Volvo Penta D16 Operator's Manual
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Volvo Penta D16 Operator's Manual

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  • Page 1 Operator’s manual D16/genset...
  • Page 2 Do not modify or tamper with the exhaust system. • Do not idle the engine except as necessary. For more information www.P65warnings.ca.gov/marine www.p65warnings.ca.gov/products/diesel © 2019 AB VOLVO PENTA Volvo reserves the right to make changes Printed on environmentally friendly paper...

  • Page 3: Table Of Contents

    Excessive strain on a product and components ........15 Environmental care ................. 16 Recording engine data ................16 Certified Engines ..................17 Volvo Penta Dealer Network ..............18 Volvo Penta Action Service ..............18 Instruments and Controls ................ 19 Marine Commercial Control System (MCC) ........19 MCC system, Overview ...............
  • Page 4 Battery ....................74 Electrical Welding ................76 Storage ....................... 77 Bringing Out of Storage ............... 78 Technical Data ................... 79 Viscosity ....................79 Coolant, Mixing ..................81 Identification Numbers ................. 83 Index ......................85 47711740 05-2019 © AB VOLVO PENTA...

  • Page 5: Foreword

    Pay careful attention to the safety instructions included in the manual. As the owner of a Volvo Penta engine, you become part of a worldwide network of dealers and service workshop that assist you with technical advice, service requirements and replacement parts.

  • Page 6: Safety Information

    This chapter describes how safety precautions are If anything remains unclear or if you are unsure of presented in the manual and on the product. Read the something, contact your Volvo Penta dealer for chapter through very carefully before you start the assistance.
  • Page 7 WARNING! Ensure that all machine guards and safety devices are in place and are functional. P0024482 CAUTION! Never use tools or products that show signs of damage. 47711740 05-2019 © AB VOLVO PENTA...
  • Page 8 Ensure that the workplace is well ventilated and take the necessary precautions before welding or grinding begins. Always ensure that there is a fire extinguisher close at hand in the work area. P0024470 47711740 05-2019 © AB VOLVO PENTA...
  • Page 9 Spare parts — safety WARNING! Always use spare parts with the same quality as genuine Volvo Penta parts to minimize the risk of an explosion or fire. Components in fuel systems and electrical systems on Volvo Penta engines are designed and manufactured to minimize the risk of explosions and fire, in accordance with applicable legal requirements.
  • Page 10 Information on the engine IMPORTANT: Make sure that all warning and information decals on the product are always visible. Replace decals which have been damaged or painted over. D16C-A MG 47711740 05-2019 © AB VOLVO PENTA...
  • Page 11 Before welding work IMPORTANT: Before any work with electric weld can begin, the connection to all control units must be disconnected. After finished welding, re-connect the connection to all control units before connecting any battery cable. 47711740 05-2019 © AB VOLVO PENTA...
  • Page 12 There is a risk that hot oil can spray out. Refueling WARNING! There is always a risk of fire and explosion during refueling. Smoking is forbidden and the engine must be stopped. 47711740 05-2019 © AB VOLVO PENTA...
  • Page 13 Safety Information Proper fuel quality IMPORTANT: Always use the fuel recommended by Volvo Penta. See Technical Data in Operator’s Manual. Other fuel can damage the engine. Wrong fuel quality can also lead to higher service costs. P0024477 WARNING! Risk of personal injury.
  • Page 14 Cleanliness for sensitive components IMPORTANT: Observe meticulous cleanliness when handling system components. Even minimal amounts of dirt could cause a breakdown. Adjustment of the clutch CAUTION! Clutch adjustments must be carried out with the engine stopped. 47711740 05-2019 © AB VOLVO PENTA...

  • Page 15: Introduction

    Introduction Check that you heave received the correct operator’s manual before continuing reading. If not, please contact your Volvo Penta dealer. Read the Operator’s Manual carefully and learn to handle the engine, controls and other equipment in a safe manner before you start the engine.

  • Page 16: Warranty

    Introduction Warranty Your new Volvo Penta marine engine is covered by a limited warranty, subject to the conditions compiled in the Warranty Information. Note that AB Volvo Penta’s liability is limited to the specification in the Warranty Information and Emission Control System Warranty Statement.

  • Page 17: Maintenance And Replacement Parts

    These qualities will be maintained through regular servicing and the use of spare parts with the same quality as genuine Volvo Penta parts. If reliable and purpose-built parts are not used, your safety, health, and the machine’s function may be compromised.

  • Page 18: Environmental Care

    Introduction Environmental care Environmental care is a core value at Volvo Penta. Energy efficiency and low emissions are among the most important product related aspects and priority focus areas for Volvo Penta business. Several of the global challenges the world faces are directly or indirectly related to power industries and transports.

  • Page 19: Certified Engines

    NOTICE! Neglects or failure to follow the points listed here may invalidate the engine emission certificate. This means AB Volvo Penta can no longer guarantee engine conformity with the certified model. Volvo Penta is not responsible for damages or costs arising as a result of this.

  • Page 20: Volvo Penta Dealer Network

    The Volvo Penta global network of authorized dealers is at your service. We strongly recommend that you take your product to an authorized Volvo Penta dealer for service and repair. They are specialists in Volvo Penta products and have the accessories, genuine...

  • Page 21: Instruments And Controls

    Marine Commercial Control System (MCC) Marine Commercial Control (MCC), is a type-approved control system that monitors your Volvo Penta engine. MCC comprises an marine control unit (MCU), remote panel (RP), shutdown unit (SDU) and a relay card. The MCU is the main system panel and it communicates with all of the engine control units.

  • Page 22: Mcc System, Overview

    5 Remote panel 6 Comap CAN2 7 Other Comap equipment 8 Data bus: CAN/J1939 and J11708/1587 9 EMS 10 Shutdown Senders & Switches a Oil pessure switch b Coolant temperature switch c RPM sender 47711740 05-2019 © AB VOLVO PENTA...
  • Page 23 Can be set to any function when installing. 14 Red lamp; indicates that there is an alarm. The lamp flashes when a new alarm occurs. The lamp shines continuously when an alarm is active and acknowledged. 47711740 05-2019 © AB VOLVO PENTA...
  • Page 24 E ! : There is an alarm in the alarm list. F Engine status: NotReady: the system is not ready and the engine cannot be started. Ready: the system is ready and the engine can be started. Running: the engine is in operation. 47711740 05-2019 © AB VOLVO PENTA...

  • Page 25: Menus

    When all information is shown the first image is visible again. Browse in the window using the up/ down buttons. 4 Exit the menu with the Page button (1) . 47711740 05-2019 © AB VOLVO PENTA...

  • Page 26: Settings

    Password” where 0 is shown. Press Enter (2) to confirm the selection. 4 Exit the menu by pressing Page (1). The password gives full access to the MCU. Parameters may only be changed by trained personnel. 47711740 05-2019 © AB VOLVO PENTA...
  • Page 27 4 Number of unsuccessful starts 5 Momentary average fuel consumption 6 Service time (hours until next service) Statistical values can be adjusted with PC software (password protected); contact your Volvo Penta dealer. 1. Not standard; Comap InternetBridge hardware and adaptation of software required.

  • Page 28: Alarms

    The alarm list is not activated while values, parameters and alarm history are being reviewed. For further information on how to handle alarms and take recommended actions, refer to the Fault handling, page 36 chapter. 47711740 05-2019 © AB VOLVO PENTA...

  • Page 29: Shutdown Unit (Sdu)

    Overspeed test To test overspeed function push the overspeed test button (inside the SDU). When pushed the overspeed limit drops 25%. NOTICE! Only use Volvo Penta tool supplied with SDU for reset. 47711740 05-2019 © AB VOLVO PENTA...

  • Page 30: Sdu Indications

    8 Red – S3 Shutdown active H Yellow – S2 Broken wire detected 9 Red – S2 Shutdown active Yellow – S1 Broken wire detected 10 Red – S1Shutdown active J Overspeed shutdown test button 47711740 05-2019 © AB VOLVO PENTA...

  • Page 31: Starting

    If the engine is not ready to start (Not Ready), check the following: • Check the alarm list. Acknowledge any alarms. • Check the ECU alarm list. Acknowledge any alarms. • Check the wiring between the MCC cabinet and the engine. 47711740 05-2019 © AB VOLVO PENTA...
  • Page 32 IMPORTANT: Never race the engine when it is cold. Racing the engine when it is cold can damage the engine components and decrease the engine lifetime. 47711740 05-2019 © AB VOLVO PENTA...

  • Page 33: Operation

    Take the necessary action; refer to the Fault handling, page 36 section for further information. Alarm notations remain in the alarm list until they have been acknowledged and rendered "inactive" (fault remedied). 47711740 05-2019 © AB VOLVO PENTA...

  • Page 34: Maneuvering

    Monitor running data that is not shown in the main menu: 1 Browse with the Page button (1) to the engine data menu (Monitoring page). 2 Use the up/down buttons to select the desired engine data. 47711740 05-2019 © AB VOLVO PENTA...

  • Page 35: Engine Shutdown

    In order to be able to restart the engine, the button must be reset to its original position. To do this, pull the button upwards until you hear a click. P0005904 47711740 05-2019 © AB VOLVO PENTA...

  • Page 36: After Engine Shutdown

    30 seconds after turning off the ignition. This in order to save engine data to the engine control unit. NOTICE! Depending on the model and setup, there could be more than one switch. 47711740 05-2019 © AB VOLVO PENTA...

  • Page 37: Operation Break

    Maintenance, page 66 and Seawater System, Draining, page 69 respectively for more detailed information. Check the charge status of the battery. A poorly- charged battery can freeze and burst. 47711740 05-2019 © AB VOLVO PENTA...

  • Page 38: Fault Handling

    This chapter describes some possible alarms and fault handling. Note that the content of this chapter does not provide full coverage of the possible fault messages and alarms. Contact a Volvo Penta workshop for assistance with diagnostic readouts and unresolved faults. Acknowledge message The Acknowledge button (1) acknowledges all alarms.

  • Page 39: Alarm List

    Scroll between the alarms in the list with the enter key. Status of alarm • Unacknowledged alarms are marked with * (5) • Active alarms are indicated by a black background • Inactive alarms are displayed without a black background (7) 47711740 05-2019 © AB VOLVO PENTA...
  • Page 40 Power module J1587) For more information about fault code and a complete list look in the workshop manual. Alarm list and history Abbreviations in alarm list and history Abbreviation Meaning Warning Sensor failure General alarm 47711740 05-2019 © AB VOLVO PENTA...

  • Page 41: Fault Tracing

    A number of symptoms and possible causes of engine malfunctions are described in the table below. Always contact your Volvo Penta dealer if any problems occur that you cannot solve by yourself. NOTICE! Read the safety regulations for care and maintenance in the Safety precautions for maintenance and service operations chapter before work you start work.
  • Page 42 34. Lubricating oil level too high 35. Water entry into engine 36. High back pressure in exhaust system 37. Faulty engine speed sensor 38. Unacknowledged fault codes in the alarm list or ECU alarm list 47711740 05-2019 © AB VOLVO PENTA...

  • Page 43: Fault Code Register

    Check emergency stop button if any. Reset if necessary. Remedy the problem. Reset the system by switching the main switch off and on. Contact a Volvo Penta workshop if the fault remains. EngCool Temp Wrn Coolant temperature too high Engine power is reduced.
  • Page 44 Overcurrent protection for the auxiliary supply has tripped. • Check the auxiliary stop connections for short circuits. Reset the system by switching the main switch off and on. Contact a Volvo Penta workshop if the fault remains. ExtSTOP Active Fls Emergency Stop Switch •...
  • Page 45 Check the oil level. Refer to Reverse gear, ZF. • Check that the oil strainer is not blocked. Refer to Reverse gear MGX. Contact a Volvo Penta workshop if the fault remains. Fuel Press Wrn Fuel pressure too low. •...
  • Page 46 Fault Code Register Sd Overspeed SDU Wrn ECU, Wrn J1587 Critical system fault Engine shuts down automatically. Contact a Volvo Penta workshop if the fault remains. Secondary Batt Fls Secondary Battery. Poor batteries or charging Refer to Battery, Charging SeaWater Press Wrn Seawater pressure too low Engine power is reduced.
  • Page 47 Wrn SD System Fail Internal fault in SDU system Break in wiring to sensor or internal SDU fault. Limited or no shutdown function. Contact a Volvo Penta workshop if the fault remains. Wrn Underspeed Engine Speed. Engine is emergency stopped.

  • Page 48: In Case Of Emergency

    Engine cannot be started. • The engine rpm is limited • The engine stops If a fault occurs, confirm any fault alarm and take the necessary measures. Refer to this section and Fault Code Register. 47711740 05-2019 © AB VOLVO PENTA...

  • Page 49: Starting Using Auxiliary Batteries

    Do not touch the connections during the start attempt: Risk of arcing. Do not bend over any of the batteries either. 5 Turn off the engine. Remove the start cables in the exact opposite order to their connection. 47711740 05-2019 © AB VOLVO PENTA...

  • Page 50: Maintenance Schedule

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

  • Page 51: Maintenance

    Volvo Penta recommend that all servicing with the engine running should be undertaken by an authorized Volvo Penta workshop. The intervals when maintenance items must be carried are indicated in the Maintenance Schedule.
  • Page 52 Maintenance D16 MG HE Marine genset 1 Electrical connection box with SD reset 2 Expansion tank 3 Heat exchanger 4 Coolant filler cap 5 Auxiliary stop 6 MCU connection box with panel 7 Oil filler cap, engine 8 Switchable fuel filters...
  • Page 53 Maintenance D16 MG RC Genset engine 1 Coolant filler cap 2 Expansion tank 3 Air Filter 4 Electrical connection box with SD reset 5 Auxiliary stop 6 Oil filler cap, engine 7 Switchable fuel filters 8 Fuel Shut-off Valve 9 Engine Control Unit...
  • Page 54 Maintenance D16 MG RC Marine genset 1 Coolant filler cap 2 Expansion tank 3 Air Filter 4 Electrical connection box with SD reset 5 Auxiliary stop 6 MCU connection box with panel 7 Oil filler cap, engine 8 Switchable fuel filters...
  • Page 55 Maintenance D16 MG KC Genset engine 1 Electrical connection box with SD reset 2 Expansion tank 3 Coolant filler cap 4 Auxiliary stop 5 Oil filler cap, engine 6 Switchable fuel filters 7 Keel cooling connections 8 Seawater Pump 9 Fuel Shut-off Valve...
  • Page 56 Maintenance D16 MG KC Marine genset 1 Electrical connection box with SD reset 2 Expansion tank 3 Coolant filler cap 4 Auxiliary stop 5 MCU connection box with panel 6 Oil filler cap, engine 7 Switchable fuel filters 8 Keel cooling connections...

  • Page 57: Engine, General

    4 Install a new air filter and tighten the lid. 5 Reinstate the pressure drop indicator by pressing in the indicator button. IMPORTANT: Scrap the old filter; it may not be cleaned. P0006752 47711740 05-2019 © AB VOLVO PENTA...

  • Page 58: Drive Belt, Check And Change

    P0006336 7 Raise the belt tensioner (2) and install the new alternator belt. 8 Re-install the water pump drive belt. 9 Install the belt guards. 10 Start the engine and do a function check. 47711740 05-2019 © AB VOLVO PENTA...

  • Page 59: Lubrication System

    If you want longer oil change intervals than stated in the table Technical Data, page 79, the oil change interval can under certain conditions be increased. To see if the engine complies, Volvo Penta oil analysis need to be performed. Contact your Volvo Penta dealer for further information.

  • Page 60: Engine Oil, Change

    Check that no leaks are present at the filters. 7 Stop the engine. Wait a few minutes before checking the oil level. Top up as needed. Hand in the old oil and filters to a recycling station. 47711740 05-2019 © AB VOLVO PENTA...

  • Page 61: Oil Filter/By-Pass Filter, Change

    Then tighten the filters another 3/4 to 1 turn. 7 Start the engine (idle) and make sure that no leakages occur. Check the oil level once the engine has stopped. 47711740 05-2019 © AB VOLVO PENTA...

  • Page 62: Switchable Oil Filters

    8 Put the handle in the operating position (straight up). 9 If necessary, top up the system at the first stop. Refer to section Engine Oil, Change, page 58. 47711740 05-2019 © AB VOLVO PENTA...

  • Page 63: Fuel System

    Always observe the greatest cleanliness during refueling and work on the fuel system. All work on the injectors of the engine must be carried out by an authorized Volvo Penta workshop. WARNING! Fire hazard. When carrying out work on the fuel system make sure the engine is cold.

  • Page 64: Engine Fuel Filter Replacement

    Tighten the bleeding nipple while fuel is flowing out. 9 Remove the hose and put the protective cap back on the nipple. 10 Start the engine and check for leakages. 47711740 05-2019 © AB VOLVO PENTA...
  • Page 65 7 Remove the hose and put the protective cap back on the nipple. 8 Repeat the procedure with the other filter. 9 Turn the handle to normal operating position (N). Check for leakages. 47711740 05-2019 © AB VOLVO PENTA...

  • Page 66: Fuel System, Bleeding

    5 Run the engine at idle for a few minutes to remove any remaining air from the system. The close the venting nipple (1) on the engine and check that it does not leak. 47711740 05-2019 © AB VOLVO PENTA...

  • Page 67: Fuel Pre-Filter

    Maintenance Fuel pre-filter Volvo Penta fuel pre-filters are supplied in single and double models. Checks The double filter is fitted with a pressure gauge 1 that indicates when it is time to replace the filter cartridges. The filter cartridges must be replaced according to maintenance schedule recommendations, or earlier if the pressure gauge shows a pressure drop of 6–10 in.

  • Page 68: Freshwater System

    - in the worst case - can cause engine breakdown. Volvo Penta strongly recommend the use of our own coolants, ”Volvo Penta Coolant VCS Ready Mixed” or the concentrate ”Volvo Penta Coolant VCS”, which...

  • Page 69: Coolant Level, Checking And Topping Up

    Never run the engine under full load before the system has been bled and topped up. 4 Check air vents for leakage. 5 Stop the engine and allow it to cool. Check the coolant level and top up if needed. 47711740 05-2019 © AB VOLVO PENTA...

  • Page 70: Coolant, Draining

    3 Flush until the water which runs out of the drain points is clean. 4 Close all drain points when all coolant has run out. 5 Fill up with coolant, please refer to Coolant Level, Checking and Topping Up, page 67. 47711740 05-2019 © AB VOLVO PENTA...

  • Page 71: Seawater System

    Open the drains and allow the raw water to drain off into a suitable vessel. IMPORTANT: Check that all water really does drain out. Deposits may need to be cleared away, inside the drain plug/ tap. D16C-A MG 47711740 05-2019 © AB VOLVO PENTA...

  • Page 72: Anodes, Check And Change

    6 Close the drain tap (1 ). 7 Open the sea cock before starting the engine. 8 Check that there are no leaks. D16C-A MG 47711740 05-2019 © AB VOLVO PENTA...

  • Page 73: Impeller, Check And Change

    (M8). Screw a stud into the end of the shaft and press the impeller in using a washer and nut. Fit the cover, using a new O-ring. 5 Open the sea cock. NOTICE! Always carry a spare impeller on board. 47711740 05-2019 © AB VOLVO PENTA...

  • Page 74: Seawater Filter, Check And Cleaning

    The status of the fuse functions are shown in the MCU menu. Should an automatic fuse blow, repair the fault and restart the system to reset the fuse. 47711740 05-2019 © AB VOLVO PENTA...

  • Page 75: Main Switch

    For the same reason, the charging circuits must never be re-connected with the engine running. Electrical Connections Check that electrical connections are dry, free from oxide, and that they are securely tightened. 47711740 05-2019 © AB VOLVO PENTA...

  • Page 76: Battery

    • Charge the battery regularly. A battery that is kept fully loaded has a maximum service life. The easiest way to check if a battery needs charging is to use a voltmeter. 47711740 05-2019 © AB VOLVO PENTA...
  • Page 77 1 Connect the + cable (red) to the + pole on the battery and tighten the nut. 2 Connect the – cable (black) to the – pole on the battery and tighten the nut. NOTICE! Hand in the old battery to a re-cycling station. 47711740 05-2019 © AB VOLVO PENTA...

  • Page 78: Electrical Welding

    The clamp must never be connected to the engine or in such a way that current can pass through a bearing. IMPORTANT: After finished welding, re-connect the EVC connector and the alternator terminals before connecting the battery cables. 47711740 05-2019 © AB VOLVO PENTA...

  • Page 79: Storage

    Before the engine is taken out of service for a long period of time, an authorized Volvo Penta workshop should check it over. Have any faults and deficiencies attended to, so that the equipment is in order, ready for the next start.

  • Page 80: Bringing Out Of Storage

    Check the coolant level. Top up as necessary. • Connect the fully charged batteries. • Start the engine and warm it up at fast idle with no loading. • Check that no oil, fuel or coolant leakage occurs. 47711740 05-2019 © AB VOLVO PENTA...

  • Page 81: Technical Data

    Technical Data Engine Product sales designation D16 MG HE D16 MG KC D16 MG RC Product designation D16C-A D16C-A D16C-A D16C-D D16C-D D16C-D Power, prime/stand-by 450/495 kW @1500 450/495 kW @1500 433/476 kW @1500 479/527 kW @1500 479/527 kW @1500...
  • Page 82 Sufficient fuel lubricity is essential to protect the fuel injection system against excessive wear. Restrictions for other diesel fuels Volvo Penta also approves the use of other diesel fuels as long as the here specified restrictions are followed. However Volvo Penta does not guarantee compliance with emission legislation or fulfillment of expected lifetime with these other diesel fuels.

  • Page 83: Coolant, Mixing

    Follow the mixing recommendation on the product. The coolant should be mixed with distilled, deionized water. For Volvo Penta specified water requirements; refer to Water Quality. NOTICE! Always use “Ready Mixed” coolant if water quality cannot be determined or if it does not fulfill ASTM D4985.
  • Page 84 AC alternator voltage/max. amperage 28 V / 110 A output, approx. 2240 W Battery electrolyte density at +25°C (77°F) fully charged battery 1.28 g/cm = 0.0462 lb/in battery recharged at 1.13 g/cm = 0.0408 lb/in 47711740 05-2019 © AB VOLVO PENTA...

  • Page 85: Identification Numbers

    Certification label (E) Certification plate (classified genset) (F) Product designation ......... Serial number ......... Product number ......... P0006755 P0010315 Generator plate (G) Product designation ......... Serial number ......... Product number ......... P0010316 P0010866 P0010865 47711740 05-2019 © AB VOLVO PENTA...

  • Page 87: Index

    Switchable oil filters...........60 Certified Engines............17 Cold Weather Precautions........35 Coolant Level, Checking and Topping Up....67 Viscosity..............79 Coolant, Draining............68 Volvo Penta Action Service........18 Volvo Penta Dealer Network........18 Drive belt, check and change........56 Warranty..............14 Electrical Connections..........73 Electrical System............72 Electrical Welding............76...
  • Page 89 παράδοση,μέσω διαδικτύου. http://manual.volvopenta.com/coupon/ http://manual.volvopenta.com/coupon/ Veuillez contacter votre Distributeur Volvo Penta si vous avez Εάν δεν είναι δυνατή η πρόσβαση στο ιαδίκτυο,παρακαλούμε un problème d‘accès à l‘Internet. επικοινωνήστε με το δικό σας αντιπρόσωπο της Volvo Penta.
  • Page 90 AB Volvo Penta SE-405 08 Göteborg, Sweden www.volvopenta.com...

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