Volvo Penta D8 2020 Operator's Manual
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Volvo Penta D8 2020 Operator's Manual

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  • Page 1 Operator’s manual...
  • 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 © 2020 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 ........17 Environmental care ................. 18 Recording engine data ................18 Certified Engines ..................19 Volvo Penta Dealer Network ..............20 Volvo Penta Action Service ..............20 Instruments and Controls ................ 21 Marine Commercial Control System (MCC) ........21 MCC system, Overview ...............
  • Page 4 Battery ....................70 Electrical Installations ................71 Electrical Welding ................73 Storage ....................... 74 Technical Data ................... 75 Lubrication System .................. 76 Viscosity ....................76 Coolant, Mixing ..................79 Identification Numbers ................. 82 Index ......................83 47712598 09-2020 © AB VOLVO PENTA...

  • Page 5: Foreword

    Pay careful attention to the safety instructions included in the manual. As the owner of a Volvo Penta marine engine, you become part of a worldwide network of dealers and service workshops 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 Use protective gloves and avoid oil-soaked clothes and rags. Wash regularly, especially before eating. Wear suitable protective creams to prevent skin from drying out and to facilitate cleaning. 47712598 09-2020 © AB VOLVO PENTA...
  • Page 8 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 9 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. 47712598 09-2020 © AB VOLVO PENTA...
  • Page 10 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. 47712598 09-2020 © AB VOLVO PENTA...
  • Page 11 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. 47712598 09-2020 © AB VOLVO PENTA...
  • Page 12 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 13 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. 47712598 09-2020 © AB VOLVO PENTA...

  • Page 14: Maneuvering

    Instead, try to change the speed, trim or load distribution. If possible, take down or open the cockpit awning. Contact your boat dealer for the best solution for your boat. 47712598 09-2020 © AB VOLVO PENTA...
  • Page 15 • anchor • paddle • flashlights Spare Parts and Tools: • impeller • fuel filters • fuses • tape • hose clamps • engine oil • other tools that may be required 47712598 09-2020 © AB VOLVO PENTA...

  • Page 16: 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 17: 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 18: Running In The Engine

    Make sure to always use suitable and correctly mixed coolant. If an unsuitable coolant has been used, or if the instructions for coolant mixture have not been followed, future warranty claims related to engine and accessories may be denied. 47712598 09-2020 © AB VOLVO PENTA...

  • Page 19: 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 20: 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 21: 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 22: 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 23: Instruments And Controls

    Instruments and Controls This chapter describes the instruments, panels and controls Volvo Penta sells for your engine. If you would like to complement your instrumentation, or if your boat is equipped with instruments not described here, we ask that you contact your Volvo Penta dealer.

  • Page 24: Mcc System, Overview

    5 Remote panel 6 Comap CAN2 7 Other Comap equipment 8 Data bus: CAN/J1939 9 EMS 10 Power ON 11 Shutdown Senders & Switches a Press. switch b Temp. switch c RPM sender 12 Shutdown module 47712598 09-2020 © AB VOLVO PENTA...
  • Page 25 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. LoadShar: the engine is under load and in operation with another engine. 47712598 09-2020 © AB VOLVO PENTA...

  • Page 26: 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) . 47712598 09-2020 © AB VOLVO PENTA...

  • Page 27: Alarms

    1 Press the Enter button (2) and hold it down to reach the info menu. Press the Page button (1). 2 Browse using the up/down buttons. 3 Press Enter (2) to select the language and close the menu. 47712598 09-2020 © AB VOLVO PENTA...
  • Page 28 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. 47712598 09-2020 © AB VOLVO PENTA...
  • Page 29 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 30: Shutdown Module (Sdm)

    Therefore, if the shutdown override mode is active, Volvo Penta’s product liability may cease. In shutdown override mode the engine will not shut down for any reason other than overspeed. The shutdown override mode is active for as long as the switch remains in override mode.
  • Page 31 Instruments and Controls Fuses In SDM there are six fuses mounted marked: F1 = Primary battery F2 = Secondary battery F3 = EVC/MCC F4 = EMS F5 = EATS F6 = SDM unit/Terminal 1,2 P0027954 47712598 09-2020 © AB VOLVO PENTA...

  • Page 32: Starting

    • Start the engine bay fan, where fitted, and allow it to run for at least four minutes. • Check that there is sufficient fuel for the planned trip. 47712598 09-2020 © AB VOLVO PENTA...

  • Page 33: Starting The Engine

    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. 47712598 09-2020 © AB VOLVO PENTA...

  • Page 34: Overheating Protection

    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. 47712598 09-2020 © AB VOLVO PENTA...

  • Page 35: Operation

    Take the necessary action; refer to the Fault handling, page 39 section for further information. Alarm notations remain in the alarm list until they have been acknowledged and rendered "inactive" (fault remedied). 47712598 09-2020 © AB VOLVO PENTA...

  • Page 36: Maneuvering

    If the engine is regularly tested without load, limit the duration of the operation to 5 minutes. Run the engine at full load for about 4 hours once a year, for the carbon deposits in the engine and exhaust system to burn off. 47712598 09-2020 © AB VOLVO PENTA...
  • Page 37 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. 47712598 09-2020 © AB VOLVO PENTA...

  • Page 38: Engine Shutdown

    EATS system from urea solution. Stop the Engine Auxiliary Stop If the engine cannot be stopped using a normal procedure, the engine can be stopped via the auxiliary stop installed on the back of the engine. 47712598 09-2020 © AB VOLVO PENTA...

  • Page 39: 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. 47712598 09-2020 © AB VOLVO PENTA...

  • Page 40: Operation Break

    Maintenance, page 65 and Draining the Seawater System, page 67 respectively for more detailed information. Check the charge status of the battery. A poorly- charged battery can freeze and burst. 47712598 09-2020 © AB VOLVO PENTA...

  • Page 41: 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. Message from engine and MCC system...

  • Page 42: Acknowledge Message

    • Number of active alarms (1) • Number of unacknowledged alarms (2) • Total number of alarms (3) • Number of pages (4). Scroll between the alarms in the list with the enter key. 47712598 09-2020 © AB VOLVO PENTA...
  • Page 43 E2: Which control unit. (E1=EMS, E2=ACM, E3=SDM) 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 47712598 09-2020 © AB VOLVO PENTA...

  • Page 44: 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 problems occur which you can not solve by yourself. NOTICE! Read through the safety advice for care and maintenance work in the Safety precautions for maintenance and service operations chapter before starting work.
  • Page 45 37. Faulty engine speed sensor 38. Stored fault codes 39. Non-return valve in feed pump leaks 40. Alternator drive belt slips/broken 41. Check that the AUX stop button on the engine is in the RUN position (not depressed) 47712598 09-2020 © AB VOLVO PENTA...

  • Page 46: Fault Code Register

    Check the cable connections in the Shutdown relay. Engine Oil Filter Possible cause: There is an oil pressure difference and engine power is reduced. Corrective action: Contact your Volvo Penta workshop. Engine Oil Level Possible cause: The oil level is too low.
  • Page 47 Fault Code Register Engine Speed Possible cause: Engine performance may be compromised and engine power is reduced. Corrective action: Contact your Volvo Penta workshop. Exhaust Temperature Possible cause: The exhaust temperature is too high and engine power is reduced. Corrective action: Contact your Volvo Penta workshop.
  • Page 48 Check engine fuses. Refer to Fuses, page 69. Sensor Failure Possible cause: A sensor failure may be affecting engine performance. Corrective action: Contact your Volvo Penta workshop. Transmission Oil Pressure Possible cause: The reversing gear oil pressure is too low.
  • Page 49 Low coolant level. • Check for coolant leakage. • Check coolant level. Refer to Coolant Level. CalibrMemFail Software corrupt. CAN BB1 CAN communication failure. CAN BB2 CAN communication failure. Com.Fail Communication failure. Shutdown Module (SDM). 47712598 09-2020 © AB VOLVO PENTA...
  • Page 50 • 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 Coolant temperature too high. •...
  • Page 51 Check that no leakage occurs. • If engine is shut down, check SDM and make a reset. EngOverspeed Critical system fault Engine shuts down automatically. Contact a Volvo Penta workshop if the fault remains. EATS Failure Malfunction detected in the SCR/EATS system. ECUMainRelay Smart Relay Module (SRM).
  • Page 52 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 53 Check the oil level. Refer to Reversing gear, ZF. • Check that the oil strainer is not blocked. Refer to Reversing gear MGX. Contact a Volvo Penta workshop if the fault remains. GearOilPres Reversing gear oil pressure too low. Critical system fault Engine shuts down automatically.
  • Page 54 Engine is difficult to start or does not start. PickupCrank Crankshaft speed sensor Cable failure or deviation in the measured value against camshaft. • Engine runs unevenly. • Engine is difficult to start or does not start. 47712598 09-2020 © AB VOLVO PENTA...
  • Page 55 Check that the seawater filter is not blocked., Refer to Seawater Filter, page 68. • Check the impeller in the seawater pump., Refer to Impeller, Check and Change, page 68. Contact a Volvo Penta workshop if the fault remains. Sd Oil Pressure Wrn ECU, Wrn J1587 Critical system fault Engine shuts down automatically.
  • Page 56 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 SeaWaterPress Seawater pressure too low Engine power could be reduced.
  • Page 57 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 58: In Case Of Emergency

    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. 47712598 09-2020 © AB VOLVO PENTA...

  • Page 59: Emergency Shifting

    P0004983 5 Turn the button a 1/2 turn anti-clockwise (the button is forced out by spring action). The reverse gear is now connected for forward motion and cannot be disengaged by the control lever. 47712598 09-2020 © AB VOLVO PENTA...

  • Page 60: 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 61: 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 62: Engine, General

    Stop the engine before doing any maintenance work. General The drive belt has an automatic tensioner and does not need manual adjustments. Regularly check the belt condition and belt tension. Make sure that the belt tensioner does not bottom. 47712598 09-2020 © AB VOLVO PENTA...
  • Page 63 3 Remove the drive belt. 4 Install the new drive belt and release the locking of the belt tensioner. Make sure the drive belt fits properly into the grooves. 5 Fit the protective cover over the drive belt. 47712598 09-2020 © AB VOLVO PENTA...

  • Page 64: Lubrication System

    If you want longer oil change intervals than stated in the table Lubrication System, page 76, 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 65: 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 66: 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 67: 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 68: Coolant Level

    Be careful when opening the coolant filler cap and release pressure before removing the cap. IMPORTANT: Only use coolant recommended by Volvo Penta. Top up with the same type of coolant as already used in the system. Different types of coolant must not be mixed.

  • Page 69: Seawater System

    If it is not possible to avoid this, carefully flush with fresh water and make sure it is properly dried up afterwards. Drainage point for heat exchanger. 47712598 09-2020 © AB VOLVO PENTA...

  • Page 70: Impeller, Check And Change

    2 Unscrew the cover (1) and remove the sealing plate (2). 3 Lift out the insert (3) and clean it. 4 Reinstall the parts as illustrated. 5 Open the sea cock and check for leaks. 47712598 09-2020 © AB VOLVO PENTA...

  • Page 71: Electrical System

    Always stop the engine and break the current using the main switches before working on the engine. IMPORTANT: Contact a Volvo Penta dealer for information if any arc welding will be performed on the application. Arc welding can cause damage to the engine and the electronics.

  • Page 72: Electrical Connections

    NOTICE! If low starter battery alarm occur, the battery may get drained which might result in loss of functions and engine stopping. 47712598 09-2020 © AB VOLVO PENTA...

  • Page 73: Electrical Installations

    Leakage current can in turn render galvanic protection inadequate in respect of propellers, propeller shafts, rudder posts, the keel etc., and may cause damage through electrochemical corrosion. 47712598 09-2020 © AB VOLVO PENTA...
  • Page 74 All equipment connected to the auxiliary battery must have separate main switches. For simultaneous charging of two independent battery circuits a separate charging distributor (accessory) should be installed on the standard alternator. 47712598 09-2020 © AB VOLVO PENTA...

  • Page 75: 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 alternator terminals and cables connected to EMS, MCC before connecting the battery cables. 47712598 09-2020 © AB VOLVO PENTA...

  • Page 76: Storage

    All information on how to prepare and handle the engine and its equipment before, during and after storage is included in the “Service and Maintenance manual”. The manual is available for downloading (or purchasing) at volvopenta.com, Manuals & Handbooks. 47712598 09-2020 © AB VOLVO PENTA...

  • Page 77: Technical Data

    16.5:1 600 (±10) rpm Idling speed 1) According to ISO 8665 2) At delivery, the idle speed is adjusted to 600 rpm. If needed, the speed can be adjusted within the range 600–800 rpm. 47712598 09-2020 © AB VOLVO PENTA...

  • Page 78: Lubrication System

    Oil change interval, reached first in operation: VDS 4.5 500 hours or 12 months VDS = Volvo Drain Specification Viscosity Select the viscosity according to the table. The temperature values refer to stable ambient temperatures. 47712598 09-2020 © AB VOLVO PENTA...
  • Page 79 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 80 Penta approves the use of paraffinic diesel fuels that complies with standard EN 15940. The fuel guarantees compliance with emission legislation and fulfills the expected lifetime as long as the service requirements are followed. Volvo Penta also approves the use of fuel blends between these paraffinic fuels and diesel fuels that comply with the quality requirements.

  • Page 81: 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 82 5.5–9 Silica (acc. ASTM D859) <20 mg SiO Iron (acc. ASTM D1068) <0.10 ppm Manganese (acc. ASTM D858) <0.05 ppm Conductivity (acc. ASTM D1125) <500 µS/cm Organic content, COD (acc. ISO8467) <15 mg KMnO 47712598 09-2020 © AB VOLVO PENTA...
  • Page 83 1.28 g/cm = 0.0462 lb/in (1.24 g/cm = 0.0448 lb/in battery recharged at 1.24 g/cm = 0.0448 lb/in (1.20 g/cm = 0.0434 lb/in NOTICE! * Applies to batteries with tropical acid. 47712598 09-2020 © AB VOLVO PENTA...

  • Page 84: Identification Numbers

    * The numbers refer to the position of the identification numbers on the information decal/plate. 5, 6, 7, 8 A Engine serial number P0022680 B Product information (Black label) P0022680 C Reversing gear plate D Electrical rudder actuator plate (10) (11) P0022778 47712598 09-2020 © AB VOLVO PENTA...

  • Page 85: Index

    Oil Level..............62 Operation at low load..........34 Operation Break............38 Overheating protection..........32 Read the instruments and warm the engine up..32 Reading the Instruments........... 33 Recording engine data..........18 Running in the engine..........16 47712598 09-2020 © AB VOLVO PENTA...
  • Page 87 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 88 AB Volvo Penta SE-405 08 Göteborg, Sweden www.volvopenta.com...

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