OPERATOR’S MANUAL

D13
MCC
 This Operator’s Manual may be ordered in a diffe- Tämä käyttöohjekirja on tilattavissa Internetin kau-
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If internet access isn‘t possible, please contact your Jos sinulla ei ole Internet-yhteyttä, ota yhteys lähimpään
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Diese Betriebsanleitung kann bis zu 12 Monate

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kontakte din Volvo Penta forhandler. contact op met uw Volvo Penta dealer.

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12 ‫من الممكن طلب دليل المشغل بلغة أخرى مجا ًنا عبر اإلنترنت لفترة تصل إلى‬
.‫شهرً ا من بعد التسليم‬
/http:// manual.volvopenta.com/coupon
.Volvo Penta ‫ فالرجاء االتصال بوكيل‬،‫إذا كان الوصول إلى اإلنترنت غير متاح‬

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. Additionally, lubricants, fuels, and other fluids used in engines – including any waste created
through the wearing of engine parts – contain or produce chemicals known to the State of California to cause cancer and birth defects or
other reproductive harm.
Battery posts, terminals, and related accessories contain lead and lead compounds. Wash your hands after handling. Used engine oil
contains chemicals that have caused cancer in laboratory animals. Always protect your skin by washing thoroughly with soap and water.
 Content
Foreword ...................................................................................................... 2
Safety Information ...................................................................................... 3
Introduction ................................................................................................. 8
Instruments and Controls ........................................................................ 10
Starting ...................................................................................................... 17
Operation ................................................................................................... 19
Engine Shutdown ...................................................................................... 21
Fault Handling ........................................................................................... 23
Fault Code Register .................................................................................. 28
In Case of Emergency .............................................................................. 33
Maintenance Schedule ............................................................................. 35
Maintenance .............................................................................................. 38
Storage ....................................................................................................... 66
Technical Data ........................................................................................... 68
Alphabetical index .................................................................................... 73

47702495 09-2015 © AB VOLVO PENTA 1

Foreword
Volvo Penta marine engines are used all over the world. They are used in all possible operating conditions for
professional as well as leisure purposes. This is not a coincidence. After 100 years as an engine manufacturer
the Volvo Penta name has become a symbol of reliability, technical innovation, top of the range performance and
long service life. We also believe that this is what you demand and expect of your Volvo Penta engine.

We would like you to read this operator’s manual thoroughly and consider the advice we give on running and
maintenance before your maiden voyage so that you will be ensured of fulfilling your expectations. Please pay
attention to the safety instructions contained in the manual.

As owner of a Volvo Penta marine engine, we would also like to welcome you to a worldwide network of dealers
and service workshops to assist you with technical advice, service requirements and replacement parts. Please
contact your nearest authorized Volvo Penta dealer for assistance.

You will find your closest dealer at our home page on the Internet www.volvopenta.com - amongst other
useful information about your Volvo Penta engine - we invite you to visit!

2 47702495 09-2015 © AB VOLVO PENTA

Safety Information
Read this chapter very carefully. It has to do with your safety. This describes how safety information is presented
in the operator’s manual and on the product. It also gives you an introduction to the basic safety rules for using
and looking after the engine.

Check that you heave received the correct operator’s manual before you read on. If not, please contact
your Volvo Penta dealer.

!
This symbol is used in the operator’s manual and on the product, to call your attention
to the fact that this is safety information. Always read such information very carefully.
Safety texts in the operator’s manual have the following order of priority:

DANGER!
Indicates a hazardous situation which, if not avoided, will result in death or serious
injury.

WARNING!
Indicates a hazardous situation which, if not avoided, could result in death or serious
personal injury.

CAUTION!
Indicates a hazardous situation which, if not avoided, could result in minor or moderate
personal injury.

IMPORTANT!
Indicates a situation which, if not avoided, could result in property damage.

NOTICE! Used to draw attention to important information that will facilitate work or
operations.

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.

47702495 09-2015 © AB VOLVO PENTA 3

Safety Information

The new engine Fuel filling

Read the instruction books and other information There is always a risk of fire and explosion during fuel
carefully, which came with your new vessel. Learn to filling. Smoking is not permissible, and the engine
handle the engine, controls and other equipment in a should be stopped.
safe and correct manner. Never over-fill the tank. Shut the tank cap securely.
Remember that the captain of every vessel is required Only use the fuel recommended in the instruction
by law to know and to observe applicable rules for book. The wrong grade of fuel can cause serious mal-
traffic and safety at sea. Get to know the rules which functions, power loss or stop the engine.
apply to you and your waters, by contacting the rele-
vant authority or sea safety organization.

Daily checks Do not start the engine

Make it a habit to give the engine and engine bay a Do not start the engine if you suspect a fuel or LPG
visual check before driving (before starting the leak in the boat, close to explosive media, or if there
engine) and after operation (when you have stopped is a spillage of explosive media. An explosive envi-
the engine). This helps you to quickly discover ronment entails a risk of fire and/or explosion.
whether any leakage of fuel, coolant, oil or any other
abnormal event has happened, or is about to happen.

Manoeuvring Accidents and near misses

Avoid sudden or surprising rudder movements and
gear shifting. There is a risk that passengers could fall Life saving statistics show that inadequate care of
over, or overboard. boats and engines, and deficiencies in safety equip-
A rotating propeller can cause severe injury. Check ment are frequent causes of accidents and near
that there is nobody in the water before you engage misses at sea.
forward / astern (reverse) drive. Never drive close to Make sure that your boat and engine are maintained
bathers or in areas where you could reasonably in accordance with the advice in each instruction
expect that people could be in the water. book, and that the necessary safety equipment is on
board, and is in working condition.

4 47702495 09-2015 © AB VOLVO PENTA

 Safety Information

Carbon monoxide poisoning

When a boat moves forwards, an area of low pressure Most modern boats are designed so that the problem
air forms behind the boat. In adverse conditions, this of low-pressure suction is very rare, however. If low-
low pressure can be so strong that the boat’s own pressure suction does occur anyway, do not open
exhaust fumes are sucked into the cockpit or cabin, hatches or ventilators in the forward part of the boat.
which entails a risk of carbon monoxide poisoning for Strangely enough, this makes the problem worse. Try
all aboard. changing speed, trimming or load distribution instead.
The problem of low-pressure suction is worst in high, Also try taking down/opening the hood or modifying it
wide boats with a square transom. But even in other in some other manner. Ask your boat dealer for advice
types of boats, low-pressure suction can be a problem about the best solution for your particular boat.
in some conditions, such as if you drive with the hood
up. Other factors which increase the low-pressure
effect are wind conditions, load distribution, pitching,
trimming, open windows and ventilators etc.

P0003073

Remember

• Safety equipment: Life jackets for everybody aboard, communication equipment, emergency
rockets, approved fire extinguisher, first aid kit, life buoy, anchor, paddle, torches etc.
• Spare parts and tools: Impeller, fuel filters, fuses, tape, hose clamps, engine oil, propeller and
tools for the jobs you could be expected to have to do.
• Take your chart out and study your planned route. Calculate distance and fuel consumption.
Listen to weather reports.
• Tell your friends/relatives about route plans if you undertake a long journey. Remember to
notify changed plans or delays.
• Inform everybody aboard about where the safety equipment is located, and how it works. Make
sure that there is more than one person aboard who can start and operate the boat safely.

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.

47702495 09-2015 © AB VOLVO PENTA 5

Safety Information

Preparations Before starting the engine

Knowledge Reinstall all protective parts removed during service

The operator’s manual contains instructions on how operations before starting the engine. Check that no
to carry out general maintenance and service opera- tools or other items have been left on the engine.
tions safely and correctly. Read the instructions care-
Never start a turbocharged engine without installing
fully before starting work.
the air cleaner (ACL). The rotating compressor in the
Service literature covering more complicated opera- Turbocharger unit can cause serious personal injury.
tions is available from your Volvo Penta dealer. Foreign objects can also be sucked in and cause
mechanical damage to the unit.
Never carry out any work on the engine if you are
unsure of how it should be done, contact your Volvo Fire and explosion
Penta dealer who will be glad to offer assistance.
Fuel and lubrication oil
Stop the engine All fuel, most lubricants and many chemicals are
Stop the engine before opening or removing engine inflammable. Read and follow the instructions on the
hatches. Unless otherwise specified all maintenance packaging.
and service must be carried out with the engine stop-
ped. When carrying out work on the fuel system, make sure
the engine is cold. A fuel spill onto a hot surface or
To prevent accidental start of the boat engine, remove electrical components can cause a fire.
the ignition key, turn off the power supply to the engine
at the main switches and lock them in the OFF posi- Store fuel soaked rags and other flammable material
tion before starting work. Put up a warning sign in the so that there is no danger of them catching fire. Fuel-
control position that work on the engine is being car- soaked rags can self-ignite under certain conditions.
ried out. Do not smoke when filling fuel, oil or in proximity of a
Approaching or working on an engine which is running filling station or in the engine room.
is a safety risk. Loose clothing, hair, fingers or a drop- Non-original components
ped tool can be caught in the rotating parts of the
engine and cause serious personal injury. Volvo Components used in the fuel and electrical systems
Penta recommend that all servicing with the engine on Volvo Penta products are designed and con-
running should be undertaken by an authorized Volvo structed to minimize the risk of fire and explosion.
Penta workshop. Using spare parts other than by Volvo Penta
Lifting the engine approved spare parts can result in fire or explosion on
board.
When lifting the engine, use the lifting eyes installed
on the engine (reverse gear where installed). Always Batteries
check that lifting equipment is in good condition and The batteries contain and emit oxyhydrogen gas,
has sufficient load capacity to lift the engine (engine especially during charging. This gas is easily ignited
weight including reverse gear and any extra equip- and highly volatile.
ment installed). For safety’s sake lift the engine using
an adjustable lifting beam. All chains and cables Do not under any circumstances smoke or use naked
should run parallel to each other and as perpendicular flame or allow sparks in the vicinity of the batteries or
as possible in relation to the top of the engine. Bear battery compartment.
in mind that extra equipment installed on the engine
may alter its center of gravity. Special lifting equip- An incorrect connection of a battery terminal cable or
ment may then be required in order to maintain the jump-start cable can cause a spark which in its turn
correct balance and make the engine safe to handle. can be sufficient to cause an explosion.
Never carry out work on an engine suspended on a
Start spray
hoist.
Never use start spray or similar agents to start an
engine equipped with air pre-heating (glow plugs/
starter element). This may cause an explosion in the
inlet manifold. Danger of personal injury.

6 47702495 09-2015 © AB VOLVO PENTA

 Safety Information

Hot surfaces and fluids Fuel system

There is always a risk of burns when working with a Always use protective gloves when tracing leaks. Liq-
hot engine. Beware of hot surfaces. For example: the uids ejected under pressure can penetrate body tis-
exhaust pipe, turbo unit, oil pan, charge air pipe, sue and cause serious injury. There is a danger of
starter element, hot coolant and hot oil in oil lines and blood poisoning.
hoses.
Always cover the generator if it is located under the
Carbon monoxide poisoning fuel filter. The generator can be damaged by spilled
fuel.
Only start the engine in a well-ventilated area. If oper-
ating the engine in an enclosed space, ensure that Marine Commercial Control (MCC)
there is proper ventilation in order to remove exhaust
gases and crankcase ventilation emissions from the The boat has a advanced control system. Never cut
working area. or modify connectors, wiring or splice of the compo-
nents.
Chemicals Installing non Volvo Penta components may cause
Most chemicals such as anti-freeze, rustproofing the system to malfunction.
agent, inhibiting oil, degreasing agent etc. are haz-
Service must be done by approved workshops.
ardous to health. Read and follow the instructions on
the packaging.
Electrical system
Some chemicals such as inhibiting oil are inflammable
Cutting off power
and dangerous if breathed in as well. Ensure good
Always stop the engine and break the current using
ventilation and use a protective mask when spraying.
the main switches before working on the electrical
Read and follow the instructions on the packaging.
system. Isolate shore current to the engine block
Store chemicals and other hazardous materials out of heater, battery charger, or accessories mounted on
the reach of children. To protect the environment, the engine.
please dispose of used or leftover chemicals at a
Batteries
properly designated disposal site for destruction.
The batteries contain an extremely corrosive electro-
lyte. Protect your skin and clothes when charging or
Cooling system handling batteries. Always use protective goggles and
There is a risk of flooding when working on the sea- gloves.
water system. Turn off the engine and close the sea
If battery electrolyte comes into contact with unpro-
cock (where installed) before starting work on the sys-
tected skin, wash off immediately using plenty of
tem.
water and soap. If battery acid comes into contact with
Avoid opening the coolant filler cap when the engine the eyes, flush immediately with plenty of water and
is hot. Steam or hot coolant can spray out and cause obtain medical assistance without delay.
burns.

If work must be carried out with the engine at operat-

ing temperature and the coolant filler cap or a cock
open or a coolant hose disconnected, open the cool-
ant filler cap carefully and slowly to release pressure
before removing the cap completely. Note that the
coolant may still be hot and can cause burns.

Lubrication system
Hot oil can cause burns. Avoid skin contact with hot
oil. Ensure that the lubrication system is not under
pressure before commencing work on it. Never start
or operate the engine with the oil filler cap removed,
oil can spray out.

47702495 09-2015 © AB VOLVO PENTA 7

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.
Always have the Operator's Manual available. Store it safely and do not forget to hand it over to the next owner
if you sell your boat.

The Operator’s Manual describes the engine and equipment sold by Volvo Penta. The illustrations in this book
covers several varieties and might differ, the essential information is always correct though. The specifications,
design features and illustrations in this manual are not binding. We reserve the right to make alterations without
prior notification.
Installations with e.g. different controls and instrumentation might occur, in these cases we refer to this products
manual.

Warranty Service and spare parts

Your new Volvo Penta marine engine is covered by a Volvo Penta marine engines are designed for high
limited warranty, under the conditions compiled in the reliability and long life. They are built to withstand a
Warranty Information. marine environment, but also to have the smallest
Please note that AB Volvo Penta’s liability is limited to possible environmental impact. Through regular serv-
the specification in the Warranty Information. Read it ice and use of by Volvo Penta approved spare parts,
carefully, as soon as possible after delivery. It these qualities are retained.
includes important information about service, mainte- Volvo Penta’s world-wide network of authorised deal-
nance, which it is the responsibility of the owner to ers is at your service. They are Volvo Penta product
know, check and carry out. If this is not done, AB Volvo specialists, and have the accessories, original
Penta may fully or partly refuse to honour its warranty spares, test equipment and special tools needed for
undertakings. high quality service and repair work.
Please contact your Volvo Penta dealer if you Always observe the maintenance intervals in the
have not received the Warranty Information or Operator's manual, and remember to note the engine/
Service Book. transmission identification number when you order
service and spare parts.

Running in Fuel, oils and coolant

The engine must be “run in” during its first 10 hours, Only use the fuels and oils recommended in the Oper-
as follows: ator's Manual. Other grades can cause malfunctions,
Use the engine in normal operation. Full load should increased fuel consumption and eventually even
only be applied for short periods. Never run the engine shorten the life of the engine.
for a long period of time at constant speed during this Always change the oil, oil filters and fuel filter at the
period. specified intervals.
Higher oil consumption is normal during the running
in period. For this reason, check the oil level more fre- Future warranty claims related to engine and acces-
quently than normally recommended. sories may be refused if an unsuitable coolant has
After the first period of operation, the specified war- been used, or if the instructions for coolant mixture
ranty inspection “First service inspection” can be have not been followed.
done. For more information: Please refer to the Main-
tenance Schedule.

8 47702495 09-2015 © AB VOLVO PENTA

 Introduction

Environmental care Certified engines

All of us want to live in a clean, healthy environment. If you own or operate an emission certified engine it
Where we can breathe clean air, see healthy trees, is important to be aware of the following:
have clean water in lakes and seas, and be able to
enjoy the sunlight without fearing for our health. Certification means that an engine type has been
Unfortunately, this is not self-evident these days, it is checked and approved by the relevant authority. The
something all of us must work hard for. engine manufacturer guarantees that all engines
As a manufacturer of marine engines, Volvo Penta made of the same type are equivalent to the certified
has particular responsibility and for this reason, envi- engine.
ronmental care is a core value in our product devel- This makes special demands on the care and
opment. Volvo Penta has a wide engine programme maintenance you give your engine, as follows:
these days, where considerable progress has been • Maintenance and service intervals recom-
made in reducing exhaust fumes, fuel consumption, mended by Volvo Penta must be complied with.
engine noise etc.
We hope that you will be want to preserve these val- • Only by Volvo Penta approved spares may be
ues. Always observe the advice in the Operator's used.
Manual about fuel grades, operation and mainte- • 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
increased exhaust smoke. • The engine must not be converted or modified,
Moderate your speed and distance so that wake and except for the accessories and service kits
noise do not disturb or damage animal life, moored which Volvo Penta has approved for the engine.
boats, jetties etc. Leave the archipelago and harbours • Installation changes to the exhaust pipe and
in the same state you would like to find them. engine air inlet ducts must not be done.
Remember to always hand in drained oil, coolant,
paint and wash residue, used batteries etc. for • No seals may be broken by unauthorised per-
destruction at a recycling station. sonnel.
If we all pull together, we can make a valuable con-
The general advice in the Operator's manual about
tribution to the environment together.
operation, care and maintenance apply.

Late or inadequate maintenance/service or the use of

spare parts not approved by Volvo Penta will invalid-
ate AB Volvo Penta’s responsibility for the engine
specification being in accordance with the certificated
variant.
Volvo Penta accepts no responsibility or liability for
any damage or costs arising due to the above.

47702495 09-2015 © AB VOLVO PENTA 9

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. The slave
panel may be located outside the engine compartment
and handles in exactly the same way as the MCU.

The SDU manages automatic engine shutdown should

the engine show critically low oil pressure (including
reverse gear) or high coolant temperature. It also has
overspeed protection. Electronic systems in the vicinity
of the engine comprise the engine management sys-
tem (EMS) and a power management unit (PM). The
engine management unit manages the injection of fuel
with the aid of a number of sensors. The power man-
agement system manages primary and secondary bat-
tery supply and supplies electrical power to the engine
management unit, MCU and SDU. The unit has over-
current protection with automatic reset.

10 47702495 09-2015 © AB VOLVO PENTA

 Instruments and Controls

MCU panel
The MCU, Marine Control Unit, is the control system's
control unit. A panel on the unit shows engine infor-
mation and alarms.
1 Display
2 Acknowledgement of audible alarms
3 Changing modes, switching to OFF
4 Changing modes, switching to PRP
5 Start button
6 Stop button
7 Green lamp; indicates engine is running
8 Up button; selecting and increasing
9 Down button; selecting and decreasing
10 Enter; confirming selection
11 Page; switching windows between Measurement
(engine data), Adjustment and History.
12 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.
13 Ackn: acknowledge selection, acknowledge alarm
The button is also used to reset the SDU.

47702495 09-2015 © AB VOLVO PENTA 11

Instruments and Controls

Display

A Highlighted text indicates engine mode; in operation

or start mode (PRP), or OFF.
B LOC: local mode. The engine can only be controlled
from the main panel.

PRP C R: a remote connection – a slave panel – is on line.

D L: locked. The main panel is locked and the slave
panel is in control.
E ! There is an alarm in the alarm list.
0.1 bar
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
P0012966
started.
Running: the engine is in operation.
LoadShar: the engine is under load and in operation
with another engine.

Menues
The system has four menus:
• Main Menue
• Measurements
• Adjustment
• History
Main Menue
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.

12 47702495 09-2015 © AB VOLVO PENTA

 Instruments and Controls

Adjustment
The review and changing of setpoints is carried out in
the adjustment menu.

1 Browse with the Page button to the Adjustments

menu.
2 Browse between the different setpoints using the
up/down buttons.
3 Press Enter to confirm the selection.
4 Browse with the up/down buttons to the desired
P0010302 setpoint. Setpoints marked with an asterisk (*) are
password protected.
Press Enter to confirm the selection.
5 Use the up/down buttons to adjust the setpoint.
Depress the up/down buttons for 2 seconds to acti-
vate automatic repetition.
6 Press Enter to confirm the selection. To finish with-
out any change press the Page button.
Press the Page button to select setpoint group.

History

1 Browse to the History menu using the Page button.

2 Browse with the up/down buttons to the desired
event.
3 Press Enter to see more detailed information about
the event. 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.

47702495 09-2015 © AB VOLVO PENTA 13

Instruments and Controls

Settings
Serial number and software version
In order to see the engine serial number and software
version installed go to the main menu.
Press the Enter button and hold it down and press the
P0010300
page button at the same time.
The system returns automatically to the main menu.

Backlighting
Panel backlighting is adjusted in the info menu.
Press the Enter button and hold it down; adjust back-
lighting with the up/down buttons.

Contrast is adjusted in the main menu. Press the Enter

button and hold it down; adjust the contrast with the up/
down buttons.
P0010301

Changing language
Setting the language the information on the screen will
be shown in. There are six languages to choose from.

1 Press the Enter button and hold it down to reach the

info menu. Press the Page button.
2 Browse using the up/down buttons.
3 Press Enter to select the language and close the
menu.

Setting password
P0010302
The password consists of 1–4 numerals.
The default password is 0 on delivery.
1 Navigate to the Adjustments menu.
2 Browse to “Password” using the up/down buttons.
Press Enter to confirm the selection.
3 Browse using the up/down buttons to “Enter Pass-
word” where 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.

14 47702495 09-2015 © AB VOLVO PENTA

 Instruments and Controls

Working mode
Local mode
In Local Mode the engine can only be started from the
P0010303 main panel. External start/stop commands are
ignored.

The mode is activated by pressing Enter and the right

Mode button.

Exit mode by pressing Enter and the left Mode button.

Operations mode (PRP)

In operations mode (PRP) the engine is ready for start
P0010304 when the status shows "Ready".

Off mode (OFF)

The engine cannot be started in OFF mode. All relay
output signals are temporarily disconnected and the
status is changed to “Not Ready”.
P0010305 Activate OFF mode by pressing the left Mode button.

NOTICE! The engine cannot be started; if the engine

is running it will be shut down when OFF mode is acti-
vated.

Activate OFF mode by repeatedly pressing the left

Mode button until "off" is shown in the display's top left
corner.

Statistics
Eng Hours 336 h In the main menu, press the up button three times.
Fuel Used 100 L
1 Operation hours
NumSuccStarts 30
NumUnscStarts 3 2 Total quantity of fuel used
MomAvgFlCon L 20 /nm 3 Number of successful starts
Service time 3640 h 4 Number of unsuccessful starts
5 Momentary average fuel consumption(1)
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.

47702495 09-2015 © AB VOLVO PENTA 15

Instruments and Controls

Alarms

If the system discovers a fault the alarm list is shown

on the display when the main menu is active.
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 23 chapter.

P0010307
Alarm list

16 47702495 09-2015 © AB VOLVO PENTA

Starting
Make a habit of visually checking the engine, engine bay and transmission before start. This will help you to
discover quickly if anything abnormal has happened, or is about to happen. Also check that instruments and
warning displays show normal values when you have started the engine.
To minimize cold start smoke we recommend the installation of an engine heater or engine bay heater if temper-
atures below +5°C (41°F) are encountered.

WARNING!
Never use start spray or similar agents to start an engine. This may cause an explosion in the inlet manifold.
Danger of personal injury.

Before Starting
• Open the fuel cock.
• Open the sea cock where fitted.
• Check the engine and transmission oil level.
• Check the coolant level.
• Turn the main switches on.
IMPORTANT!
Never disconnect the current with the main
switches when the engine is running. The alter-
nator and electronics could be damaged.
• 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.

P0005851

47702495 09-2015 © AB VOLVO PENTA 17

Starting

Starting the Engine

1 In the main menu, browse to start mode (PRP)
(A) using the Mode button

PRP 2 Check that engine status is "Ready" (B).

3 Depress the Start button; engine status will
change to "Running" (C).

If the engine is not ready to start (Not Ready), check

the following:
0.1
• 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.

PRP

P0012969

Running data

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

18 47702495 09-2015 © AB VOLVO PENTA

Operation
Learn to handle the engine, controls and other equipment in a safe and proper manner before casting off on your
maiden voyage. Remember to avoid sudden and extreme rudder maneuvers and gear shifts. There is a risk for
passengers and crew falling over or falling overboard.

WARNING!
A rotating propeller can cause serious injury. Check that nobody is in the water before engaging ahead or astern.
Never drive near bathers or in areas where people could be in the water.

Alarms
The alarm is shown in two different alarm lists depend-
ing on the cause of the alarm. Alarms discovered by
EMS or PM are shown in the ECU Alarmlist, and
alarms from the SDU or MCU are shown in the Alarm-
list.

1 Acknowledge the audible alarm by pressing the

Horn Reset button.
2 Reading alarms.
To see active alarms, press the up button in the
P0010311 main menu once for the SDU/MCU alarm list and
twice for the ECU alarm list.
If there are several alarms, browse in the alarm list
using the Enter button.
3 Depress the Ackn button to acknowledge all
alarms.
Take the necessary action; refer to the Fault
Handling page 23 section for further information.
P0010312 Alarm notations remain in the alarm list until they have
been acknowledged and rendered "inactive" (fault
remedied).

47702495 09-2015 © AB VOLVO PENTA 19

Operation

Maneuvering
Shifting between ahead and astern must be done at
idle revolutions. Shifting at higher revolutions may
cause unnecessary wear on the transmission or cause
the engine to stop. Attempts to shift at revolutions that
are too high will cause an automatic protection function
to take effect which will delay shifting until revolutions
have dropped to around 1500 rpm.

Always shift between ahead and astern in

the following manner:

1 Reduce engine revolutions to idle and allow the

boat to lose most of its speed.
2 Move the control lever to the neutral position with a
quick, firm movement. Pause a moment.
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.

20 47702495 09-2015 © AB VOLVO PENTA

Engine Shutdown
Allow the engine to run at low idle, in neutral, for a few minutes after operations are completed. In this way after-
boiling is avoided at the same time as temperature equalization takes place. This is especially important when
the engine has been run at high rpm or under heavy load.

Stop the Engine

1 Disengage the reverse gear by moving the control
lever to the neutral position.
2 Press the stop button until engine speed begins to
fall.
3 Check that the rpm reading drops to 0 and that
engine status changes to “Ready".

Emergency stop
If a fault occurs that prevents you stopping the engine
in the normal way, you can stop it by pressing the
emergency button.
If the engine has been stopped using the emergency
stop button, the button locks in the down position. In
order to be able to restart the engine, the button must
be reset to its original position. To do this, pull the but-
ton upwards until you hear a click.

P0005904

After Engine Shutdown

• Check the engine and engine bay for leakages.
• Close the fuel tap.
• 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.

1
P0005914 0

47702495 09-2015 © AB VOLVO PENTA 21

Engine Shutdown

Operation Break
Operation break with the boat in water
If the boat is not used, but left in the water, the engine
must be warmed up at least once every fortnight. This
prevents corrosion damage in the engine.
If you expect the boat to be unused for two months or
more, it must be inhibited, please refer to
Storage page 66.

Cold Weather Precautions

If the engine bay cannot be kept frost free, the raw
F C water system must be drained and the freshwater sys-
tem coolant must have sufficient frost protection to
70 20

60
prevent frost bursting; refer to Seawater System,
50 10 Draining page 56 and Maintenance page 52
20 respectively for more detailed information.
32 0 Check the charge status of the battery. A poorly-
20
charged battery can freeze and burst.
10
10

P0005905

22 47702495 09-2015 © AB VOLVO PENTA

Fault Handling
Despite regular maintenance according to the maintenance schedule and perfect operation conditions faults may
occur which must be attended to before the boat can travel further. This chapter describes alarms and fault
handling.

Message from engine and MCC system

If a malfunction is discovered the driver is warned by a
ECU AlarmList buzzer sounding and a message showing in the dis-
play.
EMS supply Fls
The message toggles between cause of fault and tasks
Primary Batt Fls to perform.
Secondary Batt Fls
Exhaust Temp Fls Information regarding ”cause of fault” and ”measures
to take” is found in chapter Fault Code Register.

The engine, transmission and MCC system is moni-

tored by the diagnostic function. Should the diagnostic
PS 5 M158 OC 53 FM 5 function discover a malfunction it protects the engine
and ensures continued operation by affecting the
P0013089
engine. Depending on how serious the malfunction is
the effect on the engine varies.
• Minor malfunction which does not damage the
engine or transmission.
Affect on engine: None.
• Serious malfunction which will not immediately dam-
age the engine or transmission e.g. high coolant
temperature.
Affect on engine: Engine power is reduced until
faulty value becomes normal.
• Serious malfunction which will cause serious dam-
age to engine or transmission.
Affect on engine: Engine power is reduced.
• Serious malfunction which makes it impossible to
control the engine or transmission.
Affect on engine: Transmission is disengaged and
engine speed is reduced.
It is possible to perform emergency shifting, please
refer to Emergency Shifting.
• Serious malfunction on transmission or in the engine
fuel injection system.
Affect on engine: Engine is stopped.
It is possible to perform emergency shifting, please
refer to Emergency Shifting. In emergency situa-
tions it is also possible to start the engine with gear
engaged after acknowledging the alarm.

47702495 09-2015 © AB VOLVO PENTA 23

 Fault Handling

Acknowledge message

The Ackn button acknowledges all alarms. Alarms that

are not active disappear from the list.

P0010312

Alarm List

ECU Alarm The alarm list and ECU alarm list are the two first win-
dows in the main menu.
EMS supply Fls
Fls From the main menu press the up button once to reach
Primary Batt
Secondary Batt Fls the alarm list and twice for the ECU alarm list.
Exhaust Temp 2/ 1/ 3 Fls P1
Alarmlist Alarm List (Alarm list)
Wrn Sd Syst Fall
ECU AlarmList
* The alarm list is automatically displayed when a new
alarm is triggered and the main menu is active.
The alarm list is not activated while values, parameters
PSWrn 5 Sd
M158Syst
OCFall
*
53 FM 5
and alarm history are being reviewed.
P0015714

1 2 3 4

Alarmlist 2/ 1/ 3 P1 The alarm list heading shows:

*Wrn Sd Syst Fall

ECU AlarmList
•
•
Number of active alarms (1)
Number of unacknowledged alarms (2)

*Wrn Sd Syst Fall •

•
Total number of alarms (3)
Number of pages (4).
Scroll between the alarms in the list with the
enter key.
P0015713

Alarm List

1 3

Alarmlist 2/ 1/ 3
Status of alarm
2 *Wrn Sd Syst Fall
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)
P0015715

24 47702495 09-2015 © AB VOLVO PENTA

 Fault Handling

ECU alarm list

ECU AlarmList If ECU AlarmList is visible in the list then there are fault
EMS supply Fls codes from the engine control unit or power manage-
Primary Batt Fls ment system.
Secondary Batt Fls
Exhaust Temp Fls

PS 5 M158 OC 53 FM 5
P0013089

Alarm list and history

Abbreviations in alarm list and history

Abbreviation Meaning
Wrn Warning
Sd Automatic shutdown
Fls Sensor failure
General alarm

P0010309

47702495 09-2015 © AB VOLVO PENTA 25

Fault Handling

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 Information page 6 chapter before
work you start work.

Symptoms and possible causes

Engine cannot be stopped 2

Starter motor does not rotate 1, 2, 3, 6, 7, 9, 10, 35, 3
Starter motor rotates slowly 1, 2
Starter motor rotates normally but engine does not start 11, 12, 13, 14, 37, 38
Engine starts but stops again 4, 11, 12, 13, 14, 19, 36
Engine does not reach correct operating speed at full 5, 12, 13, 14, 15, 16, 17, 18, 19, 20, 23, 33, 36, 38,
throttle
Engine runs unevenly 5, 14, 15,
Engine vibrates 24
High fuel consumption 15, 16, 18, 21, 36
Black exhaust smoke 19
Blue or white exhaust smoke 21, 34
Lubricating oil pressure too low 22
Coolant temperature too high 25, 26, 27, 28, 29, 30, 31, 32
Coolant temperature too low 31
No charge, or poor charge 2, 8

1. Discharged batteries
2. Poor contact/open circuit in cables
3. Main switch in off position
4. Shut down system activated
5. Check valve in feed pump leaks
6. Control lever not in neutral/helm station not activated
7. Faulty shutdown relay
8. Alternator drive belt broken/slips
9. Faulty starter relay
10. Faulty starter motor
11. Lack of fuel
- fuel taps are closed
- fuel tank is empty
- wrong tank connected
12. Blocked primary fuel filter/secondary fuel filter
(due to contamination or paraffin precipitation in the fuel at low temperatures)
13. Air in the fuel system
14. Water or contaminants in fuel
15. Boat abnormally loaded
16. Fouling on hull/propeller
17. Cables for unit injector damaged (open circuit)
18. Faulty unit injector

26 47702495 09-2015 © AB VOLVO PENTA

 Fault Handling

19. Insufficient air supply to engine

- blocked filter
- leak between turbocharger and inlet manifold
- fouled compressor section in turbocharger
- faulty turbocharger
- poor engine bay ventilation
20. Coolant temperature too high
21. Coolant temperature too low
22. Oil level too low
23. Faulty/wrong propeller
24. Faulty engine mounting
25. Coolant level too low
26. Air in the freshwater system
27. Faulty circulation pump
28. Closed seawater inlet
29. Blocked seawater inlet, lines or filters
30. Defective impeller in the seawater pump
31. Defective thermostat
32. Clogged heat exchanger insert
33. Clogged charge air cooler
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

47702495 09-2015 © AB VOLVO PENTA 27

Fault Code Register
BattPotential Wrn
Battery voltage to engine control unit.
• Check belt tension. Please refer to Drive Belt, Check and Change.
• Check battery fluid level. Please refer to Battery, Maintenance page 62.

Coolant Level Wrn

Low coolant level.
• Check for coolant leakage.
Check coolant level., Please refer to Maintenance page 54.

Crankcase Press Wrn

Crankcase pressure too high. Engine power is reduced.
• Check that the crankcase ventilation is not blocked.

EMS supply Fls

EMS supply.
• Overcurrent protection has tripped.
• 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.
• Check coolant level., Please refer to Maintenance page 54
• Check that the seawater filter is not blocked., Please refer to Seawater Filter, Check and
Cleaning page 59
• Check the impeller in the seawater pump., Please refer to Impeller, Check and Change page 58
• Check that no leakage occurs.

EngineOilLevel Wrn
Oil level too low.
The system may wrongly detect too low an engine oil level in heavy following seas or head seas. If this occurs,
acknowledge the fault and check the following items for safety's sake.
• Checking Engine Oil Level, Please refer to Oil level, checking and topping up page 43.
• Check that no leakage occurs.

EngOil Press Wrn

Oil pressure too low. Engine power is reduced.
• Checking Engine Oil Level, Please refer to Oil level, checking and topping up page 43.
• Check that no leakage occurs.

28 47702495 09-2015 © AB VOLVO PENTA

 Fault Code Register

Extra Supply Fls

Auxiliary supply
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
• Check emergency stop button if any. Reset if necessary.

Fls
Miscellaneous system faults.
Engine performance might be affected.A number of possible causes of engine problems are described below.
• Battery voltage incorrect.
Check belt tension. Please refer to Drive Belt, Check and Change.
Check battery fluid level. Please refer to Battery, Maintenance page 62.
• Fuel pressure incorrect.
Engine performance might be affected.
• Communication failure.
Gear automatically set to neutral. Engine performance might be affected.
• Oil pressure too low.
Engine power is reduced.
Check the oil level in the engine. Please refer to Oil level, checking and topping up page 43.
Check that no leakage occurs.
• Sensor failure

Please contact a Volvo Penta workshop if the fault remains.

Fls Throttle In
Engine speed demand to system lacking.
• Check Control Lever

FuelDelPress Wrn
Fuel pressure too low.
• Check fuel level.
• Check that the fuel filters are not blocked. Replace filters if necessary. Please refer to Engine Fuel Filter
Replacement page 47
• Check for fuel leakage.

47702495 09-2015 © AB VOLVO PENTA 29

Fault Code Register

Fuel Press Wrn

Fuel pressure too low.
• Check fuel level.
• Check that the fuel filters are not blocked. Replace filters if necessary. Please refer to Engine Fuel Filter
Replacement page 47
• Check for fuel leakage.

Oil Level Wrn

Oil level too low.
The system may wrongly detect too low an engine oil level in heavy following seas or head seas. If this occurs,
acknowledge the fault and check the following items for safety's sake.
• Checking Engine Oil Level, Please refer to Oil level, checking and topping up page 43
• Check that no leakage occurs.

Primary Batt Fls

Primary Battery.
Poor batteries or charging. Please refer to Battery, Charging page 63

Sd Coolant Temp
Wrn ECU, Wrn J1587
Critical system fault. Engine shuts down automatically.
Coolant temperature too high. Engine power is reduced.
• Check coolant level., Please refer to Maintenance page 54.
• Check that the seawater filter is not blocked., Please refer to Seawater Filter, Check and
Cleaning page 59.
• Check the impeller in the seawater pump., Please refer to Impeller, Check and Change page 58.

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.
Reverse gear oil pressure too low.
• Check the oil level. Please refer to Reverse gear, ZF.
• Check that the oil strainer is not blocked. Please refer to Reverse gear MGX.

Please contact a Volvo Penta workshop if the fault remains.

Sd Oil Pressure
Wrn ECU, Wrn J1587
Critical system fault. Engine shuts down automatically.
Oil pressure too low.
• Checking Engine Oil Level
• Check that no leakage occurs.

Please contact a Volvo Penta workshop if the fault remains.

30 47702495 09-2015 © AB VOLVO PENTA

 Fault Code Register

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 63

SeaWater Press Wrn

Seawater pressure too low. Engine power is reduced.
• Check that the seawater filter is not blocked., Please refer to Seawater Filter, Check and
Cleaning page 59
• Check the impeller in the sea water pump. Please refer to Impeller, Check and Change page 58.
• Check that no leakage occurs.

Water in fuel Wrn

Water in Fuel.
• Empty the water trap underneath the fuel filters. Please refer to Fuel pre-filter with water separator.

Wrn
Miscellaneous system faults.
Engine performance might be affected. A number of possible causes of engine problems are described below.
• Battery voltage incorrect.
Check belt tension. Please refer to Drive Belt, Check and Change.
Check battery fluid level. Please refer to Battery, Maintenance page 62.
• Fuel pressure incorrect.
Engine performance might be affected.
• Communication failure.
Gear automatically set to neutral. Engine performance might be affected.
• Oil pressure too low.
Engine power is reduced.
Check the oil level in the engine. Please refer to Oil level, checking and topping up page 43.
Check that no leakage occurs.

Wrn Derate Alarm

Engine performance might be affected. A number of possible causes of engine problems are described below.
• Battery voltage incorrect.
Check belt tension. Please refer to Drive Belt, Check and Change.
Check battery fluid level. Please refer to Battery, Maintenance page 62.
• Fuel pressure incorrect. Engine performance might be affected.
• Oil pressure too low. Engine power is reduced.
Checking Engine Oil Level. Please refer to Oil level, checking and topping up page 43.
Check that no leakage occurs.

Please contact a Volvo Penta workshop if the fault remains.

47702495 09-2015 © AB VOLVO PENTA 31

Fault Code Register

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.
Engine revolutions are lower than expected.

30 supply Fls
30V supply
Overcurrent protection for the supply to the MCC system has tripped. Short circuit in the system between the
engine and the MCC cabinet.
Remedy the problem. Reset the system by switching the main switch off and on
Please contact a Volvo Penta workshop if the fault remains.

32 47702495 09-2015 © AB VOLVO PENTA

In Case of Emergency
Despite regular service in accordance with the planned maintenance schedule and perfect operating conditions,
faults may occur that must be remedied before the boat can continue its trip. This chapter provides advice on how
to remedy a number of conceivable faults.
When certain faults occur safety functions engage to protect the engine. The following may occur:
• Engine cannot be started.
• 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.

47702495 09-2015 © AB VOLVO PENTA 33

In Case of Emergency

Starting Using Auxiliary

Batteries

WARNING!
Explosion hazard. Batteries contain and give off an
explosive gas which is highly flammable and
explosive. A short circuit, open flame or spark could
cause a violent explosion. Ventilate well.
P0002107

WARNING!
Never confuse the positive and negative poles on the
batteries. Risk of arcing and explosion.

1 Check that the auxiliary battery has the same

voltage as the engine system voltage.
2 Connect the red positive cable to the plus (+)
terminal on the discharged battery and then to
the plus terminal on the auxiliary battery.
3 Connect the black start cable to the minus (–)
terminal on the auxiliary battery and to a place
a little distance away from the discharged bat-
tery, e.g. the start motor's negative terminal.

WARNING!
Under no circumstances may the black jumper
cabel (–) come in contact with the positive connec-
tion on the starter motor.

4 Start the engine and let it run at fast idle for

approximately 10 minutes to charge the batter-
ies. Make sure there is no extra equipment con-
nected to the electrical system.

WARNING!
Working with or approaching a running engine is a
safety risk. Watch out for rotating components and
hot surfaces.

WARNING!
Do not touch the connections during the start
attempt: Risk of arcing.
Do not bend over any of the batteries either.

5 Turn off the engine. Remove the start cables in

the exact opposite order to their connection.

34 47702495 09-2015 © AB VOLVO PENTA

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.

CAUTION!
Read the chapter on Maintenance before starting work. It contains instructions on how to carry out maintenance
and service operations in a safe and correct manner.

Where both operational and calendar times are specified, perform the maintenance item at whichever time is the
sooner.

Volvo Penta reserves the right to modify service intervals and content after the operator's manual is published.
The valid document can be found under Publication search/Service record at www.volvopenta.com

Warranty inspection
During the initial period of use, a special warranty inspection - a First service inspection - must be carried out by
an authorized Volvo Penta workshop.
Instructions regarding when this must be done can be found in the maintenance schedule and the Service
book.

Extended service intervals

The interval between engine oil changes may be extended in certain circumstances. To determine whether the
service interval may be extended, Volvo Penta's conditions for extended service intervals must be met and an oil
analysis performed. Contact your Volvo Penta dealer for further information.
NOTICE! The maintenance schedule shown in the operator's manual does not apply to extended service intervals.

In applications that include a reverse gear, the reverse gear manufacturer's service intervals must be complied
with.

47702495 09-2015 © AB VOLVO PENTA 35

Maintenance Schedule

FSI = First Service Inspection C = Clean

S1, S2, S3 = Special Interval Service R = Replace
A - F = Type of service (regular service) A = Adjustment
L = Lubrication
I = Inspection (includes, if necessary, cleaning,
adjustment, lubrication and change)

FSI = First Service Inspection

After the first 50-100 hours (1)
Transmission: According to manufacturers recommendations I
Start and warm up engine
Engine and transmission, abnormal noises I
Engine and transmission, oil / fuel / water leakage I
1) Or within 180 days of the date of delivery, or the end of the first season, whichever comes first.

S1
Every 125-600 hours / at least every 12 month
(1)

Engine Oil and Oil Filters / By-pass filter R

1) Oil change intervals vary, depending on oil grade, sulfur content of the fuel and running conditions.

S2
Oil Analysis
See dealers recommendation for oil analysis interval. I

S3
After the first 1200 hours
Valve clearance I

A
Every 600 hours / At least every
(month)
12 24 48
Inspection with VODIA (Diagnostic Tool)(1) I ●
Coolant level and antifreeze mixture I ●
Drive belts, belt tensioner and idler wheels I ●
Batteries, electrolyte level I ●
Air Filter I ●
Fuel pre-filter, draining water / contamination C ●
Seawater filter C ●
Seawater pump, wear kit, impeller and o-ring I ●
Transmission: According to manufacturers recommendations I ●
Anode - Propeller / Propellershaft. (Must not be painted) R ●
Propellershaft seal. (Lubrication of shaft splines) I ●
Start and warm up engine
Engine and transmission, abnormal noises I ●
Engine and transmission, oil / fuel / water leakage I ●
1) Readout if any fault codes and LVD

36 47702495 09-2015 © AB VOLVO PENTA

 Maintenance Schedule

B
Every 1200 hours / At least every
(month)
12 24 48
Fuel pre-filter, filter insert R ●
Fuel fine filter R ●
Air Filter R ●
Impeller in seawater pump R ●
Anodes - Charge air cooler and / or Heat exchanger. (Must not be painted) R ●
Engine and transmission, inspect hoses and cable clamping I ●
Engine and transmission, cleaning / painting I ●

C
Every 2400 hours / At least every
(month)
12 24 48
Valve clearance I
Drive Belts R ●
Turbocharger, inspect / clean as required I ●

D
Every 3000 hours / At least every
(month)
12 24 48
Wear kit in seawater pump R

E
Every 8000 hours / At least every
(month)
12 24 48
Coolant VCS (yellow)(1) R ●
1) Different types of coolant must not be mixed with each other.

47702495 09-2015 © AB VOLVO PENTA 37

Maintenance
This chapter contains general technical information and instructions on how the prescribed maintenance items
must be carried out. Read through the instructions carefully before starting work. The times when maintenance
items must be carried are indicated in the Service Protocol.
Read through the safety precautions for maintenance and service in the Safety Information page 4 chapter before
work on the engine is begun.

WARNING!
Care and maintenance work should be done with the engine stopped unless otherwise specified. Stop the engine
before opening or removing the engine hatch/hood. Make it impossible to start the engine by removing the start
key and cutting the system voltage with the main switches.

D13B MH 1 Expansion tank

2 Coolant filler cap
3 Fuel fine filter
4 Air filter indicator
5 Auxiliary stop
6 Air Filter
7 Seawater Pump
8 Fuel feed pump (hand pump)
9 Heat exchanger
10 Oil dipstick, engine
11 Oil filler cap, engine
12 Relay
13 Alternator

1 Power Module
2 By-pass filter for engine oil
3 Oil filter
4 Charge air cooler
5 Coolant Pump

P0015621 1 2 3 4 5

38 47702495 09-2015 © AB VOLVO PENTA

 Maintenance

D13 MH RC 1 Expansion tank

2 Switchable fuel filters
3 Fuel feed pump (hand pump)
4 Engine Control Unit
5 Oil filler cap, engine
6 Air Filter
7 Emergency Stop
8 Radiator with charge air cooler
9 Switchable oil filters
10 By-pass filter for engine oil

Engine, General
General inspection
Make a habit of visually checking the engine and
engine bay before starting, and after operations when
you have stopped the engine. This will help you to dis-
cover abnormalities quickly, or if something is about to
happen.
Look especially carefully for oil, fuel and coolant lea-
kages, loose bolts, worn or poorly-tensioned drive
belts, loose cable connections, damaged electrical
cables and hoses. This inspection only takes a few
minutes and can prevent serious malfunctions and
expensive repairs.

47702495 09-2015 © AB VOLVO PENTA 39

Maintenance

WARNING!
Accumulations of fuel, oil and grease on the engine or
in the engine room is a fire hazard and must be
removed immediately they are detected.

WARNING!
If an oil, fuel or coolant leak is detected, the cause must
be investigated and the fault rectified before the engine
is started.

Never direct the jet from a high-pressure washer at

seals, rubber hoses or electrical components. Never
use the high pressure setting for engine cleaning.

Air Filter, Change

1 If indicator is all red after the engine is stopped,
change the filter insert.
2 Undo the clamps and remove the lid from the filter
housing.
3 Remove the old filter. Be careful to ensure that no
contamination gets into the engine.
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 must not be cleaned.

Drive Belt and Alternator Belt,

Inspection
WARNING!
Stop the engine before doing any maintenance work.

Inspections must be carried out after operations, while

the belts are hot.
You should be able to depress the alternator belt and
the drive belt about 3-4 mm between the pulleys.
The alternator belts and drive belts have automatic belt
tensioners and do not need to be adjusted.
Check the condition of the drive belts. Change as nec-
essary, refer to Alternator Belt, Change page 42 and
Drive Belt, Change page 41.

40 47702495 09-2015 © AB VOLVO PENTA

 Maintenance

Drive Belt, Change

IMPORTANT!
Always replace a belt that appears worn or is cracked.
D13 MH
1 Switch off at the main switch(es) and check that
the engine is not connected to voltage.
2 Remove the protective cover over the drive belt.
3 Insert a socket drive into the square socket on
the belt tensioner. Rotate the tensioner away
and lock it in position by inserting a screwdriver
or similar tool into the gap created.
4 Remove the drive belt.
5 Fit the new drive belt and release the belt ten-
sioner. Check that the belt is positioned cor-
rectly in the grooves.
6 Install the protective cover over the drive belt.
7 Start the engine and perform a function check.

D13 MH RC
1 Switch off at the main switch(es) and check that
the engine is not connected to voltage.
2 Remove the fan guard and fan ring round the
cooling fan.
3 Remove the belt guard.
4 Place a 1/2" square wrench in the belt tensioner
(1).
Lift the socket drive and remove the drive belt.
5 Thread the drive belt round the fan and remove
it.
6 Check that the pulleys are clean and undam-
aged.
7 Pass the new drive belt over the fan.
8 Lift the 1/2" wrench and install the new drive
belt.
9 Install the belt guards.
10 Install the fan guard and fan ring round the cool-
ing fan.
11 Start the engine and perform a function check.

47702495 09-2015 © AB VOLVO PENTA 41

Maintenance

Alternator Belt, Change

IMPORTANT!
Always replace a drive belt that seems worn or is
cracked.
1 Disconnect the main switch(es) and check that the
engine is not connected to system voltage.
2 Remove the fan guard and fan ring round the cool-
ing fan.
3 Remove the belt guard.
4 Place a 1/2" square wrench in the belt tensioner (1).
Lift the wrench up and lift the water pump drive belt
off.
5 Place a 1/2" square wrench in the belt tensioner (2).
Press the wrench down and remove the alternator
belt.
6 Check that the pulleys are clean and undamaged.
7 Press the 1/2" wrench in the belt tensioner (2) down
and install the new alternator drive belt.
8 Lift the 1/2" wrench in the belt tensioner (1) and re-
install the water pump drive belt.
9 Install the belt guards.
10 Install the fan guard and fan ring round the cooling
fan.
11 Start the engine and perform a function check.

Lubrication System
Oil change intervals can vary depending on oil grade
and sulphur content of the fuel, please refer toTechni-
cal Data page 69.

Oil change intervals must never exceed a period of 12

months.

If you want longer oil change intervals than given in the

table Technical Data page 69, the condition of the oil
must be checked by the oil manufacturers through reg-
ular oil testing.

P0002089

42 47702495 09-2015 © AB VOLVO PENTA

 Maintenance

Oil level, checking and topping up

The oil level must be inside the marked area on the

dipstick (1) and should be checked daily before the first
start.

Top up the oil through the filling hole on the side of the
engine (2). Check that the correct level has been ach-
ieved. Wait a few minutes to allow the oil to run down
into the sump.

IMPORTANT!
Do not fill up above the maximum oil level. Only use a
recommended grade of oil, please refer to Technical
Data, Lubrication System.

P0009747

47702495 09-2015 © AB VOLVO PENTA 43

Maintenance

Engine Oil, Change

Always follow the recommended oil change interval.
Use a manual or electric oil drain pump (optional equip-
ment) to pump the oil out of the oil pan.

WARNING!
Hot oil and hot surfaces can cause burns.

WARNING!
Working with or approaching a running engine is a
safety risk. Watch out for rotating components and hot
surfaces.

1 Run the engine until warm so that the oil is easier

to pump. Then stop the engine.
2 Connect a hose to the drain pump discharge(1) and
lead it to a collection vessel.
Alternative, remove the drain plug (2) and let the oil
run out into a collection vessel.
3 Open the tap (3) under the drain pump to the posi-
tion for draining engine oil (E). Suck up the oil.
4 Remove the drain hose (or install the bottom drain
plug).
5 Replace the oil filter and by-pass filter at every oil
change; refer to the Oil Filter/By-pass Filter,
Change page 45 section.
6 Close the drain pump tap (S).
Fit the drain plug if it has been removed.
7 Fill oil to the correct level via the filler opening on
the side of the engine; refer to theTechnical Data,
Lubrication System section for oil quantity.
IMPORTANT!
Use only oils of the recommended grades; refer to
the Oil Grade and Oil Change Interval section.
8 Start the engine and let it idle. Check that the low
oil pressure warning lamp goes out and that no
leaks are present at the filters.
9 Stop the engine. Wait a few minutes before check-
ing the oil level. Top up as needed.

Hand the old oil in to a re-cycling station.

44 47702495 09-2015 © AB VOLVO PENTA

 Maintenance

Oil Filter/By-pass Filter, Change

The oil filter and bypass filter must be replaced at every
oil change.
Remember to hand the old filters in to a re-cycling sta-
tion.

WARNING!
Hot oil and hot surfaces can cause burns.
2 1 Place a collection vessel underneath the filter drip
2 tray to avoid oil spillage.
1
2 Clean the filter bracket.
3 Unscrew the bypass filter (1) and the oil filters (2)
with a suitable puller.

P0015633 4 Check that the mating surfaces on the filter bracket

are clean and that no remains from the old gaskets
are left.
5 Moisten the gaskets on the new filters with engine
oil.
6 Screw on the filter by hand until the rubber gasket
touches the filter bracket mating surface. Then turn
a further 3/4 to 1 turn.
7 Start the engine, run at low idle, and check that no
leakage occurs. Check the oil level after the engine
has stopped.

47702495 09-2015 © AB VOLVO PENTA 45

Maintenance

Switchable oil filters

IMPORTANT!
Switchable oil filters should be replaced while the
engine is turned off.
The engine should always be run on both filters.

1 Clean the filter holder.

2 Disconnect the filter (1) by turning the handle clock-
wise to the end position. Pull down on the knob
below the handle to release the handle.
3 Unscrew the filter and scrap it. Use a filter tool if
necessary.
4 Check that the filter holder sealing surfaces are
clean and that there are no gasket residues left from
the old filter.
5 Lubricate the rubber gasket for the new filter.
6 Screw on the filter by hand until the rubber gasket
just touches the filter holder sealing surface. Then
tighten the filter a further 3/4 to 1 turn.
7 Turn the handle counterclockwise to end position
and replace the right oil filter in the same way.
8 Put the handle in the operating position, straight
down.
9 If necessary, top up the system at the first stop.
Refer to section Engine Oil, Change page 44.

Fuel System
Only use the grades of fuel recommended in the fuel
specification, see Technical Data page 70. Always
observe the greatest cleanliness during re-fuelling and
work on the fuel system.
All work on the unit injectors of the engine must be
carried out by an authorized workshop.

WARNING!
Fire hazard. When carrying out work on the fuel system
make sure the engine is cold. A fuel spill onto a hot
surface or an electrical component can cause a fire.
Store fuel soaked rags so that they cannot cause fire.

46 47702495 09-2015 © AB VOLVO PENTA

 Maintenance

Engine Fuel Filter Replacement

Stationary engine
1
1 Close the fuel valve/valves.
1
2 Clean the filter bracket and put a vessel under the
filter.
Remove the protective cap from the venting nip-
ple. Connect a transparent plastic hose to the
nipple and lower the hose into the vessel.

CAUTION!
Open the tap with caution. Hot fuel can spray out in
any direction.

3 Relieve pressure inside the filter by opening the

bleeding nipple (1).
4 Unscrew the filter, use a filter wrench if needed.
5 Clean the sealing surface on the filter bracket.
Make sure the new filter is absolutely clean and
that the sealing surfaces are undamaged. Mois-
ten the seals with engine oil, including the inner
rubber seal on the inside of the threaded hole in
the center of the filter.

NOTICE! Do not fill the new filter with fuel before

assembly. Contaminations may get into the system
2 and cause damage and malfunction.

6 Screw the new filter on by hand until the seal just

touches the mating surface. Then tighten a fur-
ther 3/4 turn.
7 Open the fuel valve/valves.
8 Open the bleeding nipple and work the pump (2)
until air-free fuel flows out. Tighten the bleeding
nipple while fuel is flowing out.
P0015712
9 Remove the hose and put the protective cap back
on the nipple.
10 Start the engine and check for leakages.

47702495 09-2015 © AB VOLVO PENTA 47

Maintenance

Running engine
WARNING!
Hot fuel can cause burns.

1 Clean the filter bracket and put a vessel under the

filter.
2 Remove the protective cap from the bleeding nip-
ple (1) Connect a transparent plastic hose to the
nipple and lower the hose into the vessel.
3 Shut off fuel flow through one of the filters by
turning the handle (2) to its end position (A).
4 Make sure the new filter is absolutely clean and
that the sealing surfaces are undamaged. Mois-
ten the seals with engine oil, including the inner
rubber seal on the inside of the threaded hole in
the center of the filter.
5 Screw the new filter on by hand until the seal just
touches the mating surface. Then tighten a fur-
ther 3/4 turn.
6 Bleed by turning the handle (2) to bleeding posi-
tion (B). This allows a reduced flow of fuel
through the filter and the air is evacuated through
the vent. Tighten the bleeding nipple when air-
free fuel flows out.
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.

P0015693

48 47702495 09-2015 © AB VOLVO PENTA

 Maintenance

Fuel system, bleeding

The fuel system must be bled if the fuel tank has been
run dry and after a long-term stoppage.
1 Remove the protective cap from the bleed nipple
(1).
1 Connect a transparent hose to the bleed nipple.
Feed the hose to a container to avoid spillage.
2 Open the bleeding nipple and pump fuel with the
hand pump (2) until the fuel is free from bubbles.
3 Close and tighten the bleed nipple.
4 Start the engine.
If the engine runs unevenly there might be air left in
the fuel system. To empty the system of remaining
air, open the bleed nipple while the engine is run-
ning.

WARNING!
Hot fuel can cause burns.

WARNING!
Working with or approaching a running engine is a
safety risk. Watch out for rotating components and hot
surfaces.

5 Close the bleed nipple. Remove the hose and fit the
protective cap to the bleed nipple.
2
6 Make sure there are no leaks.

P0015639

47702495 09-2015 © AB VOLVO PENTA 49

Maintenance

Fuel pre-filter
Volvo Penta fuel pre-filters are supplied in single and
double models.

Checks
The double filter is fitted with a pressure gauge 1 that
indicates when it is time to replace the filter cartridges.

The filter cartridges must be replaced according to

maintenance schedule recommendations, or earlier if
the pressure gauge shows a pressure drop of 6–10 in.
Hg at idle or 16–20 in. Hg at full rpm/engine load.

WARNING!
Working with or approaching a running engine is a
safety risk. Watch out for rotating components and hot
surfaces.

Draining
Place a vessel under the filter. Empty the water and
sediment through the plugs (2).

50 47702495 09-2015 © AB VOLVO PENTA

 Maintenance

Replacing filter cartridges

Double filter cartridges can be replaced while the
engine is running, by shutting off the fuel flow to one
filter holder at a time.

Fuel flow is controlled by moving the lever (1) to the

following positions:
A Normal operating position (both filters connected).
B Left filter cartridge can be replaced.
C Right filter cartridge can be replaced.
D Both filters shut off.

If the engine is stopped, begin by shutting the fuel taps

at the tank before replacing the filters. If the engine is
running the fuel flow to the filter to be replaced must be
shut off using the lever (1).

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

47702495 09-2015 © AB VOLVO PENTA 51

Maintenance

Freshwater System
The freshwater system is the engine's internal cooling
system that ensures that the engine operates at the
correct temperature. It is a closed system that must
always be filled with a coolant mixture in order to pro-
tect the engine against internal corrosion, cavitation
and frost bursting.

IMPORTANT!
Coolant of a suitable chemical composition must be
used all year round. This applies even when there is
no risk for frost damage, so that the engine always has
complete corrosion protection.
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; refer to Maintenance
Schedule. The cooling system must be flushed when-
ever the coolant is changed, refer to Freshwater sys-
tem, Flushing page 56.
ady mixed
coolant vcs re
Volvo Penta recommend ”Volvo Penta Coolant VCS,
Ready Mixed” or the concentrate ”Volvo Penta Coolant
VCS” mixed with pure water according to specifica-
tions, see Technical Data page 70.
P0013077
Volvo Penta Coolant VCS and VCS Ready Mixed are
based on organic acid technology (OAT). Using other
types of coolant, such as conventional or hybrid types,
can drastically reduce the heat transfer and result in
overheating of the engine.

52 47702495 09-2015 © AB VOLVO PENTA

 Maintenance

Coolant, Mixing

WARNING!
All coolant is hazardous and harmful to the environ-
ment. Do not consume. Coolant is flammable.

IMPORTANT!
Different types of coolant must not be mixed with each
other!

Mix: 40% “Volvo Penta Coolant” (conc. coolant)

and 60% water
This mixture protects against internal corrosion, cavi-
tation and frost bursting down to –24°C (–11°F). At
60% glycol concentration, the freezing point is lowered
to –46°C (–51°F).
Never mix more than 60% concentrate (Volvo Penta
Coolant) in the coolant. A greater concentration pro-
vides reduced cooling effect with the risk for overheat-
ing and reduced frost protection.

The coolant must be mixed with distilled, deionized

water. The water must fulfil the requirements specified
by Volvo Penta; refer to Technical Data page 70.
It is extremely important that the system is filled with
the correct coolant concentration. Mix in a separate
clean vessel before filling the cooling system. Make
sure that the liquids mix.

47702495 09-2015 © AB VOLVO PENTA 53

Maintenance

Filling with coolant

WARNING!
Burn hazard. Steam and hot fluid may spray out. Stop
the engine and allow it to cool before opening the filler
cap.

IMPORTANT!
Top up with the same type of coolant as already used
in the system. Different types of coolant must not be
mixed.

Topping up
Top up coolant to the correct level through the filler
opening on the expansion tank. Fill slowly, to allow air
that is displaced to flow out through the filler opening.

When filling an empty system, or if for some reason the

coolant level has sunk so low that it cannot be seen
through the filler opening, filling must be carried out
according to “Filling a completely empty cooling sys-
tem”.

P0009750

Filling a completely empty cooling system

1 Mix a sufficient quantity of coolant in a vessel before
filling. Note that if a heating system, water heater or
similar is connected to the engine cooling system,
a correspondingly greater quantity of coolant will be
required.
2 Also make sure that any heating system, water
heater or similar connected to the engine cooling
system is vented (open the heater regulator valve).
3 Fill coolant through the filler opening in the expan-
sion tank.
Fill slowly, to allow displaced air to flow out through
the filler opening.
4 Fill coolant to the lower rim of the filler pipe.
5 Start the engine and let it idle untill it has reached
operating temperature.

IMPORTANT!
P0009751 Do not let the engine work under load until the system
is vented and completely filled.
1 Stop the engine and let it cool. Check the coolant
level.
2 Top up.

54 47702495 09-2015 © AB VOLVO PENTA

 Maintenance

Coolant, Draining
D13 MH
WARNING!
1 Stop the engine and let it cool before starting work on
the cooling system. Hot fluids and hot surfaces can
cause burns.

WARNING!
All coolant is hazardous and harmful to the
environment. Do not consume. Coolant is flammable.

The coolant is drained via the taps (F).

1 Remove the filler cap (1) from the expansion

tank.
F F F 2 Connect a hose to each drain point. Open the
taps and allow all the coolant to drain into a ves-
sel.
Check that all coolant drains out. Deposits may
need to be cleared away inside the drain taps.
3 Also drain any heating system, hot water heat-
ers and similar which are connected to the
engine’s freshwater system.
4 Shut off all drain taps.
5 Collect the old coolant and hand it to a to a re-
cycling station
P0015637 F

D13 MH RC
1

F
P0021899

47702495 09-2015 © AB VOLVO PENTA 55

Maintenance

Freshwater system, Flushing

The cooling system should be flushed when the cool-

ant is changed, to avoid loss of cooling performance
due to deposits in the cooling system.
1 Drain the coolant, please refer to Coolant, Drain-
ing page 55.
2 Put a hose into the filling hole in the heat exchanger
and flush with fresh water.
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 Mainte-
nance page 54.

P0009752

Seawater System
The seawater system is the engine’s external cooling
system. The seawater system sucks in water through
the seawater inlet and pumps it through the heat
exchanger and the reverse gear oil cooler. The system
is protected from galvanic corrosion by means of zinc
anodes located in the heat exchanger and the reverse
gear oil cooler.

WARNING!
Risk of water entry. Water will flow into the boat if any
hose, plug etc. located below the waterline is removed
when the boat is in the water. Always close the sea
cocks. If the boat does not have sea cocks the water
flow must be blocked in a safe manner. If this is not
possible, the boat must be drawn up on land before
work starts.

Seawater System, Draining

The seawater system must be drained in cold weather,
if there is a risk of frost, to prevent frost damage.

WARNING!
Risk of water entry. Close the seawater cocks before
doing any work on the seawater system.

An alternative to draining is to keep the engine bay

above freezing temperature, by means of a fan heater
which is approved for outdoor use.

56 47702495 09-2015 © AB VOLVO PENTA

 Maintenance

1 Close the sea cock.

2 Connect a hose to each drain tap before opening
the tap (one at a time).

s 3 Open the drain taps/remove the drain plugs (S) and

allow the water to run out.
s

Drain points:
- tap under the heat exchanger
- tap above seawater pump
s
- plug below seawater pump
P0015707
IMPORTANT!
Check that all water really does drain out. Depos-
its may need to be cleared away, inside the drain
plug/tap.
4 Also drain/empty any auxiliary equipment such as
the seawater filter etc.
5 Close/install all drain taps and plugs before you
leave the boat.

Zinc Anodes, Check and Change

WARNING!
Risk of water entry. Close the seawater cocks before
doing any work on the seawater system.

1 Close the seawater tap.

2 Open the heat exchanger drain tap (1) and drain off
the seawater.
Z
3 Remove the zinc anodes (Z) (2 pcs.) from the heat
exchanger.
Check that the O-ring is in good condition, other-
wise change it.
4 Check the zinc anodes and change them if they
have been consumed below 1/3 of their original
size. If not, clean the zinc anodes with emery cloth
to remove the oxide layer before re-installing them.
IMPORTANT!
1 Use emery paper. Do not use a wire brush or
Z other steel tools when cleaning, as these may
damage the galvanic protection.
5 Install the zinc anodes. When installing, make sure
there is good metallic contact between the anode
and the casting.
P0009753
6 Close the drain tap (1 ).
7 Open the sea cock before starting the engine.
8 Check that there are no leaks.

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Maintenance

Impeller, Check and Change

WARNING!
Risk of water entry. Close the seawater cocks before
doing any work on the seawater system.

1 Remove the seawater pump lid, and pull the impel-

ler out with universal impeller puller.
2 Check the impeller. If any cracks or other defects
are visible, the impeller must be changed.
3 Lubricate the pump housing and the inside of the
lid with water-resistant grease (which is not aggres-
sive to rubber). The impeller will be easier to work
with if it is put in hot water prior to fitting.
4 Press the impeller in with a circular motion (counter
clockwise). The shaft of the pump has an internal
thread (M8). Screw a stud into the end of the shaft
and press the impeller in using a washer and nut.
Fit the cover, using a new O-ring.
5 Open the sea cock.

IMPORTANT!
Always carry a spare impeller on board.

P0015643

58 47702495 09-2015 © AB VOLVO PENTA

 Maintenance

Seawater Filter, Check and Cleaning

The seawater filter is optional equipment. Volvo Penta
offers two different seawater filters.

If the water where the boat is operated contains a lot

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

WARNING!
Risk of water entry. Close the seawater cocks before
doing any work on the seawater system.

1 1 Close the sea cock.

2 Unscrew the cover by hand counter clockwise (1).
3 Lift out the insert (2) and clean it.
2
4 If the glass vessel (3) needs cleaning from e.g.
algae fouling, this must be done from the top with
the aid of a suitable brush; use soapy water as
required. The glass vessel must (3) not be
removed!

3 5 Screw the cover back on (1) by hand. The cover

threads should be brushed with silicone-based
water-proof grease, e.g. VP part # 828250, annu-
ally; this will ensure that the cover does not seize
on removal.
Mineral oil based grease may not be used.
P0010446
6 Open the sea cock and check for leaks.

1 Close the sea cock.

2 Remove the lid (1) and lift up the insert.
3 Clean the insert and the housing (2).
4 Install the components as in the illustration. Check
the seals. Change as necessary.
5 Open the sea cock and check carefully that no leak-
age occurs.

47702495 09-2015 © AB VOLVO PENTA 59

Maintenance

Intake Manifold, Checking the Drain

Hole
Steam may be generated during operations; it drains
via a hole at the bottom of the charge air cooler. Check
that the hole is not blocked.

CAUTION!
Burn hazard! Steam may evaporate through the drain
hole.

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.

!
P0015707

60 47702495 09-2015 © AB VOLVO PENTA

 Maintenance

Electrical System
The engine is equipped with a 2-pole electrical system
and an alternator. System voltage is 24V.

WARNING!
Always stop the engine and break the current using the
main switches before working on the electrical system.
Isolate shore current to the engine block heater, bat-
tery charger or accessories mounted on the engine.

Power Module

The power module supplies power to the EMS and the

MCC control system. The power module (PM) protects
the system from high current with a built in over current
protection.
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.

Main switch
IMPORTANT!
Never disconnect the current with the main switches
when the engine is running, the alternator and elec-
tronics could be damaged.

The main switches must never be switched off before

the engine has stopped. If the circuit between the alter-
nator and the battery is disconnected when the engine
is running, the alternator and electronics can be dam-
aged. For the same reason the charging circuits must
never be re-connected with the engine running.

Electrical Connections

Check that electrical connections are dry, free from

oxide, and that they are securely tightened.

47702495 09-2015 © AB VOLVO PENTA 61

Maintenance

Battery, Maintenance
WARNING!
Risk of fire and explosion. Never allow an open flame
or electric sparks near the battery or batteries.

P0002107 WARNING!
Never confuse the positive and negative poles on the
batteries. Risk of arcing and explosion.

WARNING!
The battery electrolyte contains extremely corrosive
sulfuric acid. Protect your skin and clothes when charg-
ing or handling batteries.
Always use protective goggles and gloves. If battery
electrolyte comes into contact with unprotected skin
wash off immediately using plenty of water and soap.
If battery acid comes in contact with the eyes, flush
immediately with plenty of water and obtain medical
assistance without delay.

Connecting and disconnecting the battery

Connecting
- 1 Connect the + cable (red) to the + pole on the bat-
+

tery.
2 Connect the – cable (black) to the – pole on the
battery.

Disconnecting
1 Remove the – cable (black).
P0016902
2 Remove the + cable (red).

Cleaning
Keep the batteries clean and dry. Contamination and
oxide on the batteries and battery poles can cause
stray currents, voltage drop and discharge, especially
in wet weather. Remove oxidation from the battery
poles and terminals, using a brass brush. Tighten the
terminals securely and grease them with terminal
grease or petroleum jelly.
P0016903

Filling
The electrolyte level should be 5–10 mm (0.2– 0.4”)
above the cell plates in the battery. Top up with distilled
water as required.

After filling, the battery should be charged for at least

30 minutes by running the engine at idle.

Some maintenance-free batteries have special

instructions, which must be followed.
P0016910

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 Maintenance

Battery, Charging
WARNING!
Risk of fire and explosion. Never allow an open flame
or electric sparks near the battery or batteries.

P0002107 WARNING!
The battery electrolyte contains extremely corrosive
sulfuric acid. Protect your skin and clothes when charg-
ing or handling batteries.
Always use protective goggles and gloves. If battery
electrolyte comes into contact with unprotected skin
wash off immediately using plenty of water and soap.
If battery acid comes in contact with the eyes, flush
immediately with plenty of water and obtain medical
assistance without delay.

WARNING!
Never confuse the positive and negative poles on the
batteries. Risk of arcing and explosion.

IMPORTANT!
Observe the instruction manual for the battery charger
carefully. To avoid the risk of electrochemical corrosion
when an external charger is connected, the battery
cables should be removed from the batteries before
the charger is connected.
Always switch off the charging current before the
charging clips are removed.

• Charge batteries if they have become discharged.

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

P0002111

47702495 09-2015 © AB VOLVO PENTA 63

Maintenance

Electrical Installations
An incorrectly designed electrical installation may gen-
erate leakage current from the electrical system. Leak-
age current can in turn render galvanic protection inad-
equate in respect of propellers, propeller shafts, rudder
posts, the keel etc., and may cause damage through
electrochemical corrosion.

WARNING!
Work on the low voltage circuits in the boats should be
done by a person with electrical training or knowledge.
Installation or work on land current equipment must
only be done by a competent electrician, in accordance
with local regulations for mains electricity.

The following must always be heeded:

1 If shore power is connected it must always be

ground protected ashore, never in the boat. Fur-
thermore, the shore power installation should be
equipped with a ground fault circuit interrupter.
The shore power installation (transformer, inverter,
battery charger etc.) must be designed for marine
use where the high-tension side is galvanically
separated from the low-tension side.
2 Electrical cables must be run and clamped such
that there is no risk of exposure to chafing, damp or
bilge water.
3 Ground protection for radios, navigation instru-
ments, rudder, boarding ladders or other equipment
where separate cables for ground protection are
present, must be clustered to a common ground
P0002900
connection that is not connected to the engine or
reverser gear.
IMPORTANT!
The engine and reverse gear must never be used
as earth planes.
4 The start battery must have a main switch (1) con-
nected to the battery's positive (+) side. The main
switch must break the circuit to all equipment and
be switched off when the boat is not in use.
5 If an auxiliary battery is used, a main switch must
be placed between the auxiliary battery's positive
(+) terminal and the circuit breaker panel for the
boat's electrical equipment. The main switch must
break the circuit to all equipment connected to the
auxiliary battery and must be switched off when
power is no longer required. 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.

64 47702495 09-2015 © AB VOLVO PENTA

 Maintenance

Electrical Welding
Remove the positive and negative cables from the bat-
teries, then disconnect all cables connected to the
alternator, EMS, power module and MCC.

Always connect the welder ground clamp to the com-

ponent to be welded, and as close as possible to the
weld site. The clamp must never be connected to the
engine or in such a way that current can pass through
a bearing.

IMPORTANT!
After finished welding, re-connect the alternator termi-
nals before connecting the battery cables.

47702495 09-2015 © AB VOLVO PENTA 65

Storage
The boat must be inhibited to prevent damage to the engine and other equipment if the boat is not used for two
months or more. It is important that this is done in the correct manner, and nothing is forgotten. For this reason,
we have compiled a check list of the most important points.
Before the boat is taken out of service for a long period of time, an authorised Volvo Penta workshop should look
over the engine and other equipment. Have any faults and deficiencies attended to, so that the equipment is in
order, ready for the next start.

CAUTION!
Read the chapter on Maintenance before starting work. It contains instructions on how to carry out maintenance
and service operations in a safe and correct manner.

Some conservation oils are flammable. Some are also dangerous to breathe. Ensure good ventilation. Use a face
mask when spraying.

IMPORTANT!
Observe the following when cleaning with a high pressure washer: Never aim the water jet at seals, rubber hoses
or electrical components. Never use a high pressure washer for engine cleaning.

Inhibiting
• Warm the engine up to normal operating temper- • Close the sea cock and drain the water from the
ature and check that the oil level in the reverse gear seawater system.
reaches the MAX mark on the dipstick. Stop the
• Remove the impeller from the seawater pump.
engine.
Store the impeller in a sealed plastic bag, in a cool
• Max 8 month’s stoppage: place.
Change the oil and oil filter on the engine, then
• Drain any water and contamination from the fuel
warm it up afterwards.
filters and fuel tank. Fill the fuel tank completely, to
More than 8 month’s stoppage:
avoid condensation.
Conserve the lubrication and fuel systems with
conservation oil. Please refer to “Conservation of • Disconnect the battery cables, clean and charge
the lubrication and fuel systems for more than 8 the batteries. Trickle charge the batteries while the
months’ stoppage”. boat is laid up. A poorly charged battery can
freeze and burst.
• Check that the coolant offers sufficient frost pro-
tection. Top up as necessary. • Clean the outside of the engine. Do not use a high
Alternatively, you can drain the coolant (also drain pressure washer for engine cleaning. Touch up
the coolant filter). paint damage with Volvo Penta original paint.
• Check and rust-proof any control cables.
• Put a note on the engine with the date, type of con-
servation and the conservation oil used.
• Cover over the engine air inlet, exhaust opening
and engine if necessary.

P0002089

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 Storage

Conservation of the lubrication and fuel systems for more than 8 months’ stoppage:

• Drain the oil from the sump and engine and fill the
engine up with conservation oil* to just above the
MIN marking on the dipstick.
• Connect the fuel supply (1) and return fuel pipes (2)
to a jerrican filled with 1/3 conservation oil*and 2/3
2 diesel fuel.
• Vent the fuel system.
• Start the engine and run at a fast idle until about 2
litres (0.5 US gals.) have been used.
Stop the engine and connect the ordinary fuel pipes.
• Empty the conservation oil out of the engine.
• Follow the other instructions on the previous page.
P0010277
1
* Conservation oils are sold by oil companies.

Bringing Out of Storage

• Remove any covers from the engine, air inlet and
exhaust pipe.
• Top the engine up with the correct grade of oil if
necessary, see Technical Data page 69. Install a
new oil filter if the filter was not changed during con-
servation.
• Check that there is oil in the reverse gear.
• Install new fuel filters and vent the fuel system.
• Check the drive belt(s).
• Check the condition of all rubber hoses, and re-
tighten the hose clamps.
• Close the drain taps and install the drain plugs.
• Insert the impeller in the seawater pump, using a
rotating movement (anti-clockwise).
• Check the coolant level and anti-freeze. Top up if
necessary.
• Connect the fully charged batteries.
• Open the sea cocks.
• Start the engine (if the boat is in the water) and warm
up at a fast idle before loading the engine.
• Check that no oil, fuel or coolant leakage occurs.
• Check the oil level in the reverse gear. Top up if
necessary.

47702495 09-2015 © AB VOLVO PENTA 67

Technical Data
Type designation D13–300 D13–400 D13–450
Aftermarket designation D13B-N MH D13B-N MH D13B-N MH
D13B-E MH D13B-E MH D13B-E MH
D13B-F MH RC D13B-F MH RC D13B-F MH RC
Crankshaft power @ 2300 (1) 165 kW 294 kW 331 kW
(221 hk) (400 hk) (450 hk)
Max torque @ 1400 rpm 1460 Nm 1802 Nm 1986 Nm
(1077 lb ft) (1329 lb ft) (1465 lb ft)
No. of cylinders 6 6 6
Bore 131 mm 131 mm 131 mm
5.16") 5.16") 5.16")
Stroke 158 mm 158 mm 158 mm
6.22") 6.22") 6.22")
Displacement 12.78 dm3 12.78 dm3 12.78 dm3
(780 in3) (780 in3) (780 in3)
Engine, dry weight 1500 kg 1500 kg 1500 kg
D13B-F MH RC (3307 lb) (3307 lb) (3307 lb)
Engine, dry weight 1450 kg 1450 kg 1450 kg
D13B-N MH (Heat exchanger) (3197 lb) (3197 lb) (3197 lb)
D13B-E MH (Heat exchanger)
Compression ratio 18.5:1 18.5:1 18.5:1
Low idle, r/min.(2) 600 (±10) 600 (±10) 600 (±10)
1) According to ISO 8665
2) If needed, the speed can be adjusted within the range 550–800 rpm.

Type designation D13–500 D13–550 D13–600

Aftermarket designation D13B-N MH D13B-N MH D13B-N MH
D13B-E MH D13B-E MH D13B-E MH
D13B-F MH RC D13B-F MH RC D13B-F MH RC
Crankshaft power @ 2300 (1) 368 kW 404 kW 441 kW
(500 hk) (550 hk) (600 hk)
Max torque @ 1400 rpm 2231 Nm 2438 Nm 2460
(1645 lb ft) (1798 lb ft) (1814 lb ft)
No. of cylinders 6 6 6
Bore 131 mm 131 mm 131 mm
5.16") 5.16") 5.16")
Stroke 158 mm 158 mm 158 mm
6.22") 6.22") 6.22")
Displacement 12.78 dm3 12.78 dm3 12.78 dm3
(780 in3) (780 in3) (780 in3)
Engine, dry weight 1500 kg 1500 kg 1500 kg
D13B-F MH RC (3307 lb) (3307 lb) (3307 lb)
Engine, dry weight 1450 kg 1450 kg 1450 kg
D13B-N MH (Heat exchanger) (3197 lb) (3197 lb) (3197 lb)
D13B-E MH (Heat exchanger)
Compression ratio 18.5:1 18.5:1 18.5:1
Low idle, r/min.(2) 600 (±10) 600 (±10) 600 (±10)
1) According to ISO 8665
2) If needed, the speed can be adjusted within the range 550–800 rpm.

68 47702495 09-2015 © AB VOLVO PENTA

 Technical Data

Oil grade and oil change interval

Oil quality (1) Sulfur content in fuel, by weight

up to 0,5% 0,5–1,0% more than 1,0% (2)
Oil change interval, reached first in operation:
VDS-3 600 hours or 12 months 300 hours or 12 months 150 hours or 12 months
VDS-2
The oil must also comply with at
least one of the following specifi-
cations:
500 hours or 12 months 250 hours or 12 months 125 hours or 12 months
ACEA E7 (3)
Global DHD-1
API CH-4
API CI-4
1) Lowest recommended oil grade. Engine oil with higher oil grade is always possible to use.
2) If sulphur content is more than 1.0 per cent by weight, use oil with TBN over 15.
3) ACEA E7 has replaced ACEA E5. If available ACEA E5 can be used.

NOTICE!
Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the quality require-
ments above.

ACEA = Association des Constructeurs Européenne d'Automobiles

API = American Petroleum Institute
Global DHD = Global Diesel Heavy Duty
TBN = Total Base Number
VDS = Volvo Drain Specification

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.

47702495 09-2015 © AB VOLVO PENTA 69

Technical Data

Fuel System

Fuel specification
The fuel must comply with national and international standards for commercially supplied fuels, such as:
EN 590 (with national environment and cold requirements)
ASTM D 975 No 1-D and 2-D
JIS KK 2204
Sulfur content: Complying with legal requirements in each country.

Low density fuel (urban diesel in Sweden and city diesel in Finland) can cause a loss of up to 5% of power and
an increase in fuel consumption of about 2–3%.

Cooling System
Freshwater system capacity including heat exchanger, approx. 57 litre (15 US gal).

Water Quality

ASTM D4985:

Total solid particles <340 ppm

Total hardness <9,5° dH
Chloride <40 ppm
Sulfate <100 ppm
pH value 5.5–9
Silica (acc. ASTM D859) <20 mg SiO2/l
P0002094
Iron (acc. ASTM D1068) <0.10 ppm
Manganese (acc. ASTM D858) <0.05 ppm
Conductivity (acc. ASTM D1125) <500 µS/cm
Organic content, CODMn (acc. <15 mg KMnO4/l
ISO8467)

70 47702495 09-2015 © AB VOLVO PENTA

 Technical Data

Electrical System

System voltage 24V

AC generator:
voltage/max. amperage 28V/110A
output, approx. 2640W

Alternative generator equipment (accessory):

voltage/max. amperage 28V/110A
output, approx. 2640W

Alternative generator equipment (accessory):

voltage/max. amperage 14V/115A
output, approx. 1610W

Battery capacity 2 connected in series 12V, max. 220 Ah

Battery electrolyte density at +25°C (77°F)

fully charged battery 1.28 g/cm 3 = 0.0462 lb/in3
(1.24 g/cm3 = 0.0448 lb/in3) (1)
battery recharged at 1.24 g/cm3 = 0.0448 lb/in3
(1.20 g/cm3 = 0.0434 lb/in3) (2)
1) Applies to batteries with tropical acid.
2) Applies to batteries with tropical acid.

47702495 09-2015 © AB VOLVO PENTA 71

Technical Data

Identification Numbers
A
Product designation (1) ...........................................
Product number (2) ...........................................
Serial number (3) ...........................................
P0015924

B
Chassi ID ...........................................
Serial number ...........................................

B A

P0015685

72 47702495 09-2015 © AB VOLVO PENTA

Alphabetical index
A V
Acknowledge message............................................. 24 Viscosity.................................................................... 69
Air Filter, Change...................................................... 40 W
Alarm List.................................................................. 24 Water Quality.............................................................70
Alarms................................................................. 16, 19
Alternator Belt, Change............................................. 42 Z
Zinc Anodes, Check and Change..............................57
B
Battery, Charging...................................................... 63
Battery, Maintenance................................................ 62
Bringing Out of Storage.............................................67
C
Cold Weather Precautions........................................ 22
Coolant, Draining.......................................................55
D
Drive Belt and Alternator Belt, Inspection..................40
Drive Belt, Change.................................................... 41
E
Electrical Connections...............................................61
Electrical Installations................................................64
Electrical System.......................................................61
Electrical Welding......................................................65
Engine Fuel Filter Replacement................................ 47
Engine Oil, Change................................................... 44
Engine, General........................................................ 39
F
Fault Tracing............................................................. 26
Freshwater System................................................... 52
Freshwater system, Flushing.................................... 56
Fuel pre-filter............................................................. 50
Fuel System.............................................................. 46
Fuel system, bleeding............................................... 49
I
Identification Numbers...............................................72
Impeller, Check and Change.....................................58
Intake Manifold, Checking the Drain Hole................. 60
L
Lubrication System....................................................42
M
Main switch................................................................61
Maneuvering..............................................................20
Marine Commercial Control System (MCC).............. 10
Menues......................................................................12
O
Oil Filter/By-pass Filter, Change............................... 45
Oil level, checking and topping up.............................43
Operation Break........................................................ 22
S
Seawater Filter, Check and Cleaning........................59
Seawater System...................................................... 56
Seawater System, Draining.......................................56
Settings..................................................................... 14
Starting the Engine....................................................18
Starting Using Auxiliary Batteries.............................. 34
Stop the Engine.........................................................21

47702495 09-2015 © AB VOLVO PENTA 73

 © 2015 AB VOLVO PENTA
Volvo reserves the right to make changes
Printed on environmentally friendly paper
47706247 English 09-2015