OPERATOR’S MANUAL

D9 MG Genset Engine

CALIFORNIA
Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Foreword
Thank you for purchasing this Volvo Penta 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 engine, do not operate it until you have read and fully understood the contents of this manual. Also do not operate the engine unless in compliance with local regulations. For information on genset and/or generator specific items refer to generator information supplied by genset builder and/or 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.

............ Lubrication oil filling ................................................................ Drain points ... 60 Start with auxiliary batteries ......................................................................................... Electrical installations ............................................................................ Maintenance ................................................................. 6 Safety directions for maintenance and service .................... 10 Certified engines ........ 12 D9 MG HE Genset engine ................................................................................... Preparation ..... 52 Draining the raw water system ...................................................... Inhibiting ........................... 14 Starting ........... Breaks in operation [not using the engine] ........................................................................ Coolant specification ................... 52 Electrical system ......... 17 18 19 22 24 25 Air Inlet and Exhaust Systems .. Fuel system .......................... 11 Warranty ...................................................................................................................................................... Care during Storage ........................ 34 Maintenance schedule ...................................................................... 30 Stopping ........................... 31 After stopping ...... Coolant drain .................................................................................................... Switchable oil filters ........ 13 New engine initial service ................... 62 Technical Data .................................................................... Coolant filling ....................... Batteries........................................................................................................................ 35 Engine ................... D9 MG KC Genset engine .................... MCU menu flow chart ........................ Electrical connections ................ Keel cooled ....................... Fuel filter..................................................................................................... Stops longer than eight months: ....................................................................................................................... Operation .............................. Control and monitoring system ........................................................................................................................................................ Fuel specification ........ 46 47 47 48 48 49 49 50 50 51 51 Raw water system ................................. 12 D9 MG RC Genset engine ........................ 63 63 64 65 66 67 68 69 Notes ............................... Lubrication oil change ........ Drain points .......................................... 31 Emergency stop ............................................................................................................... 32 32 32 32 Maintenance .......................... Filters and by-pass filter change ................................................ ........................................ 29 Start using auxiliary batteries ............................................. Identification numbers ..... Return the Engine to Service .... Radiator cooling ............................................................................................................................................................................................................. 28 Operation ..... 61 Troubleshooting ............................ Fuel system venting .............. MCU Panel layout .. Electric welding .................................................... 45 Cooling system ............................................... 27 SDU indications ................. D9 MG HE Genset engine .......... Lubrication oil specification .............................................. 70 .............................................. 7 Introduction ............. Freshwater system ................................................................................................................ Menus ................... 15 Marine Commercial Control ...............Contents Safety Information .. D9 MG RC Genset engine .................. Main switches ................... 60 Auxiliary START .............................................. 37 Lubrication system ............................................................................................ Twin fuel pre-filter/water separator ................ 11 Presentation .................. Fuses ................................................. 5 Safety regulations during engine operation ............ General ................. Anti-freezing measures ...................................... Drain points ........................................................... 54 54 54 54 54 55 56 57 58 58 58 59 59 Shutdown system overview ................................................. 33 Recommendation of Daily Operation Records .................................... MCC system overview ..................................................................................................................................................................................................................................................................................................................... Freshwater system flushing ............ Engine mounted heat exchanger ..................... 38 38 38 39 39 40 40 41 44 In case of emergency ..........................

IMPORTANT! Used to draw your attention to something that can cause damage. This symbol is used in the book and on the engine to make you aware of safety information. Replace symbols that have been damaged or painted over. It also includes a summary of basic safety regulations for operation and maintenance of the engine. If operations are performed incorrectly it could result in personal injury or damage to property or the engine. For safety information on genset operation and maintenance of the generator. 5 . This section describes how safety information is presented in this manual and on the product. refer to the documentation provided by the genset builder. Ensure that warning and information symbols on the engine and transmission are always visible and legible.Safety Information Read this chapter thoroughly. Always read these safety precautions very carefully. please get in touch with your Volvo Penta dealer. In the Operator’s Manual warning texts have the following priority: WARNING! If these instructions are not followed there is a danger of personal injury. Read the Operator’s Manual carefully before operating or servicing the engine. NOTE! Used to draw your attention to important information that will facilitate work or operations. This symbol is used in certain cases on our products and refers to important information in the Operator’s Manual. It concerns your safety. This Operator’s Manual is only valid for the auxiliary engine built in the Volvo Penta factory. product malfunction or damage to property. If this is not the case. Make sure you are in possession of the right operator’s manual before reading on. extensive damage to the product or serious mechanical malfunction. If anything is unclear please contact your Volvo Penta dealer for assistance.

controls and other equipment in a safe and correct manner. are designed in such a way that this problem is very rare. The incorrect grade of fuel can disturb operation or cause breakdown. Due to the risk of fire and/or explosion. This problem is most prevalent on high. Accustom yourself with handling the engine. Never run close to bathers or in places where you have reason to believe there are people in the water. e. in the engine surroundings. it will cause a certain vacuum to form behind the vessel. This can also lead to the control rod jamming on diesel engines. trim. Never overfill the tank. Combustible enviroment Accidents and other incidents Sea rescue statistics show that deficient maintenance of vessels and engines together with defective safety equipment often causes accidents and other incidents at sea. Carbon monoxide poisoning When a vessel is moving forward. If suction should arise anyway.g. Daily inspection Make a habit of visually inspecting the engine and engine room before starting and after stopping the engine. fuel oil or LPG. you have a legal responsibility to be aware of and follow regulations concerning traffic and safety at sea. do not start or continue to run the engine if there is a suspected leak or discharge of combustible media. Smoking is prohibited and the engine must be turned off. etc. do not open hatches or portholes at the fore of the vessel. This will help you to quickly detect any fuel. Remember that when operating a vessel. Maneuvering Avoid violent and rapid rudder movement and gear shifting. Inform yourself of the regulations applicable to your vessel and the waters your in by getting in touch with the relevant authorities or marine safety organization. the suction from this vacuum can be so great that the exhaust gases from the vessel are drawn into the bridge or cabin and cause carbon monoxide poisoning. Most modern vessels. coolant or oil leaks and any other abnormalities that have occurred or are about to occur.Safety information Safety regulations during engine operation The new engine Read instruction manuals and other information accompanying the new vessel thoroughly. which will cause the engine to overspeed and risk damaging machinery and causing personal injury. open hatches and portholes. Get in touch with your Volvo Penta dealer for help in obtaining the best solution for your vessel. swells. There is a risk of the passengers falling down or falling overboard. A rotating propeller can cause serious injury. this will otherwise increase the suction. Other factors that can increase the effect of the suction are wind conditions. Close the filler cap securely. however. 6 . wide vessels with abrupt stern. Make sure your vessel and engine are maintained in accordance with directions in the instruction manuals and that the safety equipment on board is in good working order. Filling fuel There is a risk of fire and explosion when filling fuel. Surprisingly. load distribution. or load distribution instead. Make sure there is nobody in the water before engaging forward/reverse. In unfortunate circumstances. trim. Use only fuel recommended in the operators manual. Try changing speed.

Keep oil. Always make sure lifting equipment is in good condition and constructed for the lift (engine weight together with possible reverse gear and extra equipment). ignition and electrical systems on Volvo Penta engines are designed and manufactured to minimize the risk of explosion and fire in compliance with existing legislation.and fuel drenched rags and other hazardous materials where they are safe in case of fire. A faulty battery connection or jumper cable can generate sparks that can cause the battery to explode. lubrication. or close to. Make sure there are no tools or other objects left on the engine. Special lifting devices may be required to obtain the right balance and safe handling. More detailed service literature is available from your Volvo Penta dealer. The rotating compressor wheel in the turbocharger can cause severe personal injury. locking it in the off position. Working on or approaching a running engine is a safety hazard. Maintenance and service must be carried out with the engine stationary unless stated otherwise in the instructions. Use an adjustable lifting boom to ensure safe handling when lifting the engine. Lifting the engine Always use the lifting eyes mounted on the engine when lifting the engine. Prevent inadvertent start of the engine by removing the starter key and turning off the power with the main switch. Smoking. Place warning signs stating that service is in progress in every position from which the engine can be started. call your Volvo Penta dealer for assistance instead. and many chemicals are flammable substances. Never perform service on an engine suspended only from a lifting device.Safety information Safety directions for maintenance and service Preparations Knowledge The operator’s manual contains directions for performing normal maintenance and service in a safe and correct manner. There is also a risk of foreign objects being drawn in and causing mechanical damage. open flames and sparks must never occur in. Oxyhydrogen is easily ignited and extremely explosive. All chains and wires must run parallel with each other and as much at right angle as possible to the top of the engine. Oil drenched rags can selfignite in certain conditions. Volvo Penta recommend leaving all work requiring the engine to be running to an authorized Volvo Penta dealer. topping up with oil or when in the vicinity of the fuel station or the engine room. fingers or a dropped tool can be caught in rotating parts and cause serious bodily injury. Never perform a task unless you are absolutely sure how it is to be carried out. Read the directions carefully before starting work. Batteries Batteries contain and generate oxyhydrogen gas. Non-original parts Components in fuel. Before starting Refit all guards and covers that have been removed before starting the engine. Stop the engine Stop the engine before opening or dismantling the engine hatch/hood. The use of non-original parts can result in explosion or fire. 7 . Fire and explosion Fuel and lubricants All fuels. most lubricants. Fuel leaks and spills on hot surfaces or electrical components can cause fires. Never smoke when refueling. IMPORTANT! Engine must only be lifted horizontally. Always read and follow the directions on the packaging. Note that any extra equipment mounted on the engine can change the center of gravity. Work performed on the fuel system must be done on a cold engine. the batteries or battery compartment. A turbocharged engine must never be started without the air filter fitted. hair. especially when charging. Loose clothing.

Never start or run the engine with the oil filler cap removed or there will be a risk of the oil being thrown out. Avoid opening the coolant filler cap when the engine is warm. the engine must be stopped and the powered turned off with the main switch/switches. Protect your eyes. If the filler cap. Electrical system Turn off the power before commencing work on the electrical system. coolant pipe. Chemicals Most chemicals such as glycol. charge air pipe. Batteries Batteries contain a highly corrosive electrolyte. WARNING! Do not open the crankcase covers while the engine is still hot. Certain chemicals such as preservatives are flammable and harmful to inhale. 8 . Carbon monoxide poisoning Start the engine in well-ventilated spaces only. Leave left over or used chemicals to a destruction plant. hot coolant and warm lubricant in pipes and hoses. Explosions can occur in the intake manifold. Always use protective goggles and gloves. E. Steam or hot coolant may spurt out and cause burn injuries. starting heater. Cooling system There is a risk of water entering when working on the seawater system. Avoid burns and crushing or cutting! At operating temperature.. the engine coolant is hot and under pressure. Escaping fluids under pressure can pierce bodily tissue and cause serious injury. cock. Apply baking soda to help neutralize the acid. Make sure the lubricating system is depressurized before starting work. In case of splashes on the skin. Never adjust the Vbelts while the engine is running. Provide good ventilation and use breathing protection when spraying. the engine and its components are hot. are hazardous to health. Hot surfaces and fluids At operating temperature. degreasing agent. Fuel system Always protect your hands when carrying out leak detection. If electrolyte gets in your eyes. must nevertheless be opened or dismantled while the engine is warm. turbocharger. rinse immediately with large amounts of water then contact a doctor at once. Note that the coolant can still be hot and cause burn injuries.Safety information Start spray Never use start spray or similar start help. flush skin immediately with lots of water. Steam can cause personal injury. Risk for personal injury. When running in confined spaces.. anti-corrosion agent. Store chemicals and other hazardous materials out of reach of children.: exhaust manifold. Take care with hot surfaces. etc. preservatives. Therefore. Lubricating system Hot oil can cause burn injuries. Risk of blood poisoning. the filler cap must be opened carefully to release the pressure before removing it completely and starting work. Otherwise it might be damaged by fuel spills. Always cover any electric component if it is located under the fuel filter. etc. In case of splashes in the eyes. battery charger or other extra equipment fitted to the engine must be disconnected. A hot engine always involves risk for burn injuries. oil pan. Check the coolant level only after the engine has been stopped and the coolant filler cap has cooled enough to touch with your hand. wash with soap and plenty of water. Avoid skin contact with warm oil. stop the engine and close the seawater cock before starting work. Shore power to the engine heater. Service batteries carefully! If you spill electrolyte on yourself. the exhaust gases and crankcase gases must be evacuated. rinse immediately with plenty of water and call a doctor. Always read and follow the directions on the packaging.g. skin and clothing when charging and handing batteries. Always read and follow the directions on the packaging.

etc. consult your dealer. safety shoes. for your own safety. lurication oil or coolant than the recommended can cause engine damage and reduce engine service life. Failure to follow this recommendation can cause serious engine damage.Safety information Handle antifreeze carefully! Antifreeze contains alkali. Recommended fuel. ear protectors. Dispose of drained antifreeze coolant according to local regulations. heavy gloves. Dress properly for the job! Wear protective devices . Perform all recommended inspections! Perform pre-start inspection and periodic inspection on items listed in this manual. face shield.hard hat. For disposal. goggles. lubrication oil and coolant! Use of any other fuel oil. 9 . Avoid contact with skin and eyes to prevent personal injury.

Our joint efforts will make a valuable contribution to our environment. operation and maintenance and you will avoid causing unnecessary interference to the environment.. flat batteries. Always follow the maintenance intervals specified in the operator’s manual and remember to specify the engine number when ordering service and spare parts. etc. these qualities will be retained. for disposal at a destruction plant. 10 . this cannot be taken for granted nowadays but it is something we must work together to achieve. paint and wash residue. Care of the environment We would all like to live in a clean and healthy environment. Always follow any advice given in the operator’s manual concerning fuel grades. fuel consumption. etc. Adapt speed and distance to avoid wash and noise disturbing or injuring animal life. see healthy trees. original spare parts. We hope you will take part in preserving these qualities. Service and spare parts Volvo Penta marine engines are designed for high operational reliability and long service life. They are constructed to withstand the marine environment while affecting it as little as possible. controls and other equipment in a safe manner before starting the engine. Remember to always leave hazardous waste such as waste oil. coolant. Keep the operator’s manual within reach at all times. The worldwide Volvo Penta network of authorized dealers is at your service. moored boats. have clean water in our lakes and oceans. As a manufacturer of marine engines Volvo Penta has a special responsibility. etc.Introduction This operator’s manual has been produced to give you the greatest benefit of your Volvo Penta auxiliary engine. Unfortunately. That is why care of the environment is a core value in our product development. Fuel and oil Use only fuel and lubrication oil grades recommended in the technical data section of this Operator’s Manual. and enjoy the sunshine without being worried about our health. increase fuel consumption and have long-range effects on engine service life. They are specialists in Volvo Penta products and stock accessories. engine noise. test equipment and the special tools required to perform high-quality service and repairs. We would like you to read this operator’s manual thoroughly and learn how to handle the engine. Through regular service and the use of Volvo Penta original spare parts. Leave islands and harbours in the same condition as you want to find them. jetties. Other grades can cause operational problems. An environment where we can breathe clean air. Get in touch with your Volvo Penta dealer if you notice any changes such as increased fuel consumption and/or exhaust smoke. It contains the information necessary to handle and maintain your engine in a safe and correct manner. Volvo Penta has a broad range of engines where progress has been made in reducing exhaust emissions.

Introduction Certified engines It is essential that owners and operators of emission certified engines. * Only Volvo Penta original spare parts may be used. This puts special demands on the maintenance and service of your engine: * Maintenance and service intervals recommended by Volvo Penta must be followed. * Service of injector pumps. AB Volvo Penta will otherwise decline warranty liability completely or fully. 11 . * Sealed sections must not be broken by anyone other than authorized personnel. 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. It contains important information concerning the warranty card. check and perform. 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. care and maintenance given in the operator’s manual apply. general directions concerning running. service. maintenance and what the owner is responsible to be aware of. Volvo Penta will not compensate for damage and/or costs arising from the above. are aware of the following points: A certification involves the engine type being checked and approved by applicable authorities. * Installation modifications must not be made to the engine exhaust pipe or inlet channels. Otherwise. Note that AB Volvo Penta’s responsibility is limited to what is specified in the Warranty and Service Book. Engine manufacturers guarantee that all engines of the same type correspond with the certified engine. Read it carefully as soon as possible after delivery. * 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. Warranty Your new Volvo Penta auxiliary engine is covered by a limited warranty complying with the conditions and instructions given in the Warranty and Service Book. pump settings and injectors must always be performed by an authorized Volvo Penta service person. used in areas where exhaust emissions are regulated by law.

Different starting and control systems are available. Heat exchanger 10. It is equipped with an engine mounted heat exchanger suitable for seawater cooling or connection to a central cooling system. Eng. Air cooler 19. Aux. Expansion tank 3. Engine control unit 9. fuel filters w. SD reset 2. Coolant filter 12. Crankcase ventilation filter 5. starter w. El. Emergency stop button 4. Switch. direct injection. Oil filler 18. box w. oil filter 16. D9 MG HE Genset engine 1.Presentation D9 MG HE Genset engine The D9 MG HE is a turbocharged. Eng. Fresh water pump 14. Fuel shut-off valve 8. Raw water pump 7. conn. start button 12 . oil by-pass filter 17. Alternator 11. El. 6-cylinder. water separator 6. 4-stroke Genset engine. for optional starter 15. Air filter 13. Conn. in-line.

Eng. Coolant filter 9. Exp. 4-stroke Genset engine equipped with radiator cooling. El. 6-cylinder. Emergency stop 4. water separator 6. for optional starter 13. Engine oil by-pass filter 15. Different starting and control systems are available. start button 13 . Crankcase ventilation filter 5. D9 MG RC Genset engine 1. Air filter 10. air cooler 11. conn. box w. fuel filter w. oil filter 14.Presentation D9 MG RC Genset engine The D9 MG RC is an in-line. Fresh water pump 12. Radiator w. Conn. tank 2. direct injection. Eng. Engine control unit 8. Fuel shut-off valve 7. SD reset button 3. Lubrication oil filling 9. starter w. Aux. Switch.

Valves and plugs Make sure the following valves and plugs are open or closed properly: Fuel supply valve Coolant drain cocks Open Closed IMPORTANT! If the coolant drain cocks are not closed the coolant will drain from the engine and this may cause severe damage to the engine. make sure the wiring is according to the drawings. External inspection 1. Filling lubrication system Refer to chapter ”Maintenance: Lubrication system”.New engine initial service General Before starting a new or reconditioned engine for the first time. Filling cooling system Refer to chapter ”Maintenance: Cooling system”. 2. Make commissioning report for new or overhauled engine. Check the following components for loose bolts or nuts: * Plugs and covers of fuel. give it an initial inspection. 14 . Electrical wiring Check for loose or damaged electrical wiring on the engine. 3. IMPORTANT! All covers on the engine must be mounted before attempting to start your engine. This to guarantee your own safety as well as the maximum service life of the engine. If necessary firmly reconnect to terminals or cable-joint portions. If your engine is reconditioned. Check for fuel. lubrication and cooling system * Coupling of fuel injection pump and shaft * Mounting brackets * Fuel control link * Turbocharger * Timing gear case * Exhaust manifolds * Cylinder heads * Air-duct connection-hose clamp 4. 5. oil. Check the control system for loose terminals. Filling fuel system Refer to chapter ”Maintenance: Fuel system”. Damaged cables must be replaced. coolant and air leaks and repair if needed. Look for defects on engine parts.

it must be allowed to cool down for at least one minute before a new attempt is made at starting. IMPORTANT! If the starter motor has been engaged for the maximum time (30 seconds). immediately stop the engine and do not restart until the problem has been fixed. If you are starting the genset for the first time. NOTE! If the lubrication oil pressure does not increase when you have started the engine. nor tools.Starting Before starting WARNING! Before starting the genset make sure that neither people. NOTE! To warm up the engine operate at no load for a short time and then apply a low load. NOTE! Make sure that the cooling water flow is sufficient. Notify the people in the vicinity of the genset when starting. Prolonged warm-up operation causes carbon buildup in the cylinders that leads to inperfect combustion. be prepared to stop the engine immediately in case abnormal noise should occur during start up. WARNING! Make sure that you know how to stop the genset before you start it (in case of emergency). Warming-up WARNING! Do not conduct warm-up operation for an extended period of time. are in contact with moving parts of the engine or the generator. 15 .

16 . A short circuit. 5. WARNING! The black auxiliary cable (–) must not come in contact with the positive connection on the starter motor. naked flame or spark can cause a powerful explosion. which is extremely flammable and explosive. 3. 4. Connect the red auxiliary cable to the discharged battery’s + terminal and then to the auxiliary battery’s + terminal. Batteries generate oxyhydrogen gas.Starting Start using auxiliary batteries WARNING! Ventilate well. Risk of sparks and explosion. WARNING! Do not touch the connections while attempting to start. 1. Connect the black jump lead to the auxiliary battery negative terminal and then to a position slightly away from the discharged batteries. Never reverse the polarity of the battery. Start the engine and run at no load for about ten minutes to charge the batteries. Stop the engine. Remove the auxiliary cables in reverse order to connecting. Risk of sparks. Make sure the rated voltage of the auxiliary battery is the same as the system voltage of the engine. Do not bend over the batteries either. for example at the negative cable’s connection to the starter motor. 2.

Applications and Modes The MCC system can be configured for different applications.Control System Marine Commercial Control This chapter describes functions and operation of the Marine Commercial Control system (MCC) and the MCU (Marine Control Unit). 17 . Auxiliary (AUX). Combined (CMB) and Propulsion (PRP). In each application the system operate in a number of modes. Blackout start will give the number of startattempts specified in the setpoint “Crank attempts”. The difference lies in the configuration file for the software and in the connections between the MCU and SDU. Emergency (EME). Application Auxiliary Modes OFF-AUX Interface to Start/Stop the engine Note Blackout start on terminal Start on terminal Stop on terminal Start button on MCU and RP Stop button on MCU and RP Emergency OFF-EME Blackout start on terminal Start on terminal Stop on terminal Start button on MCU and RP Stop button on MCU and RP Combined OFF-EME-HRB In EME Mode Blackout start on terminal Start on terminal Stop on terminal Start button on MCU and RP Stop button on MCU and RP In HRB Mode Start on terminal Stop on terminal Start button on MCU and RP Stop button on MCU and RP Propulsion OFF-PRP Start on terminal Stop on terminal Start button on MCU and RP Stop button on MCU and RP Only on variable speed engines. Blackout start inactive Blackout start inactive. Blackout start will give unlimited number of startattempts. Blackout start will give unlimited number of startattempts.

........... all functions hard wired....................................... Remote Panel. Marine Control Unit............. RP ....................... PM ............................................ 18 .............. SDU . Engine Management Systemmonitors engine status and handles engine speed and torque governing and overall control of fuel injection and emission control algorithms........... handles power distribution and power management..... COM ......... MCU ......... Separated from the engine control system. Activates a fuel shut-off valve to shut down the engine......................... the central control unit of the system.............................................. Shudown Unit............. EMS .......... It also monitors power supply and switches to secondary power......................... for J1708/J1587 and CAN2 bus (for RP and other extension modules)..................... name of the over all system..............Control System MCC system overview Terminology MCC ................ additional display panel for remote monitoring...... for engine protection...... Communication Module..................... Marine Commercial Control...... Power Module...........

Enter (confirmation of selection) 11. Start button 6. HRB or PRP) C.Active alarm F.AUX(EME. Acknowledge button Display A. Stop button 7.HRB. Highlighted indicates operational mode AUX (EME. Up button (Select and Increase) 9. Engine state (NotReady . Down button (Select and Decrease) 10. Mode Left.PRP)] 5. LED . Highlighted indicates OFF-mode B.Remote connection (Slave Panel or PC Software) L .Ready .Active alarm 13.Engine running 8.Access lock E. Indicates Local mode D. ! .Control System MCU Panel layout 1.Running) 19 . toggles modes forwards [Off . Page.HRB. Mode Right.AUX(EME. LED . toggles modes backwards [Off . R .History) 12. toggles screens (Measurement . LCD display 2.Adjustment .PRP)] 4. Horn reset (stops sound alarm) 3.

Switch between primary and secondary speed. and 4. 4.Control System Info Serial number and software revision In the main view.) 4. Enter password 2. 20 . push and hold the ENTER button. push and hold ENTER button and then push PAGE button. push PAGE to go to Language screen. 1. Contrast .MAIN view In the MAIN view. Push STOP button (approx. Change language . Select ENTER PASSWORD (C2) with UP or DOWN buttons. Select digits with UP or DOWN buttons. Follow this procedure to switch between primary and secondary speed. 1 s.INFO view In the INFO view. Select PASSWORD (C1) with UP or DOWN buttons. Adjust the brightness with UP or DOWN button . within 10 seconds of no. Confirm with ENTER button. Confirm with ENTER button. 3. 2. Use Up and Down buttons to select language and push ENTER button to confirm selection and exit window. Go to setpoint “Speed select” in the “Basic Settings page” (C3) 3. Confirm with ENTER button.INFO view In the INFO view.) NOTE! Perform 3. 1. MCU adjustments Backlight . Enter password Password is a 4 digit code. Controller INFO screen is displayed for 10 seconds. Select Adjustment view (C1). Change to new value 5. push and hold the ENTER button and adjust the contrast by pushing the DOWN or UP buttons. 1 s. 2. Push STOP button again (approx.

EME HRB and PRP. All inputs are disabled and all outputs are switched off. Local mode is deactivated by pushing Enter + ModeLeft buttons. Activate OFF-mode by pushing left Mode-button repeatedly untill OFF is high-lighted in upper left corner of display. 21 . OFF-mode OFF mode is available in all applications – AUX.Control System Operational modes Local mode In Local Mode the MCU is operational only from the main panel. NOTE! Engine can not be started and a running engine is stopped when OFF-mode is activated. Local mode is activated by pushing Enter + ModeRight buttons. All external interfaces are disabled.

parameters or history. Service time (hours to service) Statistic values can be adjusted from PC software (password protected).Control System Menus There are 4 display menus available: Main Measurement Adjustment History Main Push the PAGE button repeatedly to toggle the menu screens. Push Up-button three (3) times. Highlighted alarms are still active. 22 . Non-active alarms then disappear from the list. Inactive not acknowledged alarm A. 1. Number of alarms Statistics Select MAIN screen. Successful starts (starter RPM>Starting RPM) 3. Select MAIN screen. scroll alarmlist using ENTER button. Active not acknowledged alarm A 1 2 3 2. contact your Volvo Penta dealer. This will list all active alarms (number of alarms indicated in the upper right corner). Unsuccessful starts (MaxCrank time exceeded ) 4. ACKNOWLEDGE button acknowledges all alarms. Select MAIN screen. Use Up and Down buttons to toggle the different screens. Running hours 2. NOTE! Alarm list is not activated when you are viewing values. Push Up-button (twice for ECU list). Alarm list ECU (Engine Control Unit) alarm list and Alarm list are the last two screens in the MAIN screen. Three state Alarm list indication 1. Active acknowledged alarm 3. NOTE! In case of multiple alarms. Alarm list appears on the screen when a new alarm is set and MAIN screen is active. The other alarms are not active but not yet acknowledged.

. Use ENTER to select requested screen (record items) within displayed records.. Use Up and Down buttons to toggle the different set points group. auto repeat function is activated......Control System Measurement Push the PAGE button repeatedly to toggle the menu screens........ 4....... 1...................... Press PAGE to leave selected set points group...................... Select the HISTORY screen.................. Push the PAGE button repeatedly to scroll the menu screens........ Use Up and Down buttons to select requested set point...................................... Push the PAGE button repeatedly to scroll the menu screens. Sensor fail 23 .... 2....... 3..... Use Up and Down buttons to select the requested record.................. Press ENTER to confirm or PAGE to leave without change.... Select MEASUREMENT screen. 6.......... History 1. Alarm Sd ........ 5............. Warning Alr ....................................... Cooldown Fls ....... Press ENTER to edit.......................... 7............... Alarm list and History Alarm list and History record prefixes Prefix Meaning Wrn . Press ENTER to confirm...... 2. When Up or Down button is pressed for 2 sec. Set points marked “*” are password protected........... Adjustment In the adjustment menu it is possible to view and edit setpoints..... Select ADJUSTMENT screen. Shutdown Cd . 3.. Up and Down buttons to modify the set point..... Use Up and Down buttons to toggle the different screens.......

C Running Operational data Monitor engine data not visible in the MAIN screen: 1. 1. Push and hold STOP button until the rpm starts decreasing (approx. Use PAGE button to select MEASUREMENT menu. 3. using MODE button (left or right)(A). scroll alarmlist using ENTER button. Push START button and the engine state should change to ”Running”(C). Push HORN RESET button to silence the alarm. 3. In MAIN menu. In MAIN view. 2. Alarms Alarms are shown in two different screens depending on the origin of the alarm. Make sure rpm indication decreases to 0 and engine state returns to ”Ready”. Use UP and DOWN arrows to select wanted engine data. Stopping the engine 1.Control System A Operation B Starting the engine 1. select mode of operation (AUX. PRP). EME. NOTE! Alarm item will stay in alarm list until acknowledged and made ”not active” (fault rectified). 4. In case of multiple alarms. To view active alarms: 2. button to acknowledge all alarms. Make sure engine status is ”Ready”(B). HRB. 1 s). refer to section ”Applications & Modes”). push UP arrow once for SDU/MCU alarm list and twice for ECU alarm list. Push ACKN. 2. 24 . 2. 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.

Control System MCU menu flow chart 25 .

C3.input inactive 1 . NOTE! Engine cannot be started with active or unacknowledged SD. A2. Adjustments (C) C1. Navigate alarmlist with Enter button. Used by Volvo Penta service technicians. Enter and change passwords. Statistic information. etc. A8. C6. & A5. Run hours of the engine. In standard configuration only Throttle input (PRP) and Finespeed input (AUX. Most setpoints are password protected to avoid accidental changing. Displays previous actions/alarms. B7. Displays analogue parameters measured by the MCU. A10. & A7. C2. 26 . C7. Used by Volvo Penta service technicians. B5. Most important parameters are shown. Page for changing parameters concerning MCU engine protection functionality. A9.g governor mode and speed select. A6. No of successful start. Measurement (B) B1. Menu for change of setpoints. EMS to MCU CAN-bus information.select with Enter.input inactive 1 . Navigate with up and down arrows . Activate signal from superior system and monitor input state change. & B6.CMB) A3. Displays alarms from the Shutdown system (SDU) and MCU. Pages display status of MCU 14 digital outputs.Control System Main page (A) A1.input active. Status of MCU 14 digital inputs. . C5. Changing these setpoints will not affect the SDU. System voltage information measured by the MCU.B4. & B8. MCU to EMS CAN-bus information. 0 . Mode change is possible. NOTE! Pages can be used to verify interface to superior system. The main page of the system. A4. C4. Navigate alarmlist with Enter button. NOTE! In the MCC system engine protection functionality is handled by the SDU. Page displays alarms origining from Engine Management System (EMS) and Power Management System (PM). Refer to section ”MCU adjustments” for details. History (D) D1. 0 .input active. Enter button for further information(D2).EME. Password 1 in standard configuration. Inverted 0 or 1 indicates alarm due to current status. NOTE! Telematics functionality is not supported by the MCC system. Page for changing Engine parameters settings. Page or changing date and time. Changing setpoints concerning MCU telematics functionality. Pages display monitoring values from (EMS). Page for changing basic settings of the systems. e.

S1 Cooling water temp S2 Lube oil pressure. NOTE! Use only Volvo Penta tool supplied with SDU for reset (see picture).S5 has a ~1 second delay: S6 has no delay. Emergency mode (shutdown override) The system can be overridden by activating the OR input (the Emergency mode lamp. When pushed the overspeed limit drops 25%. Tool for broken wire reset 27 . to eng. Marine Gear S3 Lube oil pressure. Override does not include overspeed. when installed on output SL. Overspeed test To test the overspeed function push the overspeed test button (inside the SDU). will be activated). Run detection To avoid alarms when starting and stopping the engine an interlock for the shutdown pressure switches (run detection) is implemented. Acknowledge button on MCU panel will reset shutdown and clear alarm list. Yellow LED indicates broken wire. Shutdown reset Activated shutdown must be reset before engine can be restarted. spec. S1 . Overspeed shutdown The overspeed function shuts down the engine in case of overspeed.SDU Shutdown system overview Shutdown unit (SDU) The SDU has 6 shutdown channels and one overspeed shutdown. Engine S4 Cooling water pressure S5 Oil temp (only D12 MH) S6 Exhaust temp (only D12 MH) S1 . Broken wire All channels are equipped with broken wire detection that activate an alarm if connection is lost or power supply to SDU is lost.S6 are enabled or disabled accord. Reset alarm on Broken wire reset button (A). Shutdown reset button on engine connection box or MCU ACKN. button. NOTE! Shutdown reset button will still show SD alarm in MCU alarm list as not acknowledged alarm.

Yellow – S3 Broken wire detected H. Yellow – S2 Broken wire detected I. Overspeed shutdown test button 28 . Red – Overspeed Alarm 3. Yellow – Run detection S4 4. Red – S3 Shutdown active 9. Red – S4 Shutdown active 8. Yellow – S4 Broken wire detected G. Green – Power 2. Yellow – S6 Broken wire detected E. S3 5. Red – S6 Shutdown active 6. Yellow – Speed sender Broken wire detected D. Red – S5 Shutdown active 7. Yellow – S1 Broken wire detected J. Yellow – Fuel valve Broken wire detected C. Green – Run detection S2. Yellow – S5 Broken wire detected F. Broken wire reset button B. Red – S2 Shutdown active 10. Red – S1 Shutdown active A.SDU SDU indications 1.

IMPORTANT! Always keep the engine room well ventilated. Applying Load If possible.: exhaust manifold.Operation General Learn how to handle the engine. charge air pipe. turbocharger. 2. do not apply heavy loads until the engine has reached operating temperatur. The color of the exhaust gas is normal. Insufficient airsupply to the engine means imperfect combustion and loss of power. oil pan. this may damage the starter. refer to chapter Technical Data. 5. 4. Instrument readings are normal. 29 . affecting genset life. controls and other equipment in a safe and correct manner before starting the engine WARNING! Stay clear of all rotating and moving parts during operation. starting heater. No engine related alarms occur. coolant or exhaust gas 3. Beware of hot surfaces. There are no visible leaks of fuel. This can cause incomplete fuel combustion often indicated by black exhaust. IMPORTANT! Avoid overloading. lube oil. WARNING! A hot engine may cause burns. hot coolant and warm lubricant in pipes and hoses. IMPORTANT! Do not push the START button when the engine is running. No abnormal noise or vibrations occur. E.g. During load operation make sure that: 1. high fuel consumption and carbon deposits in combustion chambers. IMPORTANT! Do not turn OFF the battery switch when the engine is running since this may damage the alternator.

which is extremely flammable and explosive. Stop the engine. Risk of sparks.Operation Start using auxiliary batteries WARNING! Ventilate well. 1. Risk of sparks and explosion. Start the engine and run at no load for about ten minutes to charge the batteries. Never reverse the polarity of the battery. for example at the negative cable’s connection to the starter motor. 5. naked flame or spark can cause a powerful explosion. WARNING! The black auxiliary cable (–) must not come in contact with the positive connection on the starter motor. 30 . 2. Batteries generate oxyhydrogen gas. 3. WARNING! Do not touch the connections while attempting to start. 4. Connect the black jump lead to the auxiliary battery negative terminal and then to a position slightly away from the discharged batteries. Do not bend over the batteries either. A short circuit. Make sure the rated voltage of the auxiliary battery is the same as the system voltage of the engine. Remove the auxiliary cables in reverse order to connecting. Connect the red auxiliary cable to the discharged battery’s + terminal and then to the auxiliary battery’s + terminal.

IMPORTANT! If the engine stops abnormally. 31 . shut off the fuel supply or block the air intake to the turbocharger. the engine can be stopped as follows: Push the emergency stop button. If the engine cannot be stopped with the emergency stop button. NOTE! If the engine has been stopped with the emergency stop button.Stopping Let the engine run at no load for a couple of minutes before turning it off. the button has to be reset (pull it upwards) before the engine can be started again. try to locate the problem and make the repairs needed before starting again. Emergency stop If the engine can not be stopped by the engine control system. After starting the engine. IMPORTANT! The procedure described above is especially important if the engine has been run at heavy loads. This will keep the engine temperature in balance and prevent it from boiling. make sure it runs properly.

This will prevent the engine from corroding. * Close the fuel cock and seawater cock. IMPORTANT! Never turn the power off using the main switch while the engine is running. Refer to chapter Inhibiting. Refer to chapter Maintenance “Seawater system” and “Freshwater system” respectively. IMPORTANT! If the coolant does not give sufficient anti-freeze protection. WARNING! If the seawater system bursts due to freezing. 32 . the engine must be run warm once a fortnight. the vessel may sink. * Read off the hour counter and carry out preventive maintenance according to the maintenance schedule. A poorly charged battery can freeze and break. when the boat is in the water. IMPORTANT! Do not forget to open the cocks before starting the engine again. the sea-water system must be drained and the coolant in the fresh-water system must contain sufficient anti-freeze to prevent it from freezing. Check the charge of the battery. IMPORTANT! The engine must be conserved if it is not to be used for longer than two months. Anti-freezing measures If the engine room cannot be protected from frost. it may cause costly damage to the engine. Breaks in operation [not using the engine] During periods out of service. This can damage the alternator.After stopping General * Check the engine and engine room for leaks. * Turn off the main switch if the engine is not to be used for a long period.

Maintenance and service must be carried out with the engine stationary unless stated otherwise in the instructions. Appropriate service intervals vary with usage and operating conditions and with fuel. When disassembling a component. Directions for when and where this is to be carried out can be found in the Warranty and Service Book. 33 . take measures to prevent dust and foreign particles from entering it. Prevent inadvertent start of the engine by disabling the start-button and turning off the power with the main switch. refer to Generator Manufacturers information.Maintenance Your Volvo Penta engine and associated equipment is designed to provide high operational reliability and long service life. lubricant and coolant used. It contains directions for performing maintenance in a safe and correct manner. Daily operation records also make trouble shooting easier and will lessen the down time (to save time and money for servicing). They are constructed to withstand the marine environment while also affecting it as little as possible. When you think the engine should be serviced more frequently due to particular operating conditions. This should result in a lower engine operation cost. WARNING! Place warning signs stating that service is in progress in every position from which the engine can be started. Preventive maintenance in accordance with the maintenance schedule will ensure that it retains these qualities and avoid unnecessary operational disturbances. Consult your Volvo Penta dealer. Due to particular operating conditions the service intervals may be adjusted accordingly. signs or indications of approaching trouble. the one occurring first is to apply. Daily operation records It is recommended to keep daily operation records. Read the directions carefully before starting work. WARNING! Read the chapter “Maintenance” thoroughly before starting any maintenance work. Daily recording is a preventive maintenance program and when comparing values with engine history it will help you recognize conditions. The maintenance schedule shows the standard service intervals. If brand or type of fuel. WARNING! Working on or approaching a running engine is a safety hazard. WARNING! Read the safety directions for maintenance and service in the chapter “Safety information” before starting work. Maintenance records Volvo Penta recommends that accurate maintenance records are kept. The following chapters contain general technical information and directions for carrying out the prescribed maintenance points. NOTE! Dust and foreign particles are the most common cause of excessive wear of parts. IMPORTANT! Handle parts carefully. Warranty inspection The prescribed warranty inspection “First Service Inspection” must be carried out at an authorized Volvo Penta workshop during this first period of operation. lubrication oil or coolant is changed this should be recorded. Fluids It is also important to keep record of the fluids used in the engine. NOTE! When both operating time and calendar time is given. adjust the intervals accordingly. With accurate maintenance records your Volvo Penta Dealer can help in fine tuning the recommended service intervals to meet the specific operating situation. locking it in the off position. Use only original Volvo Penta spare parts. NOTE! For generator related maintenance information.

Maintenance: General

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 rpm, exhaust temperature, coolant temperature, and charge air temperature and pressure. 5. Rawwater pressure and rawwater temperature before and after heat exchanger. Ambient temperature 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

Maintenance schedule

MAINTENANCE SCHEDULE D9 MG
Daily
General inspection engine and engine room Check air filter indicator Check engine oil level Check coolant level Check/drain fuel pre-filter/water separator ............................................... (refer to note 1) Drain water from fuel tank Drain fuel filter Daily operation records

Weekly
Check starting batteries; electrolyte level/load Check electrical system for loose terminals/contacts Check foundation bolts Check lubrication oil for abnormal smell or waterdilution

Every 50-400 operating hours or every 12 months
Change crankcase breather filter Change engine oil .................................................................................... (refer to note 3) Change engine oil filters/by-pass filter ..................................................... (refer to note 4)

Every 400 operating hours or every 12 months
Check/adjust drive belts Check/change zinc anodes

1) 2) 3)

Check the manometer and change filter if necessary. To be carried out at an authorized Volvo Penta workshop. Oil change intervals vary, depending on oil grade and sulphur content of the fuel. Refer to chapter ”Technical Data Lubrication oil specification” Change oil filters every time the oil is changed. Not at the same time as coolant change

4) 5)

35

Maintenance schedule

Every 800 operating hours or every 12 months
Check/adjust valve clearances ............................................................... (refer to note 2) Check/clean heat exchanger insert ......................................................... (refer to note 2) Check/clean radiator Check/clean seawater filter Change fuel pre-filter/water separator filter element Change fuel fine filter. Bleed the fuel system.

Every 2000 operating hours
Check turbocharger ................................................................................. (refer to note 2)

Every 12 months
Check control system ............................................................................. (refer to note 2) Change air filter Genral inspection of engine Clean and paint the engine

Every 24 months
Check/clean cooling system .................................................................. (refer to note 2) Change coolant

36

7. Adjusting the alternator belt The standard alternator. Clean filter cover/housing if necessary. tightening torque 30 Nm. Remove old filter. 3 1 2 6. Change the alternator belt. IMPORTANT! Do not allow impurities to enter the engine. Screw a M10 nut (3) to the tensioner screw so the spring is pressed together and it is possible to loosen the alternator belt 4. are driven by a Poly-Vee belt each. A belt which is to tense can damage the bearings and a belt which is too loose can slip. for best function and service life. Undo the fixing screw (1) and tighten it again. Remove filter cover. Tighten the fixing screw (1) tightening torque 30 Nm and fixing screw (2) tightening torque 20 Nm. 3. Adjust the alternator belt by pulling the alternator while undoing the fixing screw (1) and then tighten 37 .Maintenance: Engine Engine Change crankcase ventilation filter 1. Install the protective cover over the alternator drive belt. IMPORTANT! Always change a belt which looks worn or cracked (belts which operate in pairs must be changed together). Undo the fixing screws (1) and (2). Changing the alternator belt 1. Stop the engine after a few minutes. 2. 5. 8. Let the engine run on idle. Drive belts. General information Check belt tension and condition regularly. 1. Remove the nut (3). Fit new filter and filter cover. 2. plus the extra alternator if installed. Remove the protective cover over the alternator drive belt. Check/adjust/change WARNING! Stop the engine before doing any maintenance work.

Check the oil pressure and that there is no leakage by the filters.Maintenance: Lubrication system Lubrication system Lubrication oil level check The oil level must be within the marked range on the dipstick. 3. 2. 4. Change the oil filters and the by-pass filter at every oil change (refer to section oil filter change). Use only oil of the recommended grade (refer to chapter Technical Data). NOTE! There is a low level alarm installed as standard. but make sure to check the oil level anyway every once in a while. Start the engine and allow it to idle. Use the oil drain pump (optional) to drain the oil from the sump. 5. Top up as necessary. Stop the engine. Warm the engine up (this makes it easier to pump the oil from the sump). Then stop the engine. NOTE! Process the old oil and discarded filters in accordance with local regulations. secure filler cap. After filling oil. Fill up with oil to the correct level. Lubrication oil change Always observe the recommended oil change interval. 1. 38 . Wait a few minutes before you check the oil level. IMPORTANT! Only use recommended grades of oil (refer to chapter Technical Data). 6. Wait a few minutes to allow the oil to run into the oil sump then make sure you have filled to the right level. IMPORTANT! Do not fill above the maximum oil level. WARNING! Hot oil and hot surfaces may cause burns. Lubrication oil filling Fill lubrication oil through the filler opening on the side of the engine. Connect the suction pipe of the oil drain pump to the drain pipe. Pump the oil out.

top up the system with lubrication oil at first stop. Unscrew the bypass filter and the oil filters with a suitable filter wrench. Mount the new filter by hand until the gasket is in contact with the sealing surface. 8. Clean the filter bracket. Refer to section “Lubrication oil change”. the switchable filters should not be replaced during engine operation other than in case of an emergency 1. 4. Start the engine (idle) and make sure that no leakages occur. 3. 6. 9. Then tighten the filter a further 3/4 of a turn. Check the oil level once the engine has stopped. Use a filter wrench if necessary. 5. 1. Stop the engine. Switchable oil filters IMPORTANT! Though possible. Clean the filter bracket. pull the knob beneath the lever downwards. Oil the rubber seal for the new filter. To unlock the lever. 6. WARNING! Hot oil and hot surfaces may cause burns. 39 . Turn the lever to the left-hand end position and change the right-hand oil filter in the same way. 2. NOTE! Process the discarded oil filters in accordance with local regulations. 7. and that no traces of the seal from the old filter remain. Unscrew the left-hand oil filter and discard it. Screw the filter on by hand until the rubber seal just touches the mating surface of the filter bracket. Put a suitable vessel underneath the filters to avoid oil spill. 3. Put the lever in operating position (straight up).Maintenance: Lubrication system Filters and by-pass filter change Change the oil filter and by-pass filter every oil change. 2. 5. 4. Disconnect the left filter by turning the lever to the right-hand end position. Lightly oil the rubber seal of the new filters and make sure its mating surfaces on the filter brackets are clean. Then tighten the filter another 1/2 to 3/4 turn. Check that the mating surfaces on the filter bracket are clean. If necessary.

Repeat with second filter. Open the venting nipple and pump up fuel with the hand pump (2) until air-free fuel flows out. 5. 40 . WARNING! Hot fuel may cause burns. after changing fuel filter. Connect a transparent plastic hose to the nipple. Put a suitable vessel underneath the fuel filter. Tighten the venting nipple while fuel is flowing out.g. Single filter and Switchable filters Stationary engine: 1. 4. Remove the hose and put the protective cap back on the venting nipple. e. if the fuel tank has been run dry and after long stops. IMPORTANT! All unit injector maintenance must be carried out at an authorized workshop 1 2 2 1 Fuel system venting The fuel system must be vented. Run the engine at idling speed for a couple of minutes to get any remaining air out of the system and make sure that there are no leaks.Maintenance: Fuel System Fuel system WARNING! Fire hazard. Work on the fuel system should be carried out on a cold engine. 2. Fuel leaks and spills on hot hot surfaces or electrical componentsmay cause fire. Remove the protective cap from the venting nipple (1) on the filter bracket. 3.

Drain water and contamination from the water trap by turning the handle to venting position (B).Maintenance: Fuel System Fuel filter. 5. hot fluids might spurt out). Drain water and contamination from the water trap (1) through the tap (2) by pumping with the hand pump (3) until clean fuel flows out. Put a suitable vessel underneath the filter. Tighten the venting nipple when clean fuel flows out. Turn the handle to normal operating position (N). 4. Shut off fuel to the filter to be changed (A). 41 . Put a suitable vessel underneath the filter. 2. 1 2 3 Running engine (switchable filters only) 1. Repeat the procedure with the other filter. Open the tap (1) carefullly (pressure on the inside. 1 2 6. 3 Drain Stationary engine 1. 2. 3.

Maintenance: Fuel System 2 5 2 Change the filter elements Stationary engine: (Single and switchable filters) 1. use a filter wrench if needed. 3. 5. 6. Close the fuel valve/valves. Connect a transparent plastic hose to the nipple and lower the he into the vessel. Moisten the seals with engine oil. Contaminations may get into the system and cause damage and malfunction. Remove the hose and put the protective cap back on the nipple. including the inner rubber seal on the inside of the threaded hole in the center of the filter. Then tighten a further 3/4 turn. Clean the filter bracket and put a suitable vessel under the filter. Remove the cables from the water trap (4) and unscrew the water trap from the filter. 4 1 1 4. 11. Relieve pressure inside the filter by opening first the drain tap (1) and then the venting nipple (2) WARNING! High pressure inside. 8. 7. NOTE! Do not fill the new filter with fuel before assembly. Clean the sealing surface on the filter bracket. Make sure the new filter is absolutely clean and that the sealing surfaces are undamaged. Reinstall the water trap and the cables. 2. 10. Unscrew the filter. Open the fuel valve/valves. hot fluids may spurt out. Open the venting nipple (2) and work the pump (5) until air-free fuel flows out. Start the engine and check for leakages. 42 . Screw the new filter on by hand until the seal just touches the mating surface. Tighten the venting nipple while fuel is flowing out. close the drain tap. 9. Remove the protective cap from the venting nipple. Open tap with caution.

close the drain tap. 10. Check for leakages. Screw the new filter on by hand until the seal just touches the mating surface. Remove the protective cap from the venting nipple. Remove the cables (3) from the water trap (4) on the shut off filter. Relieve pressure inside the filter by opening first the drain tap (5) and then the venting nipple (1). 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).Maintenance: Fuel System 2 1 Running engine: (Switchable filters only) 1. 4. Moisten the seals with engine oil. 5. including the inner rubber seal on the inside of the threaded hole in the center of the filter. This allows a reduced flow of fuel through the filter and the air is evacuated through the vent. 11. Contaminations may get into the system and cause damage and malfunction. Tighten the venting nipple when air-free fuel flows out. Then tighten a further 3/4 turn. Make sure the new filter is absolutely clean and that the sealing surfaces are undamaged. NOTE! Do not fill the new filter with fuel before assembly. use a filter wrench if needed. 8. 2. Reinstall the water trap and the cables. 7. 9. Vent by turning the handle (2) to venting position (B). 3 5 4 WARNING! High pressure inside. 6. Unscrew the water trap (4) and the filter. hot fluids may spurt out. Repeat the procedure with the other filter. Connect a transparent plastic hose to the nipple and lower the he into the vessel. Open tap with caution. 43 . Turn the handle to normal operting position (N). Remove the hose and put the protective cap back on the nipple. Clean the sealing surface on the filter bracket. Clean the filter bracket and put a suitable vessel under the filter. 3.

Drain Place a receptacle under the filter. 3. If the engine is running cut off the flow of fuel with the handle (1) on the filter itself. Drain off water and contaminants through the plug (D). 1. 10. The filter inserts must be changed according to the maintenance schedule or earlier if the pressure gauge indicates a vacuum of 6–10 inHg at no load or 16–20 inHg at full load. B: Left filter insert can be changed. Change the gasket on the cover and the O-ring on the T-bolt. 5. 6. Make sure there are no leaks. C: Right filter insert can be changed. Undo the T-bolt (2) and remove the cover (3). Fit a new filter insert and fill the container with clean fuel. 4. Fit the cover and tighten it by hand. Wipe off any fuel from the heat shield. Take out the insert carefully while turning it. 44 . Open the fuel cocks and put the handle in position for normal running. Place a receptacle under the filters and shut off the filter to be changed. Change the other filter in the same way. 2. 9. D: Both filters turned off.Maintenance: Fuel System Twin fuel pre-filter/water separator The twin filter is equipped with a pressure gauge (1). Moisten the gasket and O-ring with fuel before assembling. Drain off water and contaminants through the drain plug (4). 8. Valve positions The flow of the fuel is governed by putting the handle (1) in the following positions: A: Normal running (both filters connected). 7. Change the filter elements If the engine is not running close the fuel cocks on the tank before changing filters.

Remove the old air filters (loosen hose clamp and turn air filter housing to change inner filter). It must not be cleaned. The condensate is drained via a hole in the charge air cooler. 45 . WARNING! If a large amount of water flows out of the drain hole. Check that the drain hole is not blocked. Fit the new air filters and the air filter cover. Clean the air filters cover/housing if necessary. Inlet manifold. Take care not to allow impurities to enter the engine.Maintenance: Air Inlet and Exhaust system Air Inlet and Exhaust Systems Changing the air filters Remove the air filter cover. from the inlet manifold. the aftercooler must be removed and proof tested. IMPORTANT! Scrap the old filters. Checking the drain hole Water can condense in the aftercooler during operation.

Chemical additives must therefore not be used when cleaning the system. The engine comes with an internal freshwater system connected to an engine mounted heat exchange. IMPORTANT! For coolant specification. Anticorrosive additives become less efficient with age and the coolant must therefore be changed in accordance with the recommendations in the maintenance schedule. It is a closed system and shall always be filled with coolant that protects the engine from internal corrosion and frost damage if the climate requires it. refer to chapter “technical data” in the back of this manual.Maintenance: Cooling system general Cooling system The freshwater system is the internal cooling system of the engine. Steam or hot fluid may spurt out. WARNING! The coolant is dangerous to your health and an environmental hazard. Do not add plain water. IMPORTANT! Check the coolant level on a cold stationary engine. Handle coolant with care and dispose of old coolant in accordance with local regulations. WARNING! Never open the pressure cap or drain the cooling system when the engine is warm. 46 . IMPORTANT! Certain parts of the system are made of light alloy. IMPORTANT! Coolant to be added should have the same concentration as the coolant in the engine.

Oil cooler 5. Rawwater outlet 7. Engine 4. Heat exchanger 3. Freshwater pump Drain points fresh water system Drain points raw water system 47 .Maintenance: Cooling system general Engine mounted heat exchanger The cooling system includes two circuits. and the raw water system is connected to a seawater inlet or a central cooling system. Rawwater pump 9. 1. Exp. Exhaust manifold 6. tank 2. The freshwater system is a closed circuit system. Charge air cooler 10. Rawwater inlet 8.

Maintenance: Cooling system general Radiator cooling The engine cooling water is cooled by a radiator in a one-circuit cooling system. Drain points fresh water system 48 . Schematic drawing not available.

Charge air cooler 10.g. Rawwater inlet 8. 49 . a box cooler. Drain points raw water system Pic. Exhaust manifold 5. Exp. Freshwater pump Drain points fresh water system Pic. a grid cooler. or any other external heat exchanger. e.Maintenance: Cooling system general Without engine mounted heat exchanger (Keel cooled) The engine cooling water is cooled by. Oil cooler 4. Rawwater outlet 7. not available. not available. tank 2. Rawwater pump 9. Engine 3. 1.

Make sure that systems connected to the cooling system are ventilated.g. Start the engine and let it idle for about 1 hour. water heater. for correct level. heater. but make sure to check the coolnt level anyway every once in a while. For correct level. 3. Filling when the system is empty 1. use the same coolant mixture as is already in the cooling system. Check air vents for leakage. If a separate expansion tank is installed. e. refer to section “coolant level check”. 6. 5. 50 . Check the coolant level and top up if needed. Fill slowly allowing air to bleed from the filler opening. Coolant filling Topping up IMPORTANT! When topping up. 5. NOTE! There is a low coolant level alarm installed as standard. NOTE! For coolant specification refer to section “technical data coolant”. Fill slowly so that evacuated air is able to pass the filler opening.Maintenance: Freshwater system Freshwater system Coolant level check The coolant level should be about five centimetres (2”) below the pressure cap sealing plane in the expansion tank. Fill the freshwater system with coolant to the correct level through the filler opening in the expansion tank. the coolant level must be between the MAX and MIN markings. refer to section “coolant level check”. Stop the engine and allow it to cool. IMPORTANT! The engine must not be operated under full load before the system has been bled and topped up. Fill the system with coolant through the filler opening in the expansion tank.

Freshwater system flushing The system should be flushed before changing coolant to avoid inferior cooling performance due to deposits in the cooling system. 5. 51 . 2. IMPORTANT! Check that all coolant really does drain out. Drain all other systems connected to the freshwater system. Drain the coolant as described earlier. refer to section ”Drain points”. Fill with coolant. heater. 2. Connect a suitable hose to each drain point. Remove the filler cap from the expansion tank. Close all drains.g. 4. Close all drain points when the flushing water has run out. Flush until the water running out of the drainage points is clean. Insert a hose into the filler opening on the expansion tank and flush with fresh water. Continue with all the drain points until all have been opened and all coolant has been drained off. e. etc. 4. 3. inside the drain plug(s)/tap(s). Open the drains and allow the coolant to drain off into a suitable vessel. water heater. 5. See section coolant filling when empty. 3.Maintenance: Freshwater system Coolant drain 1. 1. Deposits may need to be cleared away.

4. IMPORTANT! Check that the raw water really drains. refer to section ”Drain points”. 8. Remove the zinc anodes (Z) in the heat exchanger and in the reverse gear oil cooler. Draining the raw water system 1. and drain off the rawwater. 1 Z Z 2 6. 2. Deposits may need to be removed from inside the drain plugs/taps. Close the raw water in. Install the zinc anodes. Open the drains and allow the raw water to drain off into a suitable vessel. It cools the internal cooling system in an engine mounted or externally mounted heat exchanger and the reverse gear oil cooler. 1. 2. Close the rawwater cock.and outlet cocks. 52 . Make sure that good metallic contact is obtained between the anode and the casting. The system is protected against galvanic corrosion by zinc anodes located in the heat exchanger and in the reverse gear oil cooler. Check/change WARNING! Risk of water entry. IMPORTANT! Use an emery cloth for cleaning. Open the drain tap (1) on the heat exchanger and the tap (2) on the charge air cooler. If not. since this could impair the galvanic protection. Close the rawwater cock before doing any work on the rawwater system. 3. Connect a suitable hose to each drain point. clean the zinc anodes with emery cloth to remove the oxide layer before re-installing them. Check the zinc anodes and replace them if more than 50% of their original size has been used up.Maintenance: Raw water system Raw water system The raw water system is the engine’s external cooling system and it is either a seawater system or a central cooling system. Check that no leakage occurs. 7. WARNING! The raw water system must be closed and drained before commencing work on the system. 5. Open the rawwater cock before starting the engine. Close the drain taps (1 and 2). Zinc anodes. This due to the risk of sea water or water from the central cooling system entering the vessel. Do not use steel tools.

WARNING! Risk of water entry. The impeller will be easier to work with if it is put in hot water prior to fitting. 5. 53 . check the filter more frequently than specified in the maintenance schedule. Change as necessary. Remove the rawwater pump lid. Inspection/cleaning The rawwater filter is optional equipment. Seawater filter. Close the rawwater cock before doing any work on the rawwater system. Check/change WARNING! Risk of water entry. Lubricate the pump housing and the inside of the lid with water-resistant grease (which is not aggressive to rubber). Open the rawwater cock. Remove the lid (1) and lift up the insert. IMPORTANT! Always carry a spare impeller on board.Maintenance: Raw water system Impeller. 1. 5. Screw a stud into the end of the shaft and press the impeller in using a washer and nut. Open the rawwater cock and check carefully that no leakage occurs. Clean the insert and the housing (2). and pull the impeller out with water pump pliers. 2. which would make the engine overheat. 3. 2. 3. Check the impeller.. Fit the cover. 4. There is otherwise a risk that the filter would be blocked. Close the rawwater cock before doing any work on the rawwater system. Close the rawwater cock. If the water where the boat is operated contains a lot of contamination. If any cracks or other defects are visible. Install the components as in the illustration. 1. Press the impeller in with a circular motion (counter clockwise). 4. weed etc. using a new O-ring. the impeller must be changed. Check the O-ring. The shaft of the pump has an internal thread (M8).

Reset by pressing in the circuit breaker. read out the flash codes and take the necessary measures. IMPORTANT ! Always investigate the cause of the overload! Control and monitoring system The control system system is protected through the engine circuit breakers. the alternator and electronics can be damaged. the engine must be stopped and the current cut by switching off the battery isolator.Maintenance. System voltage is 24V. If the fault persists. The circuit breakers cut the power if the system is overloaded. battery chargers or other auxiliary equipment connected to the engine must be disconnected. WARNING! If maintenance has to be carried out on a powered up system. 54 . IMPORTANT! Never disconnect the current with the main switches when the engine is running. If the circuit between the alternator and the batteries is disconnected when the engine is running. Shore current for engine heaters. set control system to LOCAL MODE to prevent remote start. Spray these connections as necessary with water-repellent spray (Volvo Penta universal oil). Main switches The main switches must never be disconnected before the engine has been stopped. free from oxide and that they are securely tightened. for the same reason. IMPORTANT ! Always investigate the cause of the overload! Electrical connections Check that electrical connections are dry. Fuses The engine is fitted with two automatic circuit breakers. WARNING! Before any work is done on the electrical system. The charging circuits must never be re-connected with the engine running. the circuit breaker may have been activated. Electrical system Electrical system The engine is equipped with a 2-pole electrical system and an alternator. If it is not possible to start the engine or if the instrument stops working while running.

Risk of arcing and explosion. Electrolyte level The electrolyte level should be 5–10 mm (0. disconnect the – cable (black) first. which must be observed. 55 . After topping up. Maintenance WARNING! Fire and explosion hazard. Clean oxidation from the battery poles and terminals.2–0. IMPORTANT! Never confuse the positive and negative poles on the batteries. Always use protective goggles and gloves. Batteries must never be exposed to open flames or sparks. If acid comes into contact with your skin. using a copper brush. Always protect your eyes. WARNING! Never confuse the positive and negative poles on the batteries. WARNING! Battery electrolyte is highly corrosive. NOTE! Some maintenance-free batteries have special instructions. Top up with battery water as necessary. Cleaning Keep the batteries dry and clean. Connection and disconnection When you connect batteries.Maintenance.4") above the cell plates in the battery. and get medical assistance at once. especially in wet weather. then the + cable (red). first connect the + cable (red) to the + pole on the battery. Contamination and oxide on the batteries and battery poles can cause stray currents. If you get battery acid in your eyes. Tighten the terminals securely and grease them with terminal grease or Vaseline. Then connect the – cable (black) to the – pole on the battery When you disconnect batteries. the batteries should be charged by connecting them to a battery charger. or by running the engine at normal speed for 30 minutes. wash at once with soap and a lot of water. voltage drop and discharge. Electrical system Batteries. flush at once with a lot of water. skin and clothes when handling batteries.

Ventilate well. Quick charging can shorten battery life. flush at once with a lot of water. This forms an explosive mixture with air. and as close as possible to the weld site. skin and clothes. WARNING! Battery electrolyte is highly corrosive. Always connect the welder earth clamp to the component to be welded. Special instructions apply to so-called quick chargers. A short circuit. If acid comes into contact with your skin. Charging WARNING! Hydrogen is given off when batteries are charged.Maintenance. Then disconnect all cables connected to the alternator. During charging. WARNING! Always switch off the charge current before undoing the charging clamps. wash at once with soap and a lot of water. To avoid the risk of electrochemical corrosion when an external charger is connected. Electrical system Batteries. open flame or spark could cause a violent explosion. and should therefore be avoided. then trickle charged (please refer to the battery manufacturer’s recommendations). especially if the batteries are charged in an enclosed space. re-connect the control system connector and the alternator terminals before you connect the battery cables. If you get battery acid in your eyes. Never confuse the positive and negative poles on the batteries. Batteries are damaged by being left discharged. and get medical assistance at once. IMPORTANT! After you have finished welding. The clamp must never be connected to the engine or in such a way that current can pass through a bearing. 56 . If the boat is not used for a longer period of time. the battery cables in the boat should be removed from the batteries before the charger is connected. the batteries should be fully charged. and can also freeze and burst easier in cold weather. unscrew the cell plugs but leave them in the plug holes. Also undo the connector for the control system from the control unit.Press the lock tab down and pull the connector out. Electric welding Remove the positive and negative cables from the batteries. Charge batteries if they have become discharged. Protect your eyes. Risk of arcing and explosion. IMPORTANT! Observe the instruction manual for the battery charger carefully. Ventilate well.

4. Stray currents can weaken the galvanic protection of the propeller. Protective earth cables for radio. ) must be intended for marine use. a main switch (1) must be connected between the auxiliary battery positive (+) pole and the fuse box for the boat’s electrical equipment.. 1 57 . IMPORTANT! Work on the low voltage circuits in the boat should be done by a person with electrical training or knowledge. If land current is connected. The land current installation must also be provided with an earth fault breaker (RCCB). in accordance with local regulations for mains electricity. The main switch must disconnect all loads and shall be switched off when the boat is not used.Maintenance. keel etc. rudder. its protective earth must be connected ashore.. The land current installation (transformer. rudder. 5. Electrical system Electrical installations A faulty electrical installation can generate stray currents from the electrical system. shall be connected to a common earthing point which is not connected to the engine or reverse gear. All equipment connected to the auxiliary battery shall have separate switches. Electrical cables must be installed and clamped in such a way that they are not exposed to chafing. battery charger etc. The main switch must disconnect all loads connected to the auxiliary battery and shall be switched off when the loads are not used. 3. propeller shaft. IMPORTANT! The engine and reverse gear must never be used as earth planes. or other equipment which uses protective earthing. 2. NOTE! A charge splitter (optional) should be installed to charge two independent battery circuits from the standard alternator. The starter battery shall have a main switch on the positive (+) side of the battery. bathing steps etc. inverter. damp or splashing water in the bilge. never to the boat. navigation equipment. and cause damage because of electrochemical corrosion. Always consider the following: 1. Installation or work on land current equipment must only be done by a competent electrician. where the high voltage section is galvanically isolated from the low voltage section. If an extra auxiliary battery is used.

An alternative is to drain the coolant. A poorly charged battery can freeze and break. it should be checked by a Volvo Penta dealer for possible need of overhaul or repair. It contains directions for performing maintenance in a safe and correct manner. 6. Disconnect the battery cables and clean and charge the batteries. the exhaust opening and the engine. Spray electric system components with water repellant. rubber hoses or electrical components. Inspect all control cables and apply anti-corrosion agent. Clean the engine externally. IMPORTANT! For generator specific inhibiting information. IMPORTANT! The following must be considered when cleaning with a high-pressure water jet: Never point high-pressure water jets directly at seals. Drain off any water and contaminant from the fuel tank. Therefore we have compiled a checklist of the most important points. IMPORTANT! Store the engine in a well-ventilated room. Drain the rawwater system. Remove the impeller from the rawwater pump. It is of utmost importance that the conservation is performed correctly. Keep the impeller in a cool place in a closed plastic bag. 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 conservation oil. Certain preservatives are flammable. Never use the high-pressure function when washing the engine. 8. 5. Fill the tank with fuel to avoid condensation. This can result in condensation and harm the installation. 7. WARNING! Read the chapter “Maintenance” thoroughly before starting any maintenance work. 1. IMPORTANT! Put a note on the engine giving the date. the preparations must be repeated every 12 months. Use a protective mask. Cover the air intake to the engine. 3. 58 . Touch up any paint damage with Volvo Penta original paint. Provide good ventilation. IMPORTANT! Never use vinyl sheets for covering. 4. 9. Before taking the genset out of service for long periods. 2. refer to generator documentation. Trickle charge during the storage period. Some are also dangerous to inhale. Add more if necessary. it must be conserved. Care during Storage Recharge the battery at least once a month. IMPORTANT! During longer periods out of operation. type of conservation and the preservative that was used. Refer to next page. Make sure there is enough anti-freeze in the coolant.Inhibiting General To prevent the genset and other equipment from being harmed during long (2 months or more) periods out of service.

Close the drain cocks and fit the drain plugs of the rawwater system. Fit new fuel filters and bleed the fuel system. When the engine has run long enough to warm up apply the load and bring it to operating speed. Check under and around the engine for such items as loose or missing bolts. 11. 3. 1 59 . 9. 10. Remove any protective covers on the engine. oil. Fill and bleed the rawwater system. Check for oil. fuel or coolant leaks. 5. 6. Connect fully charged batteries. 6. Check drive belts. Drain the conservation oil from the engine. 7. 5. Follow the directions on the previous page in other respects. 12. 2. Top up with lubricant of the correct grade in the engine if necessary. 4. Top up if necessary. Start the engine and run it at idling speed until approximately two liters of the fuel/conservation oil mixture have been consumed. 2. Conserving the lubricating and fuel systems for stops longer than eight months: 2 1. fuel or coolant leaks and repair if needed. 3. Check the condition of rubber hoses and check the tightness of all hose clips. 8. Bleed the fuel system. air intake and exhaust pipe. 4. Drain the oil from the engine and fill with conservation oil* to just over the MIN mark on the dipstick. Fit the impeller in the rawwater pump.Inhibiting Return the Engine to Service 1. Check the coolant level and anti-freeze. Connect supply (1) and return (2) fuel lines to a fuel can filled with 1/3 conservation oil* and 2/3 diesel fuel. * Conservation oils are available from oil companies. Stop the engine and connect the ordinary fuel lines. Start the genset and run it at idling speed until it reaches operating temperature before loading it.

Connect black jumper cable to negative pole (–) of the help start battery. 3. WARNING! Never confuse positive and negative poles on the batteries. risk of arcing. Do not bend over the batteries. WARNING! Do not touch poles during start attempt. Start engine and run at fast idle for ten minutes to charge the batteries. Battery gas is explosive. 2. 4. then to the positive pole of the help start battery. 1. Remove the jumper cables in the reverse order from installation. Connect red jumper cable to positive pole (+) of the flat battery. and then to a place some distance from the flat batteries. 60 . Stop the engine. such as the negative connection on the starter motor.In case of emergency Start with auxiliary batteries WARNING! Ventilate well. WARNING! Black jumper cable (–) must not touch positive connection on the starter motor.

1. NOTE! The engine will still be monitored and protected by the EMS and the Power Module as well as the Shutdown Unit.In case of emergency Auxiliary START In case of control system(MCU) failure it is possible to by-pass the control system and start the engine “manually”. Push the button until the engine starts. refer to section ”Start with auxiliary battery”. 61 . 2. In case of battery power loss. Locate AUXILIARY START button on the bracket above the starter.

40.2.18. 38.32.43 5.20.11. make sure the emergency stop button is reset Symptoms and possible causes Starter motor does not rotate when cranking Starter motor rotates slowly when cranking Engine does not start Engine starts but stops again Engine does not reach correct operating speed Engine runs unevenly Engine knocks Engine vibrates Engine can not be stopped High fuel consumption Black or Dark gray exhaust smoke Blue or white exhaust smoke High lubrication oil consumption Lubrication oil pressure too low Coolant temperature too high Coolant temperature too low No charge or poor charge 1.14. 11. Only use original Volvo Penta spare parts. 33. 36. 13.37. refer to generator documentation. 24. Too low lubrication oil level Lubrication oil leakage Worn cylinder liners and/or piston rings Worn valve stem seals Blocked lubrication oil filter Radiator blocked Blocked heat exchanger insert Blocked aircooler Faulty engine mounting Too low coolant level Air in fresh water system Blocked sea water inlet/pipe/filter Defective impeller in seawater pump Circulation pump drive belt slips Defective fresh water pump Defective/wrong thermostat Too high lubrication oil level Defective lubrication oil pump Defective relief valve Alternator drive belt slips Defective bearings/abnormal cylinder friction 43. 2.46 8.40 27.14.2.19. 34.4.17.13.36.21. 31.9. 21. 26.28.25.42 5. 8. 20.17.15. Alternator/Rectifier broken 49. 12.24. 27.20.24.14.7.21.45 5. 15.4.41 1.31.14.6.38. 25.25. Flat batteries Poor contact/broken cables Main switch turned off A fuse/circuit breaker has blown/tripped Lack of fuel Defective Power Module Faulty starter motor/solenoid Defective fuel supply pump Blocked fuel injectors Defective fuel injectors Incorrect valve clearance Incorrect fuel injection timing Low compression pressure Improper fuel oil Improper lubrication oil Air in fuel system Water/contamination in fuel Engine speed control wrongly adjusted Insufficient air supply Too high coolant temperature Too low coolant temperature 22.44.44 14.13.21 10. 5. 37.13. 7.12. High back pressure in exhaust system Very cold engine and lubrication oil Abnormal load Engine consume lubrication oil or combustible gas 47.35. 30. If faults or hitches arise that you cannot solve alone.14.12.10.30 1. NOTE! If the engine won’t start. Cylinder liner have scalings or such that reduce cooling effect 48. 19. 41. For generator specific troubleshooting.19.20.39. 39. 28.49 1.13. 6.16. 18.17. When disassembling a component.16.2.47 36 1. 46.3. NOTE! Dust and foreign particles are the most common cause of excessive wear of parts.19. 9. 14. 4. 42.23.13.45 10.2. 16.37.24.15. take measures to prevent dust and foreign particles from entering it. you must always get in touch with your Volvo Penta dealer.38 15. 45.34.12. 35. WARNING! Read the safety directions for maintenance and service in the chapter “Safety information” before starting any work. 23.15. 10. 32.22.19. 3.11.13.19.Troubleshooting A number of symptoms and possible causes for engine disturbances are described in the table below.24 8.44 15.3. 29. 44.10.27 29.16.14.33.24.19 5. IMPORTANT! Handle parts carefully. 17.12. Water entry into engine 62 .16.26.16.17.10.

........................................................... .0177’’) 0............................... engine with heat exchanger................................................. ....................0197’’) not available not available *excl............ 6 9. AC alternator output.. Excl......................................................50 mm (0....................... No engine inclination ................. at Prime Power* .... –max.............................................. exhaust . .. 490°C/(914°F) 470°C/(878°F) 480°C/(896°F) 420°C/(788°F) Lubricating system Oil capacity.............. oil filters 26 liters (6...... Displacement ...... Valve clearance (cold engine): inlet .. AC alternator voltage/max.......... approx...................................... amperage ................... .4 liters (573 in3 ) 0................ Compression pressure at starter motor speed (120 rpm) .. 39 liters (10.......Technical Data D9 MG HE Genset engine General Number of cylinders ..................................... 24V 28V/60A 1700W 63 ...................... approx..........3 US gals) Electrical system System voltage ........... without generator and frame.................................................................... Prime Power .. Exhaust temperatures 263 kW 239 kW 1500 rpm 292 kW 265 kW 1800 rpm at Standby Power* ......9 US gals) 11 liters (2................9 US gals) Cooling system Freshwater system capacity including heat exchanger..45 mm (0....................... approx.. engine oil & coolant Performance 1500 rpm 1800 rpm Standby Power ................................... volume difference min..... approx............ Dry Weight*.....................

....................................9 US gals) 11 liters (2....................... amperage ................................. AC alternator output................................. at Prime Power* ...28 g/cm3 = 0.............. approx............... Prime Power ...50 mm (0.......................... 490°C/(914°F) 470°C/(878°F) 480°C/(896°F) 420°C/(788°F) Lubricating system Oil capacity.........................................13 g/cm3 = 0............................... engine oil & coolant Performance 1500 rpm 1800 rpm Standby Power ....................... No engine inclination . AC alternator voltage/max...... battery recharged at ..Technical Data D9 MG RC Genset engine General Number of cylinders ......... approx.................................... exhaust ...........0177’’) 0........ Exhaust temperatures 251 kW 227 kW 1500 rpm 271 kW 244 kW 1800 rpm at Standby Power* . Dry Weight*....... volume difference min............................................ Excl....................0462 lb/in3 1........ engine with heat exchanger... approx..... Electrical system System voltage ......... –max.................. .................... Compression pressure at starter motor speed (120 rpm) .................. Valve clearance (cold engine): inlet ...............................................45 mm (0.......9 US gals) Cooling system Freshwater system capacity including heat exchanger............................0197’’) not available not available *excl.......................0408 lb/in3 64 ..................... approx........................ n........... 1.. ............. 24V 28V/60A 1700W Battery electrolyte density at +25°C (77°F): fully charged battery ........ ....... ... Displacement ............... 6 9..........4 liters (573 in3 ) 0....... oil filters 26 liters (6..........................................a............... without generator and frame......................

..................................... Exhaust temperatures 263 kW 239 kW 1500 rpm 292 kW 265 kW 1800 rpm at Standby Power* ........4 liters (573 in3 ) 0.... exhaust ................................... AC alternator voltage/max........................... approx...........0408 lb/in3 65 ........................ amperage ............ 1.. 6 9.............. ....... ................ AC alternator output..........0177’’) 0........ 490°C/(914°F) 470°C/(878°F) 480°C/(896°F) 420°C/(788°F) Lubricating system Oil capacity. Compression pressure at starter motor speed (120 rpm) ...............................45 mm (0...........50 mm (0............ approx.............. Displacement ..........9 US gals) Cooling system Freshwater system capacity including heat exchanger...... Dry Weight*............................................................ ......................28 g/cm3 = 0............................................. –max. without generator and frame.......... approx...............13 g/cm3 = 0............ engine with heat exchanger........................ ......... at Prime Power* ............ battery recharged at ..............................0462 lb/in3 1............. 24V 28V/60A 1700W Battery electrolyte density at +25°C (77°F): fully charged battery .. Electrical system System voltage .................... Prime Power ................0197’’) not available not available *excl.................. volume difference min.... n........................... Excl........ Valve clearance (cold engine): inlet ........... No engine inclination .......... engine oil & coolant Performance 1500 rpm 1800 rpm Standby Power ..9 US gals) 11 liters (2......... oil filters 26 liters (6...................................... approx.......Technical Data D9 MG KC Genset engine General Number of cylinders ..............a.........................................................................

. D975 ... (refer to chapter Maintenance lubrication system). 5% and an increase in fuel consumption of approx............2-D EN590 ....5 wt%........ Type2. e.... No.. 66 . Fuels with low density (urban diesel in Sweden and city diesel in Finland) can result in a loss of power by approx..... Type1.... service intervals must be changed.............: JIS KK 2204..1-D.......... No....Technical data Fuel specification Fuel must comply with national and international standards for commercially supplied fuels.. ......g...... with national environment and cold requirements Sulfur content Complying with legal requirements in each country.. If the sulfur content exceeds 0......... Type3 ASTM. 2–3 %.

0% 1) Oil change interval: Reached first in operation: 600 hr. thus causing major damage. thus shortening the engine life. or 12 months. or 12 months. E2 API: CF. 200 hr.0% more than 1. Note. or 12 months. 100 hr. 200 hr. use oil with TBN > 15.0% by weight. or 12 months. Important! Excessively high oil viscosity causes power loss and higher oil temperature. Lubrication oil must comply with both requirements. CG-4 NOTE! Mineral based oil. VDS-2 and Global DHD-1 VDS and ACEA E3 2) ACEA: E4. = = = = Volvo Drain Specification Association des Constructeurs Européenne d’Automobiles American Petroleum Institute Total Base Number VDS ACEA API TBN Selection of oil viscosity Use the following chart to select appropriate oil viscosity according to the ambient temperature. −30 −20 −10 ±0 +10 20 30 40 o C −15oC −25oC SAE 15W/40 SAE 10W/30 ✱ SAE 5W/30 −10oC SAE 20W/30 ±0oC SAE 30 +10oC SAE 40 o 68 86 104 −22 −4 +14 32 50 F * Refers to synthetic or semi-synthetic oils. 67 . by weight 0. 50 hr. E3. or 12 months.5% VDS-3 VDS-2 and ACEA E5 Sulphur content in fuel. API: CG4 or CH4 can be approved in markets outside Europe. or 12 months. CF-4. or 12 months.5–1. or 12 months. 300 hr. or 12 months. either fully or semi-synthetic. Oil grade up to 0. 150 hr. can be used on condition that it complies with the quality requirements above. 1) 2) If sulphur content is > 1. while excessively low oil viscosity results in inadequate lubrication and leakage of combustion gas with increased wear and reduced output as a result. or 12 months. or 12 months. 100 hr. 400 hr. 100 hr.Technical Data Lubrication oil specification Recommended types of engine oil Important! Use of improper or inferior oil can cause excessive wear of bearings and moving parts. 200 hr. It can also result in sticking of piston rings and seizing of pistons in the cylinders. or 12 months. 75 hr.

Volvo Penta Coolant..................... 40% “Volvo Penta Coolant” and 60% water.... use distilled .......... Ensure that the liquids mix properly.......................5 °dH < 40 ppm < 100 ppm < 5.................. may decrease corrosion protection and may damage the engine or block the cooling system... Future claims might be rejected should Coolant 90 not have been used........ This mixture protects the engine against internal corrosion. Ready Mixed A ready-mixed coolant.......... this may cause the engine to overheat.......................................... It also lubricates the coolant pump seals and reduce the risk of cavitation............. corrosion may occur........ < 340 ppm < 9......... cavitation damage and freezing conditions down to -28 °C (18°F)........... The water must comply with the requirements in ASTM D4985.. cavitation and frost damage........ pH value .....de-ionized water......... IMPORTANT! Mixing other types of concentrated coolant with Volvo Penta Coolant.........................10 ppm < 0............... Mix in a separate........... Mixing ratio Mix 40% Volvo Penta Coolant and 60% water...Technical Data Coolant specification Always use Volvo Penta Coolant in the freshwater cooling circuit......... IMPORTANT! It is extremely important that the correct concentration of coolant is added to the system..... Water quality Always use clean water that complies with the requirements in ASTM D4985..... Chloride .... If these requirements are not complied with............ 68 ..... Iron ..... Total solid content .... Sulphate ............................05 ppm < 500 µS/cm <15 mg KMnO4/L Volvo Penta Coolant A concentrated coolant that is to be mixed with water.. (Using 60 % glycol lowers the freezing point to -54 °C (65°F))..................... cavitation and frost damage down to -28 °C (18°F)......................................... Organic content..... Total hardness .................................... If the coolant contains more than 60% Volvo Penta Coolant the cooling ability of the coolant mixture is impaired......5 – 9 < 20 mg SiO2/l < 0... Volvo Penta Coolant acts both as anti-freeze agent and provides corrosion protection for the metal parts of the cooling system... IMPORTANT! Coolant must be mixed withclean water......................................... refer to “Water quality”........... Too high concentration of Volvo Penta Coolant also impairs the frost protection..... which would result in impaired cooling performance................................. This concentration protects the engine against corrosion.. It has been developed to function optimally with Volvo Penta’s engines and provides excellent protection against corrosion............................... the cooling galleries in the engine or radiator may be blocked by contamination................... Manganese . If the coolant contains less than 40% Volvo Penta Coolant......................... clean vessel before adding into the cooling system.. Conductivity ... Silica ............. CODMn .....

........... Serial engine number ................................................................... Product number ...........) ...... Engine Model: ........................... ECU batch .................. 1. Conformas To: ....D.......................................................................... Dataset decal (1) Dataset .............. can be found on the engine and the generator... Engine Family: ........................................................................... Useful Life of Engine: ..... 4......................................... ........... ........................................................ River Rhein approval decal (4) River Ch 8a Type Approval No........ NO: ECU BATCH: kW RPM 2......................................... Warranty decal (2) Product designation .. 3................... Static Timing (degrees before T.......................) .................... Serial and basic engine number ..Technical Data Identification numbers D9 MG Genset engine Type plates with identification numbers and labels with information on certificates and classification............ / exh....... VP serial No.................................................................................... 1 2 3 4 5................. This information must always be used as a reference when ordering service and spare parts.................................................................................... EPA decal (3) Model Year: ................................................... . D9 MG RATED POWER: RATED SPEED: DATASET: SPEC. Year of Manufacture ...................................................................C..................... Low Idle Speed: .................. Spec Number .... Valve Lash (inl.................................................................................. Displacement / Cylinder: ..... 5 69 .................. Call off identity decal (4) Chassi No..........................

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7744726-6 English 04-2005 .

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