operator’s manual d8

Operator’s manualD8MCC

WARNING! Operating, servicing and maintaining a marine vessel can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead which are known to the State of California to cause cancer and birth defects or other reproductive harm.

Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other 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 more informationwww.P65warnings.ca.gov/marinewww.p65warnings.ca.gov/products/diesel

© 2020 AB VOLVO PENTA Volvo reserves the right to make changes Printed on environmentally friendly paper

Table of Content

Foreword ...................................................................................................... 3Safety Information ...................................................................................... 4

Maneuvering .......................................................................................... 12Introduction ............................................................................................... 14

About this Manual ................................................................................... 14Warranty .................................................................................................. 15Your New Boat ........................................................................................ 15Running in the engine ............................................................................. 16Fuel, oils and coolant .............................................................................. 16Maintenance and replacement parts ....................................................... 17Excessive strain on a product and components ...................................... 17Environmental care ................................................................................. 18Recording engine data ............................................................................ 18Certified Engines ..................................................................................... 19Volvo Penta Dealer Network ................................................................... 20Volvo Penta Action Service ..................................................................... 20

Instruments and Controls ........................................................................ 21Marine Commercial Control System (MCC) ........................................ 21

MCC system, Overview ....................................................................... 22Menus .................................................................................................. 24Alarms .................................................................................................. 25Settings ................................................................................................ 25

Shutdown Module (SDM) ...................................................................... 28Starting ...................................................................................................... 30

Before Starting ...................................................................................... 30Starting the Engine ............................................................................... 31

Overheating protection ......................................................................... 32Read the instruments and warm the engine up ................................... 32

Operation ................................................................................................... 33Reading the Instruments ...................................................................... 33Alarms .................................................................................................... 33Maneuvering .......................................................................................... 34

Operation at low load ........................................................................... 34Engine Shutdown ...................................................................................... 36

Before Engine Shutdown ..................................................................... 36Stop the Engine ..................................................................................... 36After Engine Shutdown ........................................................................ 37

Operation Break ................................................................................... 38Cold Weather Precautions ................................................................... 38

Fault handling ........................................................................................... 39Acknowledge message ........................................................................... 40Alarm List ................................................................................................ 40Fault Tracing .......................................................................................... 42

Fault Code Register .................................................................................. 44In Case of Emergency .............................................................................. 56

Starting Using Auxiliary Batteries ....................................................... 56Emergency Shifting .............................................................................. 57

Maintenance Schedule ............................................................................. 58Maintenance .............................................................................................. 59

Engine, General ..................................................................................... 60

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Drive belt .............................................................................................. 60Lubrication System ............................................................................... 62

Oil Level ............................................................................................... 62Fuel System ........................................................................................... 63

Bleeding the Fuel System .................................................................... 63Fuel pre-filter ........................................................................................ 64

Freshwater System ............................................................................... 65Coolant Level ....................................................................................... 66

Seawater System ................................................................................... 67Draining the Seawater System ............................................................ 67Impeller, Check and Change ............................................................... 68Seawater Filter ..................................................................................... 68

Electrical System .................................................................................. 69Main switch .......................................................................................... 69Fuses ................................................................................................... 69Electrical Connections ......................................................................... 70Battery .................................................................................................. 70Electrical Installations .......................................................................... 71Electrical Welding ................................................................................ 73

Storage ....................................................................................................... 74Technical Data ........................................................................................... 75

Lubrication System .................................................................................. 76Viscosity .................................................................................................. 76Coolant, Mixing ....................................................................................... 79Identification Numbers ......................................................................... 82

Index ........................................................................................................... 83

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ForewordWelcome!Congratulations on your new boat equipped with a Volvo Penta marine engine.Volvo Penta engines are designed to fulfill Volvo’s core values; quality, safety andenvironmental care. After more than 100 years as an engine manufacturer, theVolvo Penta brand has also become a symbol of reliability, technical innovation, top-of-the-range performance and long service life. Volvo Penta marine engines are used allover the world, in all possible operating conditions for professional as well as leisurepurposes.

Make sure to thoroughly read through this Operator’s Manual and take necessary actionsregarding running and maintenance before your maiden voyage. It contains theinformation you need to be able to operate and maintain the engine safely and correctly.Pay careful attention to the safety instructions included in the manual.

As the owner of a Volvo Penta marine engine, you become part of a worldwide networkof dealers and service workshops that assist you with technical advice, servicerequirements and replacement parts. Contact your nearest authorized Volvo Penta dealerfor assistance.

It is possible to buy additional literature about your Volvo Penta engine, e.g. the Service& Maintenance manual. More information on how to do this can be found atwww.volvopenta.com.

Information about your closest Volvo Penta dealer and other useful news andinformation can be found at www.volvopenta.com and by following Volvo Penta onFacebook.

www.volvopenta.com

www.facebook.com/volvopenta

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Safety InformationThis chapter describes how safety precautions arepresented in the manual and on the product. Read thechapter through very carefully before you start theengine or do any maintenance or service. It has to dowith your safety; an incorrect operation can lead topersonal injury and damage to products or property.It also gives you an introduction to the basic safetyrules for using and looking after the engine.

If anything remains unclear or if you are unsure ofsomething, contact your Volvo Penta dealer forassistance.

IMPORTANT:Always follow local safety instructions andregulations.

Safety texts have the following order of priority:

DANGER!Indicates a hazardous situation, which, if not avoided, result in death or serious injury.

WARNING!Indicates a hazardous situation, which, if not avoided, could result in death or seriouspersonal injury.

CAUTION!Indicates a hazardous situation, which, if not avoided, could result in minor or moderatepersonal injury.

IMPORTANT:Indicates a situation, which, if not avoided, could result in property damage.

NOTICE! Used to draw attention to important information that facilitates work oroperations.

!This symbol is may be used on the product to call your attention to the fact that this issafety information. Always read such information very carefully.

Make sure that warning and information symbols on the engine are clearly visible andlegible. Replace symbols that have been damaged or have been painted over.

In some cases, this symbol is used on our products and refers to important informationin the Operator’s Manual.

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Most chemicals such as engine and transmission oils,glycol, petrol and diesel oil and chemicals used inworkshops such as degreasing agents, paint andsolvents are harmful to health.

Carefully read the instructions on the productpackaging! Always follow the safety regulations, suchas the use of protective masks, goggles, gloves, etc.Make sure that other personnel are not exposed tosubstances that are hazardous to health. Ensure goodventilation.

Manage used and leftover chemicals in the prescribedmanner.

Personal safety equipment CAUTION!

Always use appropriate safety equipment. Personalprotective equipment does not eliminate the risk ofinjury but it will reduce the degree of injury if anaccident does happen.

Some examples are ear protection, eye and faceprotection, protective footwear, personal protectiveequipment, head protection, protective clothing,gloves and respirators.

WARNING!Ensure that all machine guards and safety devices arein place and are functional.

CAUTION!Never use tools or products that show signs ofdamage.

Protect your eyes CAUTION!

Wear safety glasses.

Always wear safety glasses if there is a risk ofsplintering, sparks and spray from the electrolyte (so-called battery acid), or other chemicals. Your eyes arevery delicate and damage can result in loss of sight!

Protect your skin CAUTION!

Risk of skin damage.

Avoid getting oil on your skin! Prolonged or repeatedexposure to oil can dry out the skin. Thereafter,irritation, dryness and eczema and other skin problemsmay occur.

Use protective gloves and avoid oil-soaked clothesand rags. Wash regularly, especially before eating.Wear suitable protective creams to prevent skin fromdrying out and to facilitate cleaning.

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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 sparksnear them. Smoking forbidden! Hydrogen from thebatteries is also very flammable and explosive incertain mixture with air.

Ensure that the workplace is well ventilated and takethe necessary precautions before welding or grindingbegins. Always ensure that there is a fire extinguisherclose at hand in the work area.

Spare parts — safety WARNING!

Always use spare parts with the same quality asgenuine Volvo Penta parts to minimize the risk of anexplosion or fire.

Components in fuel systems and electrical systems onVolvo Penta engines are designed and manufacturedto minimize the risk of explosions and fire, inaccordance with applicable legal requirements.

Used oils, filters and chemicals etc. WARNING!

Risk of fire.Store fuel soaked rags and other flammable materialso that there is no danger of them catching fire.

Oil-soaked rags can spontaneously ignite undercertain circumstances.

IMPORTANT:Used fuel and oil filters are environmentally hazardouswaste and must be taken to an approved wastemanagement facility for correct handling, as must anyused 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 supplywith the main switch(es) and lock it (them) in the offposition before starting work. Place a warning noticeat the main switch.If the engine is equipped with BMS (BatteryManagement System), always disconnect both batterycables from the battery terminals.

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Ventilation when running the engine WARNING!

Only start the engine in a well-ventilated area. Ifoperating the engine in a closed area ensure that thereis exhaust ventilation leading out of the work area toremove exhaust gases and crankcase ventilationemissions.

The engine must not be operated in areas where thereare explosive materials or stored gas.

Rotating parts and hot surfaces DANGER!

Working with or approaching a running engine is asafety risk. Watch out for rotating components and hotsurfaces.If the engine is in operation and operates anotherdevice, you must not, under any circumstances,staying close to the engine.

Work on running engines is strictly prohibited. Thereare however adjustments that require the engine to berun. Approaching a running engine is a safety risk.Loose clothing and long hair can get caught in therotating parts; careless movements or a dropped toolcan lead to serious personal injury.

Be careful to avoid hot surfaces (exhaust pipes,turbochargers, charge air manifolds, start elementsetc.) and hot fluids in pipes and hoses on engines thatare running or have just stopped. Re-install allprotective covers that were removed duringmaintenance work before starting the engine.

Information on the engineIMPORTANT:

Make sure that all warning and information decals onthe product are always visible. Replace decals whichhave been damaged or painted over.

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Prohibition on use of start spray WARNING!

Never use start spray or similar agents to start anengine. This may cause an explosion in the inletmanifold. Risk of personal injury.

Before start of engine WARNING!

Never start the engine if there is reason to suspect fueland/or gas leaks, or if there is explosive materialnearby.

IMPORTANT:Only start the engine with the air filter and protectivecaps fitted. Foreign objects in the inlet line could causemachine damage. Also make sure that no tools or otherparts have been left next to the engine.

WARNING!Never start the engine with the valve cover removed.There is a risk of personal injury.For engines with turbochargers, the rotatingcompressor turbine can in addition cause seriouspersonal injuries.

Before any work on the electrical system WARNING!

Always stop the engine first. Then disconnect thecurrent at the main switches and any external powersupply before working on the electrical system – tominimize the risk of electrical hazards.

IMPORTANT:Never disconnect the current using the main switcheswhen the engine is running or by disconnecting thebattery cables.The alternator and electronics could be damaged.

Avoid damage to the engine controlmodule and other electronicsIMPORTANT:

Switch off the main switch before connecting ordisconnecting a connector.

Before welding workIMPORTANT:

Before any work with electric weld can begin, theconnection to all control units must be disconnected.After finished welding, re-connect the connection to allcontrol units before connecting any battery cable.

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Before any work on the cooling system WARNING!

Stop the engine and let it cool before starting work onthe cooling system. Hot fluids and hot surfaces cancause burns.

Risk of water penetration/sinking WARNING!

If a launched boat is equipped with sea water tap andsafety valve, ensure that these are closed before anywork is allowed to begin on the cooling system.Remember to open the tap and valve before startingthe engine!

Hot coolant under pressure CAUTION!

Hot coolant can cause burns. Avoid opening the fillercap for the coolant when the engine is still hot. Steamor hot coolant can spray out and system pressure islost.

Open the filler cap slowly and release the pressure inthe cooling system if the filler cap or valve must beopened – or if a plug or a coolant hose must beremoved from a hot engine.

Hot oil under pressure CAUTION!

Hot oil can cause burns. Avoid getting hot oil on theskin. Ensure that the lubrication system is notpressurized before starting any work. Never start oroperate the engine without the oil filler cap is on. Thereis a risk that hot oil can spray out.

Refueling WARNING!

There is always a risk of fire and explosion duringrefueling. Smoking is forbidden and the engine mustbe stopped.

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Proper fuel qualityIMPORTANT:

Always use the fuel recommended by Volvo Penta.See Technical Data in Operator’s Manual. Other fuelcan damage the engine.Wrong fuel quality can also lead to higher servicecosts.

WARNING!Risk of personal injury.Wrong fuel quality in a diesel engine can cause the fuelcontrol mechanism to bind which can cause the engineto overspeed!

Legal requirements to use proper fuelIMPORTANT:

To meet regulatory requirements for certified emissionlevels must always recommended fuel according toTechnical Data in the Operator’s Manual be used.

At any leak detection on the fuel system WARNING!

Wear safety goggles!Be extremely careful when searching for leaks in thefuel system high-pressure circuits. There is very highpressure in the jet from pipes and injectors. The fuelmay penetrate the tissue and cause serious risk ofblood infection (septicemia).

Handling of fuel pipesIMPORTANT:

High pressure pipes for fuel must not be bent orstraightened under any circumstances. Cracks mayoccur. Damaged pipes must be replaced.

Safe handling of batteries WARNING!

Risk of fire and explosion. Never allow an open flameor electric sparks near the batteries.

A spark caused by an incorrectly connected batterycan be enough for the battery to explode with seriousinjuries.

Do not touch the connections during start attempts.Sparking hazard! Do not lean over batteries.

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Correct polarity of the batteriesIMPORTANT:

Make sure that the positive (+) and negative (–) batterycables are correctly connected to the correspondingbattery terminals. Wrong connection may causesevere damage to electrical equipment.

Risks of electrolyte in batteries WARNING!

Always wear protective goggles when charging orhandling batteries.Battery electrolyte is highly corrosive.

Rinse immediately with copious amounts of water if theelectrolyte gets in your eyes. Search directly after therinsing help by medical staff.

If it comes electrolyte to unprotected skin, washimmediately with soap and water.

Layout of the battery compartmentIMPORTANT:

Make sure the battery compartment is designedaccording to current safety standards.

Cleaning the engine and componentsIMPORTANT:

Never use a high pressure washer for cleaning ofengine or engine components.

Cleanliness for sensitive componentsIMPORTANT:

Observe meticulous cleanliness when handlingsystem components.Even minimal amounts of dirt could cause abreakdown.

Adjustment of the clutch CAUTION!

Clutch adjustments must be carried out with the enginestopped.

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Maneuvering WARNING!

A rotating propeller can cause serious injury. Checkthat nobody is in the water before engaging ahead orastern. Never drive near bathers or in areas wherepeople could be in the water.

To avoid passengers falling overboard, refrain fromextreme and sudden rudder movements and ahead/astern movements.

Lanyard switchWe recommend installing and using a lanyard switch(optional), especially if the boat is capable of highspeeds. The lanyard switch stops the engine if thedriver looses control of the boat.

Accidents at seaMaritime rescue statistics show that a large number ofboat accidents are caused by inadequate engine andboat maintenance and the lack of safety equipment.Make sure that the boat engine is properly maintainedby making sure that the recommended service isperformed, and that necessary safety equipment isavailable and functional.

Stern turbulence WARNING!

Carbon Monoxide Poisoning. When the boat movesforward, an area of lower pressure air is formed behindthe boat — so-called turbulence. In certain conditions,this turbulence can be powerful enough to draw theexhaust fumes into the cockpit or cabin, creating a riskof carbon monoxide poisoning to people on board.

The turbulence problem is most pronounced on tall,broad-beamed boats with a transom stern. But evenfor other boat types, low-pressure suction can be aproblem in certain conditions, such as driving withcockpit awnings rigged. Other factors that can increasethe effect of turbulence are wind conditions, loaddistribution, swell, trim, open hatches and ventilatorsetc.

Most modern boats are, however, designed so that theproblem of low-pressure suction is very rare. Shouldturbulence nevertheless occur, hatches or ventilatorsmust not be opened since this might exacerbate theproblem. Instead, try to change the speed, trim or loaddistribution. If possible, take down or open the cockpitawning. Contact your boat dealer for the best solutionfor your boat.

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To remember before the boat tripThe lists below includes some tips on what toremember to bring on any boat trip. The list can beextended since the need for safety equipment varieswith the boat type and where or how it is used etc. Werecommend you ask a regional boat or sea safetyorganization for more detailed maritime safetyinformation.

• Take your chart out and study your planned route.Calculate distance and fuel consumption. Listen toweather reports.

• Tell your friends/relatives about route plans if youundertake a long journey. Remember to notifychanged plans or delays.

• Inform everybody aboard about where the safetyequipment is located, and how it works. Make surethat there is more than one person aboard who canstart and operate the boat safely.

Safety Equipment:

• life jackets

• communication equipment

• emergency rockets

• approved fire extinguisher

• first aid kit

• life buoy

• anchor

• paddle

• flashlights

Spare Parts and Tools:

• impeller

• fuel filters

• fuses

• tape

• hose clamps

• engine oil

• other tools that may be required

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IntroductionCheck that you heave received the correctoperator’s manual before continuing reading. Ifnot, please contact your Volvo Penta dealer. Readthe Operator’s Manual carefully and learn to handle theengine, controls and other equipment in a safe mannerbefore you start the engine.

For engine designations, refer to TechnicalData, page 75. The designation is stated on theengine plate, refer to Technical Data, page 82.

The illustrations in this book may cover several producttypes, which means that there may be slightdifferences between the illustrations and thepurchased product. This does, however, not affect thevalidity of the information and/or instructions in themanual. Volvo Penta reserves the right to makealterations to specifications, design features, andillustrations without prior notice.

At service, software can be updated that affects thefunctionality described in this manual.

About this ManualThis Operator's Manual has been prepared to give youthe greatest possible benefit from your Volvo Pentamarine engine. It contains necessary informationregarding safe and correct engine operation andmaintenance.

Always have the Operator's Manual available. Store itsafely and do not forget to hand it over to the nextowner if you sell your boat.

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WarrantyYour new Volvo Penta marine engine is covered by alimited warranty, subject to the conditions compiled inthe Warranty Information. Note that AB Volvo Penta’sliability is limited to the specification in the WarrantyInformation and Emission Control System WarrantyStatement.

Volvo Penta warranty terms and conditions can befound via http://manual.volvopenta.com/coupon/. Usethe publication number (at the bottom of each page) ofthis the manual as reference number.

Read the information carefully, as soon as possibleafter delivery. It includes important information aboutservice and maintenance; the owner is responsible forbeing familiar with, checking and implementing these.Otherwise AB Volvo Penta may deny its warrantyobligations in part or in full.

NOTICE! Make sure that a Commissioning has beencarried out on your Volvo Penta engine. This should bedone together with your Volvo Penta dealer whenfinalizing the purchase. Without a properCommissioning registration the warranty will not bevalid.

Contact your Volvo Penta dealer if you have notreceived the Warranty Information or ServiceBook.

Your New BoatCarefully read through the instructions and otherinformation that is delivered with the new boat. Learnto handle the engine, controls and other equipment ina safe and proper manner. If this is your first boat or ifthe boat type is unfamiliar to you, we recommend thatyou practice maneuvering the boat before casting offon the maiden voyage. Make yourself familiar with theboat’s seakeeping and maneuvering qualities atdifferent speeds, sea states and load conditions.

Bear in mind that a person in charge of a boat underway bears the legal responsibility of knowing andfollowing the regulations for passage and safety afloat.Learn which regulations apply to you and your watersby contacting the relevant authorities or maritimesafety organization. We recommend that you completea boat driver’s course.

Introduction

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Running in the engineThe engine must be run in during the first 10 hours ofoperation. Do this by using the engine in normaloperation, where full load is only applied for shortperiods of time. Never run the engine at constantspeed for any longer periods of time.

Since oil consumption is higher during the running inperiod, be sure to control the oil level more frequentlythan normally recommended. See Maintenance formore information.

Fuel, oils and coolantOnly use the fuels and oils recommended in theOperator’s Manual, other viscosity and quality maycause malfunctions, increased fuel consumption andpossibly shorten the life of the engine.

Always change the oil, oil filters and fuel filters at thespecified maintenance intervals.

Make sure to always use suitable and correctly mixedcoolant.

If an unsuitable coolant has been used, or if theinstructions for coolant mixture have not beenfollowed, future warranty claims related to engine andaccessories may be denied.

Introduction

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Maintenance and replacement partsVolvo Penta engines are designed for maximumreliability and long life and built to withstand ademanding environment. The engines are alsodesigned to have a minimal environmental impact.These qualities will be maintained through regularservicing and the use of spare parts with the samequality as genuine Volvo Penta parts. If reliable andpurpose-built parts are not used, your safety, health,and the machine’s function may be compromised.Volvo Penta has a world-wide network of authorizeddealers.

The authorized dealers are Volvo Penta productspecialists, and have the accessories, genuine parts,test equipment and special tools needed for highquality service and repair work. Always observe themaintenance intervals in the manual, the completeService Protocol can be found at volvopenta.com.Remember to note the engine / transmissionidentification number when you order service andspare parts.

Excessive strain on a product andcomponentsVolvo Penta products and components are notdimensioned for external loads. Never stand or steponto an engine, transmission or its components. Loadscan bring about damage and the malfunction of aproduct or property.

Introduction

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Environmental careEnvironmental care is a core value at Volvo Penta.Energy efficiency and low emissions are among themost important product related aspects and priorityfocus areas for Volvo Penta business. Several of theglobal challenges the world faces are directly orindirectly related to power industries and transports.We recognize that Volvo Penta is part of theenvironmental problems, but we are also convincedthat we are a part of the solution.

Volvo Penta currently has a broad engine program inwhich great advances have been made in reducingexhaust emissions in the same time as the fuelconsumption has been improved. Through regularmaintenance, the Volvo Penta engines retain its lowfuel consumption and low emissions. We hope that youwill be keen to preserve these qualities.

Always follow the directions in the Operator’s Manualregarding fuel grades, operation and maintenance toavoid unnecessary environmental impact. Contactyour Volvo Penta dealer if you notice any changessuch as increased fuel consumption or exhaust smoke.

Remember always to hand in environmentalhazardous waste such as drained oil, coolant, oldbatteries, etc. for treatment at a recycling facility. Ourunited efforts can make a valuable contribution to theenvironment.

Recording engine dataOne or more computers in your Volvo Penta enginecan record detailed information. Data — such as usageand information of other systems and modules on theengine — can be included. This data can include infor-mation such as boat position and usage. Only a lim-ited amount of data can be stored.

AB Volvo Penta and authorized workshops will notdistribute this stored information without permission.AB Volvo Penta may, however, be forced to providethis information if required by national legislation. Ingeneral, AB Volvo Penta and authorised workshopsmay read and use the information.

Introduction

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Certified EnginesIf you own an emission-certified engine used in anarea where exhaust emissions are regulated bylaw, this places special demands on the care andmaintenance you provide your engine.

NOTICE! Neglects or failure to follow the points listedhere may invalidate the engine emission certificate.This means AB Volvo Penta can no longer guaranteeengine conformity with the certified model. Volvo Pentais not responsible for damages or costs arising as aresult of this.

• Certification means that an engine type has beenchecked and approved by the relevant authority.The engine manufacturer guarantees that allengines of the same type are equivalent to thecertified engine.

• It is the responsibility of the operator/user to ensurethat no intentional misuse of the engine takes place.

• Volvo Penta maintenance and service intervalsmust be complied with.

• Any case of malfunction must be rectified withoutdelay.

• Only use genuine Volvo Penta parts or spare partswith the same quality as genuine Volvo Penta parts.

• Volvo Penta recommends that service to injectionpumps, pump settings and injectors always arecarried out by a qualified workshop.

• The engine must not be converted or modified in anyway, except with accessories and service kits thatVolvo Penta has approved for the engine.

• No installation changes to the exhaust pipe andengine air inlet ducts may be made.

• No warranty seals (where present on the product)may be broken by unauthorized persons.

• The general instructions in the Operator's Manualconcerning operation, service and maintenanceapply.

Introduction

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Volvo Penta Dealer NetworkThe Volvo Penta global network of authorized dealersis at your service. We strongly recommend that youtake your product to an authorized Volvo Penta dealerfor service and repair. They are specialists in VolvoPenta products and have the accessories, genuineVolvo Penta parts, the special tools and the latestservice information for high quality service and repairwork.

Dealer Locator ServicesLocate the nearest Volvo Penta dealer through ourdealer locator on www.volvopenta.com or downloadthe dealer locator app to your smartphone.

Volvo Penta Action ServiceOur global dealer network, your first line of contact, isbacked up by Volvo Penta Action Service, a phonebased breakdown and support service providingassistance 24 hours a day, every day of the year.

How it worksA dedicated operator will support you all the waythrough your case and keep you updated on status andprogress.Whenever on-site assistance or technical support isneeded, the operator will put you in contact with theclosest Volvo Penta dealer that can support yourproduct.

Phone numbersFind your Volvo Penta Action Service phone numberand more information on www.volvopenta.com.

Introduction

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Instruments and ControlsThis chapter describes the instruments, panels and controls Volvo Penta sells for your engine.If you would like to complement your instrumentation, or if your boat is equipped with instruments not describedhere, we ask that you contact your Volvo Penta dealer.NOTICE! Your boat is not necessarily equipped with all of the instruments, panels and controls described in thischapter.

Marine Commercial ControlSystem (MCC)Marine Commercial Control (MCC), is a type-approvedcontrol system that monitors your Volvo Penta engine.MCC comprises an marine control unit (MCU), remotepanel (RP), shutdown module (SDM) and a relay card.

The MCU is the main system panel and itcommunicates with all of the engine control units. Theslave panel may be located outside the enginecompartment and handles in exactly the same way asthe MCU.

The SDM manages automatic engine shutdownshould the engine show critically low oil pressure(including reverse gear) or high coolant temperature.It also has overspeed protection. Electronic systems inthe vicinity of the engine comprise the enginemanagement system (EMS) and a powermanagement unit (PM). The engine management unitmanages the injection of fuel with the aid of a numberof sensors. The power management system managesprimary and secondary battery supply and supplieselectrical power to the engine management unit, MCUand SDM. The unit has overcurrent protection withautomatic reset.

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MCC system, Overview

1 MCC box, engine room

2 Relay board – Rb8 (8relays)

3 MCU

4 External connections:Switch inputs, outputs,Modbus RS-232,Modbus RS-485, ComapCAN2, CAN/J1939

5 Remote panel

6 Comap CAN2

7 Other Comap equipment

8 Data bus: CAN/J1939

9 EMS

10 Power ON

11 Shutdown Senders &Switches

a Press. switch

b Temp. switch

c RPM sender

12 Shutdown module

Instruments and Controls

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MCU panelThe MCU, Marine Control Unit, controls the engine andshows engine information and alarms.

1 Display

2 Acknowledgement of audible alarms

3 Changing modes, switching to OFF

4 Changing modes, switching to PRP

5 Start button

6 Stop button

7 Acknowledge selection, acknowledge alarm

8 Green lamp; indicates engine 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 oninstallation. Can be set to any function wheninstalling.

14 Red lamp; indicates that there is an alarm.The lamp flashes when a new alarm occurs. Thelamp shines continuously when an alarm is activeand acknowledged.

Display

A Highlighted text indicates engine mode; in operationor start mode (PRP), or (OFF).

B LOC: local mode. The engine can only be controlledfrom the main panel.

C R: a remote connection – a remote panel – is on line.

D L: locked. The main panel is locked and the remotepanel is in control.

E ! : There is an alarm in the alarm list.

F Engine status:NotReady: the system is not ready and the enginecannot be started.Ready: the system is ready and the engine can bestarted.Running: the engine is in operation.LoadShar: the engine is under load and inoperation with another engine.


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MenusThe system has four menus:

• Main Page

• Monitoring Page

• Settings Page

• History Page

Main PageBrowse with the Page button (1) to the main menu(Main).Browse between windows using the up/down buttons.

Monitoring Page

1 Browse with the Page button (1) to the engine datamenu (Monitoring page).

2 Browse in the engine data menu with the up/downbuttons.

Settings PageThe review and changing of setpoints is carried out inthe Settings page.

1 Browse with the Page button (1) to the Settingspage.

2 Browse between the different setpoints using theup/down buttons.

3 Press Enter (2) to confirm the selection.

4 Browse with the up/down buttons to the desiredsetpoint. Setpoints marked with an asterisk (*) arepassword 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 toactivate automatic repetition.

6 Press Enter (2) to confirm the selection. To finishwithout any change press the Page button (1).Press the Page button (1) to select setpoint group.

History Page

1 Browse to the History page using the Page button(1).

2 Browse with the up/down buttons to the desiredevent.

3 Press Enter (2) to see more detailed informationabout the event. Continue to press Enter to see allinformation about the event.When all information is shown the first image isvisible again. Browse in the window using the up/down buttons.

4 Exit the menu with the Page button (1) .


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Alarms

If the system discovers a fault the alarm list is shownon the display when the main menu is active.The alarm list is not activated while values, parametersand alarm history are being reviewed.

For further information on how to handle alarms andtake recommended actions, refer to the Faulthandling, page 39 chapter.

SettingsSerial number and software versionIn order to see the engine serial number and softwareversion installed go to the main menu.Press the Enter button (2) and hold it down and pressthe Page button (1) at the same time.The system returns automatically to the main menu.

BacklightingPanel backlighting is adjusted in the info menu.Press the Enter button (2) and hold it down; adjustbacklighting with the up/down buttons.

Contrast is adjusted in the main menu. Press the Enterbutton (2) and hold it down; adjust the contrast with theup/down buttons.

Changing languageSetting the language the information on the screen willbe shown in. There are six languages to choose from.

1 Press the Enter button (2) and hold it down to reachthe info menu. Press the Page button (1).

2 Browse using the up/down buttons.

3 Press Enter (2) to select the language and close themenu.


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Setting passwordThe password consists of 1–4 numerals.The default password is 0 on delivery.

1 Navigate to the Adjustments menu.

2 Browse to “Password” using the up/down buttons.Press Enter (2) to confirm the selection.

3 Browse using the up/down buttons to “EnterPassword” where 0 is shown. Press Enter (2) toconfirm the selection.

4 Exit the menu by pressing Page (1).

The password gives full access to the MCU.Parameters may only be changed by trainedpersonnel.


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Working modeLocal modeIn Local Mode the engine can only be started from themain panel. External start/stop commands areignored.

The mode is activated by pressing Enter (2) and theright Mode button.

Exit mode by pressing Enter (2) and the left Modebutton.

Operations mode (PRP)In operations mode (PRP) the engine is ready for startwhen the status shows "Ready".

Off mode (OFF)The engine cannot be started in OFF mode. All relayoutput signals are temporarily disconnected and thestatus is changed to “Not Ready”.Activate OFF mode by pressing the left Mode button.

NOTICE! The engine cannot be started; if the engineis running it will be shut down when OFF mode isactivated.

Activate OFF mode by repeatedly pressing the leftMode button until "off" is shown in the display's top leftcorner.

StatisticsIn 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 of unsuccessful starts

5 Momentary average fuel consumption(1)

6 Service time (hours until next service)

Statistical values can be adjusted with PC software(password protected); contact your Volvo Pentadealer.

1. Not standard; Comap InternetBridge hardware and adaptation ofsoftware required.


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Shutdown Module (SDM)

SDM is a safety system that protects the engine frombeing damaged. It automatically shuts down theengine if:

• Engine speed (RPM) is too high.

• Engine oil pressure is too low. (Optional)

• Cooling temperature is too high. (Optional)

• Reversing gear oil pressure is too low. (Optional)

• The bridge emergency stop is activated.

• The engine room emergency stop is activated.(Optional)

ResetWhen the fault that caused the shutdown is solved thesystem needs to be reset before restart. Reset theshutdown system by pushing the reset button (1) onthe control unit cabinet in the engine room.

Shutdown OverrideIMPORTANT:

When shutdown override is active the engine will notbe protected by the shutdown system, this may causedamage to the engine. Even events that wouldnormally cause a derate of the engine will beoverridden. Therefore, if the shutdown override modeis active, Volvo Penta’s product liability may cease.

In shutdown override mode the engine will not shutdown for any reason other than overspeed. Theshutdown override mode is active for as long as theswitch remains in override mode.

NOTICE! When shutdown override mode is active, thedisplay will show fault messages for engine shutdownbut no actual shut down will take place.


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FusesIn SDM there are six fuses mounted marked:

F1 = Primary battery

F2 = Secondary battery

F3 = EVC/MCC

F4 = EMS

F5 = EATS

F6 = SDM unit/Terminal 1,2

P0027954


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StartingMake a habit of visually checking the engine, engine bay and transmission before start. This will help you todiscover quickly if anything abnormal has occurred, or is about to occur. Also check that instruments and warningdisplays show normal values when you have started the engine.To minimize cold start smoke we recommend you install an engine heater or engine bay heater if temperaturesbelow +5°C (41°F) are encountered.

WARNING!Never use start spray or similar agents to start an engine. This may cause an explosion in the inlet manifold. Riskof personal injury.

Before Starting

• Open the fuel cock.

• Open the sea cock where fitted.

• Check the engine and transmission oil level.

• Check the coolant level.

• Turn the main switches on.

IMPORTANT!Never disconnect the current with the mainswitches when the engine is running. Thealternator and electronics could be damaged.

• Start the engine bay fan, where fitted, and allow it torun for at least four minutes.

• Check that there is sufficient fuel for the planned trip.

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Starting the Engine1 In the main menu, browse to start mode (PRP)

(A) using the Mode button

2 Check that engine status is "Ready" (B).

3 Depress the Start button; engine status willchange to "Running" (C).

If the engine is not ready to start (Not Ready), checkthe following:

• Check the alarm list. Acknowledge any alarms.

• Check the ECU alarm list. Acknowledge anyalarms.

• Check the wiring between the MCC cabinet andthe engine.

Starting

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Overheating protectionOverheating protection If the starter motor is engagedfor its maximum activation time (30 seconds), thestarter motor circuit is cut automatically to protect thestarter motor from overheating. If possible, leave thestarter motor to cool for at least five minutes beforemaking a new start attempt.

Read the instruments and warm theengine up

Allow the engines to idle for the first ten seconds.Check that instruments and warning displays shownormal values.Check that no messages are displayed and no warningsigns are showing. If a fault is registered, please referto section Fault handling, page 39 for furtherinformation and recommended actions.Warm the engine up at low speed and low load, sonormal operating temperature is reached before fullpower is used.

IMPORTANT:Never race the engine when it is cold.Racing the engine when it is cold can damage theengine components and decrease the engine lifetime.

Starting

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OperationLearn to handle the engine, controls and other equipment in a safe and proper manner before casting off on yourmaiden voyage. Remember to avoid sudden and extreme rudder maneuvers and gear shifts. There is a risk forpassengers and crew falling over or falling overboard.

WARNING!A rotating propeller can cause serious injury. Check that nobody is in the water before engaging ahead or astern.Never drive near bathers or in areas where people could be in the water.

Reading the InstrumentsRead all instruments and alarm displays directly afterstarting, and then regularly during the voyage.

AlarmsThe alarm is shown in two different alarm listsdepending on the cause of the alarm. Alarmsdiscovered by EMS, ACM and PM are shown in theECU Alarmlist, and alarms from the SDM or MCU areshown in the Alarmlist.

1 Acknowledge the audible alarm by pressing theHorn Reset button (1).

2 Reading alarms.To see active alarms, press the up button in themain menu once for the SDM/MCU alarm list andtwice for the ECU alarm list.If there are several alarms, browse in the alarm listusing the Enter button.

3 Depress the Acknowledge button (2) toacknowledge all alarms.Take the necessary action; refer to the Faulthandling, page 39 section for further information.

Alarm notations remain in the alarm list until they havebeen acknowledged and rendered "inactive" (faultremedied).

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Maneuvering

Operation at low loadAvoid long-term operation at idle or at low load. It takesa long time for the engine to reach workingtemperature, resulting in high viscosity of the oil andlarge clearances in the engine mechanics. In coldclimate, it takes even longer.

The combustion temperature and cylinder pressurecan become so low that an effective combustioncannot be ensured. At these conditions unburned fuelcould dilute the lubricant oil. Because of the lowcylinder pressure, the piston ring performance couldbe affected causing oil from the crankcase to pass therings and go further out with the exhaust gases. Thismixture of unburned fuel and oil in exhaust gases isreferred to as “slobber”. A new engine produces more“slobber” at low load compared to an engine with morehours of operation.

At low load, the pressure in the turbocharger is low andoil could seep past the turbocharger seals and mix withthe air into the engine. The consequences can becarbon build-up on valves, piston crowns and theexhaust turbine, which could affect engineperformance.

Both conditions can lead to increased oil consumptionand eventually external oil leakage from joints in theexhaust system. For example, leakage could be seenat the exhaust manifold, before and after the turbo,around the muffler and in worse case even in theexhaust end pipe. Consequences could lead toclogged exhaust gas recirculation systems andexhaust aftertreatment systems.

Signs of oil leaking caused by "slobber" do not indicatean engine problem but indicates low load operation. Tominimize the risk of malfunctions caused by operationat low load, follow these points as a complement tonormal maintenance:

• Run in the engine as soon as possible.

• Load the engine so it reaches working temperatureas soon as possible.

• For VE: Turn off the engine instead of running onidle for longer periods.

• For genset turn off the engine instead of runningunloaded for longer periods.

• Avoid load levels below 20% as constant operation.

• If the engine is regularly tested without load, limit theduration of the operation to 5 minutes. Run theengine at full load for about 4 hours once a year, forthe carbon deposits in the engine and exhaustsystem to burn off.

Operation

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• If visible slobber has occurred, it can be burned offby running the engine on at least 30% load for about40-60 minutes.

Running data

Monitor running data that is not shown in the mainmenu:

1 Browse with the Page button (1) to the engine datamenu (Monitoring page).

2 Use the up/down buttons to select the desiredengine data.

Operation

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Engine ShutdownAllow the engine to run at low idle, in neutral, for a few minutes after operations are completed. In this way after-boiling is avoided at the same time as temperature equalization takes place. This is especially important whenthe engine has been run at high rpm or under heavy load.

Before Engine ShutdownLet the engine run at high idle (1500 or 1800rpm) for aminimum of 5 minutes before the shutdown afternormal use. Normal use is defined as minimum 50%load. After use with less than 50% load, high idle forapproximately 3 minutes is sufficient. This allowsengine temperature equalization and prevents boilingonce stopped and also allows the turbochargers to cooldown. This contributes to long, fault-free service life.

NOTICE! Do not turn off the main switch within 30seconds after turning off the ignition. This is in order tosave engine data to the engine control unit and ACMunit to drain the EATS system from urea solution.

Stop the Engine

Auxiliary StopIf the engine cannot be stopped using a normalprocedure, the engine can be stopped via the auxiliarystop installed on the back of the engine.

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After Engine Shutdown

• Check the engine and engine bay for leakages.

• Close the fuel tap.

• Close the sea cock where fitted.

• Boats with stern drives: Trim the stern drive down tomaximum to protect the trim ram piston's untreatedsurfaces from fouling.If there is a risk of the boat striking bottom with thestern drive, the drive must instead be trimmed up tothe maximum lift position.

• Turn off the main power switch before any longstoppage.

NOTICE! Do not turn off the main power switchwithin 30 seconds after turning off the ignition. Thisin order to save engine data to the engine controlunit.

NOTICE! Depending on the model and setup, therecould be more than one switch.

Engine Shutdown

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Operation BreakOperation break with the boat in waterIf the boat is not used, but left in the water, werecommend you to warm up the engine at least onceevery fortnight. This will prevent corrosion damage inthe engine.If you expect the boat to be unused for two months ormore, we recommend you to preserve the engine,please refer to Storage, page 74.

Cold Weather PrecautionsIf the engine bay cannot be kept frost free, the seawater system must be drained and the freshwatersystem coolant must have sufficient freeze protectionto prevent freeze bursting; refer toMaintenance, page 65 and Draining the SeawaterSystem, page 67 respectively for more detailedinformation.Check the charge status of the battery. A poorly-charged battery can freeze and burst.

Engine Shutdown

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Fault handlingDespite regular maintenance according to the maintenance schedule and perfect operation conditions, faults thatneed to be attended to during travel, may occur. This chapter describes 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.

Message from engine and MCC systemIf a malfunction is discovered the driver is warned by abuzzer sounding and a message showing in thedisplay.

Information regarding ”cause of fault” and ”measuresto take” is found in chapter Fault Code Register.

The engine, transmission and MCC system ismonitored by the diagnostic function. Should thediagnostic function discover a malfunction it protectsthe engine and ensures continued operation byaffecting the engine. Depending on how serious themalfunction is the effect on the engine varies.

If following error message appears: MalfunctionIndicator Lamp (MIL). Neglects MIL: or (MIL) mayinvalidate the engine emission certificate. This meansAB Volvo Penta can no longer guarantee engineconformity with the certified model. Volvo Penta is notresponsible for damages or costs arising as a result ofthis.

• Minor malfunction which does not damage theengine or transmission.Affect on engine: None.

• Serious malfunction which will not immediatelydamage the engine or transmission e.g. highcoolant temperature.Affect on engine: Engine power is reduced untilfaulty value becomes normal.

• Serious malfunction which will cause seriousdamage to engine or transmission.Affect on engine: Engine power is reduced.

• Serious malfunction which makes it impossible tocontrol the engine or transmission.Affect on engine: Transmission is disengaged andengine speed is reduced.It is possible to perform emergency shifting, pleaserefer to In Case of Emergency, page 57.

• Serious malfunction on transmission or in the enginefuel injection system.Affect on engine: Engine is stopped.It is possible to perform emergency shifting, pleaserefer to In Case of Emergency, page 57. Inemergency situations it is also possible to start theengine with gear engaged after acknowledging thealarm.

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Acknowledge message

The Acknowledge button (1) acknowledges all alarms.Alarms that are not active disappear from the list.

Alarm List

The alarm list and ECU alarm are the two first windowsfrom the main menu.From the main menu press the arrow up button onceto reach the alarm list and twice for the ECU alarm list.

In the remote panel: Press Alarm list button.

Alarm List (Alarmlist)The alarm list is automatically displayed when a newalarm is triggered and the main menu is active.The alarm list is not activated while values, parametersand alarm history are being reviewed.

At position (7) the number in parentheses shows inwhich ECU the fault code is. (1=EMS, 2=ACM,3=SDM)

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 theenter key.

Fault handling

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Status of alarm

• Unacknowledged alarms are marked with * (5)

• Active alarms are indicated by a blackbackground (6)

• Inactive alarms are displayed without a blackbackground (7)

ECU alarm listIf ECU AlarmList is visible in the list then there are faultcodes from the engine control unit or powermanagement system.

SP5394: Specific faultcode.

OC16: (Occurence) in this case 16 times.

FM4: FMI (failure mode indicator) Indicate the type offailure.

E2: Which control unit. (E1=EMS, E2=ACM, E3=SDM)

For more information about fault code and a completelist look in the workshop manual.

Alarm list and historyAbbreviations in alarm list and history

Abbreviation MeaningWrn WarningFls Sensor failure

General alarm

Fault handling

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Fault TracingA number of symptoms and possible causes of engine malfunctions are described in the table below. Alwayscontact your Volvo Penta dealer if problems occur which you can not solve by yourself.NOTICE! Read through the safety advice for care and maintenance work in the Safety precautions formaintenance and service operations chapter before starting work.

Symptoms and possible causes

Pop-ups are shown in the tachometer display See chapter Fault Code RegisterEngine can not be stopped 2, 4, 5, 7, 8Starter motor does not rotate 1, 2, 3, 4, 5, 6, 8, 9, 10, 35, 38, 41Starter motor rotates slowly 1, 2Starter motor rotates normally but engine does not start 1, 11, 12, 13, 14, 37, 38Engine starts but stops again 1, 11, 12, 13, 14, 19, 36, 38Engine does not reach full operating speed at full throttle 12, 13, 14, 15, 16, 17, 18, 19, 20, 23, 33, 36, 38, 39Engine runs unevenly 14, 15, 39Engine vibrates 24High fuel consumption 15, 16, 18, 21, 36Black exhaust smoke 19Blue or white exhaust smoke 21, 34Lubrication oil pressure too low 22Coolant temperature too high 25, 26, 27, 28, 29, 30, 31, 32Coolant temperature too low 31No charge or poor charge 2, 40

1. Flat batteries2. Poor contact/open circuit in cables3. Main switch turned off4. One of the semi-automatic circuit breakers in the distribution box has tripped5. Faulty key switch6. Control lever not in neutral/control position not activated7. Faulty stop relay8. Faulty main relay9. Faulty starter relay10. Faulty starter motor/solenoid11. Lack of fuel:

- fuel taps closed

- fuel tank empty

- wrong tank connected12. Blocked fine fuel filter/pre-filters(caused by contamination or fuel stratification at low temperature)13. Air in the fuel system14. Water/contamination in fuel15. Boat abnormally loaded16. Fouling on hull/propeller17. Cables for unit injector damaged (open circuit)18. Faulty unit injectors (nozzles)

Fault handling

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19. Insufficient air supply to engine:

- blocked air filter

- air leakage between turbocharger and engine inlet manifold

- fouled compressor section in turbocharger

- faulty turbocharger

- poor engine bay ventilation20. Excessive coolant temperature21. Too low coolant temperature22. Too low oil level23. Faulty / wrong propeller24. Faulty engine mounting25. Coolant level too low26. Air in the freshwater system27. Faulty circulation pump28. Closed seawater inlet29. Blocked seawater inlet/pipe/filter30. Defective impeller in seawater pump31. Defective thermostat32. Blocked heat exchanger insert33. Blocked aftercooler34. Too high oil level35. Water entry into engine36. High back pressure in exhaust system37. Faulty engine speed sensor38. Stored fault codes39. Non-return valve in feed pump leaks40. Alternator drive belt slips/broken41. Check that the AUX stop button on the engine is in the RUN position (not depressed)

Fault handling

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Fault Code RegisterCrankcase PressurePossible cause: The crankcase pressure is too high and the engine power is reduced.Corrective action: Check that the crankcase ventilation is not blocked.

Emergency Stop SwitchPossible cause: The auxiliary stop has been activated.

Corrective action: Reset the auxiliary stop. Refer to Auxiliary stop.

EMS Supply FusePossible cause: • If the fault code appears after startup, it is most likely that the Auxiliary Stop is activated

and this causes the circuit to be broken.

• Short circuit in the Auxiliary Stop.

• Short circuit in the Shutdown relay.

• Internal fault in the EMS unit.

Corrective action: • Check that the Auxiliary Stop is not enabled.

• Check the cable connections for the Auxiliary Stop.

• Check the cable connections in the Shutdown relay.

Engine Oil FilterPossible cause: There is an oil pressure difference and engine power is reduced.

Corrective action: Contact your Volvo Penta workshop.

Engine Oil LevelPossible cause: The oil level is too low.

NOTICE! If the vessel is tilted sideways the measurement might be inaccurate. If this happensacknowledge the faults and make new measurements when the boat is level.

Corrective action: • Check the engine oil level. Refer to Oil Level, page 62.

• Check that there is no leakage.

Engine Oil PressurePossible cause: Oil pressure is too low and the engine power is reduced.

Corrective action: • Check the engine oil level. Refer to Oil Level, page 62.


Engine Oil TemperaturePossible cause: The engine oil temperature is too high and the engine power is reduced.

Corrective action: • Check the oil level. Refer to Oil Level, page 62.


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Engine SpeedPossible cause: Engine performance may be compromised and engine power is reduced.


Exhaust TemperaturePossible cause: The exhaust temperature is too high and engine power is reduced.


Fuel pressurePossible cause: The fuel pressure is too low.

Corrective action: • Check the fuel level.

• Check that there is no fuel leakage.

• Check that the fuel filters are not blocked. refer to, Maintenance, page 63.

Fuel TemperaturePossible cause: The fuel temperature is too high.

Corrective action: • Check the fuel level.

• Check that there is no fuel leakage.

Helm RestartedPossible cause: The engine has lost communication with a helm station and engine power is reduced.

Corrective action: The helm station is automatically restarted.

Intake Manifold TemperaturePossible cause: Charge air temperature is too high and engine power is reduced.


Power Relay FailurePossible cause: There is a faulty relay. If the engine is off, the engine will not start until the fault is corrected.

Corrective action: Check the engine fuses. Refer to Fuses, page 69.

Primary BatteryPossible cause: • Poor batteries or poorly charged batteries.

• Overcurrent in system.

Corrective action: • Change or charge batteries. Refer to Battery, page 70.

• Check the engine fuses. Refer to Fuses, page 69.

Fault Code Register

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Sea Water PressurePossible cause: The seawater pressure is too low and the engine power is reduced.

Corrective action: • Check the impeller in the seawater pump. Refer to Impeller, Check andChange, page 68.


Secondary BatteryPossible cause: • Poor batteries or poorly charged batteries.

• Overcurrent in system.

Corrective action: • Change or charge batteries. Refer to Battery, page 70.

• Check engine fuses. Refer to Fuses, page 69.

Sensor FailurePossible cause: A sensor failure may be affecting engine performance.


Transmission Oil PressurePossible cause: The reversing gear oil pressure is too low.

Corrective action: • Check the reversing gear oil level.

Water in FuelPossible cause: Water has entered the fuel filter(s).

Corrective action: Empty the water trap underneath the fuel filters. Refer to Maintenance, page 63.

Water in drive oil

Possible cause: Leaking propeller shaft seal.

Corrective action: Contact a Volvo Penta workshop.

AirFilterIndAir filter sensor.

• Air Filter Clogged.

• Sensor failure.

AirInletTempAir Inlet Temperature /(Ambient Air Temp)/Intake Air System

• Open circuit sensor signal.

• Current above normal or short circuit to battery negative.

Fault Code Register

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AmbAirTempAir Inlet Temperature /(Ambient Air Temp)/Intake Air System

• Open circuit sensor signal

• Current above normal or short circuit to battery negative

BattPotential WrnBattery voltage to engine control unit

• Check belt tension. Refer to Drive belt, page 60.

• Check battery fluid level. Refer to Battery, page 70.

BridgeStopBridge Emergency Stop, Enable

• Electrical failure at Bridge Emergency Stop Switch

• Bridge Emergency Stop Switch is missing.

• Measurement resistors are missing.

Coolant Level WrnLow coolant level.

• Check for coolant leakage.Check coolant level., Refer to Coolant Level, page 66.

Coolant LevelLow coolant level.

• Check for coolant leakage.

• Check coolant level. Refer to Coolant Level.

CalibrMemFailSoftware corrupt.

CAN BB1CAN communication failure.

CAN BB2CAN communication failure.

Com.FailCommunication failure. Shutdown Module (SDM).

Fault Code Register

47712598 09-2020 © AB VOLVO PENTA 47

Controller#1Software corrupt.

Crankcase Press WrnCrankcase pressure too high Engine power is reduced.

• Check that the crankcase ventilation is not blocked.

EMS supply FlsEMS supply.

• Overcurrent protection has tripped.

• Check emergency stop button if any. Reset if necessary.

Remedy the problem. Reset the system by switching the main switch off and on.Contact a Volvo Penta workshop if the fault remains.

EngCool TempCoolant temperature too high.

• Check coolant level. Refer to Coolant Level.

• Check that the seawater filter is not blocked. Refer to Seawater Filter.

• Check the impeller in the sea water pump. Refer to Impeller.

• Check that no leakage occurs.

• If engine is shut down, check SDM and make a reset.

EngineOilLevel WrnOil level too low.The system may wrongly detect too low an engine oil level in heavy following seas or head seas. If this occurs,acknowledge the fault and check the following items for safety's sake.

• Checking Engine Oil Level, Refer to Oil Level, page 62.


EngOilLevelOil level too low.

The system may wrongly detect too low an engine oil level in heavy following seas or head seas. If this occurs,acknowledge the fault and check the following items for safety's sake.

• Checking Engine Oil Level. Refer to Oil level.


EngOil Press WrnOil pressure too low. Engine power is reduced.

• Checking Engine Oil Level, Refer to Oil Level, page 62.


Fault Code Register

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EngOil PressEngine Oil Pressure Too Low

• Engine Oil Level Too Low. Refer to Oil level.


• If engine is shut down, check SDM and make a reset.

EngOverspeedCritical system fault Engine shuts down automatically. Contact a Volvo Penta workshop if the fault remains.

EATS FailureMalfunction detected in the SCR/EATS system.

ECUMainRelaySmart Relay Module (SRM).

• Main relay hold EMS Electrical failure.

ECUPrgFailureSoftware corrupt.

ECUProgFailSoftware corrupt.

EmeStopSwEngEngine is emergency stopped.

• Emergency stop switch in engine room is enabled.

EMSCutRelayEMS Power Cut Relay.

• Electrical failure in Shutdown Module (SDM)

Fault Code Register

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Extra Supply FlsAuxiliary supplyOvercurrent protection for the auxiliary supply has tripped.

• Check the auxiliary stop connections for short circuits.

Reset the system by switching the main switch off and on.Contact a Volvo Penta workshop if the fault remains.

ExtSTOP Active FlsEmergency Stop Switch

• Check emergency stop button if any. Reset if necessary.

FlsMiscellaneous system faultsEngine performance can be affected.Several possible causes of engine problems are described below.

• Battery voltage incorrectCheck belt tension. Refer to Drive belt, page 60.Check battery fluid level. Refer to Battery, page 70.

• Fuel pressure incorrect.Engine performance can be affected.

• Communication failureGear 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, page 62.Check that no leakage occurs.

• Sensor failure

Contact a Volvo Penta workshop if the fault remains.

Fls Throttle InEngine speed demand to system lacking

• Check Control Lever

FuelDelPress WrnFuel pressure too low.

• Check fuel level.

• Check that the fuel filters are not blocked. Replace filters if necessary. Refer to Engine Fuel FilterReplacement

• Check for fuel leakage.

Fault Code Register

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FuelDelPressFuel pressure too low.


• Check that the fuel filters are not blocked. Replace filters if necessary.Refer to Engine Fuel Filter Replacement


DEFPumpBlkThe Urea return flush function does not work.

• Blocked AdBlue line or dosing unit.

DEFPurgValvAdBlue revert valve.

• Electrical failure.

Sd Gear Oil PressWrn ECU, Wrn J1587Critical system fault Engine shuts down automatically.Reversing gear oil pressure too low.

• Check the oil level. Refer to Reversing gear, ZF.

• Check that the oil strainer is not blocked. Refer to Reversing gear MGX.


GearOilPresReversing gear oil pressure too low.

Critical system fault Engine shuts down automatically.

• Check the oil level. Refer to Reverse gear, ZF.

• Check that the oil strainer is not blocked. Refer to Reverse gear MGX.


InjectorCyl#1Injector fault.



Fault Code Register

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Fuel Press WrnFuel pressure too low.


• Check that the fuel filters are not blocked. Replace filters if necessary. Refer to Engine Fuel FilterReplacement


Oil Level WrnOil level too low.The system may wrongly detect too low an engine oil level in heavy following seas or head seas. If this occurs,acknowledge the fault and check the following items for safety's sake.

• Checking Engine Oil Level, Refer to Oil Level, page 62


OverrideFailSDM override cable failure or resistor missing.

PickupCamCamshaft speed sensor.

Cable failure or deviation in the measured value against crankshaft.

• Engine runs unevenly.

• Engine is difficult to start or does not start.

PickupCrankCrankshaft speed sensor

Cable failure or deviation in the measured value against camshaft.

• Engine runs unevenly.

• Engine is difficult to start or does not start.

Fault Code Register

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Primary Batt FlsPrimary Battery.Poor batteries or charging Refer to Battery, Charging

PrimarySupplySDM Low power supply primary battery.

• Poor batteries or charging. Refer to Battery, Charging.

• Check F1 fuse in SDM box.

SecSupplySDM Low power supply secondary battery.

• Poor batteries or charging. Refer to Battery, Charging.

• Check F2 fuse in SDM box.

SDMPrgFailSDM corrupt software.

SensSupplyCPower supply failure for sensors.

Sd Coolant TempWrn ECU, Wrn J1587Critical system fault Engine shuts down automatically.Coolant temperature too high Engine power is reduced.

• Check coolant level., Refer to Coolant Level, page 66.

• Check that the seawater filter is not blocked., Refer to Seawater Filter, page 68.

• Check the impeller in the seawater pump., Refer to Impeller, Check and Change, page 68.


Sd Oil PressureWrn ECU, Wrn J1587Critical system fault Engine shuts down automatically.Oil pressure too low.

• Checking Engine Oil Level



Fault Code Register

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Sd Overspeed SDUWrn ECU, Wrn J1587Critical system fault Engine shuts down automatically.Contact a Volvo Penta workshop if the fault remains.

Secondary Batt FlsSecondary Battery.Poor batteries or charging Refer to Battery, Charging

SeaWaterPressSeawater pressure too low Engine power could be reduced.

• Check that the seawater filter is not blocked., Refer to Seawater Filter, Check and Cleaning.

• Check the impeller in the sea water pump. Refer to Impeller, Check and Change.


StopRelayEngine stop relay electrical failure.

WastegateWastegate actuator failure.

WastegateSolExhaust control valve electrical failure.

VBatMeasureBattery power in EMS to low.

VIN FailSDM cabinet mixed up.

WtrInFuelIndWater in Fuel.

• Empty the water trap underneath the fuel filters. Refer to Fuel pre-filter with water separator.

Water in fuel WrnWater in Fuel.

• Empty the water trap underneath the fuel filters. Refer to Fuel pre-filter with water separator.

Fault Code Register

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WrnMiscellaneous system faultsEngine performance can be affected. Several possible causes of engine problems are described below.

• Battery voltage incorrectCheck belt tension. Refer to Drive belt, page 60.Check battery fluid level. Refer to Battery, page 70.

• Fuel pressure incorrect.Engine performance can be affected.

• Communication failureGear 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, page 62.Check that no leakage occurs.

Wrn Derate AlarmEngine performance can be affected. The engine's power gradually decreases with the severity of the engine'sproblem. Soft derate. Several possible causes of engine problems are described below.

• Coolant pressure too low.

• Coolant temperature too high.

• Charge air temperature too high.

• High charge air pressure.

• Exhaust temperature too high after Turbo charger.

• Exhaust temperature too high before SCR catalyst/muffler.

• Wet Exhaust temperature is too high.

• Oil pressure too low.

• Engine oil temperature too high.

• Sea water pressure low. The engine will not derate just for this single symptom.

Wrn SD System FailInternal fault in SDU systemBreak in wiring to sensor or internal SDU fault. Limited or no shutdown function.Contact a Volvo Penta workshop if the fault remains.

Wrn UnderspeedEngine Speed.Engine is emergency stopped.Engine revolutions are lower than expected.

30 supply Fls30 V supplyOvercurrent protection for the supply to the MCC system has tripped. Short circuit in the system between theengine and the MCC cabinet.Remedy the problem. Reset the system by switching the main switch off and onContact a Volvo Penta workshop if the fault remains.

Fault Code Register

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In Case of EmergencyDespite regular service in accordance with the planned maintenance schedule and perfect operating conditions,faults may occur that must be remedied before the boat can continue its trip. This chapter provides advice on howto 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 gear is in neutral and engine speed is limited

• The engine stops

If a fault occurs, confirm any fault alarm and take the necessary measures. Refer to this section and Fault CodeRegister.

Starting Using AuxiliaryBatteries

WARNING!Explosion hazard. Batteries contain and give off anexplosive gas which is highly flammable and explosive.A short circuit, open flame or spark could cause aviolent explosion. Ventilate well.

WARNING!Never confuse the positive and negative poles on thebatteries. Risk of arcing and explosion.

1 Check that the auxiliary battery has the samevoltage as the engine system voltage.

2 Connect the red positive cable to the plus (+)terminal on the discharged battery and then to theplus terminal on the auxiliary battery.

3 Connect the black start cable to the minus (–)terminal on the auxiliary battery and to a place alittle distance away from the discharged battery,e.g. the start motor's negative terminal.

WARNING!The black jumper cable (–) must never come in contactwith the positive connection on the starter motor.

4 Start the engine and let it run at fast idle forapproximately 10 minutes to charge the batteries.Make sure there is no extra equipment connectedto the electrical system.

WARNING!Working with or approaching a running engine is asafety risk. Watch out for rotating components and hotsurfaces.

WARNING!Do not touch the connections during the start attempt:Risk of arcing.Do not bend over any of the batteries either.

5 Turn off the engine. Remove the start cables in theexact opposite order to their connection.

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Emergency ShiftingThe descriptions refer to electrically shifted reversegear.

If a fault occurs that prevents the reverse gear frombeing operated (shifted) with the control lever, it can beshifted manually, using the description below.

WARNING!In emergency shifting, the unit is locked in forwardsoperation and the reversing gear cannot bedisengaged with the control lever. Forward motion canonly be cut off by stopping the engine with the ignitionkey or stop button.

1 Stop the engine and turn off the ignition.

2 Note the valve (P or S) to which the cable marked“Primary” is connected. Then undo the connectors(1 and 2) from the solenoid valves.

3 Remove the cap nut from the valve which wasconnected to the “Primary” cable.

4 Press the button (A) on the valve.

5 Turn the button a 1/2 turn anti-clockwise (the buttonis forced out by spring action).

The reverse gear is now connected for forward motionand cannot be disengaged by the control lever.

2

1

P0004983

In Case of Emergency

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Maintenance ScheduleYour Volvo Penta engine and its equipment are designed for high reliability and long life. The engines are built tohave the smallest possible environmental impact. If given preventive maintenance, according to the maintenanceschedule, these qualities will be retained and unnecessary malfunctions will be avoided. In order for the warrantyto be valid, the owner must make sure that the services in the service intervals are performed.

NOTICE! For emission related warranty rights see Emission Control System Warranty Statement.

Service IntervalsService intervals are shown below. The service content can be found in the Service Protocol available fordownload at www.volvopenta.com.

NOTICE! More information on how to perform service and maintenance can be found in the Service andMaintenance handbook. Information on how to purchase the Service and Maintenance handbook can be foundat www.volvopenta.com.

Extended service intervalsThe interval between engine oil changes may be extended in certain circumstances. To determine whether theservice interval may be extended, Volvo Penta's conditions for extended service intervals must be met and an oilanalysis performed. Contact your Volvo Penta dealer for further information.

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MaintenanceThis chapter contains general technical information and instructions on how the common maintenance items thatmust be carried out. Read through the instructions carefully before starting work.Read through the safety precautions for maintenance and service in the Safety precautions for maintenance andservice operations chapter before work on the engine is begun.Volvo Penta recommend that all servicing with the engine running should be undertaken by an authorized VolvoPenta workshop. The intervals when maintenance items must be carried are indicated in the MaintenanceSchedule.

WARNING!Care and maintenance work should be done with the engine stopped unless otherwise specified. Stop the enginebefore opening or removing the engine hatch/hood. Make it impossible to start the engine by removing the startkey 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 andMaintenance handbook. The manual is available for download at www.volvopenta.com.

1 Coolant filler cap

2 Oil filter

3 Fuel fine filter

4 Emergency Stop

5 Reversing gear, ZF

6 Impeller

7 Oil filler cap, engine (¹)

8 Oil dipstick, engine(2)

9 Oil dipstick, reversing gear

10 Oil filler cap, engine (¹)

11 Oil dipstick, engine (¹)

12 Air Filter

2. Located on both sides of the engine.

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Engine, General

General inspectionMake a habit of visually checking the engine andengine bay before starting, and after operations whenyou have stopped the engine. This will help you toquickly discover abnormalities, or if something is aboutto happen.Look especially carefully for oil, fuel and coolantleakages, loose bolts, worn or poorly-tensioned drivebelts, loose cable connections, damaged electricalcables and hoses. This inspection only takes a fewminutes and can prevent serious malfunctions andexpensive repairs.

WARNING!Risk of fire.Remove all accumulations of fuel, oil and grease whendetected on the engine or in the engine room.

WARNING!If an oil, fuel or coolant leak is detected, the cause mustbe investigated and the fault rectified before the engineis started.

Never direct the jet from a high-pressure washer atseals, rubber hoses or electrical components. Neveruse the high pressure setting for engine cleaning.

Drive belt WARNING!

Stop the engine before doing any maintenance work.

GeneralThe drive belt has an automatic tensioner and does notneed manual adjustments. Regularly check the beltcondition and belt tension. Make sure that the belttensioner does not bottom.

Maintenance

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IMPORTANT:Always change a belt which looks worn or cracked.

Changing the Drive Belt1 Remove the protective cover over the drive belt by

pulling it out from the engine.

2 Put a socket wrench in the tensioning roller squarefitting. Turn the tensioning roller aside and secureit by inserting a screwdriver or similar into the spacewhich opens up.

3 Remove the drive belt.

4 Install the new drive belt and release the locking ofthe belt tensioner. Make sure the drive belt fitsproperly into the grooves.

5 Fit the protective cover over the drive belt.

Maintenance

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Lubrication System

Oil change intervals can vary depending on oil quality,refer to Lubrication System, page 76.

Oil change intervals must never exceed a period of 12months.

If you want longer oil change intervals than stated inthe table Lubrication System, page 76, the oil changeinterval can under certain conditions be increased. Tosee if the engine complies, Volvo Penta oil analysisneed to be performed. Contact your Volvo Pentadealer for further information.

Oil LevelNOTICE! Check the oil level with engine shut downand in a horizontal level.

The oil level must be within the marked area on thedipstick. We recommend that the oil level be checkedon a daily basis.

When checking the oil level; take the oil dipstick outand wipe it. Put it back and remove it again to read theoil level.

NOTICE! There are two oil filling holes, drain pipes anddipsticks, one on each side of the engine.

IMPORTANT:Do not fill up above the maximum oil level. Only use arecommended viscosity and quality of oil.

1 Top up the oil through the filling hole at the side ofthe engine.

2 Wait 15 minutes after topping up to allow the oil toreach the sump before checking the level again.

3 Check the level again.

MA

XM

IN

MIN

MA

X

MAX

MIN

P 2185700

Maintenance

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Fuel SystemOnly use the grades of fuel recommended in the fuelspecification, refer to Technical Data, page 77.Always observe the greatest cleanliness duringrefueling and work on the fuel system.

All work on the injectors of the engine must be carriedout by an authorized Volvo Penta workshop.

WARNING!Fire hazard. When carrying out work on the fuel systemmake sure the engine is cold. A fuel spill onto a hotsurface 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 materialso that there is no danger of them catching fire. Fuelsoaked rags can ignite spontaneously under certainconditions.

Bleeding the Fuel SystemThe fuel system must be vented, e.g. after changing afuel filter, if the fuel tank has been run dry and after longstops.

1 Place a suitable vessel underneath the hose.

2 Remove the protective cap from the bleeding nipple(1) on the filter bracket and connect a rubber hose.

3 Open the bleeding nipple and pump up fuel with thehand pump (2) until air-free fuel flows out. Tightenthe venting nipple while fuel is flowing out.

4 Fold the hose back and put the protective cap backon the venting nipple.

5 Run the engine at idling speed for a couple ofminutes to allow any remaining air out of thesystem. Make sure there are no leaks.

Maintenance

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Fuel pre-filterVolvo Penta fuel pre-filters are supplied in single anddouble models.

ChecksThe double filter is fitted with a pressure gauge 1 thatindicates when it is time to replace the filter cartridges.

The filter cartridges must be replaced according tomaintenance schedule recommendations, or earlier ifthe 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 asafety risk. Watch out for rotating components and hotsurfaces.

DrainingPlace a vessel under the filter. Empty the water andsediment through the plugs (2).

Maintenance

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Freshwater SystemThe cooling system ensures that the engine operatesat the correct temperature. It is a closed system thatshould always be filled with a coolant mixture.

IMPORTANT:Coolant of a suitable chemical composition must beused all year round to protect the engine againstinternal corrosion, cavitation and freeze bursting.This even applies when there is no risk for freezedamage, to make sure the engine always has acomplete corrosion protection.

Therefore, the use of anti-corrosion agents alone, orwater alone as a coolant, is not permitted in VolvoPenta engines.

The coolant must be based on Organic AcidTechnology (OAT). Using an improper coolant ormixing with another coolant will rapidly reduce theperformance and lifetime of the engine. Materialincompatibility can lead to leakages, which - in theworst case - can cause engine breakdown.

Volvo Penta strongly recommend the use of our owncoolants, ”Volvo Penta Coolant VCS Ready Mixed” orthe concentrate ”Volvo Penta Coolant VCS”, whichensure the protection of the cooling systemcomponents from corrosion, ageing, swelling andcracking, thereby ensuring optimal engine lifetime.

Over time the corrosion protection additives becomeless effective, and consequently the coolant must bechanged at regular intervals to maintain sufficientprotection of the engine. The latest Service Protocolthat specifies service intervals can be found atvolvopenta.com.

Coolant, MixingIt is extremely important that the system is filled withthe correct coolant concentration; refer to TechnicalData, page 79.The coolant should be mixed with distilled, deionizedwater. For Volvo Penta specified water requirements;refer to Technical Data, page 79.

NOTICE! If water quality can not be guaranteed, useready mixed coolant.

Maintenance

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Coolant Level WARNING!

Do not open the coolant filler cap when the engine ishot, except in emergencies, as this could causeserious personal injury. Steam or hot fluid could sprayout.

Be careful when opening the coolant filler cap andrelease pressure before removing the cap.

IMPORTANT:Only use coolant recommended by Volvo Penta.Top up with the same type of coolant as already usedin the system.Different types of coolant must not be mixed.

Checking and filling coolant levelCheck the coolant level when engine is cold. Thecoolant level must be between the MAX and MINmarkings.

Filling completely empty systemFill coolant to the rim of the expansion tank filling hole.Top up slowly, to allow air that is displaced to flow outthrough the filler opening.

Maintenance

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Seawater System

Draining the Seawater System

Drainage points for charge air cooler and impeller.

Drainage point for heat exchanger.

The seawater system must be drained in coldweather, if there is a risk of freezing, to prevent freezedamage.An alternative to draining is to keep the engine bayabove freezing temperature, by using a fan heaterapproved for outdoor use.

WARNING!Risk of water entry. Close the seawater cocks beforedoing any work on the seawater system.

Draining:

1 Close the sea cock.

2 Drain sea water from the heat exchanger andthe charge air cooler and release the cap on theimpeller.Use hoses to lead the water in to a container.Check that all water really does drain out.Deposits may need to be cleared away, insidethe drain plug/tap.

3 Also drain/empty any auxiliary equipment suchas the seawater filter.

4 Reinstall plugs and caps.

NOTICE! Once the engine is drained of sea water/saltwater, check that this does not get onto the alternator,the fuel pump or other corrodible parts. If it is notpossible to avoid this, carefully flush with fresh waterand make sure it is properly dried up afterwards.

Maintenance

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Impeller, Check and Change WARNING!

Risk of water entry. Close the seawater cocks beforedoing any work on the seawater system.

1 Remove the seawater pump lid, and pull theimpeller out with water pump pliers.

2 Check the impeller. If any cracks or other defectsare visible, the impeller must be changed.

3 Lubricate the pump housing and the inside of thelid with water-resistant grease (which is notaggressive to rubber). The impeller will be easier towork with if it is put in hot water prior to fitting.

4 Press the impeller in with a clockwise circularmotion. The shaft of the pump has an internalthread (M8). Screw a stud into the end of the shaftand press the impeller in using a washer and nut.Fit the cover, using a new O-ring.

5 Open the sea cock.

NOTICE! Always carry a spare impeller on board.

Seawater FilterThe seawater filter is auxiliary equipment.

If the water where the boat is used has a lot ofcontaminants, seaweed, etc., the filter should bechecked more frequently than stated in themaintenance schedule, otherwise there is a risk thatthe filter may become blocked resulting in engineoverheating.

WARNING!Risk of water entry. Close the seawater cocks beforedoing any work on the seawater system.

1 Close the sea cock.

2 Unscrew the cover (1) and remove the sealing plate(2).

3 Lift out the insert (3) and clean it.

4 Reinstall the parts as illustrated.

5 Open the sea cock and check for leaks.

Maintenance

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Electrical SystemThe engine is equipped with a 2-pole electrical systemand an alternator.

WARNING!Always stop the engine and break the current using themain switches before working on the engine.

IMPORTANT:Contact a Volvo Penta dealer for information if any arcwelding will be performed on the application.Arc welding can cause damage to the engine and theelectronics.

Main switchIMPORTANT:

Never disconnect the current using the main switcheswhen the engine is running or by disconnecting thebattery cables.The alternator and electronics could be damaged.

The main switches must never be switched off beforethe engine has stopped. If the circuit between thealternator and the battery is disconnected when theengine is running, the alternator and electronics maybe damaged. For the same reason, the chargingcircuits must never be re-connected with the enginerunning.

FusesThe engine is fitted with two automatic circuit breakers.

NOTICE! These circuit breakers are not active in thecommercial setup. The active fuses av located in theSDM cabinet.

If you are not able to start the engine or if the instrumentstops working while running, the circuit breaker mayhave been activated. Reset by pressing in the circuitbreaker.

IMPORTANT:Always investigate the cause of the overload. If thefuse trips frequently, contact an authorized VolvoPenta workshop.

Maintenance

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Electrical Connections

Check that electrical connections are dry, free fromoxide, and that they are securely tightened.

Battery WARNING!

Risk of fire and explosion. Never allow an open flameor electric sparks near the batteries.

WARNING!Battery electrolyte is a corrosive acid and should behandled with care. If you spill or splash electrolyte onany part of the body, immediately flush the exposedarea with liberal amounts of water and seek medicalattention as soon as possible.

WARNING!Ventilate the engine compartment before working onbatteries or battery connections.

IMPORTANT:Batteries can be damaged if they are left discharged,and can also freeze and burst easier in cold weather.If the engine is not going to be used for a longer periodof time, the batteries should be fully charged, tricklecharged if possible.

MaintenanceIt is important to always follow the batterymanufacture’s recommendation and instruction whenreplacing and charging batteries. Depending onbattery type, the instructions for maintenance andcharging may vary.Modern batteries are normally maintenance free, butthere are some actions that are recommended toincrease the battery service life and avoid accidents:

• Keep the batteries clean and dry. Contaminationand oxide on the batteries and battery poles canresult in stray currents, voltage drop and discharge,especially in wet weather.

• Remove oxidation from the battery poles andterminals, using a brass brush.

• Tighten the terminals securely and grease them withterminal grease or petroleum jelly. Loose batteryconnections may cause damage to the engine’selectrical system.

• Charge the battery regularly. A battery that is keptfully loaded has a maximum service life. The easiestway to check if a battery needs charging is to use avoltmeter.

NOTICE! If low starter battery alarm occur, the batterymay get drained which might result in loss of functionsand engine stopping.

Maintenance

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Replacing BatteryIMPORTANT:

Make sure that the new battery fulfills the specificationsin Technical Data. Read the information supplied withthe battery before you begin the installation.

IMPORTANT:Do not disconnect the batteries with the enginerunning.Sensitive electrical components can be immediatelydamaged.

WARNING!Never confuse the positive and negative poles on thebatteries. 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 thebattery and tighten the nut.

2 Connect the – cable (black) to the – pole on thebattery and tighten the nut.

NOTICE! Hand in the old battery to a re-cycling station.

Electrical InstallationsAn incorrectly designed electrical installation maygenerate leakage current from the electrical system.Leakage current can in turn render galvanic protectioninadequate in respect of propellers, propeller shafts,rudder posts, the keel etc., and may cause damagethrough electrochemical corrosion.

Maintenance

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WARNING!Work on the low voltage circuits in the boats should bedone by a person with electrical training or knowledge.Installation or work on land current equipment mustonly be done by a competent electrician, in accordancewith local regulations for mains electricity.

The following must always be heeded:

1 If shore power is connected it must always beground protected ashore, never in the boat.Furthermore, the shore power installation should beequipped with a ground fault circuit interrupter.The shore power installation (transformer, inverter,battery charger etc.) must be designed for marineuse where the high-tension side is galvanicallyseparated from the low-tension side.

2 Electrical cables must be run and clamped suchthat there is no risk of exposure to chafing, damp orbilge water.

3 Ground protection for radios, navigationinstruments, rudder, boarding ladders or otherequipment where separate cables for groundprotection are present, must be clustered to acommon ground connection that is not connectedto the engine or reverser gear.

IMPORTANT:The engine and reversing gear must never beused as earth planes.

4 The start battery must have a main switch (1)connected to the battery's positive (+) side. Themain switch must break the circuit to all equipmentand be switched off when the boat is not in use.

5 If an auxiliary battery is used, a main switch mustbe placed between the auxiliary battery's positive(+) terminal and the circuit breaker panel for theboat's electrical equipment. The main switch mustbreak the circuit to all equipment connected to theauxiliary battery and must be switched off whenpower is no longer required. All equipmentconnected to the auxiliary battery must haveseparate main switches.

For simultaneous charging of two independent batterycircuits a separate charging distributor (accessory)should be installed on the standard alternator.

Maintenance

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Electrical WeldingRemove the positive and negative cables from thebatteries, then disconnect all cables connected to thealternator, EMS and MCC.

Always connect the welder ground clamp to thecomponent to be welded, and as close as possible tothe weld site. The clamp must never be connected tothe engine or in such a way that current can passthrough a bearing.

IMPORTANT:After finished welding, re-connect the alternatorterminals and cables connected to EMS, MCC beforeconnecting the battery cables.

Maintenance

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StorageIf the boat is not going to be used for two months or more, it is important to reduce the risk of damage to theengine and other equipment. Measures need to be taken to prevent freeze bursting and reduce the formation ofcondensation, mold and corrosion.

All information on how to prepare and handle theengine and its equipment before, during and afterstorage is included in the “Service and Maintenancemanual”.

The manual is available for downloading (orpurchasing) at volvopenta.com, Manuals &Handbooks.

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Technical DataEngine

Product sales designation D8–MHProduct designation D8A5–A MH

Crankshaft power (1) @1800–2200 rpm154 kW (210 hp)169 kW (230 hp)195 kW (265 hp)221 kW (300 hp)261 kW (355 hp)@2100–2200 rpm296 kW (405 hp)313 kW (425 hp)

Max torque @900–1500 rpm980 Nm (723 lbf ft)@1000–1500 rpm1076 Nm (794 lbf ft)@1100–1500 rpm1242 Nm (916 lbf ft)@1200–1500 rpm1407 Nm (1038 lbf ft)@1300–1600 rpm1536 Nm (1133 lbf ft)@1300–1950 rpm1536 Nm (1133 lbf ft)

No. of cylinders 6Bore 110 mm

(4.3”)Stroke 135 mm

(5.3”)Displacement 7.7 dm3

(469.9 inch3)Engine, dry weight 850 kg

(1874 lb)Compression ratio 16.5:1

Idling speed (2) 600 (±10) rpm

1) According to ISO 86652) At delivery, the idle speed is adjusted to 600 rpm. If needed, the speed can be adjusted within the range 600–800 rpm.

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Lubrication System

EngineOil capacity including oil filters,approximately

32.4 liters (8.56 US gals)

Oil volume difference MIN – MAX 6 liters (1.59 US gals)

Oil pressure, hot engineAt normal running rpm (1100 rpm orhigher)

300–500 kPa (43.5–72.5 PSI)

At low idle 200 kPa (29 PSI)

Oil quality Oil change interval, reached first in operation:VDS 4.5 500 hours or 12 months

VDS = Volvo Drain Specification

Viscosity

Select the viscosity according to the table.

The temperature values refer to stable ambienttemperatures.

Technical Data

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Fuel quality requirements for diesel engines

General requirementsVolvo Penta diesel engines are certified for compliance with emission legislations with the diesel test fuelsspecified by law. These fuels correspond with diesel fuel standards EN 590, ASTM D975 and JIS K2204 andparaffinic diesel fuel standard EN 15940. Volvo Penta engines will be compliance with emission legislation, if theengine is maintained according to service instructions and used according to intended purpose.

It is the responsibility of the fuel suppliers to always ensure that their fuels meet relevant requirements and arefit for their intended purpose. Their responsibility includes any use of additives for proper engine performance andfunction.Special requirements are placed on cold-flow properties, that is, temperature limit values of fuel filterability duringoperation in winter conditions.

Restrictions for specified diesel fuels

• Max density for ASTM D975 No 2–D: 860 kg/m3

Insufficient density reduces the power and increases the fuel consumption. Excessive density endangersthe durability and function of the fuel injection equipment.

• Max lubricity (wsd 1.4) for JIS K 2204: 460 μmSufficient fuel lubricity is essential to protect the fuel injection system against excessive wear.

Restrictions for other diesel fuelsVolvo Penta also approves the use of other diesel fuels as long as the here specified restrictions are followed.However Volvo Penta does not guarantee compliance with emission legislation or fulfillment of expected lifetimewith these other diesel fuels.

NOTICE! Operators must check permission for usage of these fuels according to regional, national or localregulations.

Technical Data

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• Min cetane number: 40An 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. Excessive density endangersthe durability and function of the fuel injection equipment.

• Viscosity between 1.9 to 4.6 mm/s2 at 40°C:Insufficient viscosity reduces the power and increases the fuel consumption. Excessive viscosity endangersthe durability and function of the fuel injection equipment.

• Max lubricity (wsd 1.4): 520 μmSufficient fuel lubricity is essential to protect the fuel injection system against excessive wear.

• Max FAME (biodiesel) content: 10% (V/V)FAME is blended into diesel fuel.

• Max sulfur content: 5000 mg/kg

Paraffinic fuels - HVO and GTLParaffinic diesel fuels (“Synthetic Diesel”) have higher cetane numbers and lower densities than diesel fuels. HVO(Hydrotreated Vegetable Oils) is renewable paraffinic fuels. GTL (Gas-To-Liquid) is fossil paraffinic fuels. VolvoPenta approves the use of paraffinic diesel fuels that complies with standard EN 15940. The fuel guaranteescompliance with emission legislation and fulfills the expected lifetime as long as the service requirements arefollowed. Volvo Penta also approves the use of fuel blends between these paraffinic fuels and diesel fuels thatcomply with the quality requirements.

Service requirements HVO and GTLWhen shifting from diesel fuel to paraffinic fuel, the fuel hoses and sealings must be replaced.

Technical Data

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Cooling SystemFreshwater system capacity including heat exchanger,approximately.

25 liters6.6 US gal

Coolant, Mixing

WARNING!All coolant is hazardous and harmful to theenvironment. Do not consume. Coolant is flammable.

IMPORTANT:Always use the same type of coolant that is already inthe engine.Different types of coolant must not be mixed with eachother.Risk of reduced cooling function and performance byclogging and isolation.

Coolant shall be based on Organic AcidTechnology (OAT).

Follow the mixing recommendation on theproduct.The coolant should be mixed with distilled, deionizedwater. For Volvo Penta specified water requirements;refer to Water Quality.

NOTICE! Always use “Ready Mixed” coolant if waterquality cannot be determined or if it does not fulfillASTM D4985.

NOTICE! Never mix more than 60% concentratedcoolant with water. A greater concentration providesreduced cooling effect with the risk for overheating andreduced freeze protection.

Technical Data

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Water QualityASTM D4985:Total solid particles <340 ppmTotal hardness <9,5° dHChloride <40 ppmSulfate <100 ppmpH value 5.5–9Silica (acc. ASTM D859) <20 mg SiO2/l

Iron (acc. ASTM D1068) <0.10 ppmManganese (acc. ASTM D858) <0.05 ppmConductivity (acc. ASTM D1125) <500 µS/cmOrganic content, CODMn (acc. ISO8467) <15 mg KMnO4/l

Technical Data

80 47712598 09-2020 © AB VOLVO PENTA

Electrical System

System voltage 24V

AC generator,voltage/max. amperage 28V/80Aoutput, approx. 2240W

Alternative generator equipment (accessory):voltage/max. amperage 14V/115Aoutput, approx. 1610W

voltage/max. amperage 28V/110Aoutput, approx. 3080W

Battery capacity 2 connected in series 12V, max. 152Ah

Battery electrolyte density at +25°C (77°F):fully charged battery 1.28 g/cm3 = 0.0462 lb/in3 (1.24 g/cm3 = 0.0448 lb/in3)*battery recharged at 1.24 g/cm3 = 0.0448 lb/in3 (1.20 g/cm3 = 0.0434 lb/in3)*

NOTICE! * Applies to batteries with tropical acid.

Technical Data

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Identification NumbersEngine A

XXXXXXX (3)

P 2226000

B

REVERSE GEAR

DRIVE UNIT

TRANSOM ASSEMBLY

ENG

INE

(1)(2)

(3)(4)

P0022294

xxxxxxxxx

C

P0022680

5, 6, 7, 8

P0022680

(10)(11)

P0022778

D

(9)

Product designation (1*) ...........................................Chassis ID (2*) ...........................................Serial number (3*) ...........................................Date of manufacturing (4*) ...........................................

TransmissionProduct designation (5*) ...........................................Gear ratio (6*) ...........................................Serial number (7*) ...........................................Product number (8*) ...........................................

Electrical Rudder ActuatorPart number (9*) ...........................................Product designation (10*) ...........................................Serial number (11*) ...........................................

* The numbers refer to the position of the identificationnumbers on the information decal/plate.

A Engine serial number

B Product information (Black label)

C Reversing gear plate

D Electrical rudder actuator plate

D

P 22 97700

Technical Data

82 47712598 09-2020 © AB VOLVO PENTA

AAbout this Manual......................................................14Acknowledge message............................................. 40After Engine Shutdown..............................................37Alarm List.................................................................. 40Alarms................................................................. 25, 33BBattery....................................................................... 70Before Engine Shutdown...........................................36Bleeding the Fuel System......................................... 63CCertified Engines....................................................... 19Cold Weather Precautions........................................ 38Coolant Level............................................................ 66DDraining the Seawater System..................................67Drive belt................................................................... 60EElectrical Connections...............................................70Electrical Installations................................................71Electrical System.......................................................69Electrical Welding......................................................73Emergency Shifting................................................... 57Engine, General........................................................ 60Environmental care................................................... 18Excessive strain on a product and components........17FFault Tracing............................................................. 42Freshwater System................................................... 65Fuel pre-filter............................................................. 64Fuel System.............................................................. 63Fuel, oils and coolant................................................ 16Fuses.........................................................................69IIdentification Numbers...............................................82Impeller, Check and Change.....................................68LLubrication System..............................................62, 76MMain switch................................................................69Maintenance and replacement parts......................... 17Maneuvering........................................................12, 34Marine Commercial Control System (MCC).............. 21MCC system, Overview.............................................22Menus........................................................................24OOil Level.................................................................... 62Operation at low load................................................ 34Operation Break........................................................ 38Overheating protection.............................................. 32RRead the instruments and warm the engine up.........32Reading the Instruments........................................... 33Recording engine data.............................................. 18Running in the engine............................................... 16

SSeawater Filter.......................................................... 68Seawater System...................................................... 67Settings..................................................................... 25Shutdown Module (SDM).......................................... 28Starting the Engine....................................................31Starting Using Auxiliary Batteries.............................. 56Stop the Engine.........................................................36VViscosity.................................................................... 76Volvo Penta Action Service....................................... 20Volvo Penta Dealer Network..................................... 20WWarranty....................................................................15YYour New Boat.......................................................... 15

Index

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This Operator’s Manual may be ordered in a different language free of charge up to 12 months after delivery, via internet.http://manual.volvopenta.com/coupon/If internet access isn‘t possible, please contact your Volvo Penta dealer.

Diese Betriebsanleitung kann bis zu 12 Monate nach-der Lieferung über Internet kostenlos in einer anderenSprache bestellt werden. http://manual.volvopenta.com/coupon/Wenn Sie keinen Internet-Zugriff haben, kontaktierenSie bitte Ihren Volvo Penta-Händler.

Ce manuel d‘utilisation peut être commandé gratu-itement sur Internet en différentes langues, jusqu‘à 12 mois après la date de livraison.http://manual.volvopenta.com/coupon/Veuillez contacter votre Distributeur Volvo Penta si vous avez un problème d‘accès à l‘Internet.

El presente libro de instrucciones puede solicitarse en otro idioma diferente, libre de cargo, hasta 12 meses des-pués de la entrega, mediante internet.http://manual.volvopenta.com/coupon/Si no se tiene acceso a internet, contacten al su concesionario Volvo Penta.

Denna instruktionsbok kan beställas via internet på ett annat språk gratis i upp till 12 månader efter leverans.http://manual.volvopenta.com/coupon/Kontakta din Volvo Penta-återförsäljare om du inte har tillgång till internet.

Dit instructieboek kan gratis via internet in een a dere taal worden besteld tot 12 maanden na aflevering.http://manual.volvopenta.com/coupon/Als toegang tot het internet niet mogelijk is, neem dan contact op met uw Volvo Penta dealer.

Denne instruktionsbog kan bestilles gratis på et andet sprog via Internettet i op til 12 måneder efter leveringen.http://manual.volvopenta.com/coupon/Hvis det ikke er muligt at bestille via Internettet, bedes du kon-takte din Volvo Penta forhandler.

Tämä käyttöohjekirja on tilattavissa Internetin kautta veloituksetta eri kielillä 12 kuukauden ajan toimituksen jälkeen.http://manual.volvopenta.com/coupon/Jos sinulla ei ole Internet-yhteyttä, ota yhteys lähimpään Volvo Penta jälleenmyyjään.

Este Manual do Operador pode ser encomendad em idiomas diferentes isento de custos até 12 meses após entre-ga, via internet.http://manual.volvopenta.com/coupon/Se não for possível aceder à internet, contacte o seu conces-sionário Volvo Penta.

To παρόν Βιβλίο Χρήσης μπορεί να παραγγελθεί δωρεάν σε άλλη γλώσσα μέχρι 12 μήνες μετά την παράδοση,μέσω διαδικτύου.http://manual.volvopenta.com/coupon/Εάν δεν είναι δυνατή η πρόσβαση στο ιαδίκτυο,παρακαλούμε επικοινωνήστε με το δικό σας αντιπρόσωπο της Volvo Penta.

Данное руководство по эксплуатации можно бес-платно заказать на другом языке по Интернету в течение 12 месяцев после доставки.http://manual.volvopenta.com/coupon/Если доступ к Интернету отсутствует, обратитесь к своему дилеру компании Volvo Penta.

Bu Kullanım Kılavuzu, teslimden 12 ay sonrasına kadar İnternet yoluyla ücretsiz olarak farklı bir dilde sipariş edilebilir.http://manual.volvopenta.com/coupon/İnternet mümkün değilse, lütfen Volvo Penta yetkili satıcınızla temasa geçin.

Il manuale per l‘operatore può essere ordinato tra-miteInternet, in varie lingue e per consegna gratuita, entro 12 mesi dalla consegna del prodottohttp://manual.volvopenta.com/coupon/Se l‘accesso a Internet risulta impossibile, contattare la con-cessionaria Volvo Penta.

本操作手册可通过互联网以不同的言进行订购，交付后可免费使用达12 个月。http://manual.volvopenta.com/coupon/如果无法访问互联网，请与沃尔沃遍达经销商联系。

Este Manual de operador pode ser encomendado em um idioma diferente, gratuitamente, até 12 meses após a entrega, via internet.http://manual.volvopenta.com/coupon/Caso o acesso à internet não for possível, contatar seu distri-buidor Volvo Penta.

このオペレーターズマニュアルの他言語版が、発行

後最高12か月間、インターネットより無料で発注可能です。http://manual.volvopenta.com/coupon/インターネットにアクセスできない場合は、担当のボルボペンタディーラーまでご連絡ください。

© 2020 AB VOLVO PENTA Volvo reserves the right to make changes Printed on environmentally friendly paper

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