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Volvo Penta Md7aib Workshop Manual



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FOREWORDBefore you start your new Volvo Penta marine engine you are advised to readthrough this instruction book carefully It contains information relevant to theproper operation and maintenance of your engineVolvo 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 needof service and partsWARRANTY CERTIFICATEA 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 boat sellerand forwarded to Volvo PentaHowever if our warranty is to apply it is an absolute condition that the measuresgiven in the Check and Service Scheme are carried out and that your engineand equipment are looked after according to the instructions in this book When indoubt always get in touch with an authorized Volvo Penta dealerIn all correspondence with your dealer and when ordering parts always state thetype designation and serial number of the engine and reverse gear or drive seestarboard side of engineMake certain that the engines specification coincides with what is described inthis instruction book                                                        AB VOLVO PENTA                                                 Technical Publications Dept                                                                and Controls                                                  2General Information                                                  34Running Instructions                                                 56                        Starting the engine                              5                        Running instructions                             6                        Shutdown procedure                               6Technical Description                                               8  11Checks and Service Scheme                                              12Checks 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  28Fault Tracing Scheme                                                    29Technical Data                                                     30  31Wiring Diagram                                                         32Engine Component Guide                                             33  34Index alphabetical order                                              35                                                                      1INSTRUMENTS 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                                gearchanging 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 control2                                     GENERAL  information on the function of your engineFUEL                   Use diesel fuel oil of quality Autodiesel Lower fuel                       quality can cause interruptions in operation                       Use only oil with quality CD DS according to theLUBRICATING 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 careRUNNINGIN             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 ServiceENGINE 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                       rpm                       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 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 ins talled 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 persons on board who have never been in a boat before inform them how theboat functions and where the lifejackets and  are located Also informthem 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 howsafety equipment 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            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 decompression 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 investigation            made            Run the engine warm at rapid idle Check to make sure that the            cooling water flows out with the exhaust gas es            NOTE The key switch should always be switched on as long            as the engine is running to ensure battery charging            Reduce to idle and check that the engine is running smoothly            Engage the control lever for 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                                                                               5RUNNING              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             position6                        RUNNING  propeller Sdrive  When switching from engineoperated running to sailing the propeller rotation is stopped byengaging reverse gear When sailing maintain the controllever in the reverse positionFixed propeller When sailing the control lever should be inthe neutral or reverse position During long sailing trps withthe lever in the neutral position the engine should be run forsome time every tenth hour in order to ensure lubrication inthe drive or reverse gearSwitch off the main switch NOTE The main switch mustnever be switched off until the engine has stopped completelythe charging regulator can be damagedClose the fuel and cooling water cocks if the boat is not goingto be used for some timeCheck for leakage before leaving the beatIn cold weather and whenever there is a risk of  zero the cooling water must be drained from the engineand the reverse gear Close the cock on the cooling waterintake Sdrive model 110S See page 19 Close all thedrainage cocks if the boat is left without regular supervisionAn incorrectly performed draining can result in a sunken boatSee positions 15 and 16 page 34                                                            7    TECHNICAL DESCRIPTIONThe MD7A is a 2 cylinder 4stroke marine diesel engine with direct injection and seawater coolingENGINE ASSEMBLYThe engine block and cylinder head are made of cast iron The engine has  SYSTEMThe lubricating system has a fullflow oil filter which cleans the oil before it reaches thelubrication points The oil pump has a relief valve which prevents the oil pressure frombecoming  SYSTEMThe engine has a starter motor and an alternator with builtin rectifier Voltage regulationis performed by a transistorized regulator mounted on the alternator The  it possible to charge two batteries independent of each other if a  is fitted to 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 328                                                  TECHNICAL  SYSTEMThe 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 equippedwith a hand priming leverThere is a builtin cold start device in the fuel injection pump On the CAV fuel injectionpump the coldstart device is operated manually and on the BOSCH fuel injection pumpthe coldstart device is operated  SYSTEMThe engine is cooled by sea water The cooling system has a sea water pump and awater distributor housing with a thermostatThe seawater pump has an impeller made of neoprene rubber which is driven via arubber flange from the camshaftThe thermostat in the water distribution housing regulates the water flow so that water isalways flowing in the exhaust manifold and out in the exhaust elbow regardless ofwhether the engine is cold or hot                                                                                         9 TECHNICAL  GEAR MD7AMSBThe reduction gear is integrally built with the reverse gear The power from the engine tothe reverse gear is transmitted via a rubber flangeFor operating Forward and Reverse the Volvo patented cone clutch is used whichensures smooth and quiet engagement Very small forces are required to operate thereverse gear10                                                 TECHNICAL  MODEL 110S MD7A110SThe power from the engine is transmitted via a rubber flange carrier to the SDriveFor operating Forward and Reverse the Volvo patented cone clutch is used whichensures smooth and quiet engagement Very small forces are required to operate thereverse gear                                                                                       11CHECKS AND SERVICE SCHEMEChecks and service should be carried out regularly in accordance with the intervals givenbelow 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                                               2712                                   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                            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                                                                    13CHECKS 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 30THE ELECTROLYTE LEVEL IN BATTERYThe level should be between 510mm 316  38 above the cell plates in thebattery If necessary top up with distilled water NOTE Exercise great care when doingthis The electrolyte is corrosive and the gas being formed is explosiveTHE 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 1814                                   CHECKS AND SERVICESERVICE EVERY 50 HOURS OF OPERATIONOIL 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 17OIL CHANGE IN REVERSE GEAR every 200 hours ofoperation 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                                                                   15CHECKS AND SERVICEOIL CHANGE IN SDRIVE every 200 hours of operation or atleast 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 30VALVE CLEARANCE                            Checking and adjusting the valve                            clearance should be done by an authorized                            Volvo penta Service Workshop See further                            under Valves  Technical Data16                                                         CHECKS AND SERVICESERVICE 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 Unscrew and discard theoil 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                                              out                                              Check oil level and that there are no leaks                                              from the contact surface of the oil filterCLEANING 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                                                                                        17CHECKS 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 1318                                                    CHECKS AND SERVICECHECK THE COOLING SYSTEMThe cooling system is functioning normally when the temperature warning lamp is outand the buzzer is silent Too high water temperature the warning lamp is on and thebuzzer 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 watercoming into the boat                                             The impeller can be damaged by lack ofCHECKING AND                                 water among other things Close theCANGING THE                                  bottom intake valve Remove the seaIMPELLER                                     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 valveCOOLING SYSTEMSDRIVE 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                                                                                    19CHECKS AND  SYSTEM                          Alternator                                           The engine is equipped with an alternator                                           To ensure that the alternator with the built                                           on regulator functions without interruptions                                           the following important points must be                                           observed                                           1   The main switch must never be                                                switched off until the engine has                                                stopped                                                Otherwise the charging regulator will be                                                ruined                                           2   The battery connection poles must                                                never be mixed up A plus sign and a                                                minus sign are marked on the respective                                                poles The minus pole is connected to                                                the cylinder block The cable terminals                                                should be greased and well tightened                                           3   Switching between the charging                                                circuits may not be carried out while                                                the engine is running Fit a Volvo                                                Penta charging distributor accessory                                                on the alternator when more than one                                                battery is connected up                                           4   Observe the following whenever the                                                engine is started with an auxiliary                                                battery                                                Let the ordinary battery remain                                                connected Connect the auxiliary                                                battery to the ordinary battery plus to                                                plus and minus to minus When the                                                engine has started remove the                                                auxiliary battery but do not break the                                                ordinary 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 connections20                                                       CHECKS AND  the FuseA fusebox is mounted on the engine The fuse breaks the electrical system whenoverloaded Reconnect the electrical system by transferring the cable connection to thenext fuse contactStarter motor and alternatorAll 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 ofthe  the state of the battery chargeThe charging of the battery should be checked at least once each season This is doneby using a hydrometer which shows the specific gravity of the electrolyte this varyingwith the state of charge See Technical DataFUEL SYSTEMObserve the greatest cleanliness when working on the fuel system NOTE Try to avoidspilling 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                                                                                     21CHECKS 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 forcleaning and checking the opening pressure leakage and spray pattern22                                                         CHECKS AND SERVICEVenting the fuel systemVenting of the fuel system must be carried out prior to the first start of the engine andafter work has been carried out on the fuel system when the fuel tank has been runempty or if the engine has been out of operation for some timeVenting is carried out as follows Regarding location See Engine Component Guide                      Open venting screw on fuel filter about 4 turns Be careful not to                      spill fuel Use rags around the vent opening 1                      Pump up the fuel by using the hand primer until fuel free from air                      bubbles flows out Close venting screw If the pump action is poor                      turn the engine so that the cam driving the pump changes position 2                      If the injection pump has been removed or when first starting a                      new engine the injection pump must be vented BOSCH Fuel                      Injection pump Operate the handprimer for approximately half a                      minute The injection pump is then automatically vented                      CAV Fuel Injection pump has two air venting screws see picture                      Vent No 1 and then No 2 Operate handprimer until fuel free from                      air bubbles flows out at screw No 1 Tighten screw No 1 Put                      throttle control lever in position full speed and turn engine using                      starter motor until fuel free from air bubbles flows out of screw No                      2 Tighten screw No2 3                      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 4                                                                                     23LAYINGUP AND  IN CONNECTION WITH LAYINGUP ANDLAUNCHING THE BOAT INHIBITING ENGINE AND  engine for short periods of time with the boat in thewaterIn order to prevent damage to the engine caused by corrosion the engine should berun warm at least once every 14 days as long as the boat is in the water If the boat isnot be used for over a month a longterm inhibiting should be carried outInhibiting for the winter layupPrior to inhibiting the engine for the winter layup an authorized Volvo Penta  should test the engine and equipment It is advisable to check thecompression in order find out the condition of the engine If the inhibiting work can bemade directly after the boat is out of the water it is advisable to run the engine warm inthe 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 231                    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 gear2                     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                     container324                         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 rotate4    Remove all oil from the engine and from the reverse gear and    SDrive respectively5    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 boat6    Prepare a rustprotection 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 Glycolmixture can also be used    Following for MD7A with reverse gear An EthyleneGlycol    mixture must be used when and if engine inclination exceeds    10 Otherwise the water which still remains can cause7   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 water8                                                                    25LAYINGUP 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 Glycolmixture 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            respectively            Close all draining cocks If a vacuum valve is installed it has to9           be disassembled and saltsediments 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 spray10            Remove the battery For proper maintenance it needs to be            charged to prevent it from being damaged11            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 located12            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            propeller1326                                 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            operation14            Check the tightening of all hose clamps Check that all drain            cocks are closed15            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 well16            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 propeller17            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 anodes18            Pump up the fuel and vent the fuel system see page 2319                                                                        27 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 properly20             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 scheme2128                                                                                                                                                 FAULT TRACING SCHEMETRACING FAULTS WHEN HAVING INTERRUPTIONS INOPERATIONThe 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 theowner can generally remedy most of the faults listed below When in doubt alwayscontact the nearest Volvo Penta workshopFollow 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                                             X                                                                                                                                      Marine growth on hull                Page 3                                             X                                                                                                                                      Damaged propeller                    Page 18                                                                               X                                                                                                                                      Blocked cooling water intake        Page 19                                                                                                      X                               cooling jackets defective                                                                                                                                      impeller or thermostat                                                                                                                                                                                     29  TECHNICAL DATATechnical  designation                                             MD7ANumber of cylinders                                            2Propeller shaft output1 kW HP at 434 rs 2600 rpm        96 13Max operating speed rs rpm                                 433 2600Cylinder diameter mm inches                                 760 299Stroke mm inches                                            820  din3 in3                                       0744 454Compression pressure kpcm 3 psi starter motor speed       2024 285340Idling Speed rs rpm                                        1113  of rotation looking at flywheel                      clockwiseMax rearwards inclination boat underway                       15Max sideways inclination boat underway                        15Engine weight incl reverse gear kg lbs                     175 385Engine weight incl SDrive model 110S kg lbs               192 423ValvesValve clearance hot engineinlet mm in                                                 030 0012exhaust mm in                                               030  device max downwards movement ofexhaust valve mm in                                         05   capacity din3 imp qts  US qtsincl filter                                                   28 25 29excl filter                                                   25 22 27Oil quality                                                    Diesel Lubricating Oil                                                                100C                                                    SAE 202below 100C                                                    SAE lOW3Oil pressure hot engineidling speed kpcm 2 psi                                  0815 1421at full speed kpcm 3 psi                                 3540 5057MSB reverse gear with reduction gearRatio with reduction gear                                     1911Oil capacity din3 imp qts  US qts                         060 0506Oil quality same as for the engine                         Diesel Lubricating Oil                                                               CDViscosity                                                               See under engine                                                               above1 Propeller shaft output to DIN Leusting B fr Dauerbetrieb2 Volvo Penta CD oil Double grade3 Volvo Penta CD oil Single grade30                                                TECHNICAL DATASDrive Model 110SRatio                                             1661Oil quantity dm 3 Imp qts  US qts            23 2024Oil quality same as for the engine              Diesel Lubricating Oil                                                  CDViscosity                                           at CF                                    60140fully open CF                                  75167Fuel  pump make                              CAV model DPAFeed pressure kpcm 2  psi                     07511Opening pressure kpcm 2  psi                   180188                                                   angle crankshaft degrees BTDC      1012Electrical systemBattery voltage volt                             12Battery capacity max Ah                          70Starter motor rating kW Hp                     0811Alternator rating A W                          35 420Battery electrolyte specgrav Charging to be carried out at gcm t3            1230 Fully charged battery gcm t3                    bolts cylinder head M10x 15 Nm kpm     20 2Cylinder head nuts M10x 10 Nm kpm           70 7Connecting rod bolts M10x 15 Nm kpm         70 7Crankshaft main bearing M10x 15 Nm kpm      8 08Flywheel nut M16x2 Nm kpm                    180 18                                                                       31WIRING 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   Switch extra lighting                    10   Plug in connector wire harness2   Warning lamp no battery charging         11   Starter motor3   Warning lamp high temperature            12   Alternator4   Warning lamp low oil pressure            13   Fuse box5   Key switch                                14   Main switch6   Buzzer                                    15   Battery7   Alarmunit                                16   Sender temperature8   NA                                       17   Sender oil pressure32                             ENGINE COMPONENT GUIDESMD7A 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                                                                      33 ENGINE COMPONENT GUIDES21 Oil drainage reverse and           MD7A  110S    reduction gear22 Oil filter23 Sender low oil pressure24 Control cable bracket25 Shift lever26 Water cooled exhaust elbow27 Sea water pump28 Fuel injection pump29 Oil drainage SDrive30 Zinc anode31 Alternator32 Closed crankcase ventilation33 Oil dipstick and oil filler hole    SDrive34 Closing cock for incoming    cooling water35 Flexible engine mounting36 Flexible rubber seal between    SDrive and engine    foundation37 Cooling water intake SDrive38 Engine foundation39 Starter motor34                                    INDEX ALPHABETICAL                 20 21      Launching                         27                                      Lubricating oil                    3Battery                   14 20      Lubricating system                 8Belt tension              14 18                                      Main Switch                     5 20Charging regulator          7 20Checks  Service                      Oil changing                   15 16Scheme                         12     Oil dipstick rev gear             13Controls                        2                   engine               13Cooling system              9 19                   SDrive              14Cylinder head nuts             18     Oil filter                         17                                      Oil level checking                 13Deinhibiting                 27Drain cocks               33 34      Preparations before starting       4Electrical system       8 20 32     Reverse gear                      10Engine body                     8     Running                            6Engine component           33 34guides                                Safety equipment                   4Engine speed                   3      SDrive Model 110S                11                                      Seawater pump                    19Fault tracing scheme           29     Spare battery                     20Finefilter            21 22 34     Starter motor                     21Fuel                            3     Starting                           5Fuel filters               21 22Fuel pump                      22     Technical data                 30 31Fuse box                       21     Thermostat housing             33 34Hand priming pump         23 33      Valve clearance                   16Hand starter                   5      Venting fuel system             23Impeller                      19      W iring diagram                   32Inhibiting                 2428Injectors                     22Instruments                    2                                                                          35IMPORTANT  the engine before opening the hatch to the engine compartment An enginewhich is in operation has rotating and moving parts which is dangerous to touchBear in mind the risk of a fire All engine fuel is potentially inflammable Let anexpert correct any faults in the fuel system and always use genuine Volvo Pentaspare partsFrost RiskThe cooling system is filled with liquid and should be drained when there is riskof frost Note that in certain cases a suction action may occur when the seawater system is being drained Close all drainage points when the boat is notunder constant supervision Any incorrectly performed drainage can cause theboat to become filled with water and sink Also bear in mind that the fresh watertank and the toilet can be damaged by frostTo Be CheckedThe steering gear and controls must function perfectly and their  be checked at regular intervals Never take any chances if you suspectthat something is wrong Take immediate action to remedy faultsAll rubber ages so check all rubber parts at regular intervals Parts which are ofspecial importance are the fuel hoses and those rubber parts which have to dowith the boats flotation ability If the hoses feel dry and hard or display anytendencies to crack they should be replaced  OnboardCheck safety materials onboard Run through your mind what can happen andlet yourself and your crew practice drills to cope with events that you know canhappen You will benefit by being prepared if anything does happen If you takegood care of your boat and its engine then the risk of anything happening is asmall one Read the instruction book  before it happens

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