Fault Handling

Despite regular maintenance according to the maintenance schedule and perfect operation conditions faults may
occur which must be attehded 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.

I Fls
The message toggles between cause of fault and tasks
to perform.

Information regarding "cause of fault" and "measures

to take" is found in chapter Fault Code Register.

• PS 5 M158 OC 53 FM 5
P0013089
The engine, transmission and MCG system is moni-
tored by the diagnostic function. Should the diagnostic
function discover a malfunction it protects the engine
and ensures continued operation by affecting the

•
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.

•
4770250806-2013 © AB VOLVO PENTA 25
Fault Handling

Acknowledge message

The Ackn button acknowledges all alarms. Alarms that

are not active disappear from the list.
t
P0010312

Alarm List

ECU Alarm The alarm list and ECU alarm list are the two first win-
dows in the main menu.

I
3 P1
From the main menu press the up button once to reach
the alarm list and twice for the ECU alarm list.

Alarm List (Alarm list) l

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 Mill>
and alarm history are being reviewed. ~"

;!
in
~ ~================~

1 2 3 4

rr====~-l
Alarmlist 21 I 3
L=L
P1 The alarm list heading shows:
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
fL,
~

iii
enter key. t)
~
~==================~
Alann List
t1

Status of alarm
2 Active alarms are indicated by a black back-
ground (1)
Unacknowledged alarms are marked with * (2)
Inactive alarms are displayed without a black
~
background (3)
iii
g
~~=============

26 4770250806-2013 © AB VOLVO PENTA

 Fault Handling

ECU alarm list

ECU Alarmlist If ECU AlarmList is visible in the list then there are fault
codes from the engine control unit or power manage-
ment system.

Fls

PS 5 M158 OC 53 FM 5
P0013089

Alarm list and history

No. Reason
Abbreviations in alarm list and history
•.
'\~ > 0 Fault Reset
- 1 CAN control Abbreviation Meaning
- 2 Wrn SOU Syst Fa: Wrn Warning

•
- 3 Wrn SOU Syst Fa: Sd Automatic shutdown
- 4 Wrn SOU Syst Fa: Fls Sensor failure
- 5 Fault Reset General alarm
25/02105 12:34:49.6
P0010309

•
••
•

•
4770250806-2013 ©AB VOLVO PENTA 27
 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 5 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
j'
, ,
Blue or white exhaust smoke 21,34
Lubricating oil pressure too low 22
,:i Coolant temperature too high 25,26,27,28,29,30,31,32
I Coolant temperature too low 31
If
"

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 t
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
i,,.

t.,.
28 4770250806-2013 © AB VOLVO PENTA
t
 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 alanm list or ECU alarm list

••
•

4770250806-2013 © AB VOLVO PENTA 29

Fault Code Register
BattPotential Wrn
Battery voltage to engine control unit.
Check belt tension. Please refer to Drive Belt, Check and Change. l
Check battery fluid level. Please refer to Battery, Maintenance page 66.

Coolant Level Wrn

Low coolant level.
Check for coolant leakage.
Check coolant level., Please refer to Maintenance page 56.

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 56
Check that the seawater filter is not blocked., Please refer to Seawater Filter, Check and
Cleaning page 63
~.,
Check the impeller in the seawater pump., Please refer to Impeller, Check and Change page 62
Check that no leakage occurs.

4fj:.""
EngineOilLevel Wrn 'JL'
Oil level too low,
The system may wrongly detect too Iowan 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 45.
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 45,
Check that no leakage occurs.

30 4770250806-2013 © AB VOLVO PENTA

 Fault Code Register

Extra Supply Fis

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 Fis

Emergency Stop Switch
• Check emergency stop button if any. Reset if necessary.

Fis
Miscellaneous system faults.
I
Engine performance might be affected.A number of possible causes of engine problems are described below. .i
I

Battery voltage incorrect.

Check belt tension. Please refer to Drive Belt, Check and Change.
Check battery fluid level. Please refer to Battery. Maintenance page 66.
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 45.
Check that no leakage occurs.
Sensor failure

Please contact a Volvo Penta workshop if the fault remains.

•• Fis 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 49
Check for fuel leakage.

•
4770250806-2013 © AB VOLVO PENTA 31
 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 49 .
Check for fuel leakage.

Oil Level Wrn

Oil level too low.
The system may wrongly detect too Iowan 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 45
Check that no leakage occurs.

Primary Batt Fls

Primary Battery.
Poor batteries or charging. Please refer to Battery, Charging page 67

Sd Coolant Temp
Wrn ECU, Wrn J1587
Critical system faull. Engine shuts down automatically.
Coolant temperature too high. Engine power is reduced.
Check coolant level., Please refer to Maintenance page 56.
Check that the seawater filter is not blocked., Please refer to Seawater Filter, Check and
Cleaning page 63.
Check the impeller in the seawater pump., Please refer to Impeller, Check and Change page 62.

Please contact a Volvo Penta workshop if the fault remains.

Sd Gear Oil Press

Wrn ECU, Wrn J1587
t/
Critical system faull. Engine shuts down automatically. eiw
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 faull. 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.

i 32 4770250806-2013 © AB VOLVO PENTA

l
 Fault Code Register l
:1
Sd Overspeed SDU
Wrn ECU, Wrn J1587
Critical system fault. Engjne 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 67

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 63
Check the impeller in the sea water pump. Please refer to Impeller, Check and Change page 62.
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 66.
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 45.
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 66.
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 45.
Check that no leakage occurs.

Please contact a Volvo Penta workshop if the fault remains.

4770250806-2013 © AB VOLVO PENTA 33

 Fault Code Register

Wrn SO 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.

il
II
II
I
I
I

tu
t)il

34 4770250806-2013 © 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.

,.I'•,'
•

•
4770250806-2013 © AS VOLVO PENTA 35
In Case of Emergency

Starting Using Auxiliary

Batteries

'&WARNING!
L
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.
POO02107

'&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. l
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 going close to 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.

36 4770250806-2013 © AB VOLVO PENTA