ignition protection requirements of the U.S. Coast Guard regulations. When nonmetallic parts look to be in poor shape . . . replace them!
Wires Cracked!
Torn Boots!
Cracked Fuel Lines! Using parts which meet U.S. Coast guard requirements is only half the job. The other half is your job . . . It's time for replacement BEFORE sparks and/or fuel leaks occur. Replace parts carefully. Make sure nuts and bolts are tight especially when they anchor electrical wires (to prevent sparking). If lock washers are specified - use them. No short cuts or missing parts with either of these CRITICAL safety related systems. When refueling, always ground fuel nozzle to the inlet fitting on the boat to prevent the buildup of electrostatic sparks. If you use a funnel, make sure it's metal and ground the fuel nozzle to the funnel.
STOP
If you smell gasoline in the engine compartment . . . find its source and stop the leakage.
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Safety
Follow "Starting Procedure" outlined in the operator's manual. Always make sure there are no gasoline fumes in the engine compartment before starting the engine. Open the compartment and use your nose. Don't gamble.
Backfire flame arrestor must be in place and securely attached to the air intake.
Do not alter the backfire backfi re flame arrestor. If loose, damaged, or altered, an engine "backfire" may pass through the flame arrestor assembly into the engine compartment. If fumes are present in compartment, fire and explosion could result.
Safety
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Summing Up Now you know some things that can take the joy out of enjoyable boating. No doubt about it . . . it takes time! Reading and understanding instructions. Reading and understanding warnings marked with
...
Putting parts together correctly . . . Making correct adjustments . . . Testing you work.
and making sure Worn or damaged parts are replaced, Replaced parts are like originals . . . in every way. Customer is told of things which need attention . . .
But do you really want the alternative?
S-10
Safety
Part B - Marine Products and Safety of People* Who Fix Them
Part A talked about safe boating and how you, the mechanic, mechani c, can help keep it safe for the boater. But what about you? Mechanics can be hurt while . . . Servicing boats Servicing sterndrives Troubleshooting problems Testing their work Some items you'll know . . . others you may not.
When Lifting Engines If hoist is poor shape . . . or too small for the job Engine may drop suddenly
DR3471
DR3469
Make sure shop aids have extra capacity — and keep them in good repair!
When Running Engine with Engine Compartment Cover Removed The engine compartment cover is a guard. When you remove the cover / guard to work on the engine, remember: Loose clothing (open shirt sleeves, neckties), long hair, jewelry (rings, watches, bracelets), hands, arms, belts can be caught by moving belts or spinning pulleys Handle high voltage ignition components carefully. They can shock you and may cause you to recoil into moving parts. Two people working together on a running engine eng ine must look out for each other. Never, ever, ever, hit the key to start the engine before signalling to your partner. (He may be leaning over the engine with his hands on a belt, or a "hot" electrical part, near the propeller, propell er, etc.) *Mechanics, technicians, backyard do-it-yourselfers.
Safety
S-11
Exhaust gasses of running engines contain carbon monoxide. . . you can't see it. . . you can't smell it. . . you can't taste it. . . but it's there whenever an engine runs. . . and it's deadly! When you smell the other gasses in the exhaust, you are inhaling carbon monoxide. Run engines only in well ventilated areas.
Eyes Need help
Grinding
Sprayed Cleaners, Paints
End of Cables
Acid
Chiseling (steel on steel) (Tip: Use plastic or brass type hammers. They don't chip off as easily as steel hammers.)
Handling Lead Acid Batteries
If spilled or splashed on any part of body.. b ody..
Wash with lots of water. . .
If solution gets into eyes. . . Wash. . . and see a Doctor, fast!
Charging Lead Acid Batteries Attach and remove these cables with charger unplugged from 110 volt wall socket. (Prevents shocks if the charger is defective.) Observe correct polarity when connecting these charger leads. Always charge in a well ventilated area. Charging causes acid solution to give off hydrogen gas through the vents in the caps. . . Make sure vents are open. If clogged, pressure inside may build. . . battery may explode.
S-12
Safety
Never yank cables off battery posts. . . it's a sure way to make lots of sparks. . .surrounded by battery gas
Battery gas is explosive! While charging or discharging, remember. . .
No Smoking No Flames No Sparks
After Charging. . .
Don't check battery condition by placing metal objects across posts.
Shut off charger Remove charger plug from wall socket Then. . .
You're sure to make sparks and serious burns are possible.
Take charger cable c able off battery posts
Gasoline! Handle With Care When you smell any odor of gasoline, explosion is possible Gasoline fumes are heavier than air and will sink to the lowest point in the boat or room, and will stay there. . . waiting Gasoline explodes easily and violently when mixed with air
If the air around you is quiet . . . the pilot light in the heater may ignite the heavy fumes before your nose ever smells the fumes . .
5 Parts Gasoline 100 Parts Air
What Can you Do?
Store in sturdy stu rdy,, sealed gas can . . .and . . . keep outside Safety
Store properly . . . Fill portable tanks outside boat to prevent spillage in boat Use fuel for fuel . . . not for a solvent If fumes are smelled (in shop, basement, garage), immediately: Put out open flames, cigarettes, sparking devices Wipe up spill or leak; get towels, rags outside fast Check lowest area for fumes; open doors or windows
S-13
Know items in and around repair area which can ignite gasoline fumes . . . Control them if fumes are smelled. Matches, cigarettes, torches, welders Electric motors (with unsealed cases) Electric generators (with unsealed cases) Light switches Appliance pilot lights (furnace, dryer, water heater) ????????? How many of these are in your area?
Hazardous Products
Read the container label. It tells you . . . "How, and where, to use," "How to give First Aid," and have "recommended" first aid materials on hand- should an emergency arise "How to dispose of can," Remember: Little children are very curious and will try to taste everything, so . . . Keep containers away from children
. . . yummmmmmmmmmm
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Safety
®
Volvo Penta of the Americas, Inc. 1300 Volvo Penta Drive Chesapeake, Virginia 23320 U.S.A.
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