FOREWORD Before you start running your new Volvo Penta marine engine, you would be advised to read through this instruction book carefully. It contains all the information you need to run and service your engine in the best possible way. Volvo Penta has built up an extensive service organization with service shops and specially trained personnel at your service. Always contact your local Volvo Penta representative for advice and when in need ot service and parts.
CONTENTS 2 Presentation 3-4 General Information 5-6 Running Instructions Starting the engine Running instructions Shutdown procedure Technical Description Checks and Service Scheme 5 6 6 7-9 10 Fault Tracing Scheme 11 - 17 11 11 - 12 12 - 13 13 - 19 20 - 23 24 Technical Data 25 - 26 Checks and Service Check daily before starting Check every 14 days Service every 50 hours of operation Service every 100 hours of operation Laying-up and launching Wiring Diagram 27 Engine Component Guide 28 In
PRESENTATION INSTRUMENT PANEL 1. 2. 3. Switch, optional equipment Warning lamp, “Excess temp.” Place for instrument (ø 52 mm opt. equipment) 4. 5. 6. 7. 8. Warning lamp, “No oil pressure” Switch, optional equipment Warning lamp, “No battery charging” Siren, “No oil pressure, excess temp.” Key switch Volvo Penta Single Control System CONTROL SYSTEM For side mounting 1. 2. Control lever Disengaging button Push in the button when the control lever is in neutral and move the lever a bit forwards.
GENERAL INFORMATION Important information on the function of your engine: FUEL Use diesel fuel oil of quality “Autodiesel”. Poorer fuel quality can cause interruptions in operation. LUBRICATING OIL Use only oil with quality CD (DS) according to the API system. Volvo Penta oil for diesel engines can be used with advantage since it meets these quality demands. See under “Technical Data” concerning the viscosity.
GENERAL INFORMATION SAFETY EQUIPMENT Irrespective of whether the boat is being used for long cruises or short bathing trips, the boat should be equipped with the safety equipment listed below. It can, of course, be supplemented further according to personal tastes. Investigate at regular intervals to ensure that there is safety equipment on board and that it is in working order. LIFE-JACKETS for all on board. FIRE EXTINGUISHER, approved, at least one and installed where it is easy to get at.
RUNNING INSTRUCTIONS STARTING THE ENGINE Switch on the main switch. Start the engine room fan (if fitted) and let it run several minutes before starting the engine. Open the cock for the cooling water intake. Disengage the engine speed control from the gearchanging as follows: Move the control lever to neutral, push in the red disengaging button, and move the lever slightly forwards. Release the button. The lever can now only operate the engine speed. Check to make sure that the stop control is pushed in.
RUNNING INSTRUCTIONS Reduce to idle and check that the engine is running smoothly. Engage the control lever for gear-changing as follows: Push in the red disengaging button and pull the lever back to neutral. Release the button. The control lever can now be used both for gear-changing and engine speed. RUNNING The single lever control has both engine speed and manoeuvering functions.
TECHNICAL DESCRIPTION The MD5A is a single-cylinder, 4-stroke, marine diesel engine with direct injection and sea-water cooling. ENGINE ASSEMBLY The engine block and cylinder head are made of cast iron. Cylinder angle 45o. The cylinder liner is replaceable. The engine has overhead valves. LUBRICATING SYSTEM The lubricating system includes a full-flow oil filter which filters all the oil before it reaches the lubricating points.
TECHNICAL DESCRIPTION FUEL SYSTEM The fuel system contains a feed pump with pre-filter, fine filter, injection pump and injector. The feed pump, which is of the diaphragm type, has also a hand priming lever. Also fitted is a cold-start device with lever for connection of the push-pull control. COOLING S YSTEM The engine is sea-water cooled. The cooling system includes a sea-water pump as well as a water distributor housing with thermostat.
TECHNICAL DESCRIPTION REVERSE GEAR The Volvo Penta reverse gear, type Mono Shift (MSB) has a reduction ratio of 1.91:1. The reduction gear is integrally built with the reverse gear. Power transmission from the engine to the reverse gear is via a rubber flange. The Volvo Penta patented cone clutch is used for “Forward” and “Reverse” operation and ensures smooth and quiet engagement. Very small forces are required to operate the reverse gear.
CHECKS AND SERVICE SCHEME Checks and service should be regularly carried out according to the intervals given below. Let an authorized Volvo Penta Service Shop look after your engine.
CHECKS AND SERVICE CHECK DAILY BEFORE STARTING OIL LEVEL IN ENGINE Each day before starting check that the oil level is between the marks on the dipstick. Top up with oil if necessary through the oil filler hole. NOTE. Do not top up above the MAX. mark. Concerning choice of oil, see under “Technical Data”. CHECKS every 14 days OIL LEVEL IN REVERSE GEAR Screw up the dipstick, wipe it clean and insert it again without screwing it down.
CHECKS AND SERVICE ELECTROLYTE LEVEL IN BATTERY The level should be between 5—10mm (3/16 – 3/8”) above the cell plates in the battery. If necessary top up with distilled water. IMPORTANT. Observe great care when doing this since the electrolyte is abrasive and the gas which is formed is explosive. BELT TENSIONING Correct belt tension is necessary for full alternator output. The belt should be so tensioned that it can be depressed 5 mm (3/16”) with the thumb midway between the pulleys.
CHECKS AND SERVICE CHANGE OIL IN REVERSE GEAR The oil can be drained from the reverse gear by removing the plug under it or by sucking up the oil through the dipstick hole with the help of an oil scavenging pump. Fill with oil through the filler hole to the correct level on the dipstick. NOTE. Do not fill above the ‘MAX. mark on the dipstick. Concerning choice of oil, see under “Technical Data” VALVE CLEARANCE The valve clearance should be checked and adjusted by authorized personal.
CHECKS AND SERVICE Coat the new filter rubber gasket with oil. Check the area on the engine in contact with the filter and screw on the filter by hand until it just touches the engine. Then screw the filter a further half turn, but not more. NOTE. Only use a genuine oil filter. Start the engine, allow it to idle and immediately check that the oil pressure warning lamp is out. Check the oil level and also for any leakage round the oil filter. CHECK THE BELT Check the belt thoroughly for wear and cracks.
CHECKS AND SERVICE CHECK-TIGHTEN THE CYLINDER HEAD BOLTS Authorized personal should check-tighten the bolts with a torque wrench before starting a new or newly reconditioned engine for the first time and again after it has been in operation for 20 hours. Check the valve clearance after tightening up the bolts. The bolt-tightening sequence can be seen from the adjacent illustration. Concerning the tightening torque, see under “Technical Data”.
CHECKS AND SERVICE ELECTRIC SYSTEM Alternator The engine is equipped with an alternator. To ensure that the alternator with the built-on regulator functions without interruptions the following important points must be observed: 1. Never switch off the main switch until the engine has been stopped. To do otherwise would be to ruin the charging regulator. 2. Do not mix up the battery connection poles. A plus sign and a minus sign are marked on the respective poles.
CHECKS AND SERVICE Change Fuse A fusebox is mounted on the cylinder. A fuse breaks the electrical system when the system is overloaded. Re-connect the electrical system by transferring the cable connection to the next fuse contact. Starter motor and alternator All work connected with the starter motor and alternator shoold be done by an authorized service shop. Inspection and control should he carried out in connection with a general inspection of the engine.
CHECKS AND SERVICE Extra fuel filter If an extra fuel filter is fitted together with a water separator, check the transparent bowl to see if there is any water in the fuel. If necessary, drain the filter via the cock in the bottom of the bowl. Try to avoid fuel splash. Pump up the fuel with the hand primer and vent the system. The fuel filter element should be changed at least once a season. FUEL STRAINER The fuel pump on the engine has a built-in strainer which is accessible after removing the cover.
CHECKS AND SERVICE Venting the fuel system In order for the engine to be able to start, the fuel system must be vented on the following occasions: When changing the fine filter. When draining through the drain hole. When cleaning the fuel pump strainer. After running the fuel tank empty. When installing the fuel injection pump. With leakage and work on the fuel lines. When the engine has not been used for a long time. Venting is as follows: 1. Open the vent screw on the fuel filter. 2.
LAYING-UP AND LAUNCHING SERVICE IN CONNECTION WITH LAYING-UP AND LAUNCHING THE BOAT INHIBITING ENGINE AND REVERSE GEAR IDLE ENGINE FOR BRIEF PERIODS WITH BOAT IN THE WATER To prevent the engine from corrosion attacks, it must be run warm at least once every 14 days as long as the boat is in the water. If it is anticipated that the boat will not be used for more than a month, long-term inhibiting should be carried out.
LAYING-UP AND LAUNCHING Drain the fuel filter. 4 Disconnect the fuel pump flexible suction hose from the fuel system and insert the free end in a can filled with 1/3rd Volvo Penta oil or preservative oil and 2/3rds diesel fuel oil. Bleed the fuel system. Let the engine run at rapid idle for about 10 minutes. NOTE! If the fuel system has an electrically operated fuel pump, it must be switched off before the engine is started.
LAYING-UP AND LAUNCHING Insert the hose into the rustproofing mixture. Start the engine and allow it to idle until the mixture is finished. NOTE! The water pump must never be allowed to run dry. 9 Since the rustproofing mixture does not provide any protection against freezing, it must be drained from the engine and reverse gear. Remove the cover from the cooling water pump. Check to make sure the impeller is in good condition. NOTE! Do not pull out the impeller if it is in good condition.
LAYING-UP AND LAUNCHING Screw tight the cover with its gasket on the cooling water pump. Connect the hose between the cooling water intake and the reverse gear. Check-tighten all the hose clamps. Close the drain cocks. Clean the outside of the engine and the reverse gear. 15 Install the battery, which should be fully charged. Grease the cable shoes. Connect up the battery cables. IMPORTANT! Do not mix up the polarity. Tighten up the cable shoes well. 16 Remove the injector.
FAULT TRACING SCHEME TRACING FAULTS WITH INTERRUPTIONS IN OPERATION Engine becomes abnormally hot Engine runs unevenly or vibrates abnormally Engine does not reach correct operating speed at full throttle Engine stops Engine does not start The fault tracing scheme given below lists only the most usual reasons for faults that give rise to interruptions in operation. With the help of the instructions given in this handbook, the owner can generally remedy most of the reasons for the faults listed below.
TECHNICAL DATA Technical Data General Engine designation MD5A 4-stroke diesel with direct injection Operation Number of cylinders Propeller shaft output kW (h.p.) at 2500 rev/min (acc. To DIN Leistung B f ür Dauberbetrieb) 1 5.5 (7.5) Max operating speed rev/min 2500 Bore, mm (in) 84 (3.307) Stroke, mm (in) 80 (3.150) 3 3 Displacement, dm (in ) 0.443 (27) 2 2 Compr.
TECHNICAL DATA Reverse Gear Oil quality/Viscosity See under “Engine” Oil capacity, litre (qt.) 0.55 (0.5) Cooling System Thermostat, starts to open at °C (°F) 60°±2 (140±2) fully open at °C (°F) 90° (195) Fuel System Fuel injection pump, make & type 2 Bosch PFR1K 2 Feed pressure, MPa (kp/cm = lbf/in ) 7.5 (0.75 = 11) Injector, make Bosch, holder KBAL 65 nozzle DLLA 150 2 2 opening pressure, MPa (kp/cm = lbf/in ) 1800 (180 = 2560) Pre-injection angle, crankshaft degrees B.T.D.C.
WIRING DIAGRAM Cable Colour Code Marking A B B’ B” C C’ C” F G H’ I I’ J J’ J” K L M Colour White Black Black Black Red Red Red Yellow Brown Blue Green/Red Green/Red Green Green Green Blue/Yellow White/Red Blue/Red 2 mm 6 1.5 0.6 0.75 6 35 0.6 1.5 1.5 35 1.5 0.75 1.5 0.6 0.75 0.75 0.75 0.75 A.W.G. 9 15 19 18 9 1 19 15 15 1 15 18 15 19 18 18 18 18 List of Components 9. Place for instruments, opt. equipment) 1. Extra switch 10. Rapid connector 2. Battery charging warning lamp 11.
ENGINE COMPONENT GUIDE 1. Connection for manual starting crank 2. Fusebox 3. Thermostat housing 4. Decompression handle 5. Injector 6. Oil filler cap, engine 7. Reverse gear water drainage 8. Reverse gear oil drainage 9. Engine water drainage 10. Reverse gear oil filler 11. Cooling water pump 12. Reverse gear oil dipstick 13. Fuel filter 14. Vent screw 15. Fuel hand primer 16. Engine oil dipstick 17.
INDEX Alternator Battery Belt tensioning Charging regulator Controls Cooling system Cylinder head bolts 7, 14, 16, 27 12 12, 14 7, 16 2, 6 8 15 De-inhibiting Drain cocks 22 28 Electrical system Engine assembly 16 7 Fault tracing scheme Fuel Fuel filters Fuel pump Fusebox Hand primer Hand starter Impeller Inhibiting Injector Instruments 24 3 17 8 7, 17 8, 17, 23, 28 5, 28 15 20 18, 23 2, 27 Lubricating oil Main Switch Oil change Oil dipstick, engine Oil dipstick, reverse gear Oil filter Oil level che
