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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