Volvo Penta D16 MH MCC Operator's Manual
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Volvo Penta D16 MH MCC Operator's Manual

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OPERATOR'S MANUAL
D16 MH
MCC

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  • Page 1 OPERATOR’S MANUAL D16 MH...
  • Page 2 .‫شهرً ا من بعد التسليم‬ /http:// manual.volvopenta.com/coupon Volvo Penta ‫إذا كان الوصول إلى اإلنترنت غير متاح، فالرجاء االتصال بوكيل‬ CALIFORNIA PROPOSITION 65 WARNING Engine exhaust, some of its constituents, and a broad range of engine parts are known to the State of California to cause cancer, birth defects, and other reproductive harm.

  • Page 3: Table Of Contents

    Engine Shutdown ..................23 Fault Handling ................... 25 Fault Code Register .................. 30 In Case of Emergency ................35 Maintenance Schedule ................38 Maintenance ....................41 Storage ....................... 71 Technical Data ................... 74 Alphabetical index ..................79 47706582 09-2015 © AB VOLVO PENTA...

  • Page 4: Foreword

    Do not hesitate to consult your Volvo Penta dealer. Failure to follow the instructions and cautions in this manual may result in serious accidents.

  • Page 5: Safety Information

    This symbol is used on our products in some cases and refers to important information in the operator’s manual. Make sure that warning and information symbols on the engine are clearly visible and legible. Replace symbols which have been damaged or painted over. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 6 47706582 09-2015 © AB VOLVO PENTA...
  • Page 7 This list can be extended, since the need for safety equipment varies with the type of boat, and where or how it is used etc. We recommend that you ask a regional boat or sea safety organization for more detailed maritime safety information. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 8 Turbocharger unit can cause serious personal injury. Service literature covering more complicated opera- Foreign objects can also be sucked in and cause tions is available from your Volvo Penta dealer. mechanical damage to the unit. Never carry out any work on the engine if you are...
  • Page 9 Chemicals Installing non Volvo Penta components may cause the system to malfunction. Most chemicals such as anti-freeze, rustproofing agent, inhibiting oil, degreasing agent etc. are haz- Service must be done by approved workshops.

  • Page 10: Introduction

    Introduction This Operator's Manual has been prepared to give you the greatest possible benefit from your Volvo Penta marine engine. It contains the information you need to be able to operate and maintain the engine safely and correctly. Please read the Operator's Manual carefully and learn to handle the engine, controls and other equipment in a safe manner before you cast off on your maiden voyage.
  • Page 11 Service on injection pumps, pump settings and nance, to avoid unnecessary environmental impact. injectors must always be done by an authorised Please contact your Volvo Penta dealer if you notice Volvo Penta workshop. any changes such as increased fuel consumption or •...

  • Page 12: 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 communi- cates with all of the engine control units.
  • Page 13 The lamp flashes when a new alarm occurs. The lamp shines continuously when an alarm is active and acknowledged. 13 Ackn: acknowledge selection, acknowledge alarm The button is also used to reset the SDU. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 14 Browse with the Page button to the main menu (Main). Browse between windows using the up/down buttons. Measurements 1 Browse with the Page button to the engine data menu (Measurement). P0010306 2 Browse in the engine data menu with the up/down buttons. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 15 Continue to press Enter to see all infor- mation about the event. When all information is shown the first image is P0010302 visible again. Browse in the window using the up/ down buttons. 4 Exit the menu with the Page button. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 16 0 is shown. Press Enter to confirm the selection. 4 Exit the menu by pressing Page. The password gives full access to the MCU. Parame- ters may only be changed by trained personnel. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 17 5 Momentary average fuel consumption 6 Service time (hours until next service) P0012968 Statistical values can be adjusted with PC software (password protected); contact your Volvo Penta dealer. 1. Not standard; adaptation of software required. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 18 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 25 chapter. P0010307 Alarm list 47706582 09-2015 © AB VOLVO PENTA...
  • Page 19 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. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 20 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 47706582 09-2015 © AB VOLVO PENTA...

  • Page 21: Starting

    This raises the temperature in the combustion cham- bers, which ensures reliable starting and reduces start- ing smoke. The idling speed is also governed by engine tempera- ture, and is somewhat raised after a cold start. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 22 Monitor running data that is not shown in the main menu: 1 Browse with the Page button to the engine data menu (Measurements). 2 Use the up/down buttons to select the desired engine data. P0010306 47706582 09-2015 © AB VOLVO PENTA...

  • Page 23: Operation

    Take the necessary action; refer to the Fault Handling page 25 section for further information. Alarm notations remain in the alarm list until they have P0010312 been acknowledged and rendered "inactive" (fault remedied). 47706582 09-2015 © AB VOLVO PENTA...
  • Page 24 3 Move the control lever back with a quick, firm move- ment and increase revolutions. IMPORTANT! All engines must be running during maneuvers astern, otherwise there is a risk of water entering the exhaust system on the stopped engine. 47706582 09-2015 © AB VOLVO PENTA...

  • Page 25: Engine Shutdown

    Close the sea cock where fitted. • Take an hour meter reading and carry out preven- tive maintenance according to the maintenance schedule. • Turn off the main switch before any long stoppage. P0005914 47706582 09-2015 © AB VOLVO PENTA...
  • Page 26 Raw Water System, Draining page 60 and Maintenance page 56 respectively for more detailed information. Check the charge status of the battery. A poorly- charged battery can freeze and burst. P0005905 47706582 09-2015 © AB VOLVO PENTA...

  • Page 27: Fault Handling

    It is possible to perform emergency shifting, please refer to In Case of Emergency page 37. In emer- gency situations it is also possible to start the engine with gear engaged after acknowledging the alarm. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 28 ECU AlarmList • Active alarms are indicated by a black back- ground (1) Wrn Sd Syst Fall • Unacknowledged alarms are marked with * (2) • Inactive alarms are displayed without a black background (3) 47706582 09-2015 © AB VOLVO PENTA...
  • Page 29 Primary Batt Secondary Batt Exhaust Temp PS 5 M158 OC 53 FM 5 P0013089 Alarm list and history Abbreviations in alarm list and history Abbreviation Meaning Warning Automatic shutdown Sensor failure General alarm P0010309 47706582 09-2015 © AB VOLVO PENTA...
  • Page 30 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 Information page 6 chapter before work you start work.
  • Page 31 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 47706582 09-2015 © AB VOLVO PENTA...

  • Page 32: 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. Please contact a Volvo Penta workshop if the fault remains. EngCool Temp Wrn Coolant temperature too high. Engine power is reduced.
  • Page 33 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. Please contact a Volvo Penta workshop if the fault remains. ExtSTOP Active Fls Emergency Stop Switch •...
  • Page 34 Cleaning page 62. • Check the impeller in the seawater pump., Please refer to Impeller, Check and Change page 61. Please contact a Volvo Penta workshop if the fault remains. Sd Gear Oil Press Wrn ECU, Wrn J1587 Critical system fault. Engine shuts down automatically.
  • Page 35 Sd Overspeed SDU Wrn ECU, Wrn J1587 Critical system fault. Engine shuts down automatically. Please contact a Volvo Penta workshop if the fault remains. Secondary Batt Fls Secondary Battery. Poor batteries or charging. Please refer to Battery, Charging page 65 SeaWater Press Wrn Seawater pressure too low.
  • Page 36 Wrn SD System Fail Internal fault in SDU system. Break in wiring to sensor or internal SDU fault. Limited or no shutdown function. Please contact a Volvo Penta workshop if the fault remains. Wrn Underspeed Engine Speed. Engine is emergency stopped.

  • Page 37: In Case Of Emergency

    The gear is in neutral and 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. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 38 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. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 39 Forward drive is now engaged and cannot be disen- gaged by the control lever. Forward drive can only be interrupted by stopping the motor with the start lock or the stop button. 47706582 09-2015 © AB VOLVO PENTA...

  • Page 40: Maintenance Schedule

    Maintenance Schedule Your Volvo Penta engine and its equipment are designed for high reliability and long life. The engines are built to withstand the marine environment, but also to have the smallest possible environmental impact. If the engine and transmission are serviced regularly according to the schedule, these qualities will be retained and unnecessary malfunctions will be avoided.
  • Page 41 Transmission: According to manufacturers recommendations ● Start and warm up engine Engine and transmission, abnormal noises ● Engine and transmission, oil / fuel / water leakage ● 1) Readout if any fault codes and LVD 47706582 09-2015 © AB VOLVO PENTA...
  • Page 42 Every 3000 hours / At least every (month) Wear kit in seawater pump Every 8000 hours / At least every (month) ● Coolant VCS (yellow) 1) Different types of coolant must not be mixed with each other. 47706582 09-2015 © AB VOLVO PENTA...

  • Page 43: Maintenance

    12 Filling coolant 13 Heat exchanger 14 Filling lubrication oil 15 Auxiliary stop 16 Oil filter, reverse gear 17 Change-over fuel filter 18 Raw water pump 19 Fuel shut-off valve 20 Engine control unit 21 Alternator 47706582 09-2015 © AB VOLVO PENTA...
  • Page 44 7 Switchable fuel filters 8 Fuel Shut-off Valve 9 Engine Control Unit 10 Alternator 11 Charge air cooler 12 Radiator 13 Fresh water pump 14 Oil filter 15 By-pass filter for engine oil 16 Starter motor P0010385 47706582 09-2015 © AB VOLVO PENTA...
  • Page 45 4 Install a new air filter and tighten the lid. 5 Reinstate the pressure drop indicator by pressing in the indicator button. IMPORTANT! P0006752 Scrap the old filter. It must not be cleaned. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 46 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. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 47 6 Stop the engine. Wait a few minutes before you check the oil level. Top up as necessary. NOTICE! Dispose of the old oil and discarded filters at an authorized recycling station. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 48 Then tighten the filters another 3/4 to 1 turn. 7 Start the engine (idle) and make sure that no lea- kages occur. Check the oil level once the engine has stopped. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 49 Fire hazard. When carrying out work on the fuel system make sure the engine is cold. A fuel spill onto a hot surface or an electrical component can cause a fire. Store fuel soaked rags so that they cannot cause fire. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 50 Tighten the purging nipple while the fuel flows out. 9 Remove the hose and fit the protective cap to the bleed nipple. 10 Start the engine and check for leaks. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 51 9 Remove the hose and fit the protective cap to the bleed nipple. 10 Repeat the procedure on the other filter. 11 Turn the handle to the normal operating position (N). Check that no leaks are present. P0022003 47706582 09-2015 © AB VOLVO PENTA...
  • Page 52 The close the venting nipple (1) on the engine and check that it does not leak. 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.
  • Page 53 8 Dry up any fuel spills. 9 Replace the other filter in the same way. 10 Open the fuel taps and put the lever in the normal operating position. Check that there are no leaks. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 54 Expansion vessel Engine Oil cooler Exhaust manifold Inlet manifold Cylinders Thermostat Charge air cooler Freshwater pump 10 Raw water pump 11 Heat exchanger 12 Gear box oil cooler 13 HT-water inlet 14 HT-water outlet 47706582 09-2015 © AB VOLVO PENTA...
  • Page 55 Maintenance D16 MH Drain points R = Raw water drain points F = Fresh water drain points P0010415 D16 MH RC 47706582 09-2015 © AB VOLVO PENTA...
  • Page 56 Coolant Vent P00100390 Expansion tank Engine Oil cooler Exhaust manifold Inlet manifold Cylinders Thermostat Charge air cooler LT-water pump 10 LT-water outlet 11 LT-water inlet 12 HT-water pump 13 HT-water inlet 14 HT-water outlet 47706582 09-2015 © AB VOLVO PENTA...
  • Page 57 Maintenance Drain points F = Fresh water drain points P0010417 47706582 09-2015 © AB VOLVO PENTA...
  • Page 58 The use of anti-corrosion agents alone is not permitted in Volvo Penta engines. Never use water alone as the coolant. The corrosion protection additives become less effec- tive over time, which means that the coolant must be changed at regular intervals;...
  • Page 59 The coolant must be mixed with distilled, deionized water. The water must fulfil the requirements specified by Volvo Penta; refer to Technical Data page 76. It is extremely important that the system is filled with the correct coolant concentration. Mix in a separate clean vessel before filling the cooling system.
  • Page 60 The engine must not be operated 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. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 61 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 58. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 62 IMPORTANT! Check that all water really does drain out. Deposits may need to be cleared away, inside the drain plug/ tap. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 63 (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. IMPORTANT! Always carry a spare impeller on board. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 64 IMPORTANT! If a large amount of coolant flows out of the drain hole, the charge air cooler must be removed and pressure tested. This work must be carried out by an authorized work- shop. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 65 For the same reason the charging circuits must never be re-connected with the engine running. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 66 Remove oxidation from the battery poles and terminals, using a brass brush. Tighten the terminals securely and grease them with terminal grease or petroleum jelly. P0016903 47706582 09-2015 © AB VOLVO PENTA...
  • Page 67 • Special instructions apply to boost charging. Boost charging can shorten battery life, and should there- fore be avoided. P0002111 47706582 09-2015 © AB VOLVO PENTA...
  • Page 68 All equipment con- nected 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. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 69 The clamp must never be connected to the engine or in such a way that current can pass through a bearing. IMPORTANT! After finished welding, re-connect the alternator termi- nals before connecting the battery cables. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 70 Never over-fill the reverse gear. 4 Start the engine and run until the reverse gear has reached operating temperature. 5 Check the oil level, as in the description in section “Oil level, Checking and topping up”. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 71 2 Clean the strainer and other components in paraffin (kerosene). 3 Carefully put the components back again. 4 Tighten the plug/screw. 5 Start the engine and check carefully that no leakage occurs. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 72 Applies only to Twin Disc reverse gear Lubricate the seal on the output shaft bearing (with the lubricating nipple) using a hand gun and lithium-based grease such as Mobilux EP2, Statoil Uniway EP2N, Texaco Multifak EP2, Q8 Rembrandt EP2. P0003754 47706582 09-2015 © AB VOLVO PENTA...

  • Page 73: Storage

    7 Disconnect the battery cables and clean and charge the batteries. Trickle charge during the stor- age period. A poorly charged battery can freeze and break. 8 Clean the engine externally. Touch up any paint damage with Volvo Penta original paint. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 74 Stop the engine and connect the ordinary fuel lines. 5 Drain the conservation oil from the engine. 6 Follow the directions in section “Preparations” in other respects. 2. Conservation oils are available from oil companies. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 75 11 Check for oil, fuel or coolant leaks. 12 When the engine has run long enough to warm up apply the load and bring it to operating speed. 47706582 09-2015 © AB VOLVO PENTA...

  • Page 76: Technical Data

    1945 kg 1945 kg D16 MH RC Weight, dry 1750 kg 1750 kg 1750 kg 1750 kg 1750 kg D16 MH (heat exchanger) Idle 550-800 550-800 550-800 550-800 550-800 * According to ISO 8665. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 77 Global Diesel Heavy Duty American Petroleum Institute Total Base Number Viscosity Select the viscosity according to the table. The temperature values refer to stable ambient tem- peratures. * SAE 5W/30 refers to synthetic or semi-synthetic oils. 47706582 09-2015 © AB VOLVO PENTA...
  • Page 78 Capacity Freshwater system capacity, approx. 56 liters (14.8 US gals) Coolant Volvo Penta Coolant VCS and VCS Ready Mixed (yel- low colour) are based on Organic Acid Technology, OAT. Volvo Penta Coolant and Coolant Ready Mixed (green ad y m ix ed co ol an t vc s re colour) are silicate based.
  • Page 79 4.50:1 2.50:1 5.03:1 5.95:1 6.53:1 6.95:1 Angle, output shaft 7° 15° Oil volume, quality & pressure See reverse gear plate See reverse gear plate Weight, dry 203 kg 368 kg (448 lb) (811 lb) 47706582 09-2015 © AB VOLVO PENTA...
  • Page 80 ........... P0006167 Serialnumber (3) ........... Product desination (1) ........... TRANSOM ASSEMBLY Product number (2) ........... Serialnumber (3) ........... REVERSE GEAR DRIVE UNIT P0006357 Chassis ID ........... Serial number ........... Certification decal ........... P0006755 P0006756 47706582 09-2015 © AB VOLVO PENTA...

  • Page 81: Alphabetical Index

    Marine Commercial Control System (MCC)....10 Menues..............12 No Engine Mounted Heat Exchanger (Keel Cooled).54 Oil filter, Change............69 Oil Filter/By-pass Filter, Change....... 46 Oil level, checking and topping up......45 Oil Strainer, Cleaning..........69 Operation Break............24 47706582 09-2015 © AB VOLVO PENTA...
  • Page 83 © 2015 AB VOLVO PENTA Volvo reserves the right to make changes Printed on environmentally friendly paper...

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