Volvo Penta D16 Operator'S Manual Download

Page: 53 / 90

D16 MG RC Genset engine

P0010385

1 Coolant filler cap

2 Expansion tank

3 Air Filter

4 Electrical connection box with SD reset

5 Auxiliary stop

6 Oil filler cap, engine

7 Switchable fuel filters

8 Fuel Shut-off Valve

9 Engine Control Unit

10 Alternator

11 Charge air cooler

12 Radiator

13 Fresh water pump

14 Oil filter

15 By-pass filter for engine oil

16 Starter motor

Maintenance

47711740 05-2019 © AB VOLVO PENTA

Summary of Contents for D16

Page 1: ...Operator s manual D16 genset ...

Page 2: ...r reproductive harm To minimize exposure avoid breathing exhaust when operating servicing and maintaining the engine Always start and operate the engine in a well ventilated area If in an enclosed area vent the exhaust to the outside Wear gloves or wash your hands frequently when servicing the vessel Do not modify or tamper with the exhaust system Do not idle the engine except as necessary For mor...

Page 3: ...Shutdown Unit SDU 27 SDU Indications 28 Starting 29 Before Starting 29 Starting the Engine 29 Operation 31 Reading the Instruments 31 Alarms 31 Maneuvering 32 Engine Shutdown 33 Before Engine Shutdown 33 Stop the Engine 33 After Engine Shutdown 34 Operation Break 35 Cold Weather Precautions 35 Fault handling 36 Acknowledge message 36 Alarm List 37 Fault Tracing 39 Fault Code Register 41 In Case of...

Page 4: ...shing 68 Seawater System 69 Seawater System Draining 69 Anodes Check and Change 70 Impeller Check and Change 71 Seawater Filter Check and Cleaning 72 Intake Manifold Checking the Drain Hole 72 Electrical System 72 Power Module 72 Main switch 73 Electrical Connections 73 Battery 74 Electrical Welding 76 Storage 77 Bringing Out of Storage 78 Technical Data 79 Viscosity 79 Coolant Mixing 81 Identific...

Page 5: ...afely and correctly Pay careful attention to the safety instructions included in the manual As the owner of a Volvo Penta engine you become part of a worldwide network of dealers and service workshop that assist you with technical advice service requirements and replacement parts Contact you nearest authorized Volvo Penta dealer for assistance It is possible to buy additional literature about your...

Page 6: ...f not avoided result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious personal injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate personal injury IMPORTANT Indicates a situation which if not avoided could result in property damage NOTICE Used to draw attention to important inf...

Page 7: ... give the engine and engine compartment a visual check before the engine is started and after operations once the engine has stopped This helps you to quickly discover fuel coolant or oil leakages or any other abnormality that has occurred or is about to occur Personal safety equipment CAUTION Always use appropriate safety equipment Personal protective equipment does not eliminate the risk of inju...

Page 8: ...clothes and rags Wash regularly especially before eating Wear suitable protective creams to prevent skin from drying out and to facilitate cleaning Fire safety WARNING Fire and Explosion Risk Accidental spark could ignite fuel vapors All fuels as well as many lubricants and chemicals are flammable Do not allow open flames or sparks near them Smoking forbidden Hydrogen from the batteries is also ve...

Page 9: ...ked rags can spontaneously ignite under certain circumstances IMPORTANT Used fuel and oil filters are environmentally hazardous waste and must be taken to an approved waste management facility for correct handling as must any used lubricating oil contaminated fuel paint residue solvents degreasers and wash residue Prevent start of the engine WARNING Immobilize the engine by turning off the power s...

Page 10: ...k on running engines is strictly prohibited There are however adjustments that require the engine to be run Approaching a running engine is a safety risk Loose clothing and long hair can get caught in the rotating parts careless movements or a dropped tool can lead to serious personal injury Be careful to avoid hot surfaces exhaust pipes turbochargers charge air manifolds start elements etc and ho...

Page 11: ...tion cause serious personal injuries Before any work on the electrical system WARNING Always stop the engine first Then disconnect the current at the main switches and any external power supply before working on the electrical system to minimize the risk of electrical hazards IMPORTANT Never disconnect the current using the main switches when the engine is running or by disconnecting the battery c...

Page 12: ...he engine is still hot Steam or hot coolant can spray out and system pressure is lost Open the filler cap slowly and release the pressure in the cooling system if the filler cap or valve must be opened or if a plug or a coolant hose must be removed from a hot engine Hot oil under pressure CAUTION Hot oil can cause burns Avoid getting hot oil on the skin Ensure that the lubrication system is not pr...

Page 13: ...ty goggles Be extremely careful when searching for leaks in the fuel system high pressure circuits There is very high pressure in the jet from pipes and injectors The fuel may penetrate the tissue and cause serious risk of blood infection septicemia Handling of fuel pipes IMPORTANT High pressure pipes for fuel must not be bent or straightened under any circumstances Cracks may occur Damaged pipes ...

Page 14: ...insing help by medical staff If it comes electrolyte to unprotected skin wash immediately with soap and water Layout of the battery compartment IMPORTANT Make sure the battery compartment is designed according to current safety standards Cleaning the engine and components IMPORTANT Never use a high pressure washer for cleaning of engine or engine components Cleanliness for sensitive components IMP...

Page 15: ...llustrations and the purchased product This does however not affect the validity of the information and or instructions in the manual Volvo Penta reserves the right to make alterations to specifications design features and illustrations without prior notice At service software can be updated that affects the functionality described in this manual About this Manual This Operator s Manual has been p...

Page 16: ...g registration the warranty will not be valid Contact your Volvo Penta dealer if you have not received the Warranty Information or Service Book Running in the engine The engine must be run in during the first 10 hours of operation Do this by using the engine in normal operation where full load is only applied for short periods of time Never run the engine at constant speed for any longer periods o...

Page 17: ...orized dealers The authorized dealers are Volvo Penta product specialists and have the accessories genuine parts test equipment and special tools needed for high quality service and repair work Always observe the maintenance intervals in the manual the complete Service Protocol can be found at volvopenta com Remember to note the engine transmission identification number when you order service and ...

Page 18: ...rding fuel grades operation and maintenance to avoid unnecessary environmental impact Contact your Volvo Penta dealer if you notice any changes such as increased fuel consumption or exhaust smoke Remember always to hand in environmental hazardous waste such as drained oil coolant old batteries etc for treatment at a recycling facility Our united efforts can make a valuable contribution to the envi...

Page 19: ...ility of the operator user to ensure that no intentional misuse of the engine takes place Volvo Penta maintenance and service intervals must be complied with Any case of malfunction must be rectified without delay Only use genuine Volvo Penta parts or spare parts with the same quality as genuine Volvo Penta parts Volvo Penta recommends that service to injection pumps pump settings and injectors al...

Page 20: ...wnload the dealer locator app to your smartphone Volvo Penta Action Service Our global dealer network your first line of contact is backed up by Volvo Penta Action Service a phone based breakdown and support service providing assistance 24 hours a day every day of the year How it works A dedicated operator will support you all the way through your case and keep you updated on status and progress W...

Page 21: ...ay as the MCU The SDU manages automatic engine shutdown should the engine show critically low oil pressure including reverse gear or high coolant temperature It also has overspeed protection Electronic systems in the vicinity of the engine comprise the engine management system EMS and a power management unit PM The engine management unit manages the injection of fuel with the aid of a number of se...

Page 22: ...ns Switch inputs outputs Modbus RS 232 Comap CAN2 CAN J1939 5 Remote panel 6 Comap CAN2 7 Other Comap equipment 8 Data bus CAN J1939 and J11708 1587 9 EMS 10 Shutdown Senders Switches a Oil pessure switch b Coolant temperature switch c RPM sender Instruments and Controls 20 47711740 05 2019 AB VOLVO PENTA ...

Page 23: ...gine is running 9 Up button selecting and increasing 10 Down button selecting and decreasing 11 Enter confirming selection 12 Page switching windows between Measurement engine data Adjustment and History 13 I O button varied function depending on installation Can be set to any function when installing 14 Red lamp indicates that there is an alarm The lamp flashes when a new alarm occurs The lamp sh...

Page 24: ... connection a remote panel is on line D L locked The main panel is locked and the remote panel is in control E There is an alarm in the alarm list F Engine status NotReady the system is not ready and the engine cannot be started Ready the system is ready and the engine can be started Running the engine is in operation Instruments and Controls 22 47711740 05 2019 AB VOLVO PENTA ...

Page 25: ...esired setpoint Setpoints marked with an asterisk are password protected Press Enter to confirm the selection 5 Use the up down buttons to adjust the setpoint Depress the up down buttons for 2 seconds to activate automatic repetition 6 Press Enter 2 to confirm the selection To finish without any change press the Page button 1 Press the Page button 1 to select setpoint group History Page 1 Browse t...

Page 26: ...ge the information on the screen will be shown in There are six languages to choose from 1 Press the Enter button 2 and hold it down to reach the info menu Press the Page button 1 2 Browse using the up down buttons 3 Press Enter 2 to select the language and close the menu Setting password The password consists of 1 4 numerals The default password is 0 on delivery 1 Navigate to the Adjustments menu...

Page 27: ... pressing the left Mode button NOTICE The engine cannot be started if the engine is running it will be shut down when OFF mode is activated Activate OFF mode by repeatedly pressing the left Mode button until off is shown in the display s top left corner Statistics In the main menu press the up button three times 1 Operation hours 2 Total quantity of fuel used 3 Number of successful starts 4 Number...

Page 28: ...in menu is active The alarm list is not activated while values parameters and alarm history are being reviewed For further information on how to handle alarms and take recommended actions refer to the Fault handling page 36 chapter Instruments and Controls 26 47711740 05 2019 AB VOLVO PENTA ...

Page 29: ...down reset button on engine connection box Overspeed shutdown The overspeed function shuts down the engine in case of overspeed Overspeed test To test overspeed function push the overspeed test button inside the SDU When pushed the overspeed limit drops 25 Emergency mode shutdown override The system can be overridden by activating the OR input the Emergency mode lamp when installed on output SL wi...

Page 30: ...down active 10 Red S1Shutdown active A Broken wire reset button B Yellow Fuel valve wire detected C Yellow Speed sender Broken wire detected D Yellow S6 Broken wire detected E Yellow S5 Broken wire detected F Yellow S4 Broken wire detected G Yellow S3 Broken wire detected H Yellow S2 Broken wire detected I Yellow S1 Broken wire detected J Overspeed shutdown test button Instruments and Controls 28 ...

Page 31: ...tarting Engine and engine room General inspection Checking Engine Oil Level Check the coolant level Fuel Tank sludge trap Drain Fuel Filters Drain Fuel pre filter draining water contamination Starting the Engine 1 In the main menu browse to start mode AUX EME HBR A using the Mode button 2 Check that engine status is Ready B 3 Depress the Start button engine status will change to Running C If the e...

Page 32: ...first ten seconds Check that instruments and warning displays show normal values Check that no messages are displayed and no warning signs are showing If a fault is registred please refer to section Fault handling page 36 for further information and recomended actions Warm the engine up at low speed and low load so normal operating temperature is reached before full power is used IMPORTANT Never r...

Page 33: ...udible alarm by pressing the Horn Reset button 1 2 Reading alarms To see active alarms press the up button in the main menu once for the SDU MCU alarm list and twice for the ECU alarm list If there are several alarms browse in the alarm list using the Enter button 3 Depress the Acknowledge button 2 to acknowledge all alarms Take the necessary action refer to the Fault handling page 36 section for ...

Page 34: ...itor running data that is not shown in the main menu 1 Browse with the Page button 1 to the engine data menu Monitoring page 2 Use the up down buttons to select the desired engine data Operation 32 47711740 05 2019 AB VOLVO PENTA ...

Page 35: ...in 30 seconds after turning off the ignition This is in order to save engine data to the engine control unit Stop the Engine 1 Press the stop button until engine speed begins to fall 2 Check that the rpm reading drops to 0 and that engine status changes to Ready Emergency stop If a fault occurs that prevents you stopping the engine in the normal way you can stop it by pressing the emergency button...

Page 36: ... risk of the boat striking bottom with the stern drive the drive must instead be trimmed up to the maximum lift position Turn off the main power switch before any long stoppage NOTICE Do not turn off the main power switch within 30 seconds after turning off the ignition This in order to save engine data to the engine control unit NOTICE Depending on the model and setup there could be more than one...

Page 37: ...torage page 77 Cold Weather Precautions If the engine bay cannot be kept frost free the sea water system must be drained and the freshwater system coolant must have sufficient freeze protection to prevent freeze bursting refer to Maintenance page 66 and Seawater System Draining page 69 respectively for more detailed information Check the charge status of the battery A poorly charged battery can fr...

Page 38: ...some possible alarms and fault handling Note that the content of this chapter does not provide full coverage of the possible fault messages and alarms Contact a Volvo Penta workshop for assistance with diagnostic readouts and unresolved faults Acknowledge message The Acknowledge button 1 acknowledges all alarms Alarms that are not active disappear from the list 36 47711740 05 2019 AB VOLVO PENTA ...

Page 39: ...ed while values parameters and alarm history are being reviewed At position 7 the number in parentheses shows in which ECU the fault code is 1 EMS J1939 2 EMS and Power module J1587 The alarm list heading shows Number of active alarms 1 Number of unacknowledged alarms 2 Total number of alarms 3 Number of pages 4 Scroll between the alarms in the list with the enter key Status of alarm Unacknowledge...

Page 40: ...6 times FM4 FMI failure mode indicator Indicate the type of failure E2 Which control unit 1 EMS J1939 2 EMS and Power module J1587 For more information about fault code and a complete list look in the workshop manual Alarm list and history Abbreviations in alarm list and history Abbreviation Meaning Wrn Warning Fls Sensor failure General alarm Fault handling 38 47711740 05 2019 AB VOLVO PENTA ...

Page 41: ...nsumption 15 16 18 21 36 Black exhaust smoke 19 Blue or white exhaust smoke 21 34 Lubricating oil pressure too low 22 Coolant temperature too high 25 26 27 28 29 30 31 32 Coolant temperature too low 31 No charge or poor charge 2 8 1 Discharged batteries 2 Poor contact open circuit in cables 3 Main switch in off position 4 Shut down system activated 5 Check valve in feed pump leaks 6 Control lever ...

Page 42: ...5 Coolant level too low 26 Air in the freshwater system 27 Faulty circulation pump 28 Closed seawater inlet 29 Blocked seawater inlet lines or filters 30 Defective impeller in the seawater pump 31 Defective thermostat 32 Clogged heat exchanger insert 33 Clogged charge air cooler 34 Lubricating oil level too high 35 Water entry into engine 36 High back pressure in exhaust system 37 Faulty engine sp...

Page 43: ... remains EngCool Temp Wrn Coolant temperature too high Engine power is reduced Check coolant level Refer to Coolant Level Checking and Topping Up page 67 Check that the seawater filter is not blocked Refer to Seawater Filter Check and Cleaning page 72 Check the impeller in the seawater pump Refer to Impeller Check and Change page 71 Check that no leakage occurs EngineOilLevel Wrn Oil level too low...

Page 44: ...e page 56 Check battery fluid level Refer to Battery page 74 Fuel pressure incorrect Engine performance can be affected Communication failure Gear automatically set to neutral Engine performance can be affected Oil pressure too low Engine power is reduced Check the oil level in the engine Refer to Oil level checking and topping up page 57 Check that no leakage occurs Sensor failure Contact a Volvo...

Page 45: ...ing Engine Oil Level Refer to Oil level checking and topping up page 57 Check that no leakage occurs Primary Batt Fls Primary Battery Poor batteries or charging Refer to Battery Charging Sd Coolant Temp Wrn ECU Wrn J1587 Critical system fault Engine shuts down automatically Coolant temperature too high Engine power is reduced Check coolant level Refer to Coolant Level Checking and Topping Up page ...

Page 46: ...Check belt tension Refer to Drive belt check and change page 56 Check battery fluid level Refer to Battery page 74 Fuel pressure incorrect Engine performance can be affected Communication failure Gear automatically set to neutral Engine performance can be affected Oil pressure too low Engine power is reduced Check the oil level in the engine Refer to Oil level checking and topping up page 57 Check...

Page 47: ...gine is emergency stopped Engine revolutions are lower than expected 30 supply Fls 30 V supply Overcurrent protection for the supply to the MCC system has tripped Short circuit in the system between the engine and the MCC cabinet Remedy the problem Reset the system by switching the main switch off and on Contact a Volvo Penta workshop if the fault remains Fault Code Register 47711740 05 2019 AB VO...

Page 48: ...s trip This chapter provides advice on how to remedy a number of conceivable faults When certain faults occur safety functions engage to protect the engine The following may occur Engine cannot be started The engine rpm is limited The engine stops If a fault occurs confirm any fault alarm and take the necessary measures Refer to this section and Fault Code Register 46 47711740 05 2019 AB VOLVO PEN...

Page 49: ... on the auxiliary battery and to a place a little distance away from the discharged battery e g the start motor s negative terminal WARNING The black jumper cable must never come in contact with the positive connection on the starter motor 4 Start the engine and let it run at fast idle for approximately 10 minutes to charge the batteries Make sure there is no extra equipment connected to the elect...

Page 50: ...tement Service Intervals Service intervals are shown below The service content can be found in the Service Protocol available for download at www volvopenta com NOTICE More information on how to perform service and maintenance can be found in the Service and Maintenance handbook Information on how to purchase the Service and Maintenance handbook can be found at www volvopenta com Extended service ...

Page 51: ...uld be done with the engine stopped unless otherwise specified Stop the engine before opening or removing the engine hatch hood Make it impossible to start the engine by removing the start key and cutting the system voltage with the main switches NOTICE More information on how to perform service and maintenance can be found in the Service and Maintenance handbook The manual is available for downlo...

Page 52: ...filler cap engine 8 Switchable fuel filters 9 Seawater Pump 10 Fuel Shut off Valve 11 Engine Control Unit 12 Alternator 13 Charge air cooler 14 Air Filter 15 Fresh water pump 16 Oil filter 17 By pass filter for engine oil 18 Starter motor 19 Air outlet generator 20 Flexible engine mounting 21 Lifting eye 4 22 Air inlet generator Maintenance 50 47711740 05 2019 AB VOLVO PENTA ...

Page 53: ...n box with SD reset 5 Auxiliary stop 6 Oil filler cap engine 7 Switchable fuel filters 8 Fuel Shut off Valve 9 Engine Control Unit 10 Alternator 11 Charge air cooler 12 Radiator 13 Fresh water pump 14 Oil filter 15 By pass filter for engine oil 16 Starter motor Maintenance 47711740 05 2019 AB VOLVO PENTA 51 ...

Page 54: ...panel 7 Oil filler cap engine 8 Switchable fuel filters 9 Fuel Shut off Valve 10 Engine Control Unit 11 Alternator 12 Charge air cooler 13 Radiator 14 Fresh water pump 15 Oil filter 16 By pass filter for engine oil 17 Starter motor 18 Air outlet generator 19 Flexible engine mounting 20 Lifting eye 4 21 Air inlet generator Maintenance 52 47711740 05 2019 AB VOLVO PENTA ...

Page 55: ...y stop 5 Oil filler cap engine 6 Switchable fuel filters 7 Keel cooling connections 8 Seawater Pump 9 Fuel Shut off Valve 10 Engine Control Unit 11 Alternator 12 Charge air cooler 13 Air Filter 14 Fresh water pump 15 Oil filter 16 By pass filter for engine oil 17 Starter motor Maintenance 47711740 05 2019 AB VOLVO PENTA 53 ...

Page 56: ... 7 Switchable fuel filters 8 Keel cooling connections 9 Seawater Pump 10 Fuel Shut off Valve 11 Engine Control Unit 12 Alternator 13 Charge air cooler 14 Air Filter 15 Fresh water pump 16 Oil filter 17 By pass filter for engine oil 18 Starter motor 19 Air outlet generator 20 Flexible engine mounting 21 Lifting eye 4 22 Air inlet generator Maintenance 54 47711740 05 2019 AB VOLVO PENTA ...

Page 57: ... or in the engine room WARNING If an oil fuel or coolant leak is detected the cause must be investigated and the fault rectified before the engine is started Never direct the jet from a high pressure washer at seals rubber hoses or electrical components Never use the high pressure setting for engine cleaning Air Filter Check and Replace 1 Check the air filter indicator If indicator is all red afte...

Page 58: ...lt tensioner 1 and release the belt 4 Remove the drive belt 5 Check that the pulleys are clean and undamaged 6 Lower the belt tensioner 1 and install the new drive belts 7 Install the belt guards 8 Start the engine and do a function check Alternator belt replacement 1 Switch off the manin switch es and check that the engine is not connected to system power 2 Remove the belt cover 3 Remove the wate...

Page 59: ...Oil level checking and topping up Check the oil level with the engine shut down and in a horizontal level The oil level must be within the marked range on the dipstick There is a low level alarm installed as standard but make sure to check the oil level anyway every once in a while Fill lubrication oil through the filler opening on the side of the engine Wait a few minutes to allow the oil to run ...

Page 60: ...en the tap 2 under the drain pump to the position for draining engine oil E 4 Replace the oil filter and by pass filter at every oil change Refer to the section Oil Filter By pass Filter Change page 59 5 Close the tap S Refill with new oil to the correct level IMPORTANT Only use oil of recommend quality and viscosity Refer to Technical Data page 79 for oil quantity and quality and viscosity 6 Star...

Page 61: ...racket 3 Unscrew the bypass filter 1 and the oil filters 2 with a suitable filter wrench 4 Make sure the seal s mating surfaces on the filter brackets are clean 5 Lightly oil the rubber seal of the new filters 6 Mount the new filters by hand until the gasket is in contact with the sealing surface Then tighten the filters another 3 4 to 1 turn 7 Start the engine idle and make sure that no leakages ...

Page 62: ...the filter holder sealing surfaces are clean and that there are no gasket residues left from the old filter 5 Lubricate the rubber gasket for the new filter 6 Screw on the filter by hand until the rubber gasket just touches the filter holder sealing surface Then tighten the filter a further 3 4 to 1 turn 7 Turn the handle to the left closed position and replace the right oil filter in the same way...

Page 63: ...ized Volvo Penta workshop WARNING Fire hazard When carrying out work on the fuel system make sure the engine is cold A fuel spill onto a hot surface or an electrical component can cause a fire Store fuel soaked rags so that they cannot cause fire WARNING Store fuel soaked rags and other flammable material so that there is no danger of them catching fire Fuel soaked rags can ignite spontaneously un...

Page 64: ...e the new filter is absolutely clean and that the sealing surfaces are undamaged Moisten the seals with engine oil including the inner rubber seal on the inside of the threaded hole in the center of the filter NOTICE Do not fill the new filter with fuel before assembly Contaminations may get into the system and cause damage and malfunction 6 Screw the new filter on by hand until the seal just touc...

Page 65: ...re undamaged Moisten the seals with engine oil including the inner rubber seal on the inside of the threaded hole in the center of the filter 5 Screw the new filter on by hand until the seal just touches the mating surface Then tighten a further 3 4 turn 6 Bleed by turning the handle 2 to bleeding position B This allows a reduced flow of fuel through the filter and the air is evacuated through the...

Page 66: ...ansparent hose to the nipple and lead it to the recovery container 3 Open the venting nipple and pump fuel with the hand pump 2 until the fuel is free from bubbles Close and tighten the venting nipple while fuel is running out 4 Remove the hose and fit the protective cap back onto the venting nipple 5 Run the engine at idle for a few minutes to remove any remaining air from the system The close th...

Page 67: ... be replaced according to maintenance schedule recommendations or earlier if the pressure gauge shows a pressure drop of 6 10 in Hg at idle or 16 20 in Hg at full rpm engine load WARNING Working with or approaching a running engine is a safety risk Watch out for rotating components and hot surfaces Draining Place a vessel under the filter Empty the water and sediment through the plugs 2 Maintenanc...

Page 68: ...which in the worst case can cause engine breakdown Volvo Penta strongly recommend the use of our own coolants Volvo Penta Coolant VCS Ready Mixed or the concentrate Volvo Penta Coolant VCS which ensure the protection of the cooling system components from corrosion ageing swelling and cracking thereby ensuring optimal engine lifetime Over time the corrosion protection additives become less effectiv...

Page 69: ... correct level through the filler opening in the expansion tank For correct level refer to section Check Fill slowly so that evacuated air is able to pass the filler opening For coolant specification refer to Maintenance page 66 Filling when the system is empty 1 Make sure that systems connected to the cooling system are ventilated e g heater water heater 2 Fill the system with coolant through the...

Page 70: ...cted to the freshwater system e g heater water heater etc 5 Close all drains Freshwater system Flushing The cooling system should be flushed when the coolant is changed to avoid loss of cooling performance due to deposits in the cooling system 1 Drain the coolant please refer to Coolant Draining page 68 2 Put a hose into the filling hole in the heat exchanger and flush with fresh water 3 Flush unt...

Page 71: ...es located in the heat exchanger WARNING Risk of water entry Close and drain the raw water system before starting any work on the system Seawater System Draining 1 Close the raw water in and outlet cocks 2 Connect a suitable hose to each drain point S Open the drains and allow the raw water to drain off into a suitable vessel IMPORTANT Check that all water really does drain out Deposits may need t...

Page 72: ...them if they have been consumed below 1 3 of their original size If not clean the zinc anodes with emery cloth to remove the oxide layer before re installing them IMPORTANT Use emery paper Do not use a wire brush or other steel tools when cleaning as these may damage the galvanic protection 5 Install the zinc anodes When installing make sure there is good metallic contact between the anode and the...

Page 73: ... housing and the inside of the lid with water resistant grease which is not aggressive to rubber The impeller will be easier to work with if it is put in hot water prior to fitting 4 Press the impeller in with a circular motion counter clockwise The shaft of the pump has an internal thread M8 Screw a stud into the end of the shaft and press the impeller in using a washer and nut Fit the cover usin...

Page 74: ...ks Intake Manifold Checking the Drain Hole Steam can be formed during operation Drain the steam via a hole in the bottom of the charge air cooler Check that the hole is not blocked CAUTION Burn hazard Steam may evaporate through the drain hole IMPORTANT If a large amount of water flows out of the drain hole from the inlet manifold the charge air cooler must be removed and proof tested This work sh...

Page 75: ...ff before the engine has stopped If the circuit between the alternator and the battery is disconnected when the engine is running the alternator and electronics may be damaged For the same reason the charging circuits must never be re connected with the engine running Electrical Connections Check that electrical connections are dry free from oxide and that they are securely tightened Maintenance 4...

Page 76: ...battery manufacture s recommendation and instruction when replacing and charging batteries Depending on battery type the instructions for maintenance and charging may vary Modern batteries are normally maintenance free but there are some actions that are recommended to increase the battery service life and avoid accidents Keep the batteries clean and dry Contamination and oxide on the batteries an...

Page 77: ...ed WARNING Never confuse the positive and negative poles on the batteries Risk of arcing and explosion Disconnecting A 1 Untighten the nut and remove the cable black 2 Untighten the nut and remove the cable red Remove the battery Connecting B Place the new battery 1 Connect the cable red to the pole on the battery and tighten the nut 2 Connect the cable black to the pole on the battery and tighten...

Page 78: ...the welder ground clamp to the component to be welded and as close as possible to the weld site The clamp must never be connected to the engine or in such a way that current can pass through a bearing IMPORTANT After finished welding re connect the EVC connector and the alternator terminals before connecting the battery cables Maintenance 76 47711740 05 2019 AB VOLVO PENTA ...

Page 79: ...ver aim the water jet at seals rubber hoses or electrical components For up to 8 month s stoppage Change the oil and oil filter on the engine then warm it up afterwards More than 8 month s stoppage Conserve the lubrication and fuel systems with conservation oil Please refer section Storage page 78 Check that the coolant offers sufficient freeze protection Top up as necessary Alternatively you can ...

Page 80: ... the previous page 1 Conservation oils are sold by oil companies Bringing Out of Storage Remove any covers from the engine air filter and exhaust pipe Put the correct quality and viscosity of oil into the engine if necessary refer to Technical Data page 79 Install a new oil filter if the filter was not changed during conservation Install new fuel filters and vent the fuel system Check the drive be...

Page 81: ... Stroke 165 mm 165 mm 165 mm Displacement 16 12 dm 16 12 dm 16 12 dm Compression ratio 17 5 1 17 5 1 17 5 1 Engine dry weight 1770 kg 1716 kg 1945 kg Lubrication System Oil capacity incl oil filters approx no inclination 55 liters 14 5 US gals volume difference MIN MAX 10 liters 2 6 US gals Oil quality and oil change interval VDS 3 VDS 4 VDS4 5 500 hours or 12 months VDS Volvo Drain Specification ...

Page 82: ... expected lifetime with these other diesel fuels NOTICE Operators must check permission for usage of these fuels according to regional national or local regulations Min cetane number 40 An insufficient cetane number ignitability leads to poor startability and increased exhaust emissions Max density at 15 C 860 kg m3 Insufficient density reduces the power and increases the fuel consumption Excessiv...

Page 83: ...olant should be mixed with distilled deionized water For Volvo Penta specified water requirements refer to Water Quality NOTICE Always use Ready Mixed coolant if water quality cannot be determined or if it does not fulfill ASTM D4985 NOTICE Never mix more than 60 concentrated coolant with water A greater concentration provides reduced cooling effect with the risk for overheating and reduced freeze...

Page 84: ...ernator voltage max amperage 28 V 110 A output approx 2240 W Battery electrolyte density at 25 C 77 F fully charged battery 1 28 g cm 3 0 0462 lb in3 battery recharged at 1 13 g cm3 0 0408 lb in3 Technical Data 82 47711740 05 2019 AB VOLVO PENTA ...

Page 85: ... C C P0015924 D Product designation Product number Serial number Serial number and CHASSIS ID D Chassis ID Serial number Certification label E E P0006755 F P0010315 Certification plate classified genset F Product designation Serial number Product number Generator plate G G P0010316 F G P0010866 Product designation Serial number Product number P0010865 C E D B A Technical Data 47711740 05 2019 AB V...

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Page 87: ...uel pre filter 65 Fuel System 61 Fuel system bleeding 64 Fuel oils and coolant 14 I Identification Numbers 83 Impeller Check and Change 71 Intake Manifold Checking the Drain Hole 72 L Lubrication System 57 M Main switch 73 Maintenance and replacement parts 15 Maneuvering 32 Marine Commercial Control System MCC 19 MCC system Overview 20 Menus 23 O Oil Filter By pass Filter Change 59 Oil level check...

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Page 90: ...AB Volvo Penta SE 405 08 Göteborg Sweden www volvopenta com 47711740 English 05 2019 ...

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