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' Volvo/md5a: Volvomd5a user Volvo Md5a User Manual'




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you start running your new Volvo Penta marine engine you would be
advised to read through this instruction book carefully It contains all 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 contact your local Volvo Penta for advice and when in need
ot service and parts
We are convinced that the demands on good running economy and which you have every right to expect of a quality product will be met
and that your engine will serve you faithfully on many pleasant warranty certificate is supplied with each engine It contains the for the engine and
should be studied included is a report card which is to be completed by the dealer or boat
seller If our warranty is to apply however it is an absolute condition that the
measures given in the Check and Service Scheme are carried out and that your
engine and equipment are looked after according to the instructions in this
manual When in doubt always get in touch with an authorized Volvo all with your dealer and when ordering parts state the and serial number of the
engine and reverse gear see starboard side
of engine
General Information 34
Running Instructions 56
Starting the engine 5
Running instructions 6
Shutdown procedure 6
Technical Description 79
Checks and Service Scheme 10
Checks and Service 11 17
Check daily before starting 11
Check every 14 days 11 12
Service every 50 hours of operation 12 13
Service every 100 hours of operation 13 19
Layingup and launching 20 23
Fault Tracing Scheme 24
Technical Data 25 26
Wiring Diagram 27
Engine Component Guide 28
Index alphabetical order 29
INSTRUMENT PANEL
1 Switch optional equipment
2 Warning lamp Excess temp
3 Place for instrument 52 mm opt equipment
4 Warning lamp No oil pressure
5 Switch optional equipment
6 Warning lamp No battery charging
7 Siren No oil pressure excess temp
8 Key switch
Volvo Penta Single Control System
CONTROL SYSTEM For side mounting
1 Control lever
2 Disengaging button
Push in the button when the control lever is in neutral
and move the lever a bit forwards Release button
The lever is now used only for engine speed control
To use the lever for both engine speed control and
push in the button and pull back the
lever to neutral
N Neutral
F Control lever in position for running Forward
R Control lever in position for running Reverse
T Engine speed GENERAL information on the function of your engine
FUEL Use diesel fuel oil of quality Autodiesel Poorer fuel quality
can cause interruptions in operation
Use only oil with quality CD DS according to the API system
LUBRICATING Volvo Penta oil for diesel engines can be used with
OIL advantage since it meets these quality demands See under
Technical Data concerning the viscosity
A new marine engine must be runin with due care during the
RUNNINGIN first 20 hours of operation If full output is taken out during this
time it should only be done for short periods
Oil change Change the engine lubricating oil and the oil filter
after the engine has been run for 20 hours See further under
Checks and SPEED Max speed 417 revsec 2500 revmm
For choice of correct propeller refer to the Volvo Penta propeller diagram Check the
engine speed with normal load in the boat In order to utilize the maximum the engine an engine speed as high as possible should be chosen but not
than 417 revsec 2500 When the boat has been in the water for some time the speed and max revmm
can drop due to marine growth on the hull Prevent marine growth by painting the bottom
of the boat with antifouling paint See under Measures taken when
3
GENERAL 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 further according to personal tastes Investigate at regular intervals
ensure that there is safety equipment on board and that it is in working for all on board
FIRE EXTINGUISHER approved at least one and installed where it is easy to get at
DISTRESS ROCKETS and matches Packed BOX
TOOLS suitable for the equipment on board
ON BOARD KIT containing eg impeller etc
ANCHOR with line
RADAR for listening to eg weather which is HOOK and and BEFORE STARTING
Make sure that
There is no FUEL LEAKAGE
There is no WATER LEAKAGE from engine and hull
There is no OIL LEAKAGE
There is no SMELL OF LPGAS in the deep cavities in the boat or elsewhere
The OIL LEVEL is correct
There is enough FUEL for the planned voyage
The proper NAUTICAL CHARTS are on board for the planned voyage
If there are some other persons on board make sure that some of them is able to
operate the boat
If there are persons on board who have never been on a boat before tell them where are located and where the is placed Also tell them anything
more you think necessary from a safety point of view Should something during the voyage it is very often too late to tell those on board how
RUNNING 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 gear
changing 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
Turn the key switch one stage to the right The warning
lamps for battery charging and oil pressure should now go on
and the siren should sound Push in and turn the key further to
the right to start the engine Release the key when the engine
starts
Hand starter If the engine is started with the starting crank
the decompression handle on the rocker arm cover should first
be folded up Fold down this handle for running when the
cranking has got the engine up in speed
Starting in cold weather is facilitated if the coldstart control
is pulled out Push it in again after a while
Check immediately after starting that the warning lamps for
the oil pressure and battery charging are out and that the siren
is quiet If any of the lamps are on and the siren is
sounding the engine must be stopped immediately and
an investigation made
Run the engine warm at rapid idle Check to make sure that
the cooling water flows out with the exhaust gases
NOTE The key switch should always be switched on as
long as the engine is running to ensure that there is
battery charging
RUNNING Reduce to idle and check that the engine is running smoothly
Engage the control lever for gearchanging 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 gearchanging and engine The single lever control has both engine speed and
manoeuvering functions
F Forward N Neutral
R Reverse T Engine speed control
To achieve good running economy the engine should not be
run at max speed for a longer period
Make sure that the battery charging warning lamp does not
light when the engine is running The siren will sound and the
respective warning lamp go on if the engine temperature
becomes excessive or the oil pressure too PROCEDURE
After shutdown the engine should be allowed to idle for a
couple of minutes or so with the control lever in neutral
Stop the engine by pulling out the stop control when the
engine is idling Then turn back the key switch to the initial
position
Switch off the main switch NOTE This switch must never
be switched off until the engine has stopped
Close the fuel and cooling water cocks if the boat is not going
to be used for some time
Check for leakage before leaving the beat
In cold weather and whenever there is risk of icing the
cooling water should he drained from the engine and reverse
gear See under Layingup and TECHNICAL MD5A is a 4stroke marine diesel engine with direct
injection and
seawater ASSEMBLY
The engine block and cylinder head are made of cast iron Cylinder angle 45o The
cylinder liner is replaceable The engine has overhead SYSTEM
The lubricating system includes a fullflow oil filter which filters all the oil before it reaches
the lubricating points A relief valve in the oil pump prevents the oil pressure from
becoming SYSTEM
The engine has a starter motor and alternator with builtin rectifier Voltage regulation is
taken care of by a regulator mounted on the alternator The it possible to charge two battery circuits independent of each other if a accessory is
fitted on the alternator
A main fuse which can easily be reconnected is fixed to the engine It protects system from damage in the event of overloading The wiring diagrams for
engine and instrument panel are shown on page 27
TECHNICAL SYSTEM
The fuel system contains a feed pump with prefilter 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 coldstart device with lever for connection of the pushpull S YSTEM
The engine is seawater cooled The cooling system includes a seawater pump as well
as a water distributor housing with seawater pump has an impeller of neoprene rubber driven by the camshaft via a
rubber flange
The thermostat installed in the water distributor housing regulates the water flow so that
the water always flows through the exhaust manifold and out into the exhaust of whether the engine is cold or warm
TECHNICAL GEAR
The Volvo Penta reverse gear type Mono Shift MSB has a reduction ratio of 1911
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 and service should be regularly carried out according to the intervals given
below Let an authorized Volvo Penta Service Shop look after your engine
CHECK DAILY BEFORE STARTING that
Page
The oil level in the engine is between the marks on the dipstick 11
CHECK every 14 days that
The oil level in the reverse gear is between the marks on the dipstick 11
The electrolyte level in the battery is correct
The belt tension 12
SERVICE EVERY 50 HOURS OF OPERATION
Change the oil in the engine 12
Change the oil in the reverse gear 13
Check and adjust the valve clearances 13
SERVICE EVERY 100 HOURS OF OPERATIONS OR AT
LEAST ONCE EACH SEASON
Change the oil filter 13
Check the pulley belt 14
Checktighten the cylinder head bolts 15
Check the cooling system 15
Check the electrical system fuses etc 16
Fuel system filter strainer injector venting 1719
SERVICE IN CONJUNCTION WITH LAYINGUP AND
LAUNCHING THE BOAT
Inhibiting scheme I Inhibiting measures carried out with boat in the water 20
Inhibiting scheme II Inhibiting measures carried out with boat on land 21
Service in connection with launching 22
CHECKS AND 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 every 14 days
OIL LEVEL IN REVERSE GEAR
Screw up the dipstick wipe it clean and
insert it again without screwing it down
Pull up the dipstick and check the oil
level which should be between the
marks If necessary top up with oil
through the oil filler hole on the opposite
side of the reverse gear Do not top up
above the MAX mark
Screw down the dipstick again Note that
there is a sealing washer on the dipstick
Concerning choice of oil see under
Technical Data
CHECKS AND LEVEL IN BATTERY
The level should be between 510mm 316 38 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 TENSIONING
Correct belt tension is necessary for full
alternator output The belt should be so
tensioned that it can be depressed 5 mm
316 with the thumb midway between
the pulleys
To tension the belt first slacken the
alternator retaining points stretch the
belts and tighten up the points again
A well worn or crached belt should be
EVERY 50 HOURS OF OIL IN ENGINE
With a new or newly engine the oil should be changed for the
first time after 20 hours of operation and
after that after every 50 hours of
operation
Run the engine warm Suck up the oil
through the dipstick hole
Fill with oil to the correct revel See
under Technical Data concerning
choice of oil
NOTE Change also the oil filter Fram
Filter PH3614 at every other oil CHECKS AND 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 CLEARANCE
The valve clearance should be checked
and adjusted by authorized personal
See under Valves in Technical EVERY 100 HOURS OF OPERATION OR AT LEAST
ONCE EACH SEASON
OIL FILTER
The oil filter should be replaced for the first time after 20 hours of operation during the
running in period and subsequently at every other oil change IMPORTANT the filter switch off the main switch Screw off and scrap the oil filter It
be necessary in certain cases to lift off the belt and tension out the alternator to permit
free passage for the filter
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 THE BELT
Check the belt thoroughly for wear and
cracks Replace it if there is any indica
tion of such To remove the belt slacken
the alternator retaining points in order to
be able to slip the belt off Wipe clean the
belt groove on the pulleys before fitting
the new belt Tension the belt so that it
can only be depressed 5 mm 316 with
the thumb between the pulleys After the
engine has been run for an hour or so
recheck and if necessary adjust the belt
CHECKS AND THE CYLINDER HEAD BOLTS
Authorized personal should the bolts with a torque wrench before
starting a new or newly 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 sequence
can be seen from the adjacent Concerning the tightening torque see
under Technical THE COOLING SYSTEM
The cooling system is functioning normally when the Temp lamp is out and the siren is
quiet Excessive temperature Temp goes on the siren sounds may be due to clogged water intake defective impeller or flange in the seawater pump
faulty thermostat or temp gauge sender Look out for water penetration during all
work on the cooling system
The impeller can be damaged due to
Check and replace the impeller
eg shortage of water Remove the cover
on the water pump Pull out the shaft the
length required in order to screw out the
impeller lock bolt Hold against the shaft
and pull off the impeller If the impeller is
damaged fit a new one NOTE If the
shaft has been removed entirely from the
pump housing check when refitting it
that the Dring between the sealing rings
in the housing gets onto the shaft
Tighten up the impeller with the lock bolt
If the impeller and shaft can be rotated
then the flange is defective A new flange
can be fitted after the pump has been
removed Fit the cover with its gasket
CHECKS AND SERVICE
ELECTRIC SYSTEM
Alternator
The engine is equipped with an alternator To
ensure that the alternator with the builton 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 The minus pole is
connected up to the engine body Cable shoes
should be greased and wall tightened
3 Rewiring between the charging circuits
may not be carried out while the engine is
running
Fit a Volvo Penta charging distributor
accessory on the alternator when more than
one battery is connected up
4 Observe the following in the event the engine is started with an auxiliary battery
Let the ordinary battery remain connected up Connect the auxiliary battery to the
ordinary battery plus to plus and minus to minus When the engine has started
remove the auxiliary battery but do not break the ordinary batterys wiring circuit
5 Do not use a rapid charging unit when the alternator is connected to the battery
6 Before doing any work on the alternator equipment first disconnect both the
battery cables
7 In the event any electrical welding work is done on the engine or the installation
components disconnect the charging regulator cables at the alternator and
insulate the cable ends
8 Check regularly the belt tension and the cable CHECKS AND Fuse
A fusebox is mounted on the cylinder A fuse breaks the electrical system when the
system is overloaded Reconnect the electrical system by transferring the to the next fuse motor and work connected with the starter motor and
alternator shoold be done by an shop Inspection and control should he carried out in connection with a of the the state of charge of the battery
The state of charge of the battery should he checked at cast once each season This is
done by using a hydrometer which shows the specific gravity of the electrolyte this
varying with the state of charge See the Technical the greatest cleanliness when handling the fuel Try to avoid fuel splash
Change fuel filter
The filter element in the fuel filter should
be changed at least once each season
To do this remove the filter centre screw
and lift off the filter Clean the container
and contact surfaces Fit the new filter
element and its gasket Pump up the fuel
with the hand primer Vent the fuel system
If the pumping effect is poor turn over the
engine a bit so that the drive cam alters its
position
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 builtin
strainer which is accessible after removing
the cover Clean the strainer at least once
a season
Immediately after starting the engine
check for leakage
Always vent the fuel system See under
Venting the fuel injector should be removed once a season and handed in to a diesel shop for
cleaning and checking the opening pressure the spray pattern and for leakage To
remove the injector unscrew the delivery pipe and the bypass oil line Fit protective caps
over the both the nuts over the fork holding the injector to the cylinder head and lift up the
injector If the injector feels stiff to remove due to gumming grip it with eg and carefully rotate it back and forth while levering it up at the same
time with eg under the fork Before fitting check to make sure the contact surface
on the injector and copper sleeve is clean Connect up the delivery pipe and the return
line but do not tighten the delivery pipe nut at the injector Turn over the engine with the
starter motor until fuel comes from the delivery pipe Tighten up the delivery pipe nut and
make sure the delivery pipe cone is fitted properly Concerning tightening torque Data
CHECKS AND the fuel system
In order for the engine to be able to start the fuel system must be vented on the changing the fine filter With leakage and work on
the fuel lines
When draining through the drain hole When the engine has not been used for a
When cleaning the fuel pump strainer long time
After running the fuel tank empty
When installing the fuel injection is as follows
1 Open the vent screw on the fuel filter
2 Pump forward the fuel with the help of the hand primer until fuel free from air bubbles
flows out Close the vent screw If the pumping effect is poor turn over the engine a
bit so that the pump drive cam alters its position
3 If the fuel injection pump has been removed or when starting an entirely new engine
for the first time the fuel injection pump must be vent To do this open the vent
screw on the pump Pump with the hand primer until fuel free from air comes out
Slacken the injector delivery pipe nut and turn over the engine by means of the
starter motor until fuel comes from the delivery pipe Tighten up the delivery pipe nut
and start the engine
1 Vent screw fuel filter
2 Hand primer
3 Vent screw injection pump
4 Delivery pipe nut
LAYINGUP AND IN CONNECTION WITH LAYINGUP AND
LAUNCHING THE 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 longterm inhibiting should be carried FOR A LONG PERIOD
An authorized service shop should test the engine and equipment before inhibiting the
engine for a long period acc To Inhibiting Schemes I and II A suitable procedure would
be to test the Scheme I
Carried out with the boat in the water
Run the engine warm
Pump out all the oil from the engine and reverse gear
Use an oil scavenging pump
Change the oil filter Fill the engine and reverse gear to the correct
level with Volvo Penta oil which also has rustproofing properties
to the correct level The lubricating system is thereafter ready for
operation the next season
If rustproofing oil is used it should be of the type Esso Rustban
623 Sheel Ensis Oil or In this case the oil filter should be replaced when LAYINGUP
AND LAUNCHING
Drain the fuel Disconnect the fuel pump flexible suction hose from the fuel
system and insert the free end in a can filled with 13rd Volvo
Penta oil or preservative oil and 23rds 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 Scheme II
Carried out with the boat on land
Drain the cooling water from the engine and reverse gear
Check to make sure that the water runs out since impurities can
block the cock Then close all cocks and refit the drain cock in
the reverse gear
Disconnect the reverse gear suction line from the reverse gear
Connect a hose with inner diameter 12 and insert the free
hose end in a container with fresh water Arrange to have water
added to the container and run the engine at idle for about 5
10 minutes so that it is flushed throughout with fresh water
Make sure that there is no dirt near the exhaust outlet Drain all
water from the engine and reverse gear Then close all drain
7 points
Mix a rustproofing mixture consisting of 15 20 litres
13 Impqts 16 us qts 18 lmpqts 21 US qts
fresh water and 2 4 litres 18 Impqts 20 US qts 35
lmpqts 53 US qts rustproofing oil
NOTE Water first and then the oil
Use eg Esso Cutwull 40 Shell Donax C or similar As an
alternative a 30 glycol mixture can be used
LAYINGUP 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
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 Remove the injector and hand it in to a diesel shop for cleaning
and checking Inject Volvo Penta oil into the cylinder Turn over
the engine several turns with the starter motor or the crank
NOTE Prevent oil splash Fit the checked injector but do not
finaltighten it It will be removed again before Clean the outside of the engine and reverse gear Touch up any
bare patches on the paintwork with the same type of paint as
the original Spray the electrical system components and all the
controls with antimoisture spray
Remove the battery It needs to be maintained to prevent it from
being in connection with launching
If Volvo Penta oil has been used only the oil level in the engine
and reverse gear needs to be checked If another type of
preservative oil has been used both oil and filter must be
replaced See under Service 14 after every 50 hours of
LAYINGUP 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 Checktighten all the hose clamps
Close the drain cocks
Clean the outside of the engine and the reverse gear
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
Remove the injector Take measures to avoid oil splash and run
the engine several turns so that the oil on the piston crowns is
blown out
Fit the injector See under Tightening torques Technical
Data
Launch the boat Change the fuelfilter cartridge Pump forward
the fuel and vent the system See under Venting the fuel
system
Start the engine See the instructions on page 5 Run the
engine warm with the reverse gear engaged Check to make
sure there is no leakage of fuel air water or exhaust gases
Check that all the controls etc are functioning properly
If necessary contact authorized Volvo Penta service shops and
let them service the engine and reverse gear according to the
instructions in the servicing 23
FAULT TRACING FAULTS WITH INTERRUPTIONS IN OPERATION
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 When in
doubt always contact the nearest Volvo Penta service shop
Engine becomes abnormally hot
Engine does not reach correct
operating speed at full throttle
Engine runs unevenly or
Engine does not start
vibrates abnormally
Engine stops
Reason See
Main switch not switched on flat pp 5 12 16
battery breakage in electric 17 27
cables or blown fuse
Empty fuel tank closed fuel pp 17 18
X X cock blocked fuel
filter
Water air or impurities in fuel pp 17 18 19
X X X
X X X X Defective
injector pp 18 26
Idling speed not properly p 25
X X adjusted
Boat overloaded
Marine growth on boat bottom
Damaged propellor
Blockage in cooling water p 15
X intake cooling jackets defective
impeller or TECHNICAL designation
MD5A
4stroke diesel with of cylinders
Propeller shaft output kW hp at 2500 revmin 55 75
acc To DIN Leistung B f r operating speed revmin 2500
Bore mm in 84 mm in 80 3150
3 dm in 0443 27
2 2
Compr pressure MPa kpcm lbfin 200 220
starter motor speed 20 22 284 313
Idling speed revmin approx 700
Direction of rotation looking at flywheel inclination underway
Rearwards max 15
To the sides max 20
Engine weight incl Reverse gear kg lb 111 clearance hot engine
Inlet mm in 030 00012
Exhaust mm im 035 Gear
Type designation MSB
Reduction ratio Forward and Reverse Oil Capacity engine litres Impqts US qts ex cl filter 20 180 210
Incl filter 21 185 220
Oil quality Diesel lubricating oil
Service CD DS
Viscosity
Above 10C 14F Volvo Penta CD Double Grade oil SAE 20W30
Below 10C 14F Volvo Penta CD Single Grade oil SAE 10W
Oil pressure hot engine
2 2
Idling speed MPa kpcm lbfin 15 25 1525 2135
2 2
At full speed MPa kpcm lbfin 40 50 4050 5771
TECHNICAL Gear
Oil See under Engine
Oil capacity litre qt 055 starts to open at C F 602 1402
fully open at C F 90 195
Fuel System
Fuel injection pump make type Bosch PFR1K
2 2
Feed pressure MPa kpcm lbfin 75 075 11
Injector make Bosch holder KBAL 65
nozzle DLLA 150
2 2
opening pressure MPa kpcm lbfin 1800 180 angle crankshaft degrees BTDC 25 28
Fuel quality Autodiesel Cet rating minimum voltage
Battery capacity standard 60 Ah
max 120 Ah
Starter motor 08 kW 11 35A
electrolyte specific gravity
Charging carried out at gcm 1230
Fully charged battery gcm 1275 head nuts Nm kpm lbftf 70 70 rod bolts Nm
kpm lbftf 70 70 main bearings Nm kpm lbftf 70 70 50
Flywheel nut Nm kpm lbftf 500 500 362
Injector nuts Nm kpm lbftf 10 10 7
WIRING Colour Code 2
Marking Colour mm AWG
A White 6 9
B Black 15 15
B Black 06 19
B Black 075 18
C Red 6 9
C Red 35 1
C Red 06 19
F Yellow 15 15
G Brown 15 15
H Blue 35 1
I GreenRed 15 15
I GreenRed 075 18
J Green 15 15
J Green 06 19
J Green 075 18
K BlueYellow 075 18
L WhiteRed 075 18
M BlueRed 075 18
List of Components 9 Place for instruments opt Extra switch 10
Rapid connector
2 Battery charging warning lamp 11 Starter mot or
3 Excessive temp warning lamp 12 Low oil pressure warning lamp 13 Fusebox
5 Key switch 14 Main switch
6 Siren 15 Battery
7 Alarm unit 16 Temperature sender
8 Battery charging warning lamp for battery circuit 17 Oil pressure sender
opt 27
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 Oil tool kit supplied with the engine contains the following 1012 UPspanner 1416 screwdriver Phillips screwdriver flat end pliers
oil scavenging pump with hose and suction pipe as well as Allen spanners for the
7 14 16 27 Lubricating oil 3 25
Battery 12 Main Switch 5 6
Belt tensioning 12 14
Oil change 12 13
Charging regulator 7 16 Oil dipstick engine 28
Controls 2 6 Oil dipstick reverse gear 28
Cooling system 8 Oil filter 14 20 28
Cylinder head bolts 15 Oil level check 22 Preparations before starting 4
Drain cocks 28
Running 6
Electrical system 16
Engine assembly 7 Safety equipment 4
Seawater pump 8 15 28
Fault tracing scheme 24 Starter motor 17
Fuel 3 Starting 5
Fuel filters 17
Fuel pump 8 Technical data 25 26
Fusebox 7 17 Thermostat 8 26
Hand primer 8 17 23 28 Valve clearances 13 25
Hand starter 5 28 Venting the fuel system 19
Impeller 15 W iring diagrams 27
Inhibiting 20
Injector 18 2 27

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The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with L-36.com. I have no idea of they are useful or accurate, I leave that to the reader. 2) Articles others have written and submitted. If you have questions on these, please contact the author. 3) Articles that represent my personal opinions. These are intended to promote thought and for entertainment. These are not intended to be fact, they are my opinions. 4) Small programs that generate result presented on a web page. Like any computer program, these may and in some cases do have errors. Almost all of these also make simplifying assumptions so they are not totally accurate even if there are no errors. Please verify all results. 5) Weather information is from numerious of sources and is presented automatically. It is not checked for accuracy either by anyone at L-36.com or by the source which is typically the US Government. See the NOAA web site for their disclaimer. Finally, tide and current data on this site is from 2007 and 2008 data bases, which may contain even older data. Changes in harbors due to building or dredging change tides and currents and for that reason many of the locations presented are no longer supported by newer data bases. For example, there is very little tidal current data in newer data bases so current data is likely wrong to some extent. This data is NOT FOR NAVIGATION. See the XTide disclaimer for details. In addition, tide and current are influenced by storms, river flow, and other factors beyond the ability of any predictive program.