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Volvo Penta Md7aib Workshop Manual



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FOREWORD
Before you start your new Volvo Penta marine engine, you are advised to read
through this instruction book carefully. It contains information relevant to the
proper operation and maintenance of your engine.
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
of service and parts.




WARRANTY CERTIFICATE
A warranty certificate is supplied with each engine. It contains the warranty
conditions for the engine and should be studied carefully.
Also included is a report card which is to be completed by the dealer or boat seller
and forwarded to Volvo Penta.
However, if our warranty is to apply, 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 book. When in
doubt, always get in touch with an authorized Volvo Penta dealer.
In all correspondence with your dealer and when ordering parts, always state the
type designation and serial number of the engine and reverse gear or drive (see
starboard side of engine).
Make certain that the engine's specification coincides with what is described in
this instruction book.

                                                        AB VOLVO PENTA
                                                 Technical Publications Dept.
                                                               CONTENTS




Instruments and Controls                                                  2

General Information                                                  3-4

Running Instructions                                                 5-6
                        Starting the engine                              5
                        Running instructions                             6
                        Shutdown procedure                               6
Technical Description                                               8 - 11

Checks and Service Scheme                                              12

Checks and Service                                                 13  23
                        Check daily before starting                     13
                        Check every 14 days                        13 - 14
                        Service every 50 hours of operation        15 - 16
                        Service every 100 hours of operation       17  22
                        Venting the fuel system                         23
                        Service when laying-up and launching       24  28
Fault Tracing Scheme                                                    29

Technical Data                                                     30  31

Wiring Diagram                                                         32

Engine Component Guide                                             33  34

Index, alphabetical order                                              35




                                                                      1
INSTRUMENTS AND CONTROLS



    INSTRUMENT PANEL



                                1.    Switch, extra lighting
                                2.    Warning lamp, "high temperature"
                                3.    Place for instrument (dia 52 mm,
                                      opt. equipment)
                                4.    Warning lamp, "low oil pressure"
                                5.    Switch, extra lighting
                                6.    Warning lamp, "No battery charging"
                                7.    Buzzer, "low oil pressure, high tempe-
                                      rature"
                                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 lev er for both engine speed control and
                                gear-changing, push in the button and pull back the
                                lever to neutral position and move it again "Forward" or
                                "Reverse".

                       N    =   Neutral
                       F = Control lever in position for running "Forward"
                       R = Control lever in position for running "Reverse"
                       T = Engine speed control




2
                                     GENERAL INFORMATION


Important information on the function of your engine:

FUEL                   Use diesel fuel oil of quality "Autodiesel". Lower fuel
                       quality can cause interruptions in operation.

                       Use only oil with quality CD (DS) according to the
LUBRICATING OIL        API-System. Volvo Penta oil for diesel engines can
                       be used with advantage since it meets these quality
                       demands. See under "Technical Data" concerning
                       viscosity if any other oil is used.

                       A new marine engine must be run-in with due care
RUNNING-IN             during the 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 oil and oil filter after
                       the engine has been run for 20 hours. See further
                       under "Checks and Service".


ENGINE SPEED           Max. engine speed: MD7A 43.4 rev/sec (2600 rpm).
                       In order to select the correct propeller, reference is
                       made to the Volvo Penta propeller diagram. Check
                       the engine speed with normal load in the boat. I      n
                       order to obtain maximum engine performance, an
                       engine speed as high as possible should be chosen
                       but not, however, greater than 43.4 rev/sec (2600
                       rpm).
                       NOTE! When the boat has been in the water for
                       some time, the speed and max. rev/mm can drop
                       due to marine growth on the hull. Prevent marine
                       growth by painting the bottom of the boat with anti-
                       fouling paint. If the boat is equipped with S    -drive
                       model MD7A/110S  or any other S-drive model  it
                       is important not to use an anti-fouling paint which
                       contains copper. See further "Service in connection
                       with launching".




                                                                              3
    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 ins talled where it is easy to get at.
DISTRESS ROCKETS and matches. Packed watertight.
FIRST-AID BOX
TOOLS suitable for the equipment on board.
ON BOARD KIT containing, e.g. impeller, etc.
ANCHOR with line.
RADAR REFLECTOR
RADIO for listening to, e.g., weather reports.
COMPASS which is deviated.
BOAT HOOK and paddle.
MOORING ROPES
FOG-HORN and whistle.
FLOATING ANCHOR
TORCH




PREPARATIONS 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 LP-GAS 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 persons on board who have never been in a boat before, inform them how the
boat functions and where the life-jackets and fire-extinguisher are located. Also inform
them of anything more you think necessary from a safety point of view. Should anything
unexpected happen during the voyage, it is often too late to tell those on board how
safety equipment works.


4
                                         RUNNING INSTRUCTIONS

START THE ENGINE
            Switch on the main switch. Start the engine room fan (if fitted)
            and let it run several minutes before starting the engine.



            Check that cocks for fuel and water intake are open. If water in the
            boat, use bilge pump and drain the boat.


            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 position to the right. The warning lamps
            for battery charging and oil pressure should now go o        n and the
            buzzer 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 (see pages 34-35) on the rocker arm cover
            should first be folded up. Return the de-compression handle for
            running when the engine has been cranked up in speed.
            Cold weather starting
            CAV fuel injection pump: Starting is facilitated if the cold-start
            control is pulled out. The cold-start control must be pushed in after
            the engine has started.
            BOSCH fuel injection pump: The engine has a built-in automatic
            cold-start device.
            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 gas es.
            NOTE. The key switch should always be switched on as long
            as the engine is running to ensure battery charging.

            Reduce to idle and check that the engine is running smoothly.
            Engage the control lever for gear-changing as follows:
            Push in the red dis engaging 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.

                                                                               5
RUNNING INSTRUCTIONS


RUNNING

             The single lever control contains engine speed as well as gear
             shifting functions.
             NOTE! If the boat is equipped with a folding type of propeller,
             the engine speed must be reduced to idling prior to shifting to
             "FORWARD". Shifting at higher speed might easily damage
             the propeller.

             F = Forward    N = Neutral
             R = Reverse    T = Throttle

             In order to achieve good running economy, the engine should
             not be run at maximum engine speed for long periods of time.

             Check regularly during running that the warning lamp for
             battery charging is out. Should the cooling water temperature
             be too high or the oil pressure too low, the buzzer will warn
             you, at the same time the relevant warning lamp goes on.
             If this happens, the engine must be stopped immediately
             and the reason investigated.




SHUTDOWN PROCEDURE

             Before shutdown the engine should be allowed to idle for a
             few minutes 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.

6
                        RUNNING INSTRUCTIONS

Folding propeller, S-drive . When switching from engine
operated running to sailing the propeller rotation is stopped by
engaging reverse gear. When sailing maintain the control
lever in the reverse position.
Fixed propeller. When sailing the control lever should be in
the neutral or reverse position. During long sailing trps with
the lever in the neutral position, the engine should be run for
some time every tenth hour in order to ensure lubrication in
the drive or reverse gear.
Switch off the main switch. NOTE! The main switch must
never be switched off until the engine has stopped completely
(the charging regulator can be damaged).
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 a risk of temperatures
below zero, the cooling water must be drained from the engine
and the reverse gear. Close the cock on the cooling water
intake, (S-drive model 110S: See page 19). Close all the
drainage cocks if the boat is left without regular supervision.
An incorrectly performed draining can result in a sunken boat.
(See positions 15 and 16, page 34).




                                                            7
    TECHNICAL DESCRIPTION




The MD7A is a 2 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. The engine has overhead
valves.

LUBRICATING SYSTEM
The lubricating system has a full-flow oil filter which cleans the oil before it reaches the
lubrication points. The oil pump has a relief valve which prevents the oil pressure from
becoming excessive.

ELECTRICAL SYSTEM
The engine has a starter motor and an alternator with built-in rectifier. Voltage regulation
is performed by a transistorized regulator, mounted on the alternator. The alternator
makes it possible to charge two batteries independent of each other, if a double-diode
(accessory) is fitted to the alternator.

A main fuse, which can easily be re-connected, is fixed to the engine. It protects the
electrical system from damage in the event of overloading. The wiring diagrams for the
engine and instrument panel are shown on page 32.

8
                                                  TECHNICAL DESCRIPTION

FUEL SYSTEM
The fuel system has a feed pump with a fine filter, fuel filter with a fine filter insert,
injection pump and injectors. The feed pump is of the diaphragm type and is equipped
with a hand priming lever.
There is a built-in cold start device in the fuel injection pump. On the CAV fuel injection
pump the cold-start device is operated manually and on the BOSCH fuel injection pump
the cold-start device is operated automatically.


COOLING SYSTEM
The engine is cooled by sea water. The cooling system has a sea water pump and a
water distributor housing with a thermostat.
The sea-water pump has an impeller made of neoprene rubber, which is driven via a
rubber flange from the camshaft.
The thermostat in the water distribution housing regulates the water flow so that water is
always flowing in the exhaust manifold and out in the exhaust elbow regardless of
whether the engine is cold or hot.




                                                                                         9
 TECHNICAL DESCRIPTION


REVERSE GEAR (MD7A/MSB)
The reduction gear is integrally built with the reverse gear. The power from the engine to
the reverse gear is transmitted via a rubber flange.
For operating "Forward" and "Reverse" the Volvo patented cone clutch is used, which
ensures smooth and quiet engagement. Very small forces are required to operate the
reverse gear.




10
                                                 TECHNICAL DESCRIPTION

S-DRIVE MODEL 110S (MD7A/110S)
The power from the engine is transmitted via a rubber flange carrier to the S-Drive.
For operating "Forward" and "Reverse" the Volvo patented cone clutch is used, which
ensures smooth and quiet engagement. Very small forces are required to operate the
reverse gear.




                                                                                       11
CHECKS AND SERVICE SCHEME

Checks and service should be carried out regularly in accordance with the intervals given
below. Let an authorized Volvo Penta Service Work Shop look after your engine.


 CHECK DAILY BEFORE STARTING that
                                                                                  Page
 The oil level in the engine is between the marks on the dipstick                   13


 CHECK every 14 days that
 The oil level in the reverse gear is between the marks on the dipstick              13
 The oil level in the S-Drive is between the marks on the dipstick                   14
 The electrolyte level in the battery is correct                                     14
 The belt tension is sufficient to prevent the alternator from slipping              14


 SERVICE EVERY 50 HOURS OF OPERATION:
 Change the engine lubrication oil                                                   15
 Change the reverse gear lubrication oil (every 200 hours)                           15
 Change the lubrication oil in the S-Drive model 110S                                16
 Valve clearance. Checking and adjusting.                                            16


 SERVICE EVERY 100 HOURS OF OPERATIONS OR AT
 LEAST ONCE EACH SEASON:
 Change the oil filter                                                               17
 Clean the air filter                                                                17
 Checking and changing the alternator v-belt                                         18
 Check-tightening the cylinder head nuts                                             18
 Zinc anodes, propeller (model 110S)                                                 18
 Check the cooling system                                                            19
 Electrical system. Checking and changing fuses                                  20, 21
 Check the fuel system, filter, strainer, injector, injection pump, venting      21-23



 SERVICE WHEN LAYING-UP AND LAUNCHING THE BOAT

 Inhibiting scheme                                                                   24
 Service in connection with launching.                                               27

12
                                   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


                            Unscrew 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. 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".




                                                                    13
CHECKS AND SERVICE


                                            OIL LEVEL IN THE S-DRIVE
                                            Check every 14 days that the oil level is
                                            within the marks on the dipstick.
                                            The oil dipstick is provided with a bayo-
                                            net type of attachment. Therefore it has
                                            to be turned prior to removal and re-
                                            insertion. Note the seal underneath the
                                            oil dipstick head. When checking the oil-
                                            level, the dipstick has to be turned to the
                                            locked position.
                                            When topping-up oil, top-up through the
                                            oil dipstick hole. NOTE! Do not top-up
                                            above the upper mark on the dipstick.
                                            Concerning choice of oil, see under
                                            "Technical Data" Page 30.


THE 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. NOTE! Exercise great care when doing
this. The electrolyte is corrosive and the gas being formed is explosive.




THE BELT TENSION

                                           Correct belt tension is necessary for full
                                           alternator output. The belt should be
                                           tensioned in such a way that it can be
                                           depressed 5 mm (3/16") with the thumb
                                           midway between the pulleys.
                                           The belt can be tensioned after loosening
                                           the alternator mounting bolts.
                                            A well worn or cracked belt should be
                                           replaced. See page 18.




14
                                   CHECKS AND SERVICE

SERVICE EVERY 50 HOURS OF OPERATION:

OIL CHANGE IN ENGINE


                          With a new or newly reconditioned 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. Concerning
                          choice of oil, see under "Technical Data".
                          NOTE! Change also the oil filter at every
                          second change of oil. See page 17.




OIL CHANGE IN REVERSE GEAR (every 200 hours of
operation or at least once per season)

                           The oil can be drained from the reverse
                           gear by removing the plugs under the
                           reverse and reduction gears respectively
                           (see Engine Component Guide), 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. NOTE. Do not fill above the
                           Max. mark on the dipstick. Concerning
                           choice of oil, see "Technical Data".




                                                                   15
CHECKS AND SERVICE

OIL CHANGE IN S-DRIVE (every 200 hours of operation or at
least once per season)



                             Remove the oil dipstick. Remove the plug
                             underneath the propeller gear housing
                             and let the oil drain off. Install the plug
                             with its O-ring. Fill oil through the dipstick
                             hole. The oil level shall be within the
                             dipstick marks. NOTE! Do not fill oil above
                             the upper oil dipstick mark. Concerning
                             the choice of oil, see "Technical Data",
                             Page 30.




VALVE CLEARANCE



                            Checking and adjusting the valve
                            clearance should be done by an authorized
                            Volvo penta Service Workshop. See further
                            under "Valves - Technical Data".




16
                                                         CHECKS AND SERVICE


SERVICE 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. Unscrew and discard the
oil filter.
                                              Coat the new oil filter's rubber seal with oil.
                                              Check the contact surface on the engine
                                              and screw on the filter by hand until it
                                              touches the contact surface. Turn the filter
                                              a further half turn, not more.
                                              NOTE. Only use a genuine Volvo oil filter.
                                              Start the engine, run at idling and check
                                              that the oil pressure warning lamp goes
                                              out.
                                              Check oil level and that there are no leaks
                                              from the contact surface of the oil filter.




CLEANING OF AIR FILTER
                                              The air filter should be removed and
                                              cleaned after every 100 hours of operation
                                              or once per season.
                                              Loosen the clamp with a screwdriver and
                                              remove the filter.
                                              Clean the filter with diesel fuel and blow it
                                              clean with a compressed air gun. Soak it in
                                              thin engine oil.
                                              Let the engine oil drain off and refit the
                                              filter.




                                                                                        17
CHECKS AND SERVICE

CHECKING AND REPLACING THE V-BELT

                        Check the belt carefully, both for wear
                        and cracks. Any sign of such and the belt
                        must be replaced. Loosen the alternator
                        mounting bolts so that the belt can be
                        removed. Clean the pulley grooves before
                        fitting the new belt. Tension the belt so
                        that it can only be depressed 5 mm
                        (3/16") midway between the pulleys. After
                        a few hours running, recheck belt tension
                        and adjust if necessary.




RETIGHTENING CYLINDER HEAD NUTS
                        Retighten each nut with a torque wrench
                        before starting a new engine or an over-
                        hauled engine for the first time, and then
                        again after 20 hours of operation. The
                        valve clearance should always be
                        checked after the nuts have been
                        retightened. Sequence for tightening nuts
                        is shown in the figure opposite.




ZINC-ANODE, PROPELLER   Replace the zinc-anode if it is eaten away
                        to more than 50%. Remove the propeller
(S-DRIVE 110S)          and the spacer-ring with deflector and
                        remove the Allen-head screws, holding
                        the zinc anode. Clean the contact surface
                        on the S  -Drive and install a new zinc-
                        anode. Be careful to obtain a good metal-
                        lic contact between the S  -Drive and the
                        zinc-anode. Also replace the zinc-anodes
                        on the S-Drive when eaten away to more
                        than 50%. NOTE! Do not paint the zinc-
                        anodes.
                        Check to make certain that the propeller-
                        blades are folding easily, see "Inhibiting
                        Scheme), page 26, paragr 13.

18
                                                    CHECKS AND SERVICE

CHECK THE COOLING SYSTEM
The cooling system is functioning normally when the temperature warning lamp is out
and the buzzer is silent. Too high water temperature (the warning lamp is on and the
buzzer is sounding) can be due to the following reasons: Blocked water intake,
defective impeller or defective sea water pump carrier, faulty thermostat or temperature
sender. NOTE! When working on the cooling system, be careful and avoid water
coming into the boat.
                                             The impeller can be damaged by lack of
CHECKING AND                                 water among other things. Close the
CANGING THE                                  bottom intake valve. Remove the sea
IMPELLER                                     water pump cover. If it proves necessary
                                             to replace the impeller, pull out the impel-
                                             ler and the shaft as far as necessary to
                                             reach the crew on the impeller hub.
                                             NOTE! On earlier executions: Do not pull
                                             out the shaft further than that, since the
                                             sealing rings can be damaged when the
                                             shaft is pushed back. Remove the locking
                                             screw, (on earlier executions hold back
                                             the shaft) pull off the impeller. Install a
                                             new impeller, tighten the screw and push
                                             the shaft back into position.
                                             The carrier is defective if the impeller and
                                             shaft can be turned. A new carrier can be
                                             installed after having removed the pump.
                                             Install the water pump cover, using a new
                                             gasket. Open the bottom intake valve.

COOLING SYSTEM
S-DRIVE MODEL 100S                           The cooling water intake for the cooling of
                                             the engine is located in the lower gear
                                             housing of the S-Drive. Check, while the
                                             boat is on land, that the gillformed water-
                                             intake and the hole in the lower edge of
                                             the S-Drive are free from marine growth.
                                             When inhibiting or when there is a risk of
                                             temperatures below zero, drain off the
                                             cooling water from the S-Drive and pump
                                             by removing the cooling water hose from
                                             the cock on the S-Drive.
                                             NOTE! If draining with the boat in the
                                             water, close the cock prior to start of
                                             draining. Incorrect draining might easily
                                             end up with a sunken boat. Do not forget
                                             to open the cock prior to starting the
                                             engine.

                                                                                    19
CHECKS AND SERVICE

ELECTRICAL 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.   The main switch must never be
                                                switched off until the engine has
                                                stopped.
                                                Otherwise the charging regulator will be
                                                ruined.
                                           2.   The battery connection poles must
                                                never be mixed up. A plus sign and a
                                                minus sign are marked on the respective
                                                poles. The minus pole is connected to
                                                the cylinder block. The cable terminals
                                                should be greased and well tightened.
                                           3.   Switching 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 whenever the
                                                engine is started with an auxiliary
                                                battery:
                                                Let the ordinary battery remain
                                                connected. 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 battery's 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 connections.




20
                                                       CHECKS AND SERVICE
Changing the Fuse
A fusebox is mounted on the engine. The fuse breaks the electrical system when
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 should be done by an authorized
service workshop.
Inspection and control should he carried out in connection with a general inspection of
the engine.

BATTERY
Checking the state of the battery charge
The charging of the battery should be checked at least 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 "Technical Data").

FUEL SYSTEM
Observe the greatest cleanliness when working on the fuel system. NOTE! Try to avoid
spilling fuel!
 Changing the fuel filter                     The fuel filter must be replaced least once
                                              per season. NOTE! If an extra fuel filter is
                                              installed in the boat, this filter or filter
                                              element must be replaced as well.
                                              Remove the filter, if necessary push a
                                              screwdriver through the filter and use the
                                              screwdriver as a lever. NOTE! Be careful
                                              not to spill oil. The fine-filter is a throw-
                                              away-type of filter. Therefore throw away
                                              the old filter and install a new one. Check
                                              that the contact surface of the oil filter
                                              housing is clean and that the oil filter
                                              gasket is undamaged. Install the new filter




                                                                                     21
CHECKS AND SERVICE

                                              by hand until the gasket touches the
                                              contact surface of the housing. Then turn
                                              the filter a further  turn. Vent the fuel
                                              system (see page 23) and check for
                                              leakage.
 Extra fuel filter
                                              If an extra fuel filter with water separator is
                                              fitted, check the transparent bowl to see if
                                              there is any water in the fuel. If neces-
                                              sary, drain the filter via the cock in the
                                              bottom of the bowl. Try to avoid spilling
                                              fuel. Pump up the fuel 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 can be removed by remov-
                                              ing the pump's cover. The strainer must
                                              be cleaned at least once per season.
                                              Always vent the fuel system. See "Ven-
                                              ting of Fuel System" (page 23). Check
                                              immediately after starting that there is
                                              no fuel leakage.




Injectors
All work on the engine injectors shall be carried out by an authorized Volvo Penta Service
Workshop. Each third season the injectors should be handed over a diesel workshop for
cleaning and checking the opening pressure, leakage and spray pattern.




22
                                                         CHECKS AND SERVICE

Venting the fuel system
Venting of the fuel system must be carried out prior to the first start of the engine and
after work has been carried out on the fuel system, when the fuel tank has been run
empty or if the engine has been out of operation for some time.




Venting is carried out as follows: (Regarding location, See Engine Component Guide).


                      Open venting screw on fuel filter about 4 turns. Be careful not to
                      spill fuel. Use rags around the vent opening.




 1
                      Pump up the fuel by using the hand primer until fuel, free from air
                      bubbles flows out. Close venting screw. If the pump action is poor,
                      turn the engine so that the cam driving the pump changes position.

 2
                      If the injection pump has been removed, or when first starting a
                      new engine, the injection pump must be vented. BOSCH Fuel
                      Injection pump: Operate the handprimer for approximately half a
                      minute. The injection pump is then automatically vented.
                      CAV Fuel Injection pump has two air venting screws, see picture.
                      Vent No 1 and then No 2. Operate handprimer until fuel free from
                      air bubbles flows out at screw No 1. Tighten screw No 1. Put
                      throttle control lever in position full speed and turn engine using
                      starter motor until fuel free from air bubbles flows out of screw No
                      2. Tighten screw No.2.
 3
                      Loosen the injector's delivery pipe nut, push in the stop control and
                      put the throttle lever in full speed position. Turn the engine using
                      the starter motor until fuel flows out of the delivery pipes. Be
                      careful not to spill fuel! Use rags around the venting location.
                      Tighten the delivery pipe nuts and start the engine.



 4


                                                                                     23
LAYING-UP AND LAUNCHING

SERVICE IN CONNECTION WITH LAYING-UP AND
LAUNCHING THE BOAT, INHIBITING ENGINE AND REVERSE
GEAR
Idle engine for short periods of time, with the boat in the
water
In order to prevent damage to the engine caused by corrosion, the engine should be
run warm at least once every 14 days as long as the boat is in the water. If the boat is
not be used for over a month, a long-term inhibiting should be carried out.

Inhibiting for the winter lay-up
Prior to inhibiting the engine for the winter lay-up, an authorized Volvo Penta Service
Workshop should test the engine and equipment. It is advisable to check the
compression in order find out the condition of the engine. If the inhibiting work can be
made directly after the boat is out of the water, it is advisable to run the engine warm in
the water. This will facilitate the oil change.



                             INHIBITING SCHEME
                     Carried out with the boat on land
                     Change the fuel filter.
                     If an extra fuel filter is installed, drain water and impurities and
                     replace the filter insert.
                     Pump up fuel and vent the system. See "Venting the fuel system",
                     page 23.
1                    Check out the system for leakages.

                     Drain the cooling water from the engine and the reverse gear
                     (paragraphs 15 and 16, page 34). Check to make sure that the
                     water drains off, since impurities can block the cock. Then close
                     the cock and install the plug in the reverse gear.

2

                     Remove the suction line from the reverse gear (MD7A/MSB) and
                     from the cooling water pump (MD7A/110S). Install a hose with an
                     inner diameter 1/2" and insert the free end into a container with
                     fresh water. Make sure to have additional water at hand to fill the
                     container.



3


24
                         LAYING-UP AND LAUNCHING

    Run the engine at idle for 5  10 minutes in order to thoroughly
    flush the engine with fresh water. Make sure that the exhaust
    does not splash vital objects. Drain all water from engine an
    reverse gear. Then close all draining cocks. NOTE! Do not let
    the propeller rotate.
4
    Remove all oil from the engine and from the reverse gear and
    S-Drive respectively.




5
    Change the oil filter. Fill up the engine, reverse gear and S-
    Drive respectively to the correct level. Use the Volvo Penta
    diesel engine oil with protective properties against corrosion.
    Now the engine is ready to run on this oil during the coming
    seas on.
    Always use a special inhibiting oil if the lay-up will exceed one
    normal winter lay-up. This inhibiting oil should be of the type
    Esso Rustban 623, Shell Ensis Oil or of an equivalent type. If
    inhibiting oil is used the oil filter must be replaced at the time of
    launching the boat.
6
    Prepare a rust-protection mixture consisting of fresh water and
    5% Volvo Penta rust-protection-oil and emulsifying oil. NOTE!
    Water first and then the oil.
    Following rust-protection-oils can also be used: Esso Cutwell
    40, Shell Donax C or equivalent. As an alternative to these oils,
    a 40 % Ethylene Glycol-mixture can also be used.
    Following for MD7A with reverse gear: An Ethylene-Glycol
    mixture must be used when and if engine inclination exceeds
    10. Otherwise the water, which still remains, can cause
7   damage due to freezing.
    Insert the hose into the rust-protection-mixture. Start the engine
    and let it run in idling until the mixture is finished. NOTE! The
    cooling water pump will be damaged if it runs without water.




8

                                                                    25
LAYING-UP AND LAUNCHING

            Since the rust-protection-mixture does not give protection
            against freezing, it has to be drained off from the engine and
            the reverse gear (paragraphs 15 and 16, page 34). There is no
            need to drain off the Ethylene Glycol-mixture. Remove the
            cover from the cooling water pump. Check the impeller for
            possible damage. NOTE! Do not pull out the impeller if it is
            undamaged. Install the cover using a new, genuine gasket.
            Install the cooling water hose between the cooling water intake
            and reverse gear and the water pump (MD7A/110S)
            respectively.
            Close all draining cocks. If a vacuum -valve is installed, it has to
9           be disassembled and salt-sediments cleaned away.
            Clean the outside of the engine and reverse gear. Touch-in any
            bare patches on the paintwork with the original type of paint .
            Spray the components of the electrical system and all control
            components with anti-moisture spray.

10
            Remove the battery. For proper maintenance it needs to be
            charged to prevent it from being damaged.



11
            Check the flexible rubber seal between the S       -Drive and the
            engine foundation for elasticity and that it is free from mecha-
            nical damage.
            The flexible rubber seal must replaced each 5th year. Check
            further that the rubber seal underneath on the boat and around
            the S-Drive is properly located.
12


            Following concerns the folding propeller:
            Remove the propeller from the S-Drive.
            Clean the propeller in fresh water, remove the screws from the
            suspension dowel pins holding the propeller blades and remove
            the dowel pins and the propeller blades. Clean all surfaces and
            then grease all the parts with proper grease. Use the Volvo
            Penta Special Grease. Especially the bearing surfaces on
            dowels and blades need careful greasing. Protect the hub of the
            propeller.

13

26
                                 LAYING-UP AND LAUNCHING

     SERVICE IN CONNECTION WITH LAUNCHING
            If Volvo Penta diesel engine oil has been used, you only need
            to check the oil level in the engine and reverse gear and S      -
            Drive. If preservative oil has been used, both oil and filter must
            be replaced. See under "Service after every 50 hours of
            operation".
14
            Check the tightening of all hose clamps. Check that all drain-
            cocks are closed.



15
            Install the battery or batteries, which must be fully charged.
            Grease the cable terminals. Fit the battery cables.
            IMPORTANT! Do not mix the polarity. Tighten up the cable
            terminals well.


16
            Following concerns folding propellers:
            Assemble the folding propeller, remove excess grease and
            check that the blades are folding easily. Grease the propeller
            hub. Check that all the zinc anodes are in good shape. Install
            the propeller.
17
            Paint the bottom of the boat with an anti-fouling paint. If the
            boat is equipped with the S-Drive model 110S it is important to
            check that the anti-fouling paint does not contain copper, which
            will cause damage due to corrosion on the S-Drive. Further
            paint the S-Drive with the Volvo Penta anti-fouling paint. NOTE!
            Do not paint the zinc anodes.
18
            Pump up the fuel and vent the fuel system (see page 23).




19

                                                                        27
 LAYING-UP AND LAUNCHING

             Launch the boat. Start the engine. See the instructions on page
             5. Run the engine warm with the gear engaged. Check to make
             sure there is no leakage of fuel, air, water or exhaust gases.
             Check that all functions for maneuvering are working properly.
20
             When necessary contact an authorized Volvo Penta Workshop
             and have their specialist make the service on engine and
             reverse gear or S-Drive in accordance with recommendations in
             the servicing scheme.




21




28
                                                                                                                                                 FAULT TRACING SCHEME

TRACING FAULTS WHEN HAVING INTERRUPTIONS IN
OPERATION
The fault tracing scheme given below lists only the most usual of faults that cause
interruptions in operation. With the help of the instructions given in this handbook, the
owner can generally remedy most of the faults listed below. When in doubt, always
contact the nearest Volvo Penta workshop.
Follow the maintenance scheme's recommendations  it helps provide trouble-free
operation.                                                                                            Engine becomes abnormally hot
                                         Engine does not reach correct
                                         operation speed at full throttle

                                                                            Engine runs unevenly or
  Engine does not start




                                                                            vibrates abnormally
                          Engine stops




                                                                                                                                      Reason                               See


                                                                                                                                      Main switch not switched on, flat    Pages 5, 20,
 X                                                                                                                                    battery, break in electric circuit   21
                                                                                                                                      or blown fuse.

                                                                                                                                      Empty fuel tank, closed fuel         Page 22
 X                        X                                                                                                           cock, blocked fuel filter

 X                        X                                                    X                                                      Water, air or impurities in fuel     Pages 21-23
 X                        X                  X                                 X                                                      Defective injectors                  Page 22
                                                                                                                                      Idling speed incorrectly adjusted    Page 30
                          X                                                    X

                                                                                                                                      Boat overloaded                      Page 3
                                             X

                                                                                                                                      Marine growth on hull                Page 3
                                             X

                                                                                                                                      Damaged propeller                    Page 18
                                                                               X

                                                                                                                                      Blocked cooling water intake,        Page 19
                                                                                                      X                               cooling jackets, defective
                                                                                                                                      impeller, or thermostat
                                                                                                                                                                                     29
  TECHNICAL DATA

Technical Data

General
Engine designation                                             MD7A
Number of cylinders                                            2
Propeller shaft output1) kW (HP) at 43,4 r/s (2600 rpm)        9,6 (13)
Max operating speed r/s (rpm).                                 43,3 (2600)
Cylinder diameter, mm (inches)                                 76,0 (2,99)
Stroke, mm (inches)                                            82,0 (3,23)
Displacement, din3 (in3)                                       0,744 (45.4)
Compression pressure kp/cm 3 (psi) (starter motor speed)       20--24 (285--340)
Idling Speed r/s (rpm) .                                       11--13 (650-780)
Direction of rotation looking at flywheel                      clockwise
Max rearwards inclination, boat underway                       15
Max sideways inclination, boat underway                        15
Engine weight incl. reverse gear, kg (lbs)                     175 (385)
Engine weight incl. S-Drive model 110S. kg (lbs)               192 (423)
Valves
Valve clearance, hot engine:
inlet, mm (in)                                                 0,30 (0.012)
exhaust, mm (in)                                               0,30 (0.012)
Decompression device, max downwards movement of
exhaust valve, mm (in)                                         0,5 (0.0197)
Lubrication system
Engine
Oil capacity, din3 (imp qts = US qts)
incl. filter                                                   2,8 (2.5 =2.9)
excl. filter                                                   2,5 (2.2 =2.7)
Oil quality                                                    Diesel Lubricating Oil
                                                               CD
Viscosity:
above +100C                                                    SAE 202)
below +100C                                                    SAE lOW3)
Oil pressure, hot engine:
idling speed, kp/cm 2 (psi) . .                                0,8--1,5 (14--21)
at full speed, kp/cm 3 (psi) . .                               3,5--4,0 (50--57)
MSB reverse gear with reduction gear:
Ratio, with reduction gear                                     1,91:1
Oil capacity, din3 (imp qts -- US qts)                         0,60 (0,5--0,6)
Oil quality (same as for the engine) . .                       Diesel Lubricating Oil
                                                               CD
Viscosity
                                                               See under engine
                                                               above!
1) Propeller shaft output to DIN Leusting B f&r Dauerbetrieb
2) Volvo Penta CD oil, Double grade.
3) Volvo Penta CD oil, Single grade.
30
                                                TECHNICAL DATA

S-Drive Model 110S
Ratio                                             1,66:1
Oil quantity, dm 3 (Imp qts -- US qts)            2,3 (2,0--2,4)
Oil quality (same as for the engine)              Diesel Lubricating Oil
                                                  CD
Viscosity                                         SAE2OW/302)
Cooling System
Thermostat
opens at C/F                                    60/140
fully open C/F                                  75/167
Fuel System
Injection pump, make                              CAV (model DPA)
Feed pressure, kp/cm 2 -- psi                     0,75(11)
Opening pressure kp/cm 2 -- psi                   180-188
                                                  (2560-2675)
Pre-injection angle, crankshaft degrees BTDC      10-12
Electrical system
Battery voltage, volt                             12
Battery capacity, max Ah                          70
Starter motor rating, kW (Hp)                     0,8(1,1)
Alternator rating, A (W)                          35 (420)
Battery electrolyte spec.grav.:
 Charging to be carried out at g/cm t3            1,230
 Fully charged battery, g/cm t3                   1,275--1,285
Torques
Stud bolts cylinder head (M10x 1,5), Nm (kpm)     20 (2)
Cylinder head nuts (M10x 1,0), Nm (kpm)           70 (7)
Connecting rod bolts (M10x 1,5), Nm (kpm)         70 (7)
Crankshaft main bearing (M10x 1,5), Nm (kpm)      8 (0,8)
Flywheel nut (M16x2), Nm (kpm)                    180 (18)




                                                                       31
WIRING DIAGRAM

Cable Colour Code                2
Marking    Colour             mm      A.W.G.
A          White              6       9
B          Black              1.5     15
B'         Black              0.6     19
B"         Black              0.75    18
C          Red                6       9
C'         Red                35      1
C"         Red                0.6     19
F          Yellow             1.5     15
G          Brown              1.5     15
H'         Blue               35      1
I          Green/Red          1.5     15
I'         Green/Red          0.75    18
J          Green              1.5     15
J'         Green              0.6     19
J"         Green              0.75    18
K          Blue/Yellow        0.75    18
L          White/Red          0.75    18
M          Blue/Red           0.75    18




List of Components                             9.    Place for instruments, opt. equipment)

1.   Switch, extra lighting                    10.   Plug in connector, wire harness

2.   Warning lamp, no battery charging         11.   Starter motor

3.   Warning lamp, high temperature            12.   Alternator

4.   Warning lamp, low oil pressure            13.   Fuse box

5.   Key switch                                14.   Main switch

6.   Buzzer                                    15.   Battery

7.   Alarm-unit                                16.   Sender, temperature

8.   N/A                                       17.   Sender, oil pressure




32
                             ENGINE COMPONENT GUIDES



MD7A with reverse gear model MSB    1.   Oil dipstick and oil filler
                                         hole hole and oil
                                         scavenging reverse gear
                                    2.   Cover, cooling water pump
                                    3.   Venting screw, fine-filter
                                    4.   Fine-filter
                                    5.   Decompression lever
                                    6.   Fuel pressure line nut
                                    7.   Sender, temp gauge
                                    8.   Injector
                                    9.   Thermostat housing
                                    10. Oil filler hole, engine
                                    11. Hand starter
                                    12. Stop device
                                    13. Speed lever
                                    14. Oil dipstick, oil scavenging
                                        engine
                                    15. Cooling water drainage,
                                        engine
                                    16. Cooling water drainage,
                                        reverse gear
                                    17. Air filter and air intake
                                        silencer
                                    18. Sender, tachometer
                                    19. Fuel pump (with hand
                                        priming device)
                                    20. Cooling water intake,
                                        reduction gear




                                                                      33
 ENGINE COMPONENT GUIDES

21. Oil drainage, reverse and           MD7A / 110S
    reduction gear
22. Oil filter
23. Sender, low oil pressure
24. Control cable bracket
25. Shift lever
26. Water cooled exhaust elbow
27. Sea water pump
28. Fuel injection pump
29. Oil drainage, S-Drive
30. Zinc anode
31. Alternator
32. Closed crankcase ventilation
33. Oil dipstick and oil filler hole,
    S-Drive
34. Closing cock for incoming
    cooling water
35. Flexible engine mounting
36. Flexible rubber seal between
    S-Drive and engine
    foundation
37. Cooling water intake, S-Drive
38. Engine foundation
39. Starter motor




34
                                    INDEX, ALPHABETICAL ORDER

Alternator                20, 21      Launching                         27
                                      Lubricating oil                    3
Battery                   14, 20      Lubricating system                 8
Belt tension              14, 18
                                      Main Switch                     5, 20
Charging regulator          7, 20
Checks & Service                      Oil changing                   15, 16
Scheme                         12     Oil dipstick, rev gear             13
Controls                        2                   engine               13
Cooling system              9, 19                   S-Drive              14
Cylinder head nuts             18     Oil filter                         17
                                      Oil level checking                 13
De-inhibiting                 27
Drain cocks               33, 34      Preparations before starting       4

Electrical system       8, 20, 32     Reverse gear                      10
Engine body                     8     Running                            6
Engine component           33, 34
guides                                Safety equipment                   4
Engine speed                   3      S-Drive Model 110S                11
                                      Sea-water pump                    19
Fault tracing scheme           29     Spare battery                     20
Fine-filter            21, 22, 34     Starter motor                     21
Fuel                            3     Starting                           5
Fuel filters               21, 22
Fuel pump                      22     Technical data                 30, 31
Fuse box                       21     Thermostat housing             33, 34

Hand priming pump         23, 33      Valve clearance                   16
Hand starter                   5      Venting (fuel system)             23

Impeller                      19      W iring diagram                   32
Inhibiting                 24-28
Injectors                     22
Instruments                    2




                                                                          35
IMPORTANT INFORMATION
Warning!
Stop the engine before opening the hatch to the engine compartment. An engine
which is in operation has rotating and moving parts which is dangerous to touch.
Bear in mind the risk of a fire. All engine fuel is potentially inflammable. Let an
expert correct any faults in the fuel system and always use genuine Volvo Penta
spare parts.

Frost Risk
The cooling system is filled with liquid and should be drained when there is risk
of frost. Note that in certain cases, a suction action may occur when the sea-
water system is being drained. Close all drainage points when the boat is not
under constant supervision. Any incorrectly performed drainage can cause the
boat to become filled with water and sink. Also bear in mind that the fresh water
tank and the toilet can be damaged by frost.


To Be Checked
The steering gear and controls must function perfectly and their operation
should be checked at regular intervals. Never take any chances if you suspect
that something is wrong. Take immediate action to remedy faults.
All rubber ages, so check all rubber parts at regular intervals. Parts which are of
special importance are the fuel hoses and those rubber parts which have to do
with the boat's flotation ability. If the hoses feel dry and hard or display any
tendencies to crack, they should be replaced immediately.

Safety Onboard
Check safety materials onboard. Run through your mind what can happen and
let yourself and your crew practice drills to cope with events that you know can
happen. You will benefit by being prepared if anything does happen. If you take
good care of your boat and its engine, then the risk of anything happening is a
small one. Read the instruction book -- before it happens.


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