INSTRUCTION BOOK MD2010, MD2020, MD2030, MD2040
7738231 - Downloaded from www.volvopenta.com 29/03/2009 14:51:17 California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
7738231 - Downloaded from www.volvopenta.com 29/03/2009 14:51:17 Welcome aboard Congratulations on your new boat and your choice of a Volvo Penta marine engine. A choice that will give you many years of boating pleasure. Your new marine engine is the result of 90 years experience in marine engine design, coupled with revolutionary new ideas and concern for the environment, where traditional Volvo Penta qualities such as first class performance, reliability and durability have been upheld.
Contents Safety Precautions .............................................. 3–7 Introduction ......................................................... 8–9 Running-in ................................................................ 8 Fuel and oils ............................................................ 8 Certified engines ...................................................... 8 Warranty .................................................................. 9 Presentation .....................................
Safety Precautions Read this chapter carefully. It concerns your safety. This section describes how safety information is presented in the Instruction Manual and on the engine. It also gives a general account of basic safety precautions to be taken when operating the boat and maintaining the engine. 7738231 - Downloaded from www.volvopenta.com 29/03/2009 14:51:17 Check that you have the correct Instruction Manual before you read on. If this is not the case please contact your Volvo Penta dealer.
Safety precautions to be taken when operating the boat Your new boat When refueling there is always a danger of fire and explosion. Smoking is forbidden and the engine must be switched off. If this is your first boat, or is a boat type with which you are not familiar, we recommend that you practice controlling the boat in peace and quiet. Learn how the boat behaves at different speeds, weather conditions and loads before casting off for your “real” maiden voyage. Never overfill the tank.
Carbon monoxide poisoning When a boat moves forward through the water a vacuum is created behind it to a greater or lesser extent. In some circumstances this vacuum effect can be so great that the boat’s own exhaust gases are sucked into its cockpit or cabin. This poses a risk of carbon monoxide poisoning to those on-board. Most modern boats are designed so that vacuum effect problems are very rare. If a vacuum forms behind the boat do not open ventilators or hatches at the front of the boat.
Safety precautions for maintenance and service Preparations 7738231 - Downloaded from www.volvopenta.com 29/03/2009 14:51:17 Knowledge base The Instruction Manual contains instructions on how to carry out the commonest maintenance and service operations safely and correctly. Read them carefully before starting work. Fire and explosion Fuel and lubricating oil All fuels, most lubricating oils and many chemicals pose a fire hazard. Read and follow the instructions on packaging.
Carbon monoxide poisoning Only start the engine in a well-ventilated area. If operating the engine in an enclosed space, ensure that exhaust gases and crankcase emissions are ventilated out of the working area. Chemicals Most chemicals such as glycol, rustproofing agents, inhibiting oils and degreasing agents are hazardous to health. Read and follow the instructions on packaging. Certain chemicals such as inhibiting oils are inflammable and also hazardous to health if inhaled.
Introduction This Instruction Manual has been compiled to help you get the most from your Volvo Penta engine. It contains all the information you need in order to operate and maintain your engine safely and correctly. Please read the Instruction Manual carefully and learn how to operate the engine, controls and other equipment safely. 7738231 - Downloaded from www.volvopenta.com 29/03/2009 14:51:17 Always have the Instruction Manual available.
the statutory environmental regulations. This places special requirements on maintenance, service and replacement parts as follows: ● ● ● ● IMPORTANT! Use only Volvo Penta Genuine Parts. Use of non-original AB Volvo Penta spare parts will result in AB Volvo Penta being unable to assume liability for the engine meeting engine certification requirements.
Presentation 1 7738231 - Downloaded from www.volvopenta.
1 4 7738231 - Downloaded from www.volvopenta.com 29/03/2009 14:51:17 6 2 3 7 5 4 6 4 2 3 5 1. Coolant filler cap Expansion tank Relay box with fuses Flexible mounting Starter motor AC generator Dipstick, reverse gear/S-drive Oil filler cap, reverse gear/S-drive 16 4 9. 10. 11. 12. 13. 14. 15. 16.
Identification number Your engine and transmission has identification plates with identification numbers. This information should always be quoted when ordering service and replacement parts. There are probably similar plates on your boat and its equipment. Make a note of the details below, make a copy of the page and keep it so that you have a copy should the boat be stolen. The appearance and location of identification plates is shown below.
Instrumentation This chapter only describes the instrument panels available as standard for your engine from Volvo Penta. Note that in certain boats instruments, alarm panels, key switches etc. may be installed separately without the instrument panels shown here. If you want to install additional instrumentation, or your boat is equipped with instruments not described here, please contact your Volvo Penta dealer. 6 7 3 8 Instrument panel with ignition switch 1. Tachometer and hour counter (accessory).
S = The mechanical restart inhibitor is disengaged. The key springs back automatically to the 0 position. 0 = The key can be inserted and removed. I = Operating position. II = Glow plug position. The glow plugs are connected and pre-heating the engine. III = Starting position. The starter motor is engaged. IMPORTANT! Read the starting instructions in the chapter: Starting the engine. 7738231 - Downloaded from www.volvopenta.
Warning display If the acoustic alarm sounds, one of the three warning lamps (16-18) on the instrument panel starts to flash to indicate the source of the alarm. 16. Engine coolant temperature too high. 17 18 16 19 IMPORTANT! If the alarm sounds: Reduce engine speed to idle (neutral). Stop the engine if the temperature does not drop. Investigate and correct the malfunction. 17. Low oil pressure. IMPORTANT! If the alarm sounds: Stop the engine immediately and investigate. 18. Generator not charging. 19.
Controls The shift function and engine speed control are combined in one lever. If necessary the shift function can be easily disengaged so that only the engine speed (rpm) is affected by the lever. The control lever has an adjustable friction brake. A neutral position switch is available as an accessory, this will only permit the engine to be started with the drive/reverse gear disengaged. Maneuvering T T Shifting and engine speed are controlled with the same lever (1). N = Neutral position.
Starting the engine Make a habit of checking the engine and engine compartment visually before operating the boat. This will help you to quickly detect anything unusual that has or is about to happen. Also check that instruments and the warning display are indicating normal values when you have started the engine. Before starting ● Open the cooling water intake sea cock. ● Open fuel cock. ● Check that there are no fuel, engine coolant or oil leaks.
3. Turn key to the “II” position. The indicator light comes on and the glow plugs are connected to pre-heat the engine. Let the glow plugs remain activated for 10 seconds (max. 30 seconds). IMPORTANT! Always pre-heat the engine (even when it is at operating temperature). 4. Turn the key to position “III” to start. Release the key as soon as the engine has started, the key will automatically spring back to the “I” position.
4. Press the starter button. Release the starter button as soon as the engine starts. IMPORTANT! If the starter motor is engaged for its maximum engagement time (20–30 seconds) let it cool down for five minutes before trying to start the engine again. 5. Warm up the engine at low speed and low load. 7738231 - Downloaded from www.volvopenta.com 29/03/2009 14:51:17 IMPORTANT! Do not race the engine while it is cold. Starting using auxiliary batteries WARNING! Batteries produce oxyhydrogen.
Operation Avoid violent and unexpected changes in course and gear engagement. There is a risk that someone aboard will fall over or 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. B A C Checking instruments Check the instruments and warning display directly after starting the engine and then at regular intervals while driving the boat.
1. Maneuvering All shifting between ahead and astern must be done at engine idle speed. Shifting at higher speeds may damage the drive or reverse gear and will also be uncomfortable for those on board. 2. 1. Reduce engine speed to idling and, if possible, let the boat lose most of its speed. 2. Move the reverse gear control lever quickly and firmly into the neutral position. Wait for a moment. 3. 7738231 - Downloaded from www.volvopenta.com 29/03/2009 14:51:17 3.
Stopping the engine The engine should be run for a few minutes at idle (in neutral) before turning it off. This will avoid boiling and even out the temperature. This is especially important if the engine has been operated at high engine speeds and loads. Stopping Pull and hold out the stop control until the engine has stopped. Push in the stop control. Turn the key to stop position “S”. The key will automatically spring back to the “0” position when it is released and can then be removed.
Maintenance schedule Your Volvo Penta engine and its transmission is designed for maximum service life and reliability. They are built to survive in a tough marine environment, but also to cause as little environmental impact as possible. Regular maintenance according to the following schedule is necessary if the engine and transmission are to operate without problems. WARNING! Read the chapter on Maintenance carefully before starting work.
Maintenance This chapter describes how to carry out the above maintenance. Read the instructions carefully before starting work. Maintenance intervals are contained in the chapter above. Maintenance schedule WARNING! Read the safety precautions for maintenance and service in the chapter: Safety Precautions, before starting work. WARNING! Unless otherwise specified all maintenance and service must be carried out with the engine stopped.
Drive belt. Check The belt drives both the circulation pump and the generator. A belt that is too loose can result in slippage, poor cooling and poor charging. A belt that is too tight can damage the bearings in the circulation pump and damage the generator. Check the tension of the belt regularly. Adjust if necessary. Check that the belt is not cracked or damaged. Replace a worn belt. Keep a spare belt onboard. 7738231 - Downloaded from www.volvopenta.com 29/03/2009 14:51:17 Drive belt.
Lubrication system IMPORTANT! With a new or reconditioned engine, the oil and oil filters must be changed after 20–50 hours of operation. After that they should be changed every 100 operating hours or at least once a year. Use only the recommended grades of oil: See the chapter “Technical Data”. 2 Oil level. Checking and topping up The oil level should be within the marked area on the dipstick (1). It should be checked every day before the engine is started. Topping up is done through the valve cover (2).
Cooling system The cooling system is divided into a freshwater and a seawater system. The seawater pump sucks water into the seawater system through the drive/reverse gear. Seawater is then pumped through the heat exchanger and into the exhaust elbow pipe where it is mixed with the exhaust gases. The freshwater system is the internal engine coolant system. It is a closed system driven by the circulation pump. The freshwater system engine coolant is cooled in the heat exchanger by the seawater.
Coolant. Changing The corrosion-proofing additives become less effective with time and the coolant must be changed. If the freshwater system is filled with antifreeze mixture it must be changed every other year. If the system is filled with anti-corrosion agent mixture it must be changed every year. 7738231 - Downloaded from www.volvopenta.com 29/03/2009 14:51:17 Drain the coolant and clean the heat exchanger as follows. Close the drain cock and fill with fresh coolant. Coolant.
Seawater system. Draining 1. 2. To prevent freezing damage the seawater system must be drained in cold weather where there is a risk of frost. WARNING! Risk for water penetration. Close the sea cock if the boat is in the water. If the boat is laid up then the sea cock can be open. 1. Drain seawater filter (accessory). Remove the cover and sealing plate on the sea water filter. Disconnect hoses and drain them. 3. 2. Remove the cover from the seawater pump and let the water run out. 3.
Seawater system. Cleaning and inhibiting To prevent the build up of deposits and salt crystals in the seawater system it must be flushed with freshwater. When the boat is laid up it must also be inhibited. WARNING! There is a risk of water penetration. Cleaning and inhibiting the seawater system should be carried out with the boat on land. 1. Open the sea cock. 2. Secure a container by the exhaust outlet. 3.
Vacuum valve. Cleaning Some engines have a vacuum valve installed in the seawater piping. WARNING! Risk for water penetration. Close the sea cock. 7738231 - Downloaded from www.volvopenta.com 29/03/2009 14:51:17 Close the sea cock. Disassemble the valve. Unscrew the hexagonal cover. In the cover there is a membrane and a gasket. Clean all the parts. Turn the cover upside down. Install the membrane first and then the gasket. Turn the valve housing upside down as well.
Fuel system All work on the engine injection pump or injectors must be carried out at an authorized workshop. Use only the recommended grade of fuel: See the chapter “Technical Data”. WARNING! Fire risk. Work on the fuel injection system must be carried out on a cold engine. A fuel spill onto a hot surface or an electrical component can cause a fire. Store fuel soaked rags and other flammable material in fireproof conditions.
Fuel pre-filter. Draining The fuel pre-filter is an accessory. Position a container under the fuel filter. Drain off water and contaminants using the cock/plug at the bottom of the glass. IMPORTANT! Wait a few hours after the engine has been turned off before draining the filter. 7738231 - Downloaded from www.volvopenta.com 29/03/2009 14:51:17 1 Fuel pre-filter. Replacing filter insert Close fuel cock at the fuel tank. Position a container under the fuel filter.
Electrical system 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, battery charger, or accessories mounted on the engine. Main switch 7738231 - Downloaded from www.volvopenta.com 29/03/2009 14:51:17 The main switch must never be turned off before the engine has stopped.
Starting using auxiliary batteries See instructions for starting the engine with an auxiliary battery in the chapter: Starting the engine. Battery. Maintenance WARNING! Risk of fire and explosion. Never allow an open flame or electric sparks near the battery or batteries. 7738231 - Downloaded from www.volvopenta.com 29/03/2009 14:51:17 WARNING! Never mix up battery positive and negative terminals. This may cause sparks and an explosion.
Battery. Charging WARNING! Danger of explosion! The batteries give off hydrogen gas during charging which when mixed with air can form an explosive gas – oxyhydrogen. A short-circuit, naked flame or spark can cause a large explosion. Ensure that the ventilation is good. WARNING! The battery electrolyte contains extremely corrosive sulfuric acid. Protect your skin and clothes when charging or handling batteries. Always use protective goggles and gloves.
Electrical installations Leakage current from the electrical system can be caused by incorrect installation of electrical equipment. Leakage current can knock out the galvanic protection of components such as the drive, propeller, propeller shaft, rudder stock and keel and cause damage by electrolytic corrosion. IMPORTANT! Work on the boat’s low tension circuit should only be carried out by qualified or experienced persons.
5. If an auxiliary battery is in use, a main switch (D) should be connected between its + terminal and the fuse block. The main switch for the auxiliary battery must cut off all power consuming equipment connected to that battery and be turned off when power is no longer needed. All equipment connected to the auxiliary battery should have separate switches. 7738231 - Downloaded from www.volvopenta.
7738231 - Downloaded from www.volvopenta.com 29/03/2009 14:51:17 Wiring Diagrams Engine 2010, 2020, 2030, 2040 1. Battery 6. 2. Main switch 3. Starter motor 4. Generator 5. Glow plugs. MD2010: x 2. Others x 3. Starter relay 11. Oil pressure sensor 7. Glow plug relay 12. Coolant temperature switch 8. Fuses, max. 15A (+) 13. Engine coolant temperature sensor 9. Excitation resistor 14. Connector, 16-pin. 10.
7738231 - Downloaded from www.volvopenta.com 29/03/2009 14:51:17 Wiring Diagrams Instrument panel without ignition switch 1. 2. 3. 4. 5. 6. 7. Instrument lighting Tachometer with built-in hours run meter (accessory) Dummy plug Connector for connecting extra warning display (accessory) Electronics module (alarm) Engine coolant temperature warning lamp Oil pressure warning lamp Charge warning lamp 8. 9. 10. 11. 12. 13. 14. 15. Glow plug indicator lamp Starter button Button.
7738231 - Downloaded from www.volvopenta.com 29/03/2009 14:51:17 Wiring Diagrams Instrument panel with ignition switch (Alt. 1) Spring back Spring back Cable color BL BN GN GR OR R SB VO W Y = = = = = = = = = = Blue Brown Green Gray Orange Red Black Violet White Yellow 1. Instrument lighting 2. Tachometer with built-in hours run meter (accessory) Dummy plug 3. Connector for connecting extra warning display (accessory) 4. Electronics module (alarm) 5. Engine coolant temperature warning lamp 6.
7738231 - Downloaded from www.volvopenta.com 29/03/2009 14:51:17 Wiring Diagrams Instrument panel with ignition switch (Alt. 2) Spring back 1. 2. 3. 4. 5. Spring back Cable color BL = Blue LBL = Light-blue BN = Brown LBN = Light-brown GN = Green GR = Gray OR R SB VO W Y = = = = = = Orange Red Black Violet White Yellow Cable areas in mm2 are indicated after the color codes in the wiring diagrams. 2 Areas not indicated = 1.0 mm . 42 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
S-drive and reverse gear The S drive and in certain cases the propeller (reverse gear) is equipped with a sacrificial anode which prevents galvanic corrosion. Faulty electrical installation can also cause the break down of the galvanic protection. Damage due to electrolytic corrosion occurs rapidly and is often extensive.
Corrosion protection. Checking/ Replacing Check the sacrificial anodes, if 50% of the material has been corroded replace the anode (also applies to anodes on the propeller and reverse gear). Remove a folding propeller according to the instructions on the next page. Remove anode by removing the two screws. Scrape mating surface on the drive really clean. Install and tighten the new anode so that there is a good metal contact. Clean the new anode to remove oxidation just before the boat is launched.
Folding propeller. Removing and installing WARNING! Iimmobilize the engine before starting work. Remove the ignition key and turn off the power supply with the main switch. The line cutter (10) has very sharp edges and must be handled with care. IMPORTANT! The locking screw (5) and the tab washer (7) must be replaced every fourth year. Only a Volvo Penta original locking screw (8) may be used. 9 3 10 1 1. Propeller hub 2 2. Shaft studs 3. Propeller blade 5 4. Cogs 7738231 - Downloaded from www.
Laying up and launching Before taking the boat out of the water for winter/out-of-season storage have an authorized Volvo Penta workshop inspect the engine and other equipment. Have any necessary repairs or service work carried out so that your boat is in top condition for the new season. Inhibition should be carried out to ensure that the engine and transmission are not damaged while out of commission during the winter/off-season. It is important this is done properly and than nothing is forgotten.
Bringing out of storage ● 7738231 - Downloaded from www.volvopenta.com 29/03/2009 14:51:17 ● Check oil level in the engine and drive/reverse gear. Top up if required. If there is inhibiting oil in the system drain and fill with new oil, change oil filter. For correct oil grade: See the chapter “Technical Data”. ● Paint the drive and hull: See following page. ● Check the sacrificial anode on the drive. If there is less than 50% of the anode left it must be replaced.
Painting the drive and underwater hull Drive Before treating the drive with anti-fouling agent any damaged paintwork must be repaired. Sand down metal surfaces lightly using a 120 grade paper and a finer grade for painted surfaces. Wash off using thinners or similar. Any pores in the surface should be filled and sanded down. Paint using Volvo Penta original primer and topcoat. Let the paint dry. A further two coats of Volvo Penta anti-fouling primer should then be applied. Let them dry.
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Technical Data General Engine designation .................................................. No. of cylinders ....................................................... Cylinder bore ........................................................... Cylinder stroke ........................................................ Overall cylinder displacement ................................ Power, see sales literature Idling speed ............................................................. Rotation, viewed from in front ..
Reverse gear Type designation ...................................................... Gear ratios: MS2L-D ............................................................... MS2A-D ............................................................... Angle (output shaft): MS2L-D ............................................................... MS2A-D ............................................................... Oil capacity, approx. ...............................................
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English 04-1997 7738231-5 AB Volvo Penta SE-405 08 Göteborg, Sweden www.volvopenta.
