Operator'S Manual: D16 MG Genset Engine D16 MG Marine Genset

OPERATOR’S MANUAL
D16 MG Genset Engine

D16 MG Marine Genset
An English version of this Operator’s Manual may Pode-se encomendar uma versão gratuita deste
be ordered free of charge up to 12 months after delivery, via manual de instruções em português, até 12 meses após a
internet, mail or fax. Refer to the order form in the back of entrega, através de Internet, correio ou fax. Consultar o for-
the book. mulário de encomenda no fim do manual.
All information is stored internally at AB Volvo Penta and will Todas as informações são armazenadas internamente pela
not be passed on to third parties. Volvo Penta e não são partilhadas com terceiros.
Diese deutsche Version dieses Handbuches kann Вариант настоящего руководства по

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per Brief oder per Fax bestellt werden. Bitte Bestellformular бесплатно в течение 12 месяцев после доставки по
hinten im Buch verwenden. Интернету, электронной почте или по факсу. См. бланк
Alle Angaben werden bei AB Volvo Penta gespeichert und заказа на обложке руководства.
nicht Dritten übermittelt. Вся информация используется компанией AB Volvo Pen-
ta конфиденциально и не передается третьим сторонам.
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la fin de ce document. muna bakınız.
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Volvo Penta et ne sont divulguées à aucun tiers. verilmez.
Hay disponible una versión en español gratuita de Een Nederlandse versie van dit instructieboek kan
este manual de instrucciones, la cual puede pedirse, a tra- kosteloos worden besteld tot 12 maanden na aflevering, in-
vés de Internet, correo postal o fax, en el plazo de 12 meses ternet, post of fax. Zie het bestelformulier achterin het boek.
después de la entrega del producto. Véase el formulario de Alle gegevens worden intern opgeslagen bij AB Volvo Penta
pedido en las últimas páginas del manual. en niet verstrekt aan derden.
Todos los datos recibidos son almacenados de forma in-
terna por Volvo Penta AB y no se ponen a disposición de
terceras partes.
CALIFORNIA PROPOSITION 65 WARNING

Engine exhaust, some of its constituents, and a broad range of engine parts are known to the State ofCalifornia to cause cancer, birth
defects, and other reproductive harm. Additionally, lubricants, fuels, andother fluids used in engines–including any waste created through
the wearing of engine parts–contain orproduce chemicals known to the State of California to cause cancer and birth defects or other
reproductiveharm.
Battery posts, terminals, and related accessories contain lead and lead compounds. Wash your hands afterhandling. Used engine oil
contains chemicals that have caused cancer in laboratory animals. Alwaysprotect your skin by washing thoroughly with soap and water.
Content
Foreword ...................................................................................................... 2
Safety Information ...................................................................................... 3
Introduction ................................................................................................. 8
Instruments and Controls ........................................................................ 10
Starting ...................................................................................................... 23
Operation ................................................................................................... 26
Engine Shutdown ...................................................................................... 28
Fault Handling ........................................................................................... 30
In Case of Emergency .............................................................................. 32
Maintenance Schedule ............................................................................. 33
Maintenance .............................................................................................. 37
Storage ....................................................................................................... 71
Technical Data ........................................................................................... 74
Alphabetical index .................................................................................... 79
1
Foreword
Thank you for purchasing this Volvo Penta Marine Genset/Marine Auxiliary Engine.
The Operator’s Manual contains operation instructions and maintenance and inspection information. In order to
ensure safety and bring out the maximum performance of the genset, do not operate it until you have read and
fully understood the contents of this manual. Also do not operate the genset unless in compliance with local
regulations.
For information on generator specific items refer to generator information supplied by generator manufacturer. In
case of contradictions, the information in this Volvo Penta Operator’s Manual overrules any information given in
the documentation provided by the generator manufacturer. Do not hesitate to consult your Volvo Penta dealer.
Failure to follow the instructions and cautions in this manual may result in serious accidents.
• Keep this manual at hand for easy reference.
• If this manual is damaged or misplaced, immediately order a new one from your dealer.
All information and illustrations in this manual are based on the specifications that were available at the time of
printing. This manual does not cover all available variants of accessories and options.
You will find your closest dealer at our home page on the Internet www.volvopenta.com - amongst other
useful information about your Volvo Penta engine - we invite you to visit!
2 47700366 09-2009
Safety Information
Read this chapter thoroughly. It concerns your safety. This section describes how safety information is presented
in this manual and on the product. It also includes a summary of basic safety regulations for operation and main-
tenance of the engine.
This Operator’s Manual is only valid for the genset/auxiliary engine built in the Volvo Penta factory. Make sure
you are in possession of the right operator’s manual before reading on. If this is not the case, please get in touch
with your Volvo Penta dealer.
If operations are performed incorrectly it could result in personal injury or damage to property or the engine. Read
the Operator’s Manual carefully before operating or servicing the engine. For safety information on genset oper-
ation and maintenance of a generator, refer to the documentation provided by the genset builder. If anything is
unclear please contact your Volvo Penta dealer for assistance.
!
This symbol is used in the Operators Manual and on the product, to call your atten-
tion to the fact that this is safety information. Always read such information very
carefully.
Safety texts in the Operators Manual have the following order of priority:
DANGER!
Indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING!
Indicates a hazardous situation which, if not avoided, could result in death or serious
personal injury.
CAUTION!
Indicates a hazardous situation which, if not avoided, could result in minor or mod-
erate personal injury.
IMPORTANT!
Indicates a situation which, if not avoided, could result in property damage.
NOTICE! Used to draw your attention to important information that will facilitate the
work or operation in progress.
This symbol is used on our products in some cases and refers to important infor-
mation in the Operators Manual. Make sure that warning and information symbols
on the engine are clearly visible and legible. Replace symbols which have been
damaged or painted over.
47700366 09-2009 3
Safety Information
Safety Regulations During Engine

Operation
The new engine Filling fuel

Read instruction manuals and other information There is a risk of fire and explosion when filling fuel.
accompanying the new genset throughly. Accustom Smoking is prohibited and the engine must be turned
yourself with handling the engine, controls and other off. Never overfill the tank. Close the filler cap
equipment in a safe and correct manner. securely. Use only fuel recommended in the operators
manual. The incorrect grade of fuel can disturb oper-
Accidents and other incidents ation or cause breakdown. This can also lead to the
control rod jamming on diesel engines, which will
Sea rescue statistics show that deficient maintenance cause the engine to overspeed and risk damaging
of vessels and engines together with defective safety machinery and causing personal injury.
equipment often causes accidents and other incidents
at sea.
Combustible enviroment
Make sure your genset engine are maintained in Due to the risk of fire and/or explosion, do not start or
accordance with directions in the instruction manuals continue to run the engine if there is a suspected leak
and that the safety equipment on board is in good or discharge of combustible media, e.g. fuel oil or
working order. LPG, in the engine surroundings.
Daily inspection
Make a habit of visually inspecting the engine and
engine room before starting and after stopping the
engine. This will help you to quickly detect any fuel,
coolant or oil leaks and any other abnormalities that
have occurred or are about to occur.
WARNING!
Accumulations of fuel, oil and grease on the engine or
in the engine room is a fire hazard and must be
removed immediately they are detected.
IMPORTANT!
If an oil, fuel or coolant leak is detected, the cause
must be investigated and the fault rectified before the
engine is started.
4 47700366 09-2009
Safety Information
Safety Directions for Maintenance

and Service
Preparations
Knowledge Lifting a genset
The operator’s manual contains directions for per- Always use the lifting eyes on the frame when lifting
forming normal maintenance and service in a safe a genset. Always make sure lifting equipment is in
and correct manner. Read the directions carefully good condition and constructed for the lift (engine
before starting work. More detailed service literature weight together with generator and extra equipment).
is available from your Volvo Penta dealer. Never per- Use an adjustable lifting boom to ensure safe han-
form a task unless you are absolutely sure how it is to dling when lifting the engine. All chains and wires
be carried out. When in doubt, contact your Volvo must run parallel with each other and as much at right
Penta dealer. angle as possible to the genset frame. Note that any
extra equipment mounted on the genset can change
Dress properly for the job! the center of gravity. Special lifting devices may be
Wear protective devices – hard hat, face shield, safety required to obtain the right balance and safe handling.
shoes, goggles, heavy gloves, ear protectors, etc. – Never perform service on an engine suspended only
for your own safety. from a lifting device.
Recommended fuel, lubrication oil and coolant! IMPORTANT!
Use of any other fuel oil, lurication oil or coolant than The genset and engine must only be lifted horizon-
the recommended can cause engine damage and tally.
reduce engine service life.
IMPORTANT!
Perform all recommended inspections! Engine lifting eyes are designed only for lifting an
Perform pre-start inspection and periodic inspection engine. Do not use the engine lifting eyes when lifting
on items listed in this manual. Failure to follow this a complete genset.
recommendation can cause serious engine damage.
Before starting
Stop the engine Refit all guards and covers that have been removed
Working on or approaching a running engine is a before starting the engine. Make sure there are no
safety hazard. Maintenance and service must be car- tools or other objects left on the engine. A turbo-
ried out with the engine stationary unless stated oth- charged engine must never be started without the air
erwise in the instructions. Prevent inadvertent start of filter fitted. The rotating compressor wheel in the tur-
the engine by disableing remote start and turning off bocharger can cause severe personal injury.
the power with the main switch, locking it in the off
position. Place warning signs stating that service is in There is also a risk of foreign objects being drawn in
progress in every position from which the engine can and causing mechanical damage.
be started.
47700366 09-2009 5
Safety Information
Fire and explosion Hot surfaces and fluids

Fuel and lubricants At operating temperature, the engine and its compo-
All fuels, most lubricants, and many chemicals are nents are hot. A hot engine always involves risk for
flammable substances. Always read and follow the burn injuries. Take care with hot surfaces. E.g.:
directions on the packaging. Work performed on the exhaust manifold, turbocharger, oil pan, charge air
fuel system must be done on a cold engine. Fuel leaks pipe, starting heater, hot coolant and warm lubricant
and spills on hot surfaces or electrical components in pipes and hoses.
can cause fires.
WARNING!
Keep oil- and fuel drenched rags and other hazardous
materials where they are safe in case of fire. Oil Do not open the crankcase covers while the engine is
drenched rags can selfignite in certain conditions. still hot.
Never smoke when refueling, topping up with oil or
Carbon monoxide poisoning
when in the vicinity of the fuel station or the engine
room. Start the engine in well-ventilated spaces only. When
running in confined spaces, the exhaust gases and
Non-original parts crankcase gases must be evacuated.
Components in fuel, lubrication, ignition and electrical
Chemicals
systems on Volvo Penta engines are designed and
manufactured to minimize the risk of explosion and Most chemicals such as glycol, anti-corrosion agent,
fire in compliance with existing legislation. preservatives, degreasing agent, etc., are hazardous
to health. Always read and follow the directions on the
The use of non-original parts can result in explosion packaging.
or fire.
Certain chemicals such as preservatives are flamma-
Batteries ble and harmful to inhale. Provide good ventilation
Batteries contain and generate oxyhydrogen gas, and use breathing protection when spraying. Always
especially when charging. Oxyhydrogen is easily read and follow the directions on the packaging. Store
ignited and extremely explosive. Smoking, open chemicals and other hazardous materials out of reach
flames and sparks must never occur in, or close to, of children. Leave left over or used chemicals to a
the batteries or battery compartment. A faulty battery destruction plant.
connection or jumper cable can generate sparks that
can cause the battery to explode.
Start spray
Never use start spray or similar start help. Explosions
can occur in the intake manifold. Risk for personal
injury.
6 47700366 09-2009
Safety Information
Cooling system Fuel system

There is a risk of water entering when working on the Always protect your hands when carrying out leak
seawater system. Therefore, stop the engine and detection.
close the seawater cock before starting work.
Escaping fluids under pressure can pierce bodily tis-
Avoid opening the coolant filler cap when the engine sue and cause serious injury. Risk of blood poisoning.
is warm. Steam or hot coolant may spurt out and Always cover any electric component if it is located
cause burn injuries. under the fuel filter. Otherwise it might be damaged
by fuel spills.
If the filler cap, coolant pipe, cock, etc., must never-
theless be opened or dismantled while the engine is Electrical system
warm, the filler cap must be opened carefully to
release the pressure before removing it completely Turn off the power before commencing work on the
and starting work. Note that the coolant can still be hot electrical system, the engine must be stopped and the
and cause burn injuries. powered turned off with the main switch/switches.
Shore power to the engine heater, battery charger or
Handle antifreeze carefully! other extra equipment fitted to the engine must be
Antifreeze contains alkali. Avoid contact with skin and disconnected.
eyes to prevent personal injury. Dispose of drained
antifreeze coolant according to local regulations. For Batteries
disposal, consult your dealer. Batteries contain a highly corrosive electrolyte. Pro-
tect your eyes, skin and clothing when charging and
Avoid burns and crushing or cutting! handing batteries. Always use protective goggles and
At operating temperature, the engine coolant is hot gloves.
and under pressure. Steam can cause personal injury.
Check the coolant level only after the engine has been In case of splashes on the skin, wash with soap and
stopped and the coolant filler cap has cooled enough plenty of water. In case of splashes in the eyes, rinse
to touch with your hand. Never adjust the V-belts while immediately with plenty of water and call a doctor.
the engine is running. Service batteries carefully!
If you spill electrolyte on yourself, flush skin immedi-
Lubricating system
ately with lots of water. Apply baking soda to help
Hot oil can cause burn injuries. Avoid skin contact with neutralize the acid. If electrolyte gets in your eyes,
warm oil. Make sure the lubricating system is depres- rinse immediately with large amounts of water then
surized before starting work. Never start or run the contact a doctor at once.
engine with the oil filler cap removed or there will be a
risk of the oil being thrown out.
47700366 09-2009 7
Introduction
This operator’s manual has been produced to give you the greatest benefit of your Volvo Penta Marine Genset/
Marine Auxiliary Engine. It contains the information necessary to handle and maintain your genset/engine in a
safe and correct manner. We would like you to read this operator’s manual thoroughly and learn how to handle
the genset, engine, controls and other equipment in a safe manner before operating the genset/engine.
Keep the operator’s manual within reach at all times.
Care of the environment Fuel and oil

We would all like to live in a clean and healthy envi- Use only fuel and lubrication oil grades recommended
ronment. An environment where we can breathe in the technical data section of this Operator’s Man-
clean air, see healthy trees, have clean water in our ual. Other grades can cause operational problems,
lakes and oceans, and enjoy the sunshine without increase fuel consumption and have long-range
being worried about our health. Unfortunately, this effects on engine service life.
cannot be taken for granted nowadays but it is some-
thing we must work together to achieve. Service and spare parts
As a manufacturer of marine engines Volvo Penta has Volvo Penta marine engines are designed for high
a special responsibility. That is why care of the envi- operational reliability and long service life. They are
ronment is a core value in our product development. constructed to withstand the marine environment
Volvo Penta has a broad range of engines where while affecting it as little as possible. Through regular
progress has been made in reducing exhaust emis- service and the use of Volvo Penta original spare
sions, fuel consumption, engine noise, etc. We hope parts, these qualities will be retained.
you will take part in preserving these qualities.
The worldwide Volvo Penta network of authorized
Always follow any advice given in the operator’s man- dealers is at your service. They are specialists in
ual concerning fuel grades, operation and mainte- Volvo Penta products and stock accessories, original
nance and you will avoid causing unnecessary inter- spare parts, test equipment and the special tools
ference to the environment. Get in touch with your required to perform high-quality service and repairs.
Volvo Penta dealer if you notice any changes such as
increased fuel consumption and/or exhaust smoke. Always follow the maintenance intervals specified in
the operator’s manual and remember to specify the
Adapt speed and distance to avoid wash and noise engine number when ordering service and spare
disturbing or injuring animal life, moored boats, jetties, parts.
etc. Leave islands and harbours in the same condition
as you want to find them. Remember to always leave
hazardous waste such as waste oil, coolant, paint and
wash residue, flat batteries, etc., for disposal at a
destruction plant. Our joint efforts will make a valuable
contribution to our environment.
8 47700366 09-2009
Introduction
Certified Engines
It is essential that owners and operators of emission certified engines, used in areas where exhaust emissions
are regulated by law, are aware of the following points:
A certification involves the engine type being checked and approved by applicable authorities. Engine manufac-
turers guarantee that all engines of the same type correspond with the certified engine.
This puts special demands on the maintenance and service of your engine:
• Maintenance and service intervals recommended by Volvo Penta must be followed.
• Only Volvo Penta original spare parts may be used.
• Service of injector pumps, pump settings and injectors must always be performed by an authorized Volvo
Penta service person.
• The engine must not be modified in any way with the exception of accessories and service kits approved
by Volvo Penta for use on the engine.
• Installation modifications must not be made to the engine exhaust pipe or inlet channels.
• Sealed sections must not be broken by anyone other than authorized personnel.
Otherwise, general directions concerning running, care and maintenance given in the operator’s manual apply.
IMPORTANT!
Neglected or deficient maintenance/service and the use of non-original spare parts will entail Volvo Penta
renouncing any responsibility for the engine corresponding to the certified version. Volvo Penta will not compen-
sate for damage and/or costs arising from the above.
Warranty Information
Your new Volvo Penta Marine Genset is covered by a limited warranty complying with the conditions and instruc-
tions given in the Warranty and Service Book.
Note that AB Volvo Penta’s responsibility is limited to what is specified in the Warranty and Service Book. Read
it carefully as soon as possible after delivery. It contains important information concerning the warranty card,
service, maintenance and what the owner is responsible to be aware of, check and perform. AB Volvo Penta will
otherwise decline warranty liability completely or fully.
Get in touch with your Volvo Penta dealer if you have not received a Warranty and Service Book or a copy
of the warranty card.
47700366 09-2009 9
Instruments and Controls
MCU (Marine Control Unit)

This chapter describes functions and operation of the
Marine Commercial Control system (MCC) and the
MCU (Marine Control Unit).
MCC (Marine Commercial Control

System)
Applications and Modes
The MCC system can be configured for different appli-
cations. Auxiliary (AUX), Emergency (EME), Com-
bined (CMB) and Propulsion (PRP). The difference lies
in the configuration file for the software and in the con-
nections between the MCU and SDU. In each applica-
tion the system operate in a number of modes.
Application Modes Interface to start/stop the engine Note

Auxiliary OFF-AUX Blackout start on terminal Blackout start will give the number
Start on terminal of start attempts specified in the set-
Stop on terminal point “Crank attempts”. Default is 3
Start button on MCU and RP start attempts, for unlimited, set to
Stop button on MCU and RP zero (0).
Emergency OFF-EME Blackout start on terminal Blackout start will give unlimited
Start on terminal number of start attempts. Default is
Stop on terminal 3 start attempts, for unlimited, set to
Start button on MCU and RP zero (0).
Stop button on MCU and RP
Combined OFF-EME-HRB In EME Mode Blackout start will give unlimited
Blackout start on terminal number of start attempts. Default is
Start on terminal 3 start attempts, for unlimited, set to
Start on terminal zero (0).
Start button on MCU and RP
In HRB Mode Blackout start inactive.
Start on terminal Controller operates like in AUX
Start on terminal mode.
Propulsion OFF-PRP Start on terminal Only on variable speed engines.
Stop on terminal Blackout start inactive.
10 47700366 09-2009
MCC system, Overview
1 Connection box, engine room

2 Relay board – Rb16 (16 relays)
3 COM
4 MCU
5 SDU
6 External connections: Relay,
Modbus, CAN/J1939
7 Remote panel
8 Remote panel
9 CAN2/RS232
10 CAN2
11 Redundancy bus: J1708/J1587
12 Data bus: CAN/J1939
13 Engine Control System
14 PM
15 EMS
16 Shutdown Senders & Switches
P0010297 a Press. switches
b Temp. switches
c RPM sender
47700366 09-2009 11
Terminology
MCC Marine Commercial Control, name of the over all system.
MCU Marine Control Unit, the central control unit of the system.
SDU Shutdown Unit, for engine protection. Activates a fuel shut-off valve to shut down
the engine. Separated from the engine control system. All functions hard wired.
COM Communication Module, for J1708/J1587 and CAN2 bus (for RP and other exten-
sion modules).
RP Remote Panel, additional display panel for remote monitoring.
EMS Engine Management System monitors engine status and handles engine speed
and torque governing and overall control of fuel injection and emission control
algorithms.
PM Power Module, handles power distribution and power management. It also moni-
tors power supply and switches to secondary power.
12 47700366 09-2009
MCU (Marine Control Unit)

MCU Panel Layout
P0010298
1 LCD display
2 Horn reset (stops sound alarm)
3 Mode Left, toggles modes backwards [Off - AUX(EME,HRB,PRP)]
4 Mode Right, toggles modes forwards [Off - AUX(EME,HRB,PRP)]
5 Start button
6 Stop button
7 LED – Engine running
8 Up button (Select and Increase)
9 Down button (Select and Decrease)
10 Enter (confirmation of selection)
11 Page, toggles screens (Measurement - Adjustment - History)
12 LED – Active alarm
(Blinking light when new alarm is activated. Steady light when alarm is active but confirmed.)
13 Acknowledge button
47700366 09-2009 13
Display
A Highlighted indicates OFF-mode
B Highlighted indicates operational mode
AUX (EME, HRB or PRP)
C Indicates Local mode
D R – Remote connection
(Slave Panel or PC Software)
L - Access lock
E ! – Active alarm
F Engine state (NotReady - Ready - Running)
P0010299
14 47700366 09-2009
Menu Structure
There are 4 display menus available:
Main
Measurement
Adjustment
History
A B C D
OFF AUX LOC F Engine speed 1500 No. reason Date Time
1 1 Password UP 1 1
0 Fault Reset 25/02/05 12:34:49.6 2
NotReady PAGE Exhaust temp 326 PAGE Basic Settings(2)
Engine Params(3) PAGE 1 CAN control 25/02/05 12:34:49.5
Oil press 2 Wrn SDU Syst Fa: 25/02/05 12:34:25.3
Boost pressure 1,8 bar Engine Protect(4) 3 Wrn SDU Syst Fa: 25/02/05 12:33:55.7
3.68 bar Act.call/SMS(5) DOWN 4 Wrn SDU Syst Fa: 25/02/05 12:33:46.4
Cool temp Engine OilTemp 77 C Date/Time(6) ENTER 5 Wrn SDU Syst Fa: ENTER 25/02/05 12:26:11.3
0 RPM 75 C
to select 25/02/05 12:34:49:6 0 Faultreset
UP DOWN UP DOWN
Finespeed adj/Throttle input Load Enter Password
2 2 UP 2
Fuel cons Change Passw1
PAGE PAGE
Actual lorque Change Passw2
DOWN
Demand Torque Change Passw3 ENTER
to select
UP DOWN UP DOWN
Fuel Press Enter name
3 3 UP 3
Battery 11, PAGE Throttle Pos PAGE Engine number
Crankcase Pres bar Mode ID

DOWN
No Timer Demand Torque bar More below... ENTER
to select
UP DOWN UP DOWN
Coolant Temp Coolant Temp Starting RPM
4 UP 4
Oil pressure 4
Coolant Pres Oil Press Sterting Poil
Overspeed PAGE PAGE
UP/DOWN ARROW
SD System Fall Prestart Time

SDOverride/Harbour Mode DOWN
Idle More below... ENTER
to select
UP DOWN UP DOWN
Start Blocking Running Horn timeout UP
Acknowledge 5 MalFunctLamp 5 5
PAGE RedStopLamp PAGE RunOnlyBlkDel1
UP/DOWN ARROW
Droop
Stert Not Used In4
Stop Not Used In5 RunOnlyBlkDel2 DOWN
Blackout Start Not Used In6
Not Used Not Used In7 More below... ENTER
Not Used In8 to select
UP DOWN UP DOWN
SD Reset Not Used In9 Warning call UP 6
SD Override/Harbour Mod 6 Not Used In10 6
Engine Running Not Used In11 Shutdown call
Ready to Start PAGE Not Used In12 PAGE
Ready to Load Not Used In13 DOWN
Cooldown call
Common Alarm Not Used In14
Common SD Not Used In15
ENTER
More below...
Not Used In16 to select
UP DOWN UP DOWN
EMS Comm Fail Start Request Time UP
MCU Alive 7 Stop Pulse 7 7
Horn PAGE IdleSpeed PAGE Date
Not Used 11 Droop
Not Used 12 Freq Select Time stamp per
Not Used 13 Not Used Out6
DOWN
Not Used 14 Not Used Out7 ENTER
Not Used Out8 to select
UP DOWN UP DOWN
Run Hours 336 Not Used Out9
Num SuccStarts 9 7 Not Used Out10 8
Num UnscStarts 24 Not Used Out11
PAGE Not Used Out12
Service Time 3640 n Not Used Out13
Not Used Out14
Not Used Out15
Not Used Out16
UP DOWN
ECU Alarmlist
J1939 Datalink 8
J1939 Sync
J1587 Throttl Fls
PAGE
Fc393417 OC 5 FMI 9
UP DOWN
Alarmlist
*Wrn SD Syst Fail 7
ECU AlarmList
*Wrn SD Syst Fail
PAGE
P0010330
16 47700366 09-2009
Main page (A) Adjustments (C)

A1. C1.
The main page of the system. Most important param- Menu for change of setpoints. Navigate with up and
eters are shown. Mode change is possible. down arrows - select with Enter.
A2. C2.
Displays analogue parameters measured by the Enter and change passwords. Most setpoints are
MCU. In standard configuration only Throttle input password protected to avoid accidental changing.
(PRP) and Finespeed input (AUX,EME,CMB) Password 1 in standard configuration.
A3. C3.
System voltage information measured by the MCU. Page for changing basic settings of the systems, e.g
governor mode and speed select.
A4. & A5.
Status of MCU 14 digital inputs. C4.
0 – input inactive Page for changing Engine parameters settings. Refer
1 – input active. to section ”MCU adjustments” for details.
Inverted 0 or 1 indicates alarm due to current status.
C5.
NOTICE! Pages can be used to verify interface to Page for changing parameters concerning MCU
superior system. Activate signal from superior system engine protection functionality.
and monitor input state change.
NOTICE! In the MCC system engine protection func-
A6. & A7. tionality is handled by the SDU. Changing these set-
Pages display status of MCU 14 digital outputs. points will not affect the SDU.
0 – input inactive
1 – input active. C6.
Changing setpoints concerning MCU telematics func-
A8. tionality.
Statistic information. Run hours of the engine, No. of
successful start, etc. NOTICE! Telematics functionality is not supported by
Volvo Penta. Refer to http://www.huegli-tech.com.
A9.
C7.
Page displays alarms origining from Engine Manage-
ment System (EMS) and Power Management System Page or changing date and time.
(PM). Navigate alarmlist with Enter button.
A10.
Displays alarms from the Shutdown system (SDU)
and MCU. Navigate alarmlist with Enter button.
NOTICE! Engine cannot be started with active or

unacknowledged SD.
Measurement (B) History (D)

B1.–B4. D1.
Pages display monitoring values from (EMS). Displays previous actions/alarms. Enter button for fur-
ther information(D2).
B5. & B6.
Used by Volvo Penta service technicians. EMS to
MCU CAN-bus information.
B7. & B8.

Used by Volvo Penta service technicians. MCU to
EMS CAN-bus information.
47700366 09-2009 17
Main
Press PAGE button to toggle the menu screens. Select
MAIN page (A1). Use UP/DOWN buttons to toggle the
different screens.
Alarm list
ECU (Engine Control Unit) alarm list and Alarm list are
the last two screens in the MAIN page (A1).
P0010306
Select MAIN page (A1). Press UP button (twice for
ECU list).
This will list all active alarms (number of alarms indi-

cated in the upper right corner). Highlighted alarms are
still active. The other alarms are not active but not yet
acknowledged.
NOTICE! In case of multiple alarms, scroll alarmlist

using ENTER button.
ACKNOWLEDGE button acknowledges all alarms.

Non-active alarms disappears from the list.
Alarm list appears on the screen when a new alarm is

set and MAIN page (A1) is active.
NOTICE! Alarm list is not activated when you are view-

ing values, parameters or history.
Three state Alarm list indication

1 Active not acknowledged alarm
2 Active acknowledged alarm
3 Inactive not acknowledged alarm
A Number of alarms
P0010307
Statistics
Select MAIN page (A1). Press UP button three (3)
times.
1 Running hours
2 Successful starts
3 Unsuccessful starts
4 Service time (hours to service)
Statistic values can be adjusted from PC software

(password protected), contact your Volvo Penta
P0010308
dealer.
18 47700366 09-2009
Measurement
Press PAGE button repeatedly to toggle the menu
screens. Select MEASUREMENT view (B1). Use UP/
DOWN buttons to toggle the different screens.
Adjustment
In the Adjustment view it is possible to view and edit
setpoints. For a complete list of setpoints, see Set-
points page 20
1 Press PAGE button repeatedly to scroll the menu
screens. Select ADJUSTMENT screen.
P0010302
2 Use Up and Down buttons to toggle the different set
points group.
3 Press ENTER to confirm.
4 Use Up and Down buttons to select requested set
point. Set points marked “*” are password pro-
tected.
5 Press ENTER to edit.
6 Use Up and Down buttons to modify the set point.
When Up or Down button is pressed for 2 sec, auto
repeat function is activated.
7 Press ENTER to confirm or PAGE to leave without
change. Press PAGE to leave selected set points
group.
History
1 Press PAGE button repeatedly to scroll the menu
screens. Select the HISTORY screen.
2 Use Up and Down buttons to select the requested
record.
3 Press ENTER to select requested screen (record
P0010302
items) within displayed records.
Alarm list and History record prefixes
Prefix Meaning
Wrn Warning
Sd Shutdown
Fls Sensor fail
P0010309
47700366 09-2009 19
Setpoints
Below is a list of setpoints used in the system. The
setpoints are grouped as:
- Basic settings
- Engine parameters
- Engine protection settings
- Active calls/SMS settings
- Date/Time settings
This is how they appear in the MCU menu.
NOTICE! An “N” in column “Customer edit allowed”

implies that the setpoint MUST NOT be edited by cus-
tomer.
Basic settings
Setpoint Unit Note Edit
(if appli- allowed
cable) (Y/N)
Engine name User defined name for identification at remote (phone/mobile) con- N
nection. Max. 14 characters long.
Engine no. Visible in INFO view N
Mode ID Defines operational MODE N
Gear teeth Number of teeth on flywheel N
Nominal rpm RPM Nominal engine speed. Used to calculate overspeed protection limit N
and requested RPM %.
Gov. mode Activates/Deactivates logical binary output DROOP SW that can be N
configured to switch ECU mode
Idle/Nominal Activates/Deactivates logical binary output NOMINAL SW that can be N
configured to switch ECU mode
Speed select Activates/Deactivates logical binary output SECONDARY SW that N
can be configured to switch ECU mode
ECU diag Alarm list indication N
Contr. Addr. Controller identification number. Can be edited by user when two or Y
more MCU:s are connected, i.e. Propulsion EMS.
RS232 mode RS232 mode is default and must be used when downloading soft- Y
ware. Must be set to MODBUS if that is used.
CAN mode CAN bus speed selection. Default is Low Speed CAN (50 kbps), max. Y
bus length is 900 meters.
LightTimeOff min Time Out for automatic backlight switch off. Setpoint to 0 will give Y
backlight continously. Backligt is automatically switched on at the
touch of a button or any system event.
MODBUS bps MODBUS interface speed selection Y
20 47700366 09-2009
SDU (Shutdown Unit)
Engine imputs Control switch inputs Outputs

Shutdown Shutdown
override reset
(OR) (SR)
Shutdown
fuel valve/stop relay
(82,82,42)
Shutdown override
Switches lamp
(S1-S5) 6x (SL,2)
SDU
(2)
Sender Shutdown alarms
(S6) (7,8,9,10,11,12)
Speed Overspeed alarm

sender (OS)
(65,66,2)
Broken wire
common alarm
(SF)
Power supply
(1,2)
Power Module
P0008401
Overview
The SDU has six shutdown channels and one over- Emergency mode (shutdown override)
speed shutdown. The system can be overridden by activating the OR
S1 – Cooling water temperature input (the Emergency mode lamp, when installed on
output SL, will be activated). Override does not include
S2 – Lubricating oil pressure, marine gear overspeed.
S3 – Lubricating oil pressure, engine
Run detection
S4 – Cooling water pressure To avoid alarms when starting and stopping the engine
S5 – Oil temperature an interlock for the shutdown pressure switches (run
detection) is implemented.
S6 – Exhaust temperature
Broken wire
Shutdown reset All channels are equipped with broken wire detection
Activated shutdown must be reset before engine can that activate an alarm if connection is lost or power
be restarted. Shut down reset button on engine con- supply to SDU is lost.
nection box. Yellow LED indicates broken wire. Reset alarm on but-
ton “Broken wire reset”, see SDU control panel.
Overspeed shutdown
The overspeed function shuts down the engine in case
of overspeed.
Overspeed test
To test overspeed function push the overspeed test
button (inside the SDU). When pushed the overspeed
limit drops 25%. NOTICE! Only use Volvo Penta tool supplied with SDU
for reset.
47700366 09-2009 21
SDU Indications
P0008400
1 Green – Power A Broken wire reset button

2 Red – Overspeed Alarm B Yellow – Fuel valve wire detected
3 Yellow – Run dectection S4 C Yellow – Speed sender Broken wire detected
4 Green – Run detection S2, S3 D Yellow – S6 Broken wire detected
5 Red – S6 Shutdown active E Yellow – S5 Broken wire detected
6 Red – S5 Shutdown active F Yellow – S4 Broken wire detected
7 Red – S4 Shutdown active G Yellow – S3 Broken wire detected
8 Red – S3 Shutdown active H Yellow – S2 Broken wire detected
9 Red – S2 Shutdown active I Yellow – S1 Broken wire detected
10 Red – S1Shutdown active J Overspeed shutdown test button
22 47700366 09-2009
Starting
First Service Inspection
General
Before starting a new or reconditioned genset for the first time, give it an initial inspection. This to guarantee your
own safety as well as the maximum service life of the genset.
External inspection Valves and plugs

1 Check the control system for loose terminals. IMPORTANT!
2 Check defects of engine parts. If the coolant drain cocks are not closed the coolant
will drain from the engine and this may cause severe
3 Check the following components for loose bolts damage to the engine.
or nuts: Make sure the following valves and plugs are open or
closed properly:
• Plugs and covers of fuel, lubrication and cool-
ing system Fuel supply valve Open
Coolant drain cocks Closed
• Coupling of fuel injection pump and shaft
• Mounting brackets Electrical wiring
• Fuel control link Check for loose or damaged electrical wiring on the
engine and on the generator. If necessary firmly
• Turbocharger reconnect to terminals or cable-joint portions. Dam-
aged cables must be replaced.
• Timing gear case
If your genset is reconditioned, make sure the wiring
• Exhaust manifolds is according to the drawings.
• Cylinder heads
Filling fuel system
• Air-duct connection-hose clamp
Refer to chapter Maintenance page 48.
• Flexible coupling from engine to generator
Filling lubrication system
4 Check for fuel, oil, coolant and air leaks and
repair if needed. Refer to chapter Oil level, checking and topping
up page 45.
5 Make commissioning report for new or over-
hauled engine.
Filling cooling system
IMPORTANT! Refer to chapter Cooling System.
All covers on engine and generator must be mounted
before attempting to start your genset. Generator
Refer to manual supplied by generator manufacturer.
47700366 09-2009 23
Starting
Before Starting
Learn how to handle the engine, controls and other
equipment in a safe and correct manner before starting
the engine.
Make sure you know how to stop the genset before

starting it (in case of emergency). If the genset is
started for the first time, be prepared to stop the engine
immediately in case abnormal noise should occur dur-
ing start up.
WARNING!
Before starting the genset make sure people and tools
are out of contact with moving parts of the engine or
the generator. Notify people in the vicinity of the genset
when starting.
IMPORTANT!
Always keep the engine room well ventilated. Insuffi-
cient airsupply to the engine means imperfect com-
bustion and loss of power.
IMPORTANT!
If the starter motor has been engaged for the maximum
time (30 seconds), it must be allowed to cool down for
at least one minute before a new attempt is made at
starting.
24 47700366 09-2009
Starting
Starting the Engine
Warming-up
CAUTION!
Do not conduct warm-up operation for an extended
period of time. Prolonged warm-up operation causes
carbon build-up in the cylinders that leads to imperfect
combustion.
NOTICE! To warm up the engine operate at no load

for a short time and then apply a low load.
NOTICE! If the lubrication oil pressure does not

increase when you have started the engine, immedi-
ately stop the engine and do not restart until the prob-
lem has been fixed.
NOTICE! Make sure that the cooling water flow is suf-

ficient.
Starting the Engine

1 In MAIN menu, select mode of operation (AUX,
HRB, EME, PRP) (refer to chapter MCC (Marine
Commercial Control System) page 10, sec-
tion ”Applications and Modes”) using MODE button
(left or right) (A).
2 Make sure engine status is ”Ready” (B).
3 Press START button and the engine state should
change to ”Running” (C).
Operational data
Monitor engine data not visible in the MAIN screen:
1 Use PAGE button to select MEASUREMENT
menu.
2 Use UP and DOWN arrows to select wanted engine
data.
P0010310
47700366 09-2009 25
Operation
General
WARNING!
Working with or going close to a running engine is a
safety risk. Watch out for rotating components and hot
surfaces.
IMPORTANT!
Do not turn OFF the battery switch when the engine is
running since this may damage the alternator.
IMPORTANT!
Do not push the START button when the engine is
running, this may damage the starter.
Applying Load
IMPORTANT!
Avoid overloading. This can cause incomplete fuel
combustion often indicated by black exhaust, high fuel
consumption and carbon deposits in combustion
chambers, affecting genset life.
If possible, do not apply heavy loads until the engine

has reached operating temperature.
During load operation make sure that:

1 No engine related alarms occur.
2 There are no visible leaks of fuel, lube oil, coolant
or exhaust gas
3 No abnormal noise or vibrations occur.
4 The color of the exhaust gas is normal.
5 Instrument readings are normal, refer to chapter
Technical Data.
26 47700366 09-2009
Operation
Alarms
Alarms are shown in two different screens depending
on the origin of the alarm.
Alarms detected by the EMS or PM are shown in the

ECU alarm list and alarms generated in the SDU or the
MCU are shown in a separate alarm list.
1 Press HORN RESET button to silence the alarm.
To view active alarms:
2 In MAIN view, press UP arrow once for SDU/MCU
alarm list and twice for ECU alarm list.
P0010311
3 In case of multiple alarms, scroll alarmlist using
ENTER button.
4 Press ACKN. button to acknowledge all alarms.
NOTICE! Alarm item will stay in alarm list until

acknowledged and made “not active” (fault rectified).
P0010312
47700366 09-2009 27
Engine Shutdown
General
Let the genset run at no load for a couple of minutes
before turning it off. This will keep the engine temper-
ature in balance and prevent it from boiling.
IMPORTANT!
The procedure described above is especially important
if the genset has been run at heavy loads.
IMPORTANT!
If the genset stops abnormally, try to locate the prob-
lem and make the repairs needed before starting
again. After starting the genset, make sure it runs prop-
erly.
Stop the Engine

1 Press and hold STOP button until the rpm starts
decreasing (approx. 1 s).
2 Make sure rpm indication decreases to 0 and
engine state returns to ”Ready”.
Emergency Stop Switch
If the engine can not be stopped by the engine control

system, the engine can be stopped as follows:
Push the emergency stop button.
If the engine cannot be stopped with the emergency

stop button, shut off the fuel supply or block the air
intake to the turbocharger.
NOTICE! If the engine has been stopped with the

emergency stop button, the button has to be reset (pull
it upwards) before the engine can be started again.
P0005904
28 47700366 09-2009
Engine Shutdown
After Engine Shutdown

General
• Check the genset and engine room for leaks.
• Close the fuel cock and seawater cock.
• Read off the hour counter and carry out preventive
maintenance according to the maintenance sched-
ule.
• Turn off the main switch if the genset is not to be
used for a long period.
IMPORTANT!
Never turn the power off using the main switch while
the genset is running. This can damage the alternator.
IMPORTANT!
Make sure the generator heater is working properly to
avoid condensation in the generator.
Anti-freezing measures
If the engine room cannot be protected from frost, the
seawater system must be drained and the coolant in
the freshwater system must contain sufficient anti-
freeze to prevent it from freezing. Refer to chapter
Cooling System.
WARNING!
If the raw water system bursts due to freezing, the ves-
sel could sink.
IMPORTANT!
If the coolant does not give sufficient anti-freeze pro-
tection, it may cause costly damage to the engine.
Check the charge of the battery. A poorly charged bat-
tery can freeze and break.
Breaks in operation [not using the engine]

During periods out of service, when the boat is in the
water, the engine must be run warm once a fortnight.
This will prevent the engine from corroding.
IMPORTANT!
The engine must be conserved if it is not to be used for
longer than two months. Refer to chapter Gen-
eral page 71.
47700366 09-2009 29
Fault Handling
Fault Tracing
A number of symptoms and possible causes of engine malfunctions are described in the table below. For gen-
erator specific troubleshooting, refer to generator documentation. If faults or hitches arise that you cannot solve
alone, you must always get in touch with your Volvo Penta dealer.
NOTICE! Read through the safety advice for care and maintenance work in the Safety precautions for mainte-
nance and service operations chapter before starting work.
NOTICE! Dust and foreign particles are the most common cause of excessive wear of parts. When disassembling
a component, take measures to prevent dust and foreign particles from entering it.
NOTICE! If the engine will not start, make sure the emergency stop button is reset.
Symptoms and possible causes
Starter motor does not rotate when cranking 1, 2, 3, 4, 6, 7, 49

Starter motor rotates slowly when cranking 1, 2, 15, 42
Engine does not start 5, 13, 14, 16, 17, 19
Engine starts but stops again 5, 13, 14, 16, 17, 19, 44, 45
Engine does not reach full operating speed at full throttle 5, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 24, 27, 29, 43
Engine runs unevenly 5, 9, 10, 16, 17, 19, 20, 44
Engine knocks 14, 20, 45
Engine vibrates 10, 16, 24, 25, 30
Engine can not be stopped 1, 2, 3, 4, 46
High fuel consumption 8, 10, 12, 13, 14, 19, 21, 24
Black or Dark gray exhaust smoke 8, 10, 11, 12, 13, 14, 19, 21
Blue or white exhaust smoke 10, 12, 13, 14, 15, 21, 24, 37, 38, 44
High lubrication oil consumption 15, 23, 24, 25, 38
Lubrication oil pressure too low 15, 22, 26, 39, 40
Coolant temperature too high 27, 28, 31, 32, 33, 34, 35, 36, 37, 47
Coolant temperature too low 36
No charge or poor charge 1, 2, 41
1. Flat batteries
2. Poor contact/open circuit in cables
3. Main switch turned off
4. One of the circuit breakers in the distribution box has tripped
5. Lack of fuel:
- fuel taps closed
- fuel tank empty
- wrong tank connected
6. Defective Power Module
7. Faulty starter motor/solenoid
8. Defective fuel supply pump
9. Blocked fuel injectors
10. Defective fuel injectors
11. Incorrect valve clearance
12. Incorrect fuel injection timing
30 47700366 09-2009
Fault Handling
13. Low compression pressure

14. Improper fuel oil
15. Improper lubrication oil
16. Air in fuel system
17. Water/contamination in fuel
18. Engine speed control wrongly adjusted
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 ventilation
20. Excessive coolant temperature
21. Too low coolant temperature
22. Too low lubrication oil level
23. Lubrication oil leakage
24. Worn cylinder liners and/or piston rings
25. Worn valve stem seals
26. Blocked lubrication oil filter
27. Radiator blocked
28. Blocked heat exchanger insert
29. Blocked aircooler
30. Faulty engine mounting
31. Coolant level too low
32. Air in the freshwater system
33. Blocked seawater inlet/pipe/filter
34. Defective impeller in seawater pump
35. Circulation pump drive belt slips
36. Defective fresh water pump
37. Defective thermostat
38. Too high lubrication oil level
39. Defective lubrication oil pump
40. Defective relief valve
41. Alternator drive belt slips
42. Defective bearings/abnormal cylinder friction
43. High back pressure in exhaust system
44. Very cold engine and lubrication oil
45. Abnormal load
46. Engine consume lubrication oil or combustible gas
47. Cylinder liner have scalings or such that reduce cooling effect
48. Alternator/Rectifier broken
49. Water entry into engine
47700366 09-2009 31
In Case of Emergency
Starting Using Auxiliary

Batteries
WARNING!
Explosion hazard. Batteries contain and give off an
explosive gas which is highly flammable and explosive.
A short circuit, open flame or spark could cause a vio-
lent explosion. Ventilate well.
WARNING!
Never confuse the positive and negative poles on the
batteries. Risk of arcing and explosion.
P0002107 1 Check that the auxiliary battery has the same volt-
age as the engine system voltage.
2 Connect the red positive cable to the plus (+) ter-
minal on the discharged battery and then to the plus
terminal on the auxiliary battery.
3 Connect the black start cable to the minus (–) ter-
minal on the auxiliary battery and to a place a little
distance away from the discharged battery, e.g. the
start motor's negative terminal.
WARNING!
Under no circumstances may the black jumper cabel
(–) come in contact with the positive connection on the
starter motor.
4 Start the engine and let it run at fast idle for approx-
imately 10 minutes to charge the batteries. Make
sure there is no extra equipment connected to the
electrical system.
WARNING!
surfaces.
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 the

exact opposite order to their connection.
32 47700366 09-2009
Maintenance Schedule
General
Your Volvo Penta engine and associated equipment Fluids
is designed to provide high operational reliability and It is also important to keep record of the fluids used in
long service life. They are constructed to withstand the engine. If brand or type of fuel, lubrication oil or
the marine environment while also affecting it as little coolant is changed this should be recorded.
as possible.
Warranty inspection
Preventive maintenance in accordance with the main-
The prescribed warranty inspection “First Service
tenance schedule will ensure that it retains these
Inspection” must be carried out at an authorized Volvo
qualities and avoid unnecessary operational distur-
Penta workshop during this first period of operation.
bances. The following chapters contain general tech-
Directions for when and where this is to be carried out
nical information and directions for carrying out the
can be found in the Warranty and Service Book.
prescribed maintenance points. Read the directions
carefully before starting work.
WARNING!
The maintenance schedule shows the standard serv-
Read the safety precautions for maintenance and
ice intervals. When you think the engine should be
service in the section entitled “Safety Information”
serviced more frequently due to particular operating
before starting work.
conditions, adjust the intervals accordingly. Appropri-
ate service intervals vary with usage and operating
conditions and with fuel, lubricant and coolant used. WARNING!
Due to particular operating conditions the service Care and maintenance work should be done with the
intervals may be adjusted accordingly. Consult your engine stopped unless otherwise specified. Stop the
Volvo Penta dealer. engine before opening or removing the engine hatch/
NOTICE! Dust and foreign particles are the most hood. Make it impossible to start the engine by
common cause of excessive wear of parts. When dis- removing the start key and cutting the system voltage
assembling a component, take measures to prevent with the main switches.
dust and foreign particles from entering it.
Daily operation records WARNING!

It is recommended to keep daily operation records. Place warning signs stating that service is in progress
Daily recording is a preventive maintenance program in every position from which the engine can be
and when comparing values with engine history it will started.
help you recognize conditions, signs or indications of
IMPORTANT!
approaching trouble. Daily operation records also
make trouble shooting easier and will lessen the down Handle parts carefully. Use only original Volvo Penta
time (to save time and money for servicing). spare parts.
NOTICE! When both operating time and calendar
Maintenance records time is given, the one occurring first is to apply.
Volvo Penta recommends that accurate maintenance NOTICE! For generator related maintenance infor-
records are kept. With accurate maintenance records mation, refer to Generator Manufacturers information.
your Volvo Penta Dealer can help in fine tuning the
recommended service intervals to meet the specific
operating situation. This should result in a lower
engine operation cost.
47700366 09-2009 33
Recommendation of Daily
Operation Records
Daily recording is a preventive maintenance program
and when comparing values with engine history it will
help you recognize conditions, signs or indications of
approaching trouble. Daily operation records also
make trouble shooting easier and will lessen the down
time (to save time and money for servicing).
Items to be recorded
The following items are recommended to be recorded
once a day:
1 Operating hours.
2 The amount of lubrication oil and coolant (fresh
water) required for refilling. Fuel consumption.
3 Lubrication oil and coolant (fresh water) changes.
4 Lubrication oil pressure and temperature, engine
P0007709
rpm, exhaust temperature, coolant temperature,
and charge air temperature and pressure.
5 Rawwater pressure and rawwater temperature
before and after heat exchanger. Ambient temper-
ature and engine room temperature at turbo
charger inlet.
6 Parts serviced and kinds of service (adjustment,
repairs or replacement).
7 Change in operating conditions (for example,
“Exhaust smoke turned black,” etc.)
34 47700366 09-2009
Service Schedule
C = Clean
R = Replace
A = Adjust
L = Lubricate
I = Inspect (Clean, Adjust, Lubricate or Replace if necessary)
A Daily, Before First Start

Engine and engine room. General inspection I
Pressure drop indicator, air filter I
Oil level I
Coolant Level I
Fuel pre-filter / Water separator filter(1) I
Fuel Tank (sludge trap), Drain I
Fuel Filters, Drain I
B Weekly
Batteries, electrolyte level I
Electrical System I
Engine Mountings I
Check engine oil for abnormal smell or water I
C Every 50-400 Hours / at Least Every 12 Months

Crankcase Ventilation, Filter Change R
Engine Oil and Oil Filters / By-pass filter(2)(3) R
D Every 400 Hours / at Least Every 12 Months

Drive Belts I
Zinc anodes IR
E Every 800 Hours / at Least Every 12 Months

Valve clearance(4) I
Heat exchanger(4) IC
Radiator IC
Seawater filter IC
Fuel pre-filter / Water separator filter R
Fuel fine filter, Bleeding the Fuel System R
1 . Check the manometer and change filter if necessary.

2 . Oil change intervals vary, depending on engine type, oil grade
and sulfur content of the fuel. Refer to chapter Technical
Data page 75.
3 . Change oil filters every time the oil is changed.
4 . To be carried out at an authorized Volvo Penta workshop.
47700366 09-2009 35
F Every 2000 Hours

Turbocharger(1) I
G Every 12 Months
Control System(1) I
Air filter insert R
General inspection I
Engine, with Respect to Cleaning and Painting I
H Every 24 Months
Cooling System(1) IC
Coolant R
1 . To be carried out at an authorized Volvo Penta workshop.
36 47700366 09-2009
Maintenance
Orientation
D16 MG HE Genset engine
The D16 MG HE is a turbocharged, in-line, direct injec-
tion, 6-cylinder, 4-stroke Genset engine. It is equipped
with an engine mounted heat exchanger suitable for
seawater cooling or connection to a central cooling
system.
Different starting and control systems are available.
1 El. conn. box w. SD reset

2 Expansion tank
3 Heat exchanger
4 Coolant filling
5 Emergency stop button
6 Lubrication oil filling
7 Switchable fuel filters
8 Raw water pump
9 Fuel shut-off valve
10 Engine control unit
11 Alternator
12 Charge air cooler
13 Air filter
14 Fresh water pump
15 Eng. oil filters
16 Eng. oil by-pass filter
17 El. starter w. Aux. start button
P0010383
47700366 09-2009 37
Maintenance
D16 MG RC Genset engine

The D16 MG RC is an in-line, direct injection, 6-cylin-
der, 4-stroke Genset engine equipped with radiator
cooling.
1 Coolant filler
2 Expansion tank
3 Air filter
10 Alternator
12 Radiator
13 Fresh water pump
14 Eng. oil filters
P0010385
38 47700366 09-2009
Maintenance
D16 MG KC Genset engine

tion, 6-cylinder, 4-stroke Genset engine. It is equipped
with connections for keel cooling.

2 Expansion tank
3 Coolant filling
5 Lubrication oil filler
7 Keel cooling connections
8 Raw water pump
11 Alternator
13 Air filter
14 Fresh water pump
15 Eng. oil filters
P0010387
47700366 09-2009 39
Maintenance
D16 MG HE Marine genset

tion, 6-cylinder, 4-stroke marine genset. It is equipped
with an engine mounted heat exchanger suitable for
seawater cooling or connection to a central cooling
system.
The engine is mounted on a frame with a Stamford

single or double bearing marine generator. Different
starting and control systems are available.

2 Expansion tank
3 Heat exchanger
4 Coolant filling
6 MCU conn. box w. panel
9 Raw water pump
12 Alternator
14 Air filter
15 Fresh water pump
16 Eng. oil filters
19 Air outlet generator
20 Flexible mounting
21 Lifting eye
22 Air inlet generator
P0010384
40 47700366 09-2009
Maintenance
D16 MG RC Marine genset

tion, 6-cylinder, 4-stroke marine genset equipped with
radiator cooling.

1 Coolant filler
2 Expansion tank
3 Air filter
11 Alternator
13 Radiator
14 Fresh water pump
15 Eng. oil filters
20 Lifting eye
P0010386
47700366 09-2009 41
Maintenance
D16 MG KC Marine genset

tion, 6-cylinder, 4-stroke marine genset. It is fitted with
connections for keel cooling.


2 Expansion tank
3 Coolant filling
6 Lubrication oil filler
8 Keel cooling connections
9 Raw water pump
12 Alternator
14 Air filter
15 Fresh water pump
16 Eng. oil filters
21 Lifting eye
P0010388
42 47700366 09-2009
Maintenance
Engine, General
Drive Belt, Check and Change

WARNING!
Stop the engine before doing any maintenance work.
General
Check belts after running when they are warm. You
should be able to depress the alternator belt and the
drive belt about 3-4 mm (0.118-0.158”) between the
pulleys.
IMPORTANT!
Always replace a belt that seems worn or in cracked
(belts working in pairs should be changed together).
Both the alternator belt and the drive belt has an auto-
matic belt tensioner and should not need to be
adjusted.
Drive belt waterpump, change

1 Disconnect the main switch(es) and check that the
engine is not connected to system voltage.
2 Remove the belt guard.
3 Use a 1/2” square wrench to lower the belt ten-
sioner (1) and release drive belt.
4 Remove drive belt.
5 Check that the pulleys are clean and undamaged.
6 Lower the belt tensioner (1) and install the new
drive belt.
7 Install the belt guards.
8 Start the engine and do a function check.
47700366 09-2009 43
Maintenance
Alternator belt, change

2 1 Disconnect the main switch(es) and check that the
engine is not connected to system voltage.
2 Remove the belt guard.
3 Remove water pump drive belt (refer to section
Drive belt waterpump, change).
4 Use a 1/2” square wrench to lift the belt tensioner
(2) and release the alternator belt.
5 Remove the alternator belt.
P0006336 6 Check that pulleys are clean and undamaged.
7 Lift the belt tensioner (2) and install the new alter-
nator drive belt.
8 Reinstall the water pump drive belt.
9 Install the belt guards.
10 Start the engine and do a function check.
D16 MG KC, D16 MG RC
44 47700366 09-2009
Maintenance
Lubrication System
Oil level, checking and topping up

The oil level must be inside the marked area on the
dipstick and should be checked daily before the first
start.
NOTICE! There is a low level alarm installed as stand-

ard, but make sure to check the oil level anyway every
once in a while.
1
Top up the oil through the filling hole on the right side
of the engine (1). Check that the correct level has been
MAX achieved but wait a few minutes to allow the oil to run
down into the sump.
MIN
IMPORTANT!
Do not fill up above the maximum oil level. Only use a
recommended grade of oil, please refer to section
Technical Data page 75.
P0007285
47700366 09-2009 45
Maintenance
Engine Oil, Change

Always follow the recommended oil change interval.
Use an oil drain pump (optional) to pump the oil out of
the oil pan.
WARNING!
Hot oil and hot surfaces can cause burns.
WARNING!
surfaces.
1 Run the engine until warm so that the oil is easier

to pump. Then stop the engine.
2 Connect a suitable hose to the drain pump dis-
charge (1) and lead it to a collection vessel.
3 Open the tap (2) under the drain pump to the posi-
tion for draining engine oil (E).
4 Replace the oil filter and by-pass filter at every oil
change. Refer to the section Oil Filter/By-pass Fil-
ter, Change.
5 Close the tap (S). Refill with new oil to the correct
level. For engine oil quantity, refer to the Oil level,
checking and topping up page 45 section.
IMPORTANT! Only use a recommended grade of
oil.
6 Start the engine and let it idle. Check the oil pres-
sure. Check that no leaks are present at the filters.
7 Stop the engine. Wait a few minutes before check-
ing the oil level. Top up as needed.
Hand in the old oil and filters to a recycling station.
46 47700366 09-2009
Maintenance
Oil Filter/By-pass Filter, Change

Change the oil filter and by-pass filter every oil change.
1 Stop the engine.
WARNING!
Hot oil and hot surfaces can cause burns.
2 Put a suitable vessel underneath the filters to avoid

oil spill. Clean the filter bracket.
3 Unscrew the bypass filter and the oil filters with a
suitable filter wrench.
4 Lightly oil the rubber seal of the new filters and
make sure its mating surfaces on the filter brackets
are clean.
5 Mount the new filter by hand until the gasket is in
contact with the sealing surface. Then tighten the
filter another 1/2 to 3/4 turn.
6 Start the engine (idle) and make sure that no lea-
kages occur. Check the oil level once the engine
has stopped.
NOTICE! Process the discarded oil filters in accord-

ance with local regulations.
Switchable oil filters

IMPORTANT!
Though possible, the switchable filters should not be
replaced during engine operation other than in case of
an emergency.
1 Clean the filter bracket.
2 Disconnect the left filter by turning the lever to the
right-hand end position. To unlock the lever, pull the
knob beneath the lever downwards.
3 Unscrew the left-hand oil filter and discard it. Use a
filter wrench if necessary.
4 Check that the mating surfaces on the filter bracket
are clean, and that no traces of the seal from the
old filter remain.
5 Oil the rubber seal for the new filter.
6 Screw the filter on by hand until the rubber seal just
touches the mating surface of the filter bracket.
Then tighten the filter a further 3/4–1 turn.
7 Turn the lever to the left-hand end position and
change the right-hand oil filter in the same way.
8 Put the lever in operating position (straight up).
9 If necessary, top up the system with lubrication oil
at first stop. Refer to section Engine Oil,
Change page 46.
47700366 09-2009 47
Maintenance
Fuel System
Only use the grades of fuel recommended in the fuel
specification below, please refer to Technical Data,
Fuel System. Always observe the greatest cleanliness
during re-fueling and work on the fuel system.
IMPORTANT!
All work on the injection system of the engine must be
done by an authorized workshop.
WARNING!
Fire hazard. When carrying out work on the fuel system
make sure the engine is cold. A fuel spill onto a hot
surface or an electrical component can cause a fire.
Store fuel soaked rags so that they can not cause fire.
P0002101
Fuel system, bleeding

The fuel system must be bled, e.g. after changing fuel
filter, if the fuel tank has been run dry and after long
stops.
Switchable filters
1 Put a suitable vessel underneath the fuel filter.
2 Remove the protective cap from the bleeding nipple
(1) on the filter bracket. Connect a transparent plas-
tic hose to the nipple.
3 Open the bleeding nipple and pump up fuel with the
hand pump (2) until air-free fuel flows out. Tighten
the nipple while fuel is flowing out. Repeat with the
second switchable filter.
4 Remove the hose and put the protective cap back
on the bleeding nipple.
5 Run the engine at idling speed for a couple of
minutes to allow any remaining air out of the sys-
tem. Then close the nipple on the engine and make
sure there are no leaks.
48 47700366 09-2009
Maintenance
Engine Fuel Filter Replacement

Stationary engine
1 Close the fuel valve/valves.
2 Clean the filter bracket and put a suitable vessel
under the filter. Remove the protective cap from the
venting nipple. Connect a transparent plastic hose
to the nipple and lower the hose into the vessel.
3 Relieve pressure inside the filter by opening the
bleeding nipple (1).
CAUTION!
Open the tap with caution. Hot fuel can spray out
in any direction.
4 Unscrew the filter, use a filter wrench if needed.

5 Clean the sealing surface on the filter bracket.
Make sure the new filter is absolutely clean and that
the sealing surfaces are undamaged. Moisten the
seals with fuel, including the inner rubber seal on
the inside of the threaded hole in the center of the
filter.
NOTICE! Do not fill the new filter with fuel before

assembly. Contaminations may get into the system
and cause damage and malfunction.
6 Screw the new filter on by hand until the seal just

touches the mating surface. Then tighten a further
3/4 turn.
7 Open the fuel valve/valves.
8 Open the bleeding nipple (2) and work the pump
until air-free fuel flows out. Tighten the bleeding
nipple while fuel is flowing out.
on the nipple.
10 Start the engine and check for leakages.
Running engine
1 Clean the filter bracket and put a suitable vessel
under the filter.
2 Remove the protective cap from the bleeding nipple
(1) Connect a transparent plastic hose to the nipple
and lower the hose into the vessel.
47700366 09-2009 49
Maintenance
3 Shut off fuel flow through one of the filters by lifting

the handle (2) to release it and then turn it to its end
position (A).
4 Relieve pressure inside the filter by opening the
venting nipple (1).
5 Unscrew the filter, use a filter wrench if needed.
6 Make sure the new filter is absolutely clean and that
the sealing surfaces are undamaged. Moisten the
seals with fuel, including the inner rubber seal on
the inside of the threaded hole in the center of the
filter.
IMPORTANT!
Do not fill the new filter with fuel before assembly. Con-
taminations may get into the system and cause damage
and malfunction.
7 Screw the new filter on by hand until the seal just

touches the mating surface. Then tighten a further
3/4 turn.
8 Bleed by turning the handle (2) to bleeding position
(B). This allows a reduced flow of fuel through the
filter and the air is evacuated through the vent.
Tighten the bleeding nipple when air-free fuel flows
out.
on the nipple.
10 Repeat the procedure with the other filter.
11 Turn the handle to normal operating position (N).
Check for leakages.
50 47700366 09-2009
Maintenance
Fuel pre-filter
Volvo Penta fuel pre-filters are supplied in single and
double models.
Checks
The double filter is fitted with a pressure gauge (1) that
indicates when it is time to replace the filter cartridges.
The filter cartridges must be replaced according to

maintenance schedule recommendations, or earlier if
the pressure gauge shows a pressure drop of 6–10 in.
Hg at idle or 16–20 in. Hg at full rpm/engine load.
WARNING!
surfaces.
Draining
Place a vessel under the filter. Empty the water and
sediment through the plugs (2).
47700366 09-2009 51
Maintenance
Replacing filter cartridges

Double filter cartridges can be replaced while the
engine is running, by shutting off the fuel flow to one
filter holder at a time.
Fuel flow is controlled by moving the lever (1) to the

following positions:
A Normal operating position (both filters connected).
B Left filter cartridge can be replaced.
C Right filter cartridge can be replaced.
D Both filters shut off.
If the engine is stopped, begin by shutting the fuel taps

at the tank before replacing the filters. If the engine is
running the fuel flow to the filter to be replaced must be
shut off using the lever (1).
1 Place a vessel under the filters and shut off the filter
to be replaced.
2 Undo the T-bolt (2) and remove the cover (3).
3 Carefully remove the cartridge with a turning move-
ment.
4 Empty the water and sediment through the drain
hole (4).
5 Insert a new filter cartridge and fill the holder with
clean fuel.
6 Replace the cover gasket and the T-bolt O-ring.
Moisten the gasket and the O-ring with fuel before
they are installed.
7 Install the cover and tighten it by hand.
8 Dry up any fuel spills.
9 Replace the other filter in the same way.
10 Open the fuel taps and put the lever in the normal
operating position. Check that there are no leaks.
52 47700366 09-2009
Maintenance
Cooling System
Engine Mounted Heat Exchanger

D16 MG HE
The cooling system includes two circuits. The fresh-

water system is a closed circuit system, and the raw
water system is connected to a seawater inlet or a
central cooling system.
S.W
Air
11 Coolant
Vent
10
7
6 6 6 6 6 6
8
2
3
9
5
P0010867
1 Expansion tank
2 Engine
3 Oil cooler
4 Exhaust manifold
5 Inlet manifold
6 Cylinders
7 Thermostat
8 Charge air cooler
9 Fresh water pump
10 Raw water pump
11 Heat exchanger
47700366 09-2009 53
Maintenance
Drain points
D16 MG HE genset engine
P0010415
R = Raw water drain points

F = Fresh water drain points
54 47700366 09-2009
Maintenance
D16 MG HE marine genset
P0010418
R = Raw water drain points

47700366 09-2009 55
Maintenance
Radiator
D16 MG RC
The engine cooling water is cooled by a radiator in a

one-circuit cooling system.
7
10
6 6 6 6 6 6
12 11 8
2
9 3
Air 5
Coolant
P0010864
Vent
1 Engine expansion tank

2 Engine
3 Engine oil cooler
4 Exhaust manifold
5 Intake manifold
6 Cylinders
7 Wax thermostat
8 Charge air cooler
9 HT water pump
10 Fan
11 LT radiator
12 HT radiator
56 47700366 09-2009
Maintenance
Drain points
D9 MG RC genset engine
P0010416
D9 MG RC marine genset
P0010419
47700366 09-2009 57
Maintenance
No Engine Mounted Heat Exchanger

(Keel Cooled)
D16 MG KC
The engine cooling water is cooled by, e.g, a box

cooler, a grid cooler, or any other external heat
exchanger.
1
1
4
14 10
7
6 6 6 6 6 6
8
2 9 11
13
12 3 Air
Coolant
Vent
5
P00100390
1 Expansion tank
2 Engine
3 Oil cooler
4 Exhaust manifold
5 Inlet manifold
6 Cylinders
7 Thermostat
8 Charge air cooler
9 LT-water pump
10 LT-water outlet
11 LT-water inlet
12 HT-water pump
13 HT-water inlet
14 HT-water outlet
58 47700366 09-2009
Maintenance
Drain points
D16 MG KC genset engine
P0010417
47700366 09-2009 59
Maintenance
D16 MG KC marine genset
P0010420
60 47700366 09-2009
Maintenance
Freshwater System
The freshwater system is the engine's internal cooling

system that ensures that the engine operates at the
correct temperature. It is a closed system that must
always be filled with a mixture of concentrated coolant
and water in order to protect the engine against internal
corrosion, cavitation and frost bursting.
We recommend “Volvo Penta Coolant, Ready Mixed”,

or “Volvo Penta Coolant” (concentrated) mixed with
pure water according to specifications. Refer to the
table Water Quality page 76. Only coolant of this
grade is suitable for, and approved by, Volvo Penta.
The use of anti-corrosion agents alone is not permitted
in Volvo Penta engines. Never use water alone as the
coolant.
IMPORTANT!
Coolant of a suitable chemical composition must be
used all year round. This applies even when there is
no risk for frost damage, so that the engine always has
complete corrosion protection. Future warranty claims
related to engine and accessories may be refused if an
unsuitable coolant has been used, or if the instructions
for coolant mixture have not been followed.
The corrosion protection additives become less effec-

tive over time, which means that the coolant must be
changed at regular intervals; refer to the Maintenance
Schedule. The cooling system must be flushed when-
ever the coolant is changed, refer to the Freshwater
system, Flushing section.
“Volvo Penta Coolant” is a concentrated coolant that

must be mixed with water. It has been prepared to work
best with Volvo Penta engines and offers excellent
protection against corrosion, cavitation damage and
frost bursting.
“Volvo Penta Coolant, Ready Mixed” is a ready-

mixed coolant, 40% “Volvo Penta Coolant” and 60%
water. This mixture protects the engine from corrosion
damage, cavitation damage and frost bursting down to
–28°C (–18°F).
47700366 09-2009 61
Maintenance
Coolant, Mixing
WARNING!
All coolant is hazardous and harmful to the environ-
ment. Do not consume. Coolant is flammable.
IMPORTANT!
Volvo VCS coolant (yellow in color) must not be used
in Volvo Penta engines.
Different kinds of coolant must not be mixed with each
other!
Mix: 40% “Volvo Penta Coolant” (conc. coolant)

and 60% water
This mixture protects against internal corrosion, cavi-
tation and frost bursting down to –28°C (–18°F). At
60% glycol concentration, the freezing point is lowered
to –54°C (–65°F).
Never mix more than 60% concentrate (Volvo Penta
Coolant) in the coolant. A greater concentration pro-
vides reduced cooling effect with the risk for overheat-
ing and reduced frost protection.
The coolant must be mixed with distilled, deionized

water. The water must fulfill the requirements specified
by Volvo Penta; refer to Water Quality page 76.
It is extremely important that the system is filled with
the correct coolant concentration. Mix in a separate
clean vessel before filling the cooling system. Make
sure that the liquids mix.
62 47700366 09-2009
Maintenance
Raw Water System
General
D16 MG HE, D16 MG KC
The raw water system is the engine’s external cooling

system and it is either a seawater system or a central
cooling system. It cools the internal cooling system in
an engine mounted or externally mounted heat
exchanger. The system is protected against galvanic
corrosion by zinc anodes located in the heat
exchanger.
WARNING!
Risk of water entry. Close and drain the raw water sys-
tem before starting any work on the system.
Raw Water System, Draining

1 Close the raw water in- and outlet cocks.
2 Connect a suitable hose to each drain point, refer
to chapter Cooling System. Open the drains and
allow the raw water to drain off into a suitable ves-
sel.
IMPORTANT!
Check that the raw water really drains. Deposits may
need to be removed from inside the drain plugs/taps.
47700366 09-2009 63
Maintenance
Zinc Anodes, Check and Change

D16 MG HE
WARNING!
Risk of water entry. Close the seawater cocks before
doing any work on the seawater system.
1 Drain the external cooling water as described in the

section draining the raw water system.
2 Remove the zinc anodes (Z) from the heat
exchanger.
3 Check the zinc anodes and replace them if more
than 50 % of their original size has been used up.
If not, clean the zinc anodes with emery cloth to
remove the oxide layer before re-installing them.
IMPORTANT!
Use an emery cloth for cleaning. Do not use steel
tools, since this could impair the galvanic protection.
4 Install the zinc anodes. Make sure that good met-
allic contact is obtained between the anode and the
casting.
5 Close drains and open the rawwater cocks before
starting the engine.
P0006695
6 Check that no leakage occurs.
Impeller, Check and Change

WARNING!
1 Remove the raw water pump lid, and pull the impel-
ler out with water pump pliers.
2 Check the impeller. If any cracks or other defects
are visible, the impeller must be changed.
3 Lubricate the pump housing and the inside of the
lid with water-resistant grease (which is not aggres-
sive to rubber). The impeller will be easier to work
with if it is put in hot water prior to fitting.
4 Press the impeller in with a circular motion (clock-
wise). The shaft of the pump has an internal thread
(M8). Screw a stud into the end of the shaft and
press the impeller in using a washer and nut. Fit the
cover, using a new O-ring.
5 Open the raw water cock.
IMPORTANT!
Always carry a spare impeller on board.
64 47700366 09-2009
Maintenance
Seawater Filter, Check and Cleaning

D16 MG HE
The seawater filter is optional equipment.
If the water where the boat is operated contains a lot

of contamination, weed etc., check the filter more fre-
quently than specified in the maintenance schedule.
There is otherwise a risk that the filter would be
blocked, which would make the engine overheat.
WARNING!
1 Close the sea cock.

2 Remove the lid (1) and lift up the insert.
3 Clean the insert and the housing (2).
4 Install the components as in the illustration. Check
the seals. Change as necessary.
5 Open the sea cock and check carefully that no leak-
age occurs.
47700366 09-2009 65
Maintenance
Inlet and Exhaust System
Air Filter, Change

Check the air filter indicator. If indicator is all red after
the engine is stopped, change filter.
1 Undo the clamps and remove the lid from the

filter housing.
2 Remove the old filter. Be careful to ensure that
no contamination gets into the engine.
3 Install a new air filter and tighten the lid.
4 Reinstate the pressure drop indicator by press-
ing in the indicator button.
IMPORTANT!
Scrap the old filter. It must not be cleaned.
Charge Air Cooler, Checking the

Drain Hole
Water can condense in the charge air cooler during

operation. The condensate is drained via a hose con-
nected to a nipple mounted after the charge air cooler.
Check that the nipple is not blocked.
IMPORTANT!
If a large amount of water flows out of the drain hole,
the charge air cooler must be removed and proof
tested. This must be done by an authorised workshop.
66 47700366 09-2009
Maintenance
Electrical System
System voltage is 24 volt in a 2-pole system that con-
sists of batteries, starter motor, generator, power mod-
ule (PM) and the Engine Electronic Control Unit
(EECU), EMS2. The battery plus cable should always
be connected via a main circuit breaker.
WARNING!
Always stop the engine and break the current using the
main switches before working on the electrical system.
Isolate shore current to the engine block heater, bat-
tery charger or accessories mounted on the engine.
WARNING!
If maintenance has to be carried out on a powered up
system, precautions to prevent remote start has to be
made.
Power Module
The power module supplies power to the EECU and
the control system. The power module protects the
systems from high current with a built in over current
protection. The power module also has an easy link
bus which makes it possible to connect some easy link
instruments directly to the engine. The instruments that
can be used are tachometer, coolant temp, oil temp,
oil pressure, exhaust temp, freshwater pressure,
charge air pressure and engine hours.
Main Switch
IMPORTANT!
Never disconnect the current with the main switches
when the engine is running, the alternator and elec-
tronics could be damaged.
The main switches must never be switched off before

the engine has stopped. If the circuit between the alter-
nator and the battery is disconnected when the engine
is running, the alternator and electronics can be dam-
aged. For the same reason the charging circuits must
never be re-connected with the engine running.
47700366 09-2009 67
Maintenance
Electrical Connections
Check that electrical connections are dry, free from
oxide, and that they are securely tightened. Spray the
connections as necessary with water-repellent spray
(Volvo Penta universal oil).
Battery, Maintenance
WARNING!
Risk of fire and explosion. Never allow an open flame
or electric sparks near the battery or batteries.
P0002107
WARNING!
WARNING!
The battery electrolyte contains extremely corrosive
sulfuric acid. Protect your skin and clothes when charg-
ing or handling batteries.
Always use protective goggles and gloves. If battery
electrolyte comes into contact with unprotected skin
whas off immediately using plenty of water and soap.
If battery acid comes in contact with the eyes, flush
immediately with plenty of water and obtain medical
assistance without delay.
Connecting and disconnecting the battery
Connecting
1 Connect the + cable (red) to the + pole on the bat-
tery.
2 Connect the – cable (black) to the – pole on the
battery.
Disconnecting
1 Remove the – cable (black).
2 Remove the + cable (red).
68 47700366 09-2009
Maintenance
Cleaning
Keep the batteries clean and dry. Contamination and
oxide on the batteries and battery poles can cause
stray currents, voltage drop and discharge, especially
in wet weather. Remove oxidation from the battery
poles and terminals, using a brass brush. Tighten the
terminals securely and grease them with terminal
grease or petroleum jelly.
Filling
The electrolyte level should be 5–10 mm (0.2– 0.4”)
above the cell plates in the battery. Top up with distilled
water as required.
After filling, the battery should be charged for at least

30 minutes by running the engine at idle.
Some maintenance-free batteries have special

instructions, which must be followed.
P0002110
Battery, Charging
WARNING!
Risk of fire and explosion. Never allow an open flame
or electric sparks near the battery or batteries.
P0002107
WARNING!
The battery electrolyte contains extremely corrosive
sulfuric acid. Protect your skin and clothes when charg-
ing or handling batteries.
Always use protective goggles and gloves. If battery
electrolyte comes into contact with unprotected skin
whas off immediately using plenty of water and soap.
If battery acid comes in contact with the eyes, flush
immediately with plenty of water and obtain medical
assistance without delay.
WARNING!
IMPORTANT!
Observe the instruction manual for the battery charger
carefully. To avoid the risk of electrochemical corrosion
when an external charger is connected, the battery
cables should be removed from the batteries before
the charger is connected.
47700366 09-2009 69
Maintenance
Always switch off the charging current before the

charging clips are removed.
• Charge batteries if they have become discharged.
During charging, unscrew the cell plugs but leave
them in the plug holes. Ventilate well, especially if
the batteries are charged in an enclosed space.
• If the engine is not used for a longer period of time,
the batteries should be fully charged, then possibly
trickle charged (please refer to the battery manu-
facturer’s recommendations). Batteries are dam-
aged by being left discharged, and can also freeze
and burst easier in cold weather.
• Special instructions apply to boost charging. Boost
charging can shorten battery life, and should there-
fore be avoided.
P0002111
Electrical Welding
Remove the positive and negative cables from the bat-

teries, then disconnect all cables connected to the
alternator.
Always connect the welder ground clamp to the com-

ponent to be welded, and as close as possible to the
weld site. The clamp must never be connected to the
engine or in such a way that current can pass through
a bearing.
IMPORTANT!
After finished welding, re-connect the alternator termi-
nals before connecting the battery cables.
70 47700366 09-2009
Storage
General
To prevent the genset and other equipment from being
harmed during long (2 months or more) periods out of
service, it must be conserved. It is of utmost impor-
tance that the conservation is performed correctly.
Therefore we have compiled a checklist of the most
important points. Before taking the genset out of serv-
ice for long periods, it should be checked by a Volvo
Penta dealer for possible need of overhaul or repair.
CAUTION!
Read the chapter on Maintenance before starting
work. It contains instructions on how to carry out main-
tenance and service operations in a safe and correct
manner.
IMPORTANT!
The following must be considered when cleaning with
a high-pressure water jet: Never point high-pressure
water jets directly at seals, rubber hoses or electrical
components. Never use the high-pressure function
when washing the engine.
IMPORTANT!
For generator specific inhibiting information, refer to
generator documentation.
Preparation
Stop up to eight months:
Change oil and oil filter on the engine and then run it
warm.
Stop over eight months:

Treat the lubricating and fuel systems with conserva-
tion oil. Refer to next page.
1 Make sure there is enough anti-freeze in the cool-
ant. Add more if necessary. An alternative is to
drain the coolant.
2 Drain the rawwater system.
3 Remove the impeller from the rawwater pump.
Keep the impeller in a cool place in a closed plastic
bag.
4 Drain off any water and contaminant from the fuel
tank. Fill the tank with fuel to avoid condensation.
5 Disconnect the battery cables and clean and
charge the batteries. Trickle charge during the stor-
47700366 09-2009 71
Storage
age period. A poorly charged battery can freeze

and break.
6 Clean the engine externally. Touch up any paint
damage with Volvo Penta original paint.
7 Spray electric system components with water repel-
lant.
8 Inspect all control cables and apply anti-corrosion
agent.
9 Cover the air intake to the engine, the exhaust
opening and the engine.
IMPORTANT!
Never use vinyl sheets for covering. This can result in
condensation and harm the installation.
IMPORTANT!
Store the engine in a well-ventilated room.
IMPORTANT!
Put a note on the engine giving the date, type of con-
servation and the preservative that was used.
Storage
Recharge the battery at least once a month.
IMPORTANT!
During longer periods out of operation, the prepara-
tions must be repeated every 12 months.
Long Term Storage

Conserving the lubricating and fuel systems for
stops longer than eight months:
1 Drain the oil from the engine and fill with conserva-
tion oil(2) to just over the MIN mark on the dipstick.
2 Connect supply (1) and return (2) fuel lines to a fuel
2 can filled with 1/3 conservation oil(2) and 2/3 diesel
fuel.
3 Bleed the fuel system.
4 Start the engine and run it at idling speed until
approximately two liters of the fuel/conservation oil
mixture have been consumed. Stop the engine and
connect the ordinary fuel lines.
1 5 Drain the conservation oil from the engine.

P0010277
6 Follow the directions in section “Preparations” in
other respects.
2 . Conservation oils are available from oil companies.
72 47700366 09-2009
Storage
Bringing Out of Storage

1 Remove any protective covers on the engine, air
intake and exhaust pipe.
2 Top up with lubricant of the correct grade in the
engine if necessary.
3 Fit new fuel filters and bleed the fuel system.
4 Check drive belts.
5 Check the condition of rubber hoses and check the
tightness of all hose clips.
6 Close the drain cocks and fit the drain plugs of the
rawwater system. Fit the impeller in the rawwater
pump. Fill and bleed the rawwater system.
7 Check the coolant level and anti-freeze. Top up if
necessary.
8 Check under and around the engine for such items
as loose or missing bolts, oil, fuel or coolant leaks
and repair if needed.
9 Connect fully charged batteries.
10 Start the genset and run it at idling speed until it
reaches operating temperature before loading it.
11 Check for oil, fuel or coolant leaks.
12 When the engine has run long enough to warm up
apply the load and bring it to operating speed.
47700366 09-2009 73
Technical Data
Engines
General
Type Designation D16 MG HE D16 MG RC D16 MG KC
No. of cylinders inline 6 inline 6 inline 6
Displacement 16.12 dm3 (983.9 16.12 dm3 (983.9 16.12 dm3 (983.9
in3) in3) in3)
Valve clearance(1), inlet 0.30 mm (0.0118”) 0.30 mm (0.0118”) 0.30 mm (0.0118”)
Valve clearance(1), exhaust 0.60 mm (0.0236”) 0.60 mm (0.0236”) 0.60 mm (0.0236”)
Dry weight(2), engine without generator and 1770 kg (3902 lbs)(3) 1945 kg (4288 lbs)(4) 1716 kg (3783 lbs)(3)
frame, approx.
1) Cold engine
2) Excl. engine oil and coolant
3) Engine only, excl. cooling system
4) Engine with radiator
Performance
1500 rpm
Power, 100 % load 450 kW (612 hp) 433 kW (589 hp) 450 kW (612 hp)
Torque, 100 % load 2865 Nm (2113 lbf.ft) 2865 Nm (2113 lbf.ft) 2865 Nm (2113 lbf.ft)
1800 rpm
Power, 100 % load 500 kW (680 hp) 470 kW (639 hp) 500 kW (680 hp)
Torque, 100 % load 2653 Nm (1956 lbf.ft) 2653 Nm (1956 lbf.ft) 2653 Nm (1956 lbf.ft)
Exhaust temperatures
450 kW @ 1500 rpm 292 kW @ 1500 rpm 450 kW @ 1500 rpm
at 25 % of ISO Standard Power 309 °C (588 °F) - 309 °C (588 °F)
at 100 % of ISO Standard Power 474 °C (885 °F) 443 °C (829 °F) 474 °C (885 °F)
500 kW @ 1800 rpm 339 kW @ 1800 rpm 500 kW @ 1800 rpm
74 47700366 09-2009
Technical Data
Lubrication System
Oil Capacity, incl. oil filters, approx.
No engine inclination 49 liters (12.9 US gals)
Volume difference min.–max. 10 liters (2.6 US gals)
Oil grade1) Sulfur content in fuel, by weight

up to 0.5% 0.5–1.0% more than 1.0% 2)
Oil change interval: Reached first in operation:
VDS-3 500 hr. or 12 months 200 hr. or 12 months 100 hr. or 12 months
VDS-2 and ACEA E7 3), 4)
or VDS-2 and Global DHD-1 3) 400 hr. or 12 months 200 hr. or 12 months 100 hr. or 12 months
VDS-2 and API CH-4
VDS-2 and API CI-4
VDS and ACEA E3 3), 5) 300 hr. or 12 months 150 hr. or 12 months 75 hr. or 12 months
ACEA: E4, E3, E2,
200 hr. or 12 months 100 hr. or 12 months 50 hr. or 12 months
API: CF, CF-4, CG-4
NOTICE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the quality
requirements above.
1) Lowest recommendet oil grade. Higher quality lubrication oil is always possible to use.
2) If sulfur content is >1.0% by weight, use oil with TBN >15.
3) Lubrication oil must comply with both requirements.
4) ACEA E7 has replaced ACEA E5. ACEA E5 can be used, though, if ACEA E7 is not available.
5) ACEA E3 can be replaced by ACEA E4, E5 or E7.
6) API CG-4 can be replaced by API CI-4.
VDS = Volvo Drain Specification

ACEA = Association des Constructeurs Européens d'Automobiles
Global DHD = Global Diesel Heavy Duty
API = American Petroleum Institute
TBN = Total Base Number
Viscosity
Select the viscosity according to the table.
The temperature values refer to stable ambient tem-

peratures.
* SAE 5W/30 refers to synthetic or semi-synthetic oils.
47700366 09-2009 75
Technical Data
Fuel System
Fuel specification
The fuel must comply with national and international standards for commercially supplied fuels, such as:
EN 590 (with nationally adapted environmental and cold weather requirements)
ASTM D 975 No 1-D och 2-D
JIS KK 2204
Sulfur content: Complying with legal requirements in each country. If the sulfur content exceeds 0.5 weight-
percent, the oil change intervals shall be changed, refer to Technical Data page 75.
Extremely low sulfur content fuel (urban diesel in Sweden and city diesel in Finland) can cause a loss of up to 5
% of power and an increase in fuel consumption of about 2-3 %.
Cooling System
Freash water system capacity
D16 MG HE D16 MG RC D16 MG KC
Incl. heat exchanger, approx. 56 liters (14.8 US gals) 56 liters (14.8 US gals) -
Engine only, approx. - - 38 liters (10.0 US gals)
Water Quality
ASTM D4985:
Total solid particles <340 ppm

Total hardness <9.5° dH
Chloride <40 ppm
Sulfate <100 ppm
pH value 5.5–9
Silica (acc. ASTM D859) <20 mg SiO2/l
P0002094
Iron (acc. ASTM D1068) <0.10 ppm
Manganese (acc. ASTM D858) <0.05 ppm
Conductivity (acc. ASTM D1125) <500 µS/cm
Organic content, CODMn (acc. <15 mg KMnO4/l
ISO8467)
Electrical System
System voltage 24 V
AC alternator
voltage/max. amperage 28 V / 80 A
output, approx. 2240 W
Battery electrolyte density at +25°C (77°F)

fully charged battery 1.28 g/cm 3 = 0.0462 lb/in3
battery recharged at 1.13 g/cm3 = 0.0408 lb/in3
76 47700366 09-2009
Technical Data
Identification Numbers
Auxiliary Engine
Engine type and serial no. (A) B

(Stamped in eng. block) ......................................... xxxxxx (1) xxxxxx (2)
N . xxxxxxxxxx (3)
Engine plate (B) P0006167
Product designation: .........................................

Product number: .........................................
C
Serial number: .........................................
Warranty decal (C)

Serial and basic engine ......................................... P0002053
number: .........................................
Product number: ......................................... D E
Chassis ID and Eng. ser.no. (D)

Chassis ID: .........................................
Engine serial no.: .........................................
P0006755
Certification lables (E)
D
C E
P0010865
A B
47700366 09-2009 77
Technical Data
Genset
Engine type and serial no. (A) B

(Stamped in eng. block) ......................................... xxxxxx (1) xxxxxx (2)
N . xxxxxxxxxx (3)
Engine plate (B) P0006167

Product number: ......................................... C D
Serial number: .........................................
Warranty decal (C)

P0002053
Serial and basic engine .........................................
number: .........................................
Product number: ......................................... E F
Chassis ID and Eng. ser.no. (D)

Chassis ID: .........................................
Engine serial no.: .........................................
P0006755
Certification lables (E)
P0010315
Certification plate (classified genset) (F)
Serial number: ......................................... G
Product number: .........................................
Generator plate (G)

Serial number: .........................................
Product number: .........................................
D
C E
P0010316
P0010865
A B
P0010866 F G
78 47700366 09-2009
Alphabetical index
After Engine Shutdown......................................... 29 Storage.................................................................... 72
Air Filter, Change.................................................... 66 Switchable oil filters................................................. 47
Alarms..................................................................... 27 Warming-up........................................................... 25
Battery, Charging.................................................. 69 Warranty Information................................................. 9
Battery, Maintenance.............................................. 68 Water Quality........................................................... 76
Before Starting........................................................ 24 Viscosity................................................................. 75
Bringing Out of Storage........................................... 73 Zinc Anodes, Check and Change........................ 64
Certified Engines..................................................... 9
Charge Air Cooler, Checking the Drain Hole........... 66
Drive Belt, Check and Change............................. 43
Electrical Connections.......................................... 68
Electrical Welding.................................................... 70
Emergency Stop Switch.......................................... 28
Engine Fuel Filter Replacement.............................. 49
Engine Mounted Heat Exchanger........................... 53
Engine Oil, Change................................................. 46
Engine, General...................................................... 43
Engines................................................................... 74
Fault Tracing.......................................................... 30
Freshwater System................................................. 61
Fuel pre-filter........................................................... 51
Fuel System...................................................... 48, 76
Fuel system, bleeding............................................. 48
Identification Numbers......................................... 77
Impeller, Check and Change................................... 64
Inlet and Exhaust System........................................ 66
Long Term Storage............................................... 72
Lubrication System............................................ 45, 75
Main Switch............................................................ 67
MCC (Marine Commercial Control System)............ 10
MCC system, Overview........................................... 11
MCU (Marine Control Unit)................................ 10, 13
Menu Structure........................................................ 16
No Engine Mounted Heat Exchanger (Keel
Cooled)................................................................... 58
Oil level, checking and topping up...................... 45
Orientation............................................................... 37
Power Module........................................................ 67
Preparation.............................................................. 71
Raw Water System................................................ 63
Raw Water System, Draining.................................. 63
Recommendation of Daily Operation Records........ 34
Safety Directions for Maintenance and Serv-
ice............................................................................. 5
Safety Regulations During Engine Operation............ 4
SDU (Shutdown Unit).............................................. 21
SDU Indications....................................................... 22
Seawater Filter, Check and Cleaning...................... 65
Service Schedule.................................................... 35
Setpoints................................................................. 20
Starting the Engine.................................................. 25
Starting Using Auxiliary Batteries............................ 32
Stop the Engine....................................................... 28
47700366 09-2009 79
NOTICE: The free-of-charge Operator’s Manual offer is valid for 12 months after delivery.
Fill in your name, postal address, email address and desired language.
Publication Reference: 47700366
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Elanders Sverige AB
Order Office
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Fax: +46 31 545 772
© 2009 AB VOLVO PENTA

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Printed on environmentally friendly paper
47700366 English 09-2009

Operator'S Manual: D16 MG Genset Engine D16 MG Marine Genset

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OPERATOR’S MANUAL

D16 MG Genset Engine

Diese deutsche Version dieses Handbuches kann Вариант настоящего руководства по

CALIFORNIA PROPOSITION 65 WARNING

Safety Regulations During Engine

The new engine Filling fuel

Safety Directions for Maintenance

Fire and explosion Hot surfaces and fluids

Cooling system Fuel system

Keep the operator’s manual within reach at all times.

Care of the environment Fuel and oil

MCU (Marine Control Unit)

MCC (Marine Commercial Control

Application Modes Interface to start/stop the engine Note

MCC system, Overview

1 Connection box, engine room

MCU (Marine Control Unit)

Crankcase Pres bar Mode ID

SD System Fall Prestart Time

Main page (A) Adjustments (C)

NOTICE! Engine cannot be started with active or

Measurement (B) History (D)

B7. & B8.

This will list all active alarms (number of alarms indi-

NOTICE! In case of multiple alarms, scroll alarmlist

ACKNOWLEDGE button acknowledges all alarms.

Alarm list appears on the screen when a new alarm is

NOTICE! Alarm list is not activated when you are view-

Three state Alarm list indication

Statistic values can be adjusted from PC software

Alarm list and History record prefixes

This is how they appear in the MCU menu.

NOTICE! An “N” in column “Customer edit allowed”

SDU (Shutdown Unit)

Engine imputs Control switch inputs Outputs

Speed Overspeed alarm

1 Green – Power A Broken wire reset button

External inspection Valves and plugs

Make sure you know how to stop the genset before

Starting the Engine

NOTICE! To warm up the engine operate at no load

NOTICE! If the lubrication oil pressure does not

NOTICE! Make sure that the cooling water flow is suf-

Starting the Engine

If possible, do not apply heavy loads until the engine

During load operation make sure that:

Alarms detected by the EMS or PM are shown in the

4 Press ACKN. button to acknowledge all alarms.

NOTICE! Alarm item will stay in alarm list until

Stop the Engine

Emergency Stop Switch

If the engine can not be stopped by the engine control

Push the emergency stop button.

If the engine cannot be stopped with the emergency

NOTICE! If the engine has been stopped with the

After Engine Shutdown

Breaks in operation [not using the engine]

Symptoms and possible causes

Starter motor does not rotate when cranking 1, 2, 3, 4, 6, 7, 49

13. Low compression pressure

Starting Using Auxiliary

5 Turn off the engine. Remove the start cables in the

Daily operation records WARNING!