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Volvo Penta Md7aib Workshop Manual




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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 contact your local Volvo Penta for advice and when in need
of service and CERTIFICATE
A 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
and forwarded to Volvo if our warranty is to apply it is an absolute condition that the 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 with your dealer and when ordering parts always state the
type designation and serial number of the engine and reverse gear or drive side of engine
Make certain that the engines specification coincides with what is described in
this instruction book
AB VOLVO PENTA
Technical Publications Dept
and Controls 2
General Information 34
Running Instructions 56
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 layingup and launching 24 28
Fault Tracing Scheme 29
Technical Data 30 31
Wiring Diagram 32
Engine Component Guide 33 34
Index alphabetical order 35
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
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 GENERAL 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 OIL APISystem 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 runin with due 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 SPEED Max engine speed MD7A 434 revsec 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 434 revsec 2600
NOTE 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 anti
fouling paint If the boat is equipped with S drive
model MD7A110S or any other Sdrive model it
is important not to use an antifouling paint which
contains copper See further Service in connection
with 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 ins talled 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 persons on board who have never been in a boat before inform them how the
boat functions and where the lifejackets and are located Also inform
them of anything more you think necessary from a safety point of view Should happen during the voyage it is often too late to tell those on board how
safety equipment works
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
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 gearchanging as
follows
Move the control lever to neutral push in the red disengaging
button and move the lever slightly forwards Release the button
The lever can now only operate the engine speed
Check to make sure that the stop control is pushed in
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 3435 on the rocker arm cover
should first be folded up Return the handle for
running when the engine has been cranked up in speed
Cold weather starting
CAV fuel injection pump Starting is facilitated if the coldstart
control is pulled out The coldstart control must be pushed in after
the engine has started
BOSCH fuel injection pump The engine has a builtin automatic
coldstart 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 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 gearchanging 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 gearchanging and engine speed
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 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
RUNNING propeller Sdrive When switching from running to sailing the propeller rotation is stopped by
engaging reverse gear When sailing maintain the control
lever in the reverse 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 charging regulator can be 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 zero the cooling water must be drained from the engine
and the reverse gear Close the cock on the cooling water
intake Sdrive model 110S See page 19 Close all the
drainage cocks if the boat is left without regular incorrectly performed draining can result in a sunken boat
See positions 15 and 16 page 34
TECHNICAL MD7A is a 2 cylinder 4stroke marine diesel engine with direct injection and sea
water ASSEMBLY
The engine block and cylinder head are made of cast iron The engine has SYSTEM
The lubricating system has a fullflow oil filter which cleans the oil before it reaches points The oil pump has a relief valve which prevents the oil
pressure from
becoming SYSTEM
The engine has a starter motor and an alternator with builtin rectifier Voltage regulation
is performed by a regulator mounted on the alternator The it possible to charge two batteries independent of each other if a is fitted to the 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 the
engine and instrument panel are shown on page 32
TECHNICAL SYSTEM
The fuel system has a feed pump with a fine filter fuel filter with a fine filter pump and injectors The feed pump is of the diaphragm type and is
equipped
with a hand priming lever
There is a builtin cold start device in the fuel injection pump On the CAV fuel the coldstart device is operated manually and on the BOSCH fuel
injection pump
the coldstart device is operated SYSTEM
The engine is cooled by sea water The cooling system has a sea water pump and a
water distributor housing with a seawater 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
TECHNICAL GEAR 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 TECHNICAL MODEL 110S power from the engine is transmitted via a rubber flange carrier to
the SDrive
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
CHECKS AND SERVICE 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 SDrive 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 SDrive 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 vbelt 18
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 2123
SERVICE WHEN LAYINGUP AND LAUNCHING THE BOAT
Inhibiting scheme 24
Service in connection with launching 27
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
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
CHECKS AND SERVICE
OIL LEVEL IN THE SDRIVE
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 toppingup oil topup through the
oil dipstick hole NOTE Do not topup
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 510mm 316 38 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 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 316 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
CHECKS AND EVERY 50 HOURS OF 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
CHECKS AND SERVICE
OIL CHANGE IN SDRIVE 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 Oring 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 CHECKS AND 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 filters 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
Check oil level and that there are no leaks
from the contact surface of the oil 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
CHECKS AND AND REPLACING THE VBELT
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
316 midway between the pulleys After
a few hours running recheck belt tension
and adjust if 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 PROPELLER Replace the zincanode if it is eaten away
to more than 50 Remove the 110S and the spacerring with deflector and
remove the Allenhead 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
zincanode Also replace the zincanodes
on the SDrive 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
CHECKS AND 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 impeller or defective sea water pump carrier faulty thermostat or 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 MODEL 100S The cooling water intake for the cooling of
the engine is located in the lower gear
housing of the SDrive Check while the
boat is on land that the gillformed water
intake and the hole in the lower edge of
the SDrive are free from marine growth
When inhibiting or when there is a risk of
temperatures below zero drain off the
cooling water from the SDrive and pump
by removing the cooling water hose from
the cock on the SDrive
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
CHECKS AND SYSTEM Alternator
The engine is equipped with an alternator
To ensure that the alternator with the built
on regulator functions without 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 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 the Fuse
A fusebox is mounted on the engine The fuse breaks the electrical system Reconnect the electrical system by transferring the cable connection to the
next fuse motor and work connected with the starter motor and alternator should be done by an and control should he carried out in connection with
a general inspection of
the 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 the greatest cleanliness when working on the fuel system NOTE Try to 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 finefilter is a throw
awaytype 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
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 builtin
strainer which can be removed by remov
ing the pumps 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 work on the engine injectors shall be carried out by an authorized Volvo Penta Each third season the injectors should be handed over a
diesel workshop for
cleaning and checking the opening pressure leakage and spray CHECKS AND the fuel 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 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
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
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 No2
Loosen the injectors 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
LAYINGUP AND IN CONNECTION WITH LAYINGUP AND
LAUNCHING THE BOAT INHIBITING ENGINE AND 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 longterm inhibiting should be carried for the winter layup
Prior to inhibiting the engine for the winter layup an authorized Volvo Penta should test the engine and equipment It is advisable to check 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
Remove the suction line from the reverse gear MD7AMSB and
from the cooling water pump MD7A110S Install a hose with an
inner diameter 12 and insert the free end into a container with
fresh water Make sure to have additional water at hand to fill the
LAYINGUP 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
Remove all oil from the engine and from the reverse gear and
SDrive 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 layup will exceed one
normal winter layup 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
Prepare a mixture consisting of fresh water and
5 Volvo Penta and emulsifying oil NOTE
Water first and then the oil
Following can also be used Esso Cutwell
40 Shell Donax C or equivalent As an alternative to these oils
a 40 Ethylene can also be used
Following for MD7A with reverse gear An 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 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 25
LAYINGUP AND LAUNCHING
Since the 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 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 MD7A110S
Close all draining cocks If a vacuum valve is installed it has to
9 be disassembled and cleaned away
Clean the outside of the engine and reverse gear Touchin any
bare patches on the paintwork with the original type of paint
Spray the components of the electrical system and all control
components with antimoisture spray
Remove the battery For proper maintenance it needs to be
charged to prevent it from being 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 SDrive is properly Following concerns the folding propeller
Remove the propeller from the SDrive
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
LAYINGUP 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
Check the tightening of all hose clamps Check that all drain
cocks are 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
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 Paint the bottom of the boat with an antifouling paint If the
boat is equipped with the SDrive model 110S it is important to
check that the antifouling paint does not contain copper which
will cause damage due to corrosion on the SDrive Further
paint the SDrive with the Volvo Penta antifouling paint NOTE
Do not paint the zinc anodes
Pump up the fuel and vent the fuel system see page 23
LAYINGUP 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
When necessary contact an authorized Volvo Penta Workshop
and have their specialist make the service on engine and
reverse gear or SDrive in accordance with in
the servicing
FAULT TRACING FAULTS WHEN HAVING INTERRUPTIONS fault tracing scheme given below lists only the most usual of faults that 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 the nearest Volvo Penta the maintenance schemes it helps provide
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 2123
X X X X Defective
injectors Page 22
Idling speed incorrectly adjusted Page 30
X X
Boat overloaded Page 3
Marine growth on hull Page 3
Damaged propeller Page 18
Blocked cooling water intake Page 19
X cooling jackets defective
impeller or thermostat
TECHNICAL designation MD7A
Number of cylinders 2
Propeller shaft output1 kW HP at 434 rs 2600 rpm 96 13
Max operating speed rs rpm 433 diameter mm inches 760 mm inches
820 din3 in3 0744 pressure kpcm 3 psi starter motor speed 2024 Speed rs rpm
1113 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 SDrive model 110S kg lbs 192 clearance hot mm in 030 mm in
030 device max downwards movement of
exhaust valve mm in 05 capacity din3 imp qts US qts
incl filter 28 25 29
excl filter 25 22 27
Oil quality Diesel Lubricating Oil
100C SAE 202
below 100C SAE lOW3
Oil pressure hot speed kpcm 2 psi 0815 1421
at full speed kpcm 3 psi 3540 5057
MSB reverse gear with reduction gear
Ratio with reduction gear 1911
Oil capacity din3 imp qts US qts 060 quality same as for the engine Diesel Lubricating Oil
Viscosity
See under engine
above
1 Propeller shaft output to DIN Leusting B fr Volvo Penta CD oil Double grade
3 Volvo Penta CD oil Single grade
TECHNICAL DATA
SDrive Model 110S
Ratio 1661
Oil quantity dm 3 Imp qts US qts 23 quality same as for the engine Diesel Lubricating Oil
Viscosity at CF 60140
fully open CF 75167
Fuel pump make CAV model DPA
Feed pressure kpcm 2 psi pressure kpcm 2 psi 180188
angle crankshaft degrees BTDC voltage volt 12
Battery capacity max Ah 70
Starter motor rating kW Hp rating A W 35 420
Battery electrolyte specgrav
Charging to be carried out at gcm t3 1230
Fully charged battery gcm t3 bolts cylinder head M10x 15 Nm kpm 20 2
Cylinder head nuts M10x 10 Nm kpm 70 rod bolts M10x 15 Nm kpm 70 main bearing M10x 15 Nm kpm 8 nut M16x2 Nm kpm
180 18
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 Switch extra lighting 10 Plug in connector wire
harness
2 Warning lamp no battery charging 11 Starter motor
3 Warning lamp high temperature 12 Warning lamp low oil pressure 13 Fuse box
5 Key switch 14 Main switch
6 Buzzer 15 Battery
7 Alarmunit 16 Sender NA 17 Sender oil
ENGINE COMPONENT 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 finefilter
4 Finefilter
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
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 SDrive
30 Zinc anode
31 Closed crankcase Oil dipstick and oil filler hole
SDrive
34 Closing cock for incoming
cooling water
35 Flexible engine mounting
36 Flexible rubber seal between
SDrive and engine
Cooling water intake SDrive
38 Engine Starter INDEX ALPHABETICAL 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 SDrive 14
Cylinder head nuts 18 Oil filter 17
Oil level checking 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 SDrive Model 110S 11
Seawater pump 19
Fault tracing scheme 29 Spare battery 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 2
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 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 boats flotation ability If the hoses feel dry and hard or display to crack they should be replaced 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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Disclaimer:
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.