Volvo Penta MD 11C/110S User manual

FOREWORD
Before you start your new Volvo Penta marine engine, you are advised to read through
this instruction book carefully. It contains all the information you need to run and
service your engine in the best possible way.
Volvo Penta has built up an extensive service organization with service workshops with
specially trained personnel at your service.
Always contact your local Volvo Penta representative for advice and when in need of
service and parts.
We are convinced that the demands on good running economy and top performance,
which you have every right to expect of a quality product, will be met and that your
engine will serve you faithfully on many pleasant cruises.
Warranty Certificate
A warranty certificate is supplied with each new engine. It contains the warranty
conditions for the engine and should be studied carefully.
Included in the warranty certificate is a report card which is to be completed by the
dealer or boat seller and forwarded to Volvo Penta.
However, if our warranty is to apply, it is an absolute condition that the measures given
in the "Check and Service Scheme" are carried out and that your engine and
equipment are looked after according to the instructions in this book. When in doubt,
always get in touch with an authorized Volvo Penta dealer.
In all correspondence with your dealer and when ordering parts, always state the type
and designation and serial number of the engine and reverse gear or drive (see
starboard side of engine).
Make certain that the engine's specification coincides with what is described in this
instruction book.
AB VOLVO PENTA
Technical Information

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CONTENTS
Instruments and controls ..................................................................2
General information...............................................................................3-4
Running instructions.............................................................................5-7
Starting the engine ........................................................5
Running .........................................................................6
Shutdown procedure .....................................................6
Technical description ..............................................................8-10
Checks and service scheme .................................................................11
Checks and service .............................................................12-25
Daily checks before starting .......................................12
Checks every 14 days ...........................................12-13
Service every 50 hours of operation......................13-14
Service every 100 hours of operation....................15-21
Service when laying up and launching ..................22-25
Fault tracing scheme ..................................................................26
Technical data ........................................................27-28
Wiring diagram ..................................................................29
On board data .................................................................30
Engine component guide ..............................................................31-34
S-drive 110S ..............................................................35-37
Index, alphabetical order ..................................................................38

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INSTRUMENTS AND CONTROLS
INSTRUMENT PANEL
1. Rev counter
2. Temperature meter for cooling water
Green scale -normal emperature.
3. Switch. for extra lighting
4. Instrument panel illumination
5. Warning lamp "low oil pressure".
If lit -stop engine, oil pressure insufficient.
6 Key switch
7. Warning lamp "No battery charging"
If lit -no charging.
CONTROL SYSTEM
Volvo Penta Single Control System
For side mounting
1. Control lever
2. Disengaging button
Push in the button when the
control lever is in neutral and
move the lever a bit forwards.
Release button. The lever is now
used only for engine speed
control. To use the lever for both
engine speed control and gear
charging, push in the button and
pull back the lever to neutral.
N=Neutral position
F=Control lever in position for running
"forward".
R=Control lever in position for running "reverse”
T= Engine speed control

-3-
GENERAL INFORMATION
Important information on the function of your engine.
FUEL Use diesel fuel oil of quality "Autodiesel". Poorer fuel quality
can cause interruptions in operation.
LUBRICATING OIL Use only oil of quality CD (DS) according to the API system.
Volvo Penta oil for diesel engines can be used with advantage
since it meets these quality demands. See under "Technical
Data" concerning the viscosity if any other oil is used.
RUNNING IN A new marine engine must be run-in with due care during the
first 20 hours of operation. If full output is taken out during
this time, it should only be done for short periods.
Oil change. Change the engine oil and oil filter after the engine
has been run for 20 hours. See further under "Checks and Service".
ENGINE SPEED Max speed: MD 11 C, MD 1 7C 41.7 rev/sec (2500 rpm)
For choice of correct propeller, refer to the Volvo Penta propeller diagram. Check the
engine speed with normal load in the boat. In order to utilize the maximum performance
of the engine, an engine speed as high as possible should be chosen but not, however,
higher than 41.7 rev/sec (2500 rpm).
Note: When the boat has been in the water for some time, the speed and max rpm can
drop due to marine growth on the hull. Prevent marine growth by painting the bottom of
the boat with anti-fouling paint. See under "Measures taken when launching".

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GENERAL INFORMATION
SAFETY EQUIPMENT
Irrespective of whether the boat is being used for long cruises or short bathing trips, the
boat should be equipped with the safety equipment listed below. It can, of course, be
supplemented further according to personal tastes. Investigate at regular intervals to
ensure that there is safety equipment on board and that it is in working order.
LIFE JACKETS for all on board
FIRE EXTINGUISHER, approved, at least one and installed where it is easy to get at.
DISTRESS ROCKETS and matches. Packed watertight. FIRST AID BOX
TOOLS suitable for the equipment on board ON BOARD KIT containing, e.g. impeller,
etc. ANCHOR with line.
RADAR REFLECTOR
RADIO for listening to e.g. weather reports. COMPASS which is deviated.
BOAT HOOK and PADDLE
MOORING ROPES
FOGHORN and whistle FLOATING ANCHOR TORCH
PREPARATIONS BEFORE STARTING
Make sure that:
There is no FUEL LEAKAGE
There is no WATER LEAKAGE from the engine and hull There is no OIL LEAKAGE
There is no SMELL OF LIP GAS in the deep cavities in the boat or elsewhere The OIL
LEVEL is correct.
There is enough FUEL for the planned voyage.
The proper NAUTICAL CHARTS are on board for the planned voyage.
If there are persons on board who have never been on the boat before, inform them
how the boat functions and where the Life Jackets and Fire Extinguisher are located.
Also inform them of anything more you think necessary from a safety point of view.
Should anything unexpected happen during the voyage, it is often too late to tell those
on board how safety equipment works.

-5-
RUNNING INSTRUCTIONS
START THE ENGINE
Switch on the main switch. Start the engine room fan (if fitted) and
let it run several minutes before starting the engine.
Open the cock for cooling water intake.
Disengage the engine speed control from the gear changing as
follows: Move the control lever to neutral, push in the red
disengaging button, and move the lever slightly forwards. Release
the button. The lever can now only operate the engine speed.
Check to make sure that the stop control is pushed in.
Turn the key switch one stage to the right. The warning lamps for
battery charging and oil pressure should now go on. If there is an
alarm system fitted, the siren should sound. Push in and turn the
key further to the right to start the engine. Release the key when
the engine starts.
Handstarter (standard MID11C, extra MD17). When the engine is
started with the starting crank, the de-compression handles on the
rocker arm covers should be raised upright (see 16, pages 31-32).
Return the de-compression handles for running when the cranking
has got the engine up in speed.
Cold weather.
MD11: Starting is facilitated if the cold-start control is pushed down,
or the cold-start control (accessory) is pulled out. The cold-start
button returns automatically. The cold start control must be pushed
in after the engine
has started.
MD 17: The engine has a built-in automatic cold-start device.
Check immediately after starting that the warning lamps for the oil
pressure and battery charging are not lit. If any of the lamps are
alight, the engine must be stopped immediately and the cause
investigated. If an alarm system is fitted (accessory) the siren
should be silent.
Run the engine warm at rapid idle. Check to make sure that the
cooling water flows out with the exhaust gases. Note. The key-
switch should always be switched on as long as the engine is
running to ensure that there is battery charging.

-6-
Reduce to idle and check that the engine is running smoothly.
Engage the control lever for gear-charging as follows:
Push in the red disengaging button when the lever is in neutral.
Release the button. The control lever can now be used both for
gear changing and engine speed.
RUNNING The single lever control has both engine speed and manoeuvering
functions.
F = Forward
R = Reverse
N = Neutral
T = Engine speed control
To achieve good running economy, the engine should not be run
at max speed for a longer period.
Check during running that the temp meter, and also the lamps for
battery charging and low oil pressure are not lit. If an alarm system
is fitted and the siren sounds, -Stop the engine immediately and
investigate the cause.
SHUTDOWN PROCEDURE
Before shutdown the engine should be allowed to idle for a few
minutes with the control lever in neutral.
Stop the engine by pulling the stop control when the engine is
idling. Then turn back the key switch to the initial position.

-7-
RUNNING INSTRUCTIONS
Switch off the main switch. NOTE. This switch must never be
switched off before engine has stopped. Close the fuel and cooling
water cocks if the boat is not going to be used for some time.
Check for leakage before leaving the boat.
In cold weather and whenever there is a risk of freezing, the
cooling water must be drained from the engine and reverse gear.
(See pos. 14 and 10, pages 31-32).

-8-
TECHNICAL DESCRIPTION
MD 11 C and MD 1 7C, are 2 respectively 3 cylinder, 4 stroke marine diesel engines,
with direct injection and sea water cooling.
ENGINE ASSEMBLY
The crank case, cylinders and cylinder heads are made of cast iron. The engines
have replaceable cylinder liners and overhead valves.
LUBRICATION SYSTEM
The lubrication system has a full-flow oil filter which cleans the oil before it reaches
the lubrication points. The oil pump has a relief valve which prevents the oil pressure
from becoming excessive.
ELECTRICAL SYSTEM
The engine has a starter motor and an alternator with a built-in rectifier. Voltage
regulation is done by a transistorized regulator mounted on the alternator. The
alternator can charge two batteries, independent of other, if a charging distributor
(accessory) is fitted to the alternator. A main fuse, which can easily be reconnected,
is fixed to the engine. It protects the electrical system from damage in the event of
overloading. The wiring diagrams for the engine and instrument panel are shown on
page 29.

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TECHNICAL DESCRIPTION
FUEL SYSTEM
The fuel system has a feed pump with a fine filter, fuel filter with a fine filter insert,
injection pump and injectors. The feed pump is of the membrane type and has a hand
primer lever. There is a built-in cold start device. On the MD11C it is controlled
manually and on the MD17C it is operated automatically.
COOLING SYSTEM
The engine is cooled by sea water. The cooling system has a sea water pump and a
water distribution housing with a thermostat,
The sea water pump has an impeller made of neoprene rubber, which is driven via a
rubber flange from the camshaft.
The thermostat in the water distribution housing regulates the water flow, so that
water is always flowing in the exhaust manifold and out in the exhaust elbow,
regardless of whether the engine is cold or hot.

-10 -
TECHNICAL DESCRIPTION
REVERSE GEAR
The Volvo Penta reverse gear, type Mono Shift, has a reduction ratio of 1.9 1: 1. The
reduction gear is integrally built with the reverse gear. The power transmission from
the engine to the reverse gear is via a rubber flange.
For operating "Forward" and "Reverse" the Volvo Penta patented cone clutch 'is
used, which ensures smooth and quiet engagement. Very small forces are required to
operate the reverse gear.
Reverse Gear type Mono Shift (MSB).

-11 -
CHECKS AND SERVICE SCHEME
Checks and service should be carried out regularly in accordance with the intervals
given below. Let an authorized Volvo Penta Service Shop look after your engine.
CHECK DAILY BEFORE STARTING that
Page
The oil level in the engine is between the marks on the dipstick .............................12
CHECK EVERY 14 DAYS that
The oil level in the reserve gear is between the marks on the dipstick ....................12
The electrolyte level in the battery is correct ..........................................................13
The belt tension is sufficient to prevent the alternator from slipping ........................13
SERVICE EVERY 50 HOURS OF OPERATION
Change the oil in the engine .................................................................................13
Change the oil in the reverse gear ........................................................................14
Check and adjust the valve clearance ...................................................................14
SERVICE EVERY 100 HOURS OF OPERATION
OR AT LEAST ONCE EACH SEASON
Change the oil filter ..............................................................................................15
Clean the air filter .................................................................................................15
Check and change the pulley belt for alternator .....................................................16
Check-tighten the cylinder head bolts ....................................................................16
Check the cooling system ................................................................................16-17
Check the electrical system (fuses etc.) ...........................................................17-19
Check the fuel system, filter, strainer, injector, venting ......................................19-21
SERVICE WHEN LAYING-UP AND LAUNCHING
THE BOAT
Inhibiting scheme l. To be carried out with boat in water ........................................22
Inhibiting scheme ll. To be carried out with boat on land ........................................23
Service in connection with launching .....................................................................24
Venting of fuel system ..........................................................................................21

-12 -
CHECKS AND SERVICE
CHECK DAILY BEFORE STARTING
OIL LEVEL IN ENGINE
Each day before starting, check that the oil
level is between the marks on the dipstick.
Top up with oil if necessary, through the oil
filler hole. NOTE. Do not top up above the
max mark. MD11: Check that the dipstick is
screwed down so that no leakage can occur.
Concerning the choice of oil, see under
"Technical Data".
CHECKS EVERY 14 days
OIL LEVEL IN REVERSE GEAR
Unscrew the dipstick, wipe it clean and
insert it again without screwing it down. Pull
up the dipstick and check the oil level,
which should be between the marks. If
necessary top up with oil. Do not top up
above the Max mark.
Screw down the dipstick again. Note that
there is a sealing washer on the dipstick.
Concerning choice of oil, see under
"Technical Data".

-13 -
CHECKS AND SERVICE
ELECTROLYTE LEVEL IN BATTERY
The level should be between 5-10 mm (3/16"-3/8") above the cell plates in the
battery. If necessary top up with distilled water. NOTE. Observe great care when
doing this, as the electrolyte is corrosive, and the gas which is formed is explosive.
BELT TENSION
Correct belt tensioning is necessary for full
alternator output. The belt should be so
tensioned that it can be depressed 5 mm
(3/16") with the thumb midway between the
pulleys.
The belt can be tensioned after slackening
the alternator mounting belts.
A well worn or cracked belt should be
replaced.
SERVICE EVERY 50 HOURS OF OPERATION
OIL CHANGE IN ENGINE
NOTE: Since the printing of the book an
alteration has been made in the method of
changing oil. In the case of the MD11C it has
been indicated that the oil screen is to be
removed. If the oil screen for the MD11C
does not have a Wedged handle it must not
be removed. Remove only the oil dipstick
and push the suction tube through the hole.
This procedure has to be followed also on
earlier engines.
With a new or newly reconditioned engine,
the oil should be changed for the first time
after 20 hours of operation, and thereafter
every 50 hours of operation. Run the engine
warm. Suck up the oil with a pump through the dipstick hole.

-14 -
CHECKS AND SERVICE
On the MD11C the plug together with the oil
strainer must first be removed. NOTE.
When removing the strainer the gasket
must be checked. Re-tighten well.
Fill oil to correct level. Refer to "Technical
Data" regarding choice of oil.
NOTE. The oil filter should also be changed
at every other oil change.
OIL CHANGE IN REVERSE GEAR
The oil can be drained from the reverse
gear by removing the plug under it, or by
sucking up the oil through the dipstick hole
with the help of an oil scavenging pump.
Fill with oil through the filler hole to the
correct level. NOTE. Do not fill above the
Max mark on the dipstick. Regarding
choice of oil, refer to "Technical Data".
VALVE CLEARANCE
The valve clearance should be checked
and adjusted by an authorized workshop.
Refer to "Valves, Technical Data". When
necessary, check and adjust the
decompression device's action on the
exhaust valve.

-15 -
CHECKS AND SERVICE
SERVICE EVERY 100 HOURS OF OPERATION
OR AT LEAST ONCE EACH SEASON
OIL FILTER
The oil filter should be replaced for the first time after 20 hours of operation during the
running-in period and subsequently at every other oil change. Unscrew and discard
the oil filter.
Coat the new oil filter's rubber seal with oil.
Check the contact surface on the engine
and screw in the filter by hand until it
touches the contact surface. Turn the filter a
further half turn, not more.
NOTE. Use only genuine oil filters.
Start the engine, run at idling and check that
the oil pressure lamp goes out.
Check oil level and that there are no leaks
from the oil filters contact surface.
CLEANING OF AIR FILTER
The air filter should be removed and
cleaned after every 100 hour operation
period or once per season. Loosen the
clamps with a screwdriver and remove the
filter.
Clean the filter with diesel fuel and blow it
clean with a compressed air gun. Soak
them in thin engine oil.
Let the engine oil drain and refit the filter.

-16 -
CHECKS AND SERVICE
CHECKING AND REPLACEMENT OF PULLEY BELT
Check the belt carefully, both for wear and
cracks. Any sign of such, then the belt must
be replaced. Loosen the alternator mounting
bolts so that the belt can be removed. Dry
the pulley grooves before fitting the new belt.
Tension the belt so that the belt can only be
pressed down 5 mm (3/16") between the
pulleys. After a few hours running, recheck
belt tensioning and adjust if necessary.
RETIGHTENING CYLINDER HEAD BOLTS
Retighten each bolt with a torque wrench before
starting a new engine or an overhauled engine for
the first time, and after 20 hours of operation. The
valve clearance should always be checked after the
bolts have been retightened. Sequence for
tightening the bolts is shown in the figure opposite.
Torques:
Nos. 1, 2, 3 and 4 are torqued to 11 kpm (79 lbft)
Nos. 5 and 6 are torqued to 4.5 kpm (32 lbft)
CHECKING OF COOLING SYSTEM
The cooling system is working normally when the temp gauge is registering within the
green scale and the alarm (if fitted) is silent. Too high water temperature (red scale,
siren is sounding) can be due to the following: blocked water intake, defective
impeller or the flange in the sea water pump, faulty thermostat or temp sender. Be
observant for water ingress when working with the cooling system.

-17 -
CHECKS AND SERVICE
Checking and changing of the impeller
The impeller can be damaged by e.g. lack of
water. Remove the cover on the sea water
pump. Draw out the shaft enough so that the
impeller's locking screw can be screwed out.
Holding the shaft, draw off the impeller. If the
impeller is damaged it must be changed.
Lock the impeller on the shaft with the
locking screw.
The flange is defective if the impeller and the
shaft can be rotated. A new flange can be
fitted after the pump has been removed.
Refit the cover with its gasket.
ELECTRICAL SYSTEM
Alternator
The engine is equipped with an
alternator. To ensure that the alternator,
with the builton regulator, functions
without interruptions, the following
important points must be observed:
1. The main switch must never be
switched off until the engine has
stopped.
Otherwise would ruin the charging
regulator
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 greased and well tightened.

-18 -
CHECKS AND SERVICE
3. Re wiring 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.
4. Observe the following whenever the
engine is started with an auxiliary
battery:
Let the ordinary battery remain
connected up. Connect the auxiliary
battery to the ordinary battery, plus to
plus and minus to minus. When the
engine has started, remove the auxiliary
battery, but do not break the ordinary
battery's wiring circuit.
5. Do not use a rapid charging unit when the alternator is connected to the battery.
6. Disconnect both the battery cables before doing any work on the alternator
equipment.
7. When electrical welding work is done to the engine or installation components,
disconnect the charging regulator cables at the alternator and insulate the cable ends.
8. Check regularly the belt tension and the cable connections.
Changing the fuse
A fusebox is mounted on the cylinder. A fuse breaks the electrical system when
overloaded. Re-connect the electrical system by transferring the cable connection to
the next fuse contact.
Starter motor and alternator
All work connected with the starter motor and alternator should be done by an
authorized service shop.
Inspection and control should be carried out in connection with a general inspection of
the engine.