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



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FOREWORDBefore you start running your new Volvo Penta marine engine you would beadvised to read through this instruction book carefully It contains all theinformation you need to run and service your engine in the best possible wayVolvo Penta has built up an extensive service organization with service shops andspecially trained personnel at your serviceAlways contact your local Volvo Penta representative for advice and when in needot service and partsWe are convinced that the demands on good running economy and topperformance which you have every right to expect of a quality product will be metand that your engine will serve you faithfully on many pleasant  warranty certificate is supplied with each engine It contains the  for the engine and should be studied carefullyAlso included is a report card which is to be completed by the dealer or boatseller If our warranty is to apply however it is an absolute condition that themeasures given in the Check and Service Scheme are carried out and that yourengine and equipment are looked after according to the instructions in thismanual When in doubt always get in touch with an authorized Volvo PentadealerIn all correspondence with your dealer and when ordering parts state the  and serial number of the engine and reverse gear see starboard sideof engine                                                                                                                             2General Information                                                   34Running Instructions                                                  56                        Starting the engine                             5                        Running instructions                            6                        Shutdown procedure                              6Technical Description                                                 79Checks and Service Scheme                                               10Checks and Service                                                  11  17                        Check daily before starting                      11                        Check every 14 days                         11  12                        Service every 50 hours of operation         12  13                        Service every 100 hours of operation        13  19                        Layingup and launching                     20  23Fault Tracing Scheme                                                     24Technical Data                                                      25  26Wiring Diagram                                                          27Engine Component Guide                                                  28Index alphabetical order                                               29                                                                          1PRESENTATION    INSTRUMENT PANEL                                1    Switch optional equipment                                2    Warning lamp Excess temp                                3    Place for instrument  52 mm opt equipment                                4    Warning lamp No oil pressure                                5    Switch optional equipment                                6    Warning lamp No battery charging                                7    Siren No oil pressure excess temp                                8    Key switch                       Volvo Penta Single Control System    CONTROL SYSTEM     For side mounting                       1       Control lever                       2       Disengaging button                                Push in the button when the control lever is in neutral                                and move the lever a bit forwards Release button                                The lever is now used only for engine speed control                                To use the lever for both engine speed control and                                gearchanging push in the button and pull back the                                lever to neutral                       N       Neutral                       F  Control lever in position for running Forward                       R  Control lever in position for running Reverse                       T  Engine speed control2                                                GENERAL  information on the function of your engine FUEL                   Use diesel fuel oil of quality Autodiesel Poorer fuel quality                        can cause interruptions in operation                        Use only oil with quality CD DS according to the API system LUBRICATING            Volvo Penta oil for diesel engines can be used with OIL                    advantage since it meets these quality demands See under                        Technical Data concerning the viscosity                        A new marine engine must be runin with due care during the RUNNINGIN             first 20 hours of operation If full output is taken out during this                        time it should only be done for short periods                        Oil change Change the engine lubricating oil and the oil filter                        after the engine has been run for 20 hours See further under                        Checks and ServiceENGINE SPEED                        Max speed 417 revsec 2500 revmmFor choice of correct propeller refer to the Volvo Penta propeller diagram Check theengine speed with normal load in the boat In order to utilize the maximum performanceof the engine an engine speed as high as possible should be chosen but not howevergreater than 417 revsec 2500 revmmNOTE When the boat has been in the water for some time the speed and max revmmcan drop due to marine growth on the hull Prevent marine growth by painting the bottomof the boat with antifouling paint See under Measures taken when launching                                                                                               3    GENERAL   of whether the boat is being used for long cruises or short bathing trips theboat should be equipped with the safety equipment listed below It can of course besupplemented further according to personal tastes Investigate at regular intervals toensure that there is safety equipment on board and that it is in working  for all on boardFIRE EXTINGUISHER approved at least one and installed where it is easy to get atDISTRESS ROCKETS and matches Packed  BOXTOOLS suitable for the equipment on boardON BOARD KIT containing eg impeller etcANCHOR with lineRADAR REFLECTORRADIO for listening to eg weather reportsCOMPASS which is deviatedBOAT HOOK and paddleMOORING ROPESFOGHORN and   BEFORE STARTINGMake sure thatThere is no FUEL LEAKAGEThere is no WATER LEAKAGE from engine and hullThere is no OIL LEAKAGEThere is no SMELL OF LPGAS in the deep cavities in the boat or elsewhereThe OIL LEVEL is correctThere is enough FUEL for the planned voyageThe proper NAUTICAL CHARTS are on board for the planned voyageIf there are some other persons on board make sure that some of them is able tooperate the boatIf there are persons on board who have never been on a boat before tell them where thelifejackets are located and where the  is placed Also tell them anythingmore you think necessary from a safety point of view Should something  during the voyage it is very often too late to tell those on board how  works4                                       RUNNING  THE ENGINE              Switch on the main switch Start the engine room fan if              fitted and let it run several minutes before starting the engine              Open the cock for the cooling water intake              Disengage the engine speed control from the gear              changing as follows              Move the control lever to neutral push in the red disengaging              button and move the lever slightly forwards Release the              button The lever can now only operate the engine speed              Check to make sure that the stop control is pushed in              Turn the key switch one stage to the right The warning              lamps for battery charging and oil pressure should now go on              and the siren should sound Push in and turn the key further to              the right to start the engine Release the key when the engine              starts              Hand starter If the engine is started with the starting crank              the decompression handle on the rocker arm cover should first              be folded up Fold down this handle for running when the              cranking has got the engine up in speed              Starting in cold weather is facilitated if the coldstart control              is pulled out Push it in again after a while              Check immediately after starting that the warning lamps for              the oil pressure and battery charging are out and that the siren              is quiet If any of the lamps are on and the siren is              sounding the engine must be stopped immediately and              an investigation made              Run the engine warm at rapid idle Check to make sure that              the cooling water flows out with the exhaust gases              NOTE The key switch should always be switched on as              long as the engine is running to ensure that there is              battery charging                                                                                  5RUNNING INSTRUCTIONS             Reduce to idle and check that the engine is running smoothly             Engage the control lever for gearchanging as follows             Push in the red disengaging button and pull the lever back to             neutral Release the button The control lever can now be             used both for gearchanging and engine speedRUNNING             The single lever control has both engine speed and             manoeuvering functions             F  Forward     N  Neutral             R  Reverse     T  Engine speed control             To achieve good running economy the engine should not be             run at max speed for a longer period             Make sure that the battery charging warning lamp does not             light when the engine is running The siren will sound and the             respective warning lamp go on if the engine temperature             becomes excessive or the oil pressure too lowSHUTDOWN PROCEDURE             After shutdown the engine should be allowed to idle for a             couple of minutes or so with the control lever in neutral             Stop the engine by pulling out the stop control when the             engine is idling Then turn back the key switch to the initial             position             Switch off the main switch NOTE This switch must never             be switched off until the engine has stopped             Close the fuel and cooling water cocks if the boat is not going             to be used for some time             Check for leakage before leaving the beat             In cold weather and whenever there is risk of icing the             cooling water should he drained from the engine and reverse             gear See under Layingup and launching6                                                     TECHNICAL DESCRIPTIONThe MD5A is a singlecylinder 4stroke marine diesel engine with direct injection andseawater coolingENGINE ASSEMBLYThe engine block and cylinder head are made of cast iron Cylinder angle 45o Thecylinder liner is replaceable The engine has overhead  SYSTEMThe lubricating system includes a fullflow oil filter which filters all the oil before it reachesthe lubricating points A relief valve in the oil pump prevents the oil pressure frombecoming  SYSTEMThe engine has a starter motor and alternator with builtin rectifier Voltage regulation istaken care of by a transistorized regulator mounted on the alternator The  it possible to charge two battery circuits independent of each other if a  accessory is fitted on the alternatorA main fuse which can easily be reconnected is fixed to the engine It protects theelectrical system from damage in the event of overloading The wiring diagrams for theengine and instrument panel are shown on page 27                                                                                                7    TECHNICAL  SYSTEMThe fuel system contains a feed pump with prefilter fine filter injection pump andinjector The feed pump which is of the diaphragm type has also a hand priming leverAlso fitted is a coldstart device with lever for connection of the pushpull controlCOOLING S YSTEMThe engine is seawater cooled The cooling system includes a seawater pump as wellas a water distributor housing with thermostatThe seawater pump has an impeller of neoprene rubber driven by the camshaft via arubber flangeThe thermostat installed in the water distributor housing regulates the water flow so thatthe water always flows through the exhaust manifold and out into the exhaust  of whether the engine is cold or warm8                                                 TECHNICAL  GEARThe Volvo Penta reverse gear type Mono Shift MSB has a reduction ratio of 1911The reduction gear is integrally built with the reverse gear Power transmission from theengine to the reverse gear is via a rubber flangeThe Volvo Penta patented cone clutch is used for Forward and Reverse operation andensures smooth and quiet engagement Very small forces are required to operate thereverse gear                                                                                            9CHECKS AND SERVICE SCHEMEChecks and service should be regularly carried out according to the intervals givenbelow Let an authorized Volvo Penta Service Shop look after your engine CHECK DAILY BEFORE STARTING that                                                                                  Page The oil level in the engine is between the marks on the dipstick                   11 CHECK every 14 days that The oil level in the reverse gear is between the marks on the dipstick               11 The electrolyte level in the battery is correct The belt tension                                                                     12 SERVICE EVERY 50 HOURS OF OPERATION Change the oil in the engine                                                         12 Change the oil in the reverse gear                                                   13 Check and adjust the valve clearances                                                13 SERVICE EVERY 100 HOURS OF OPERATIONS OR AT LEAST ONCE EACH SEASON Change the oil filter                                                               13 Check the pulley belt                                                               14 Checktighten the cylinder head bolts                                               15 Check the cooling system                                                            15 Check the electrical system fuses etc                                           16 Fuel system filter strainer injector venting                                 1719 SERVICE IN CONJUNCTION WITH LAYINGUP AND LAUNCHING THE BOAT Inhibiting scheme I Inhibiting measures carried out with boat in the water         20 Inhibiting scheme II Inhibiting measures carried out with boat on land             21 Service in connection with launching                                                2210                                    CHECKS AND SERVICECHECK DAILY BEFORE STARTINGOIL 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 DataCHECKS every 14 daysOIL LEVEL IN REVERSE GEAR                            Screw up the dipstick wipe it clean and                            insert it again without screwing it down                            Pull up the dipstick and check the oil                            level which should be between the                            marks If necessary top up with oil                            through the oil filler hole on the opposite                            side of the reverse gear Do not top up                            above the MAX mark                            Screw down the dipstick again Note that                            there is a sealing washer on the dipstick                            Concerning choice of oil see under                            Technical Data                                                                          11CHECKS AND  LEVEL IN BATTERYThe level should be between 510mm 316  38 above the cell plates in thebattery If necessary top up with distilled water IMPORTANT Observe great carewhen doing this since the electrolyte is abrasive and the gas which is formed  TENSIONING                                            Correct belt tension is necessary for full                                            alternator output The belt should be so                                            tensioned that it can be depressed 5 mm                                            316 with the thumb midway between                                            the pulleys                                            To tension the belt first slacken the                                            alternator retaining points stretch the                                            belts and tighten up the points again                                            A well worn or crached belt should be                                             EVERY 50 HOURS OF  OIL IN ENGINE                                            With a new or newly 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 See                                            under Technical Data concerning                                            choice of oil                                            NOTE Change also the oil filter Fram                                            Filter PH3614 at every other oil change12                                                       CHECKS AND SERVICECHANGE OIL IN REVERSE GEAR                                               The oil can be drained from the reverse                                               gear by removing the plug under it or by                                               sucking up the oil through the dipstick                                               hole with the help of an oil scavenging                                               pump                                               Fill with oil through the filler hole to the                                               correct level on the dipstick NOTE Do                                               not fill above the MAX mark on the                                               dipstick Concerning choice of oil see                                               under Technical DataVALVE CLEARANCE                                                The valve clearance should be checked                                                and adjusted by authorized personal                                                See under Valves in Technical DataSERVICE EVERY 100 HOURS OF OPERATION OR AT LEASTONCE EACH SEASONOIL FILTERThe oil filter should be replaced for the first time after 20 hours of operation during therunning in period and subsequently at every other oil change IMPORTANT Beforeremoving the filter switch off the main switch Screw off and scrap the oil filter It maybe necessary in certain cases to lift off the belt and tension out the alternator to permitfree passage for the filter                                                                                              13CHECKS AND SERVICE                     Coat the new filter rubber gasket with oil                     Check the area on the engine in contact                     with the filter and screw on the filter by                     hand until it just touches the engine Then                     screw the filter a further half turn but not                     more                     NOTE Only use a genuine oil filter                     Start the engine allow it to idle and                     immediately check that the oil pressure                     warning lamp is out                     Check the oil level and also for any                     leakage round the oil filterCHECK THE BELT                     Check the belt thoroughly for wear and                     cracks Replace it if there is any indica                     tion of such To remove the belt slacken                     the alternator retaining points in order to                     be able to slip the belt off Wipe clean the                     belt groove on the pulleys before fitting                     the new belt Tension the belt so that it                     can only be depressed 5 mm 316 with                     the thumb between the pulleys After the                     engine has been run for an hour or so                     recheck and if necessary adjust the belt                     tensioning14                                                    CHECKS AND  THE CYLINDER HEAD BOLTS                                             Authorized personal should checktighten                                             the bolts with a torque wrench before                                             starting a new or newly reconditioned                                             engine for the first time and again after it                                             has been in operation for 20 hours                                             Check the valve clearance after tightening                                             up the bolts The bolttightening sequence                                             can be seen from the adjacent illustration                                             Concerning the tightening torque see                                             under Technical DataCHECK THE COOLING SYSTEMThe cooling system is functioning normally when the Temp lamp is out and the siren isquiet Excessive temperature Temp goes on the siren sounds may be due to thefollowing clogged water intake defective impeller or flange in the seawater pumpfaulty thermostat or temp gauge sender Look out for water penetration during allwork on the cooling system                                             The impeller can be damaged due to    Check and replace the impeller                                             eg shortage of water Remove the cover                                             on the water pump Pull out the shaft the                                             length required in order to screw out the                                             impeller lock bolt Hold against the shaft                                             and pull off the impeller If the impeller is                                             damaged fit a new one NOTE If the                                             shaft has been removed entirely from the                                             pump housing check when refitting it                                             that the Dring between the sealing rings                                             in the housing gets onto the shaft                                             Tighten up the impeller with the lock bolt                                             If the impeller and shaft can be rotated                                             then the flange is defective A new flange                                             can be fitted after the pump has been                                             removed Fit the cover with its gasket                                                                                       15CHECKS AND SERVICE                                    ELECTRIC SYSTEM                                    Alternator                                    The engine is equipped with an alternator To                                    ensure that the alternator with the builton regulator                                    functions without interruptions the following                                    important points must be observed                                    1   Never switch off the main switch until the                                         engine has been stopped                                         To do otherwise would be to ruin the charging                                         regulator                                    2   Do not mix up the battery connection                                         poles A plus sign and a minus sign are marked                                         on the respective poles The minus pole is                                         connected up to the engine body Cable shoes                                         should be greased and wall tightened                                    3   Rewiring between the charging circuits                                         may not be carried out while the engine is                                         running                                         Fit a Volvo Penta charging distributor                                         accessory on the alternator when more than                                         one battery is connected up4   Observe the following in the event the engine is started with an auxiliary battery     Let the ordinary battery remain connected up Connect the auxiliary battery to the     ordinary battery plus to plus and minus to minus When the engine has started     remove the auxiliary battery but do not break the ordinary batterys wiring circuit5   Do not use a rapid charging unit when the alternator is connected to the battery6   Before doing any work on the alternator equipment first disconnect both the     battery cables7   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 ends8   Check regularly the belt tension and the cable connections16                                                       CHECKS AND SERVICEChange FuseA fusebox is mounted on the cylinder A fuse breaks the electrical system when thesystem is overloaded Reconnect the electrical system by transferring the  to the next fuse contactStarter motor and alternatorAll work connected with the starter motor and alternator shoold be done by an  shop Inspection and control should he carried out in connection with a  of the  the state of charge of the batteryThe state of charge of the battery should he checked at cast once each season This isdone by using a hydrometer which shows the specific gravity of the electrolyte thisvarying with the state of charge See the Technical DataFUEL SYSTEMObserve the greatest cleanliness when handling the fuel  Try to avoid fuel splash             Change fuel filter                                              The filter element in the fuel filter should                                              be changed at least once each season                                              To do this remove the filter centre screw                                              and lift off the filter Clean the container                                              and contact surfaces Fit the new filter                                              element and its gasket Pump up the fuel                                              with the hand primer Vent the fuel system                                              If the pumping effect is poor turn over the                                              engine a bit so that the drive cam alters its                                              position                                                                                             17CHECKS AND SERVICE Extra fuel filter                                               If an extra fuel filter is fitted together with a                                               water separator check the transparent                                               bowl to see if there is any water in the fuel                                               If necessary drain the filter via the cock in                                               the bottom of the bowl                                               Try to avoid fuel splash Pump up the fuel                                               with the hand primer and vent the system                                               The fuel filter element should be changed                                               at least once a season FUEL STRAINER                                               The fuel pump on the engine has a builtin                                               strainer which is accessible after removing                                               the cover Clean the strainer at least once                                               a season                                               Immediately after starting the engine                                               check for leakage                                               Always vent the fuel system See under                                               Venting the fuel  injector should be removed once a season and handed in to a diesel shop forcleaning and checking the opening pressure the spray pattern and for leakage Toremove the injector unscrew the delivery pipe and the bypass oil line Fit protective capsover the  both the nuts over the fork holding the injector to the cylinder head and lift up theinjector If the injector feels stiff to remove due to gumming grip it with eg polygrippliers and carefully rotate it back and forth while levering it up at the same time with ascrewdriver eg under the fork Before fitting check to make sure the contact surfaceon the injector and copper sleeve is clean Connect up the delivery pipe and the returnline but do not tighten the delivery pipe nut at the injector Turn over the engine with thestarter motor until fuel comes from the delivery pipe Tighten up the delivery pipe nut andmake sure the delivery pipe cone is fitted properly Concerning tightening torque seeTechnical Data18                                                          CHECKS AND SERVICEVenting the fuel systemIn order for the engine to be able to start the fuel system must be vented on the  changing the fine filter                 With leakage and work on the fuel linesWhen draining through the drain hole          When the engine has not been used for aWhen cleaning the fuel pump strainer          long timeAfter running the fuel tank emptyWhen installing the fuel injection pumpVenting is as follows1   Open the vent screw on the fuel filter2   Pump forward the fuel with the help of the hand primer until fuel free from air bubbles     flows out Close the vent screw If the pumping effect is poor turn over the engine a     bit so that the pump drive cam alters its position3   If the fuel injection pump has been removed or when starting an entirely new engine     for the first time the fuel injection pump must be vent To do this open the vent     screw on the pump Pump with the hand primer until fuel free from air comes out     Slacken the injector delivery pipe nut and turn over the engine by means of the     starter motor until fuel comes from the delivery pipe Tighten up the delivery pipe nut     and start the engine                                                            1   Vent screw fuel filter                                                            2   Hand primer                                                            3   Vent screw injection pump                                                            4   Delivery pipe nut                                                                                         19LAYINGUP AND  IN CONNECTION WITH LAYINGUP ANDLAUNCHING THE BOATINHIBITING ENGINE AND REVERSE GEARIDLE ENGINE FOR BRIEF PERIODS WITH BOAT IN THE WATERTo prevent the engine from corrosion attacks it must be run warm at least once every14 days as long as the boat is in the water If it is anticipated that the boat will not beused for more than a month longterm inhibiting should be carried outINHIBITING FOR A LONG PERIODAn authorized service shop should test the engine and equipment before inhibiting theengine for a long period acc To Inhibiting Schemes I and II A suitable procedure wouldbe to test the   Scheme ICarried out with the boat in the water                      Run the engine warm1                      Pump out all the oil from the engine and reverse gear                      Use an oil scavenging pump2                      Change the oil filter Fill the engine and reverse gear to the correct                      level with Volvo Penta oil which also has rustproofing properties                      to the correct level The lubricating system is thereafter ready for                      operation the next season                      If rustproofing oil is used it should be of the type Esso Rustban                      623 Sheel Ensis Oil or corresponding                      In this case the oil filter should be replaced when launching320                                             LAYINGUP AND LAUNCHING                    Drain the fuel filter4                    Disconnect the fuel pump flexible suction hose from the fuel                    system and insert the free end in a can filled with 13rd Volvo                    Penta oil or preservative oil and 23rds diesel fuel oil Bleed the                    fuel system Let the engine run at rapid idle for about 10                    minutes                    NOTE If the fuel system has an electrically operated fuel pump                    it must be switched off before the engine is  Scheme IICarried out with the boat on land                    Drain the cooling water from the engine and reverse gear                    Check to make sure that the water runs out since impurities can                    block the cock Then close all cocks and refit the drain cock in                    the reverse gear6                    Disconnect the reverse gear suction line from the reverse gear                    Connect a hose with inner diameter 12 and insert the free                    hose end in a container with fresh water Arrange to have water                    added to the container and run the engine at idle for about 5                     10 minutes so that it is flushed throughout with fresh water                    Make sure that there is no dirt near the exhaust outlet Drain all                    water from the engine and reverse gear Then close all drain7                   points                    Mix a rustproofing mixture consisting of 15  20 litres                    13 Impqts  16 us qts  18 lmpqts  21 US qts                    fresh water and 2  4 litres 18 Impqts  20 US qts  35                    lmpqts  53 US qts rustproofing oil                    NOTE Water first and then the oil                    Use eg Esso Cutwull 40 Shell Donax C or similar As an                    alternative a  30  glycol mixture can be used8                                                                                     21LAYINGUP AND LAUNCHING                   Insert the hose into the rustproofing mixture Start the engine                   and allow it to idle until the mixture is finished NOTE The                   water pump must never be allowed to run dry9                   Since the rustproofing mixture does not provide any protection                   against freezing it must be drained from the engine and                   reverse gear Remove the cover from the cooling water pump                   Check to make sure the impeller is in good condition                   NOTE Do not pull out the impeller if it is in good condition10                   Remove the injector and hand it in to a diesel shop for cleaning                   and checking Inject Volvo Penta oil into the cylinder Turn over                   the engine several turns with the starter motor or the crank                   NOTE Prevent oil splash Fit the checked injector but do not                   finaltighten it It will be removed again before launching11                   Clean the outside of the engine and reverse gear Touch up any                   bare patches on the paintwork with the same type of paint as                   the original Spray the electrical system components and all the                   controls with antimoisture spray12                   Remove the battery It needs to be maintained to prevent it from                   being  in connection with launching                   If Volvo Penta oil has been used only the oil level in the engine                   and reverse gear needs to be checked If another type of                   preservative oil has been used both oil and filter must be                   replaced See under Service 14 after every 50 hours of                   operation1422                         LAYINGUP AND LAUNCHING     Screw tight the cover with its gasket on the cooling water pump     Connect the hose between the cooling water intake and the     reverse gear Checktighten all the hose clamps     Close the drain cocks     Clean the outside of the engine and the reverse gear15     Install the battery which should be fully charged Grease the     cable shoes Connect up the battery cables IMPORTANT Do     not mix up the polarity Tighten up the cable shoes well16     Remove the injector Take measures to avoid oil splash and run     the engine several turns so that the oil on the piston crowns is     blown out     Fit the injector See under Tightening torques Technical     Data17     Launch the boat Change the fuelfilter cartridge Pump forward     the fuel and vent the system See under Venting the fuel     system18     Start the engine See the instructions on page 5 Run the     engine warm with the reverse gear engaged Check to make     sure there is no leakage of fuel air water or exhaust gases      Check that all the controls etc are functioning properly19     If necessary contact authorized Volvo Penta service shops and     let them service the engine and reverse gear according to the     instructions in the servicing scheme20                                                                       23 FAULT TRACING SCHEMETRACING FAULTS WITH INTERRUPTIONS IN OPERATIONThe fault tracing scheme given below lists only the most usual reasons for faults that giverise to interruptions in operation With the help of the instructions given in this handbookthe owner can generally remedy most of the reasons for the faults listed below When indoubt always contact the nearest Volvo Penta service shop                                                                                                      Engine becomes abnormally hot                                         Engine does not reach correct                                         operating speed at full throttle                                                                            Engine runs unevenly or  Engine does not start                                                                            vibrates abnormally                          Engine stops                                                                                                                                      Reason                               See                                                                                                                                      Main switch not switched on flat    pp 5 12 16                                                                                                                                      battery breakage in electric        17 27 X                                                                                                                                      cables or blown fuse                                                                                                                                      Empty fuel tank closed fuel         pp 17 18 X                        X                                                                                                           cock blocked fuel filter                                                                                                                                      Water air or impurities in fuel     pp 17 18 19 X                        X                                                    X X                        X                  X                                 X                                                      Defective injector                   pp 18 26                                                                                                                                      Idling speed not properly            p 25                          X                                                    X                                                      adjusted                                                                                                                                      Boat overloaded                                             X                                                                                                                                      Marine growth on boat bottom                                             X                                                                                                                                      Damaged propellor                                                                               X                                                                                                                                      Blockage in cooling water            p 15                                                                                                      X                               intake cooling jackets defective                                                                                                                                      impeller or thermostat24                                                                       TECHNICAL DATATechnical  designation                                                       MD5A                                                                         4stroke diesel with                                                                  of cylinders                                                      1Propeller shaft output kW hp at 2500 revmin                         55 75acc To DIN Leistung B f r  operating speed revmin                                              2500Bore mm in                                                            84 3307Stroke mm in                                                          80 3150                    3   3Displacement dm in                                                    0443 27                                 2         2Compr pressure MPa kpcm  lbfin                                    200  220starter motor speed                                                    20  22  284  313Idling speed revmin approx                                             700Direction of rotation looking at flywheel                                 inclination underway   Rearwards max                                                       15   To the sides max                                                    20Engine weight incl Reverse gear kg lb                               111 244ValvesValve clearance hot engine   Inlet mm in                                                        030 00012   Exhaust mm im                                                      035 00014Reverse GearType designation                                                         MSBReduction ratio Forward and Reverse                                   SystemEngine   Oil Capacity engine litres Impqts  US qts ex cl filter       20 180  210                                                        Incl filter     21 185  220   Oil quality                                                           Diesel lubricating oil                                                                         Service CD DS   Viscosity            Above 10C 14F  Volvo Penta CD Double Grade oil         SAE 20W30            Below 10C 14F  Volvo Penta CD Single Grade oil         SAE 10W   Oil pressure hot engine                                       2        2            Idling speed MPa kpcm  lbfin                           15  25 1525  2135                                       2         2            At full speed MPa kpcm  lbfin                          40  50 4050  5771                                                                                                       25  TECHNICAL DATAReverse Gear   Oil                                              See under Engine   Oil capacity litre qt                                         055 05Cooling  starts to open at C F                                602 1402              fully open at C F                                  90 195Fuel SystemFuel injection pump make  type                                     Bosch PFR1K                                2           2Feed pressure MPa kpcm  lbfin                                  75 075  11Injector make Bosch holder                                         KBAL 65                           nozzle                                    DLLA 150                                                        2       2                           opening pressure MPa kpcm  lbfin    1800 180   angle crankshaft degrees BTDC                     25  28Fuel quality Autodiesel                                            Cet rating minimum 45Electrical SystemBattery voltage                                                      12vBattery capacity standard                                           60 Ah                   max                                               120 AhStarter motor                                                        08 kW 11 hpAlternator                                                           35A 420WBattery electrolyte specific gravity                                        3   Charging carried out at gcm                                      1230                                    3   Fully charged battery gcm                                       1275  1285Tightening  head nuts Nm kpm  lbftf                                70 70  50Connecting rod bolts Nm kpm  lbftf                              70 70  50Crankshaft main bearings Nm kpm  lbftf                          70 70  50Flywheel nut Nm kpm  lbftf                                      500 500  362Injector nuts Nm kpm  lbftf                                     10 10  726                                                                               WIRING DIAGRAMCable Colour Code                 2Marking       Colour          mm             AWGA             White           6              9B             Black           15            15B            Black           06            19B            Black           075           18C             Red             6              9C            Red             35             1C            Red             06            19F             Yellow          15            15G             Brown           15            15H            Blue            35             1I             GreenRed       15            15I            GreenRed       075           18J             Green           15            15J            Green           06            19J            Green           075           18K             BlueYellow     075           18L             WhiteRed       075           18M             BlueRed        075           18List of Components                                         9    Place for instruments opt equipment1   Extra switch                                          10   Rapid connector2   Battery charging warning lamp                         11   Starter mot or3   Excessive temp warning lamp                          12   Alternator4   Low oil pressure warning lamp                         13   Fusebox5   Key switch                                            14   Main switch6   Siren                                                 15   Battery7   Alarm unit                                            16   Temperature sender8   Battery charging warning lamp for battery circuit   17   Oil pressure sender     opt equipment                                                                                                          27 ENGINE COMPONENT GUIDE                                                       1   Connection for manual                                                            starting crank                                                       2   Fusebox                                                       3   Thermostat housing                                                       4   Decompression handle                                                       5   Injector                                                       6   Oil filler cap engine                                                       7   Reverse gear water drainage                                                       8   Reverse gear oil drainage                                                       9   Engine water drainage                                                       10 Reverse gear oil filler                                                       11 Cooling water pump                                                       12 Reverse gear oil dipstick                                                       13 Fuel filter                                                       14 Vent screw                                                       15 Fuel hand primer                                                       16 Engine oil dipstick                                                       17 Oil filterThe tool kit supplied with the engine contains the following toolsUSspanner 1012 UPspanner 1416  screwdriver Phillips screwdriver flat end pliersoil scavenging pump with hose and suction pipe as well as Allen spanners for the drive28                                                                                   7 14 16 27   Lubricating oil                     3 25Battery                          12    Main Switch                          5 6Belt tensioning              12 14                                       Oil change                         12 13Charging regulator            7 16    Oil dipstick engine                   28Controls                       2 6    Oil dipstick reverse gear             28Cooling system                    8    Oil filter                     14 20 28Cylinder head bolts              15    Oil level check                        11Deinhibiting                    22    Preparations before starting           4Drain cocks                      28                                       Running                                6Electrical system                16Engine assembly                   7    Safety equipment                        4                                       Seawater pump                  8 15 28Fault tracing scheme             24    Starter motor                          17Fuel                              3    Starting                                5Fuel filters                     17Fuel pump                         8    Technical data                    25 26Fusebox                       7 17    Thermostat                         8 26Hand primer            8 17 23 28   Valve clearances                  13 25Hand starter                   5 28   Venting the fuel system               19Impeller                         15    W iring diagrams                      27Inhibiting                       20Injector                     18 23Instruments                   2 27                                                                               29

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