Volvo Penta MD7A User manual

FOREWORD
Before you start your new Volvo Penta marine engine, you are advised to read
through this instruction book carefully. It contains information relevant to the
proper operation and maintenance of your engine.
Volvo Penta has built up an extensive service organization with service shops and
specially trained personnel at your service.
Always contact your local Volvo Penta representative for advice and when in need
of service and parts.
WARRANTY CERTIFICATE
A warranty certificate is supplied with each engine. It contains the warranty
conditions for the engine and should be studied carefully.
Also included 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 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 Publications Dept.

1
Instruments and Controls 2
General Information 3 -4
Running Instructions
5
-
6
Starting the engine
Running instructions
Shutdown procedure
5
6
6
Technical Description 8 -11
Checks and Service Scheme 12
Checks and Service
13
–
23
Check daily before starting
Check every 14 days
Service every 50 hours of operation
Service every 100 hours of operation
Venting the fuel system
Service when laying-up and launching
13
13 -14
15 -16
17 –22
23
24 –28
Fault Tracing Scheme 29
Technical Data 30 –31
Wiring Diagram 32
Engine Component Guide 33 –34
Index, alphabetical order 35
CONTENTS

2
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
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 lev er for both engine speed control and
gear-changing, 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 control
INSTRUMENTS AND CONTROLS

3
Important information on the function of your engine:
FUEL Use diesel fuel oil of quality “Autodiesel”. Lower fuel
quality can cause interruptions in operation.
LUBRICATING OIL Use only oil with 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
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. engine speed: MD7A 43.4 rev/sec (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. In
order to obtain maximum engine performance, an
engine speed as high as possible should be chosen
but not, however, greater than 43.4 rev/sec (2600
rpm).
NOTE! When the boat has been in the water for
some time, the speed and max. rev/mm 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 MD7A/110S –or any other S-drive model –it
is important not to use an anti-fouling paint which
contains copper. See further “Service in connection
with launching”.
GENERAL INFORMATION

4
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
FOG-HORN and whistle.
FLOATING ANCHOR
TORCH
PREPARATIONS BEFORE STARTING
Make sure that:
There is noFUEL LEAKAGE
There is noWATER LEAKAGE from engine and hull
There is noOIL LEAKAGE
There is noSMELL OF LP-GAS in the deep cavities in the boat or elsewhere
The OIL LEVEL is correct
There is enoughFUEL for the planned voyage
The proper NAUTICAL CHARTS are on board for the planned voyage
If there are persons on board who have never been in a boat before, inform them how the
boat functions and where the 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.
GENERAL INFORMATION

5
START THE ENGINE
Switch on themain 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 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 position to the right. The warning lamps
for battery charging and oil pressure should now go on 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 34-35) on the rocker arm cover
should first be folded up. Return the de-compression handle for
running when the engine has been cranked up in speed.
Cold weather starting
CAV fuel injection pump: Startingis facilitated if the cold-start
control is pulled out. The cold-start control must be pushed in after
the engine has started.
BOSCH fuel injection pump: 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 out and that the siren is quiet.
If any of the lamps are on and the siren is sounding, the
engine must be stopped immediately and an investigation
made.
Run the engine warm at rapid idle. Check to make sure that the
cooling water flows out with the exhaust gases.
NOTE. The key switch should always be switched on as long
as the engine is running to ensure battery charging.
Reduce to idle and check that the engine is running smoothly.
Engage the control lever for gear-changing as follows:
Push in the red disengaging button and pull the lever back to
neutral. Release the button. The control lever can now be used
both for gear-changing and engine speed.
RUNNING INSTRUCTIONS
RUNNING INSTRUCTIONS

6
RUNNING
The single lever control contains engine speed as well as gear
shifting functions.
NOTE! If the boat is equipped with a folding type of propeller,
the engine speed must be reduced to idling prior to shifting to
“FORWARD”. Shifting at higher speed might easily damage
the propeller.
F = Forward N = Neutral
R = Reverse T = Throttle
In order to achieve good running economy, the engine should
not be run at maximum engine speed for long periods of time.
Check regularly during running that the warning lamp for
battery charging is out. Should the cooling water temperature
be too high or the oil pressure too low, the buzzer will warn
you, at the same time the relevant warning lamp goes on.
If this happens, the engine must be stopped immediately
and the reason investigated.
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 out the stop control when the
engine is idling. Then turn back the key switch to the initial
position.
RUNNING INSTRUCTIONS

7
Folding propeller, S-drive. When switching from engine
operated running to sailing the propeller rotation is stopped by
engaging reverse gear. When sailing maintain the control
lever in the reverse position.
Fixed propeller. When sailing the control lever should be in
the neutral or reverse position. During long sailing trps with
the lever in the neutral position, the engine should be run for
some time every tenth hour in order to ensure lubrication in
the drive or reverse gear.
Switch off the main switch. NOTE! The main switch must
never be switched off until the engine has stopped completely
(the charging regulator can be damaged).
Close the fuel and cooling water cocks if the boat is not going
to be used for some time.
Check for leakage before leaving the beat.
In cold weather and whenever there is a risk of temperatures
below zero, the cooling water must be drained from the engine
and the reverse gear. Close the cock on the cooling water
intake, (S-drive model 110S: See page 19). Close all the
drainage cocks if the boat is left without regular supervision.
An incorrectly performed draining can result in a sunken boat.
(See positions 15 and 16, page 34).
RUNNING INSTRUCTIONS

8
The MD7A is a 2 cylinder, 4-stroke, marine diesel engine with direct injection and sea
water cooling.
ENGINE ASSEMBLY
The engine block and cylinder head are made of cast iron. The engine has overhead
valves.
LUBRICATING SYSTEM
The lubricating 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 built-in rectifier. Voltage regulation
is performed by a transistorized regulator, mounted on the alternator. The alternator
makes it possible to charge two batteries independent of each other, if a double-diode
(accessory) is fitted to the alternator.
A main fuse, which can easily be re-connected, 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 32.
TECHNICAL DESCRIPTION

9
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 feedpump is of the diaphragm type and is equipped
with a hand priming lever.
There is a built-in cold start device in the fuel injection pump. On the CAV fuel injection
pump the cold-start device is operated manually and on the BOSCH fuel injection pump
the cold-start device is operated automatically.
COOLING SYSTEM
The engine is cooled by sea water. The cooling system has a sea water pump and a
water distributor 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.
TECHNICAL DESCRIPTION

10
REVERSE GEAR (MD7A/MSB)
The reduction gear is integrally built with the reverse gear. The power from the engine to
the reverse gear is transmitted via a rubber flange.
For operating “Forward” and “Reverse” the Volvo patented cone clutch is used, which
ensures smooth and quiet engagement. Very small forces are required to operate the
reverse gear.
TECHNICAL DESCRIPTION

11
S-DRIVE MODEL 110S (MD7A/110S)
The power from the engine is transmitted via a rubber flange carrier to the S-Drive.
For operating “Forward” and “Reverse” the Volvo patented cone clutch is used, which
ensures smooth and quiet engagement. Very small forces are required to operate the
reverse gear.
TECHNICAL DESCRIPTION

12
Checks and service should be carried out regularly in accordance with the intervals given
below. Let an authorized Volvo Penta Service Work Shop look after your engine.
CHECK DAILY BEFORE STARTING that
The oil level in the engine is between the marks on the dipstick
Page
13
CHECK every 14 days that
The oil level in the reverse gearis between the marks on the dipstick
The oil level in the S-Drive is between the marks on the dipstick
The electrolyte level in the battery is correct
The belt tension is sufficient to prevent the alternator from slipping
13
14
14
14
SERVICE EVERY 50 HOURS OF OPERATION:
Change the engine lubrication oil
Change the reverse gear lubrication oil (every 200 hours)
Change the lubrication oil in the S-Drive model 110S
Valve clearance. Checking and adjusting.
15
15
16
16
SERVICE EVERY 100 HOURS OF OPERATIONS OR AT
LEAST ONCE EACH SEASON:
Change the oil filter
Clean the air filter
Checking and changing the alternator v-belt
Check-tightening the cylinder head nuts
Zinc anodes, propeller (model 110S)
Check the cooling system
Electrical system. Checking and changing fuses
Check the fuel system, filter, strainer, injector, injection pump, venting
17
17
18
18
18
19
20, 21
21-23
SERVICE WHEN LAYING-UP AND LAUNCHING THE BOAT
Inhibiting scheme
Service in connection with launching.
24
27
CHECKS AND SERVICE SCHEME

13
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 fillerhole. NOTE. Do not
top up above the MAX. mark.
Concerning 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”.
CHECKS AND SERVICE

14
OIL LEVEL IN THE S-DRIVE
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 topping-up oil, top-up through the
oil dipstick hole. NOTE! Do not top-up
above the upper mark on the dipstick.
Concerning choice of oil, see under
“Technical Data” Page 30.
THE ELECTROLYTE LEVEL IN BATTERY
The level should be between 5—10mm (3/16 –3/8”) above the cell plates in the
battery. If necessary top up with distilled water. NOTE! Exercise great care when doing
this. The electrolyte is corrosive and the gas being formed is explosive.
THE 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 (3/16”) with the thumb
midway between the pulleys.
The belt can be tensioned after loosening
the alternatormounting bolts.
A well worn or cracked belt should be
replaced. See page 18.
CHECKS AND SERVICE

15
SERVICE EVERY 50 HOURS OF OPERATION:
OIL CHANGE IN ENGINE
With a new or newly reconditioned engine,
the oil should be changed for the first time
after 20 hours of operation and after that
after every 50 hours of operation.
Run the engine warm. Suck up the oil
through the dipstick hole.
Fill with oil to the correct revel. Concerning
choice of oil, see under “Technical Data”.
NOTE! Change also the oil filter at every
second change of oil. See page 17.
OIL CHANGE IN REVERSE GEAR (every 200 hours of
operation or at least once per season)
The oil can be drained from the reverse
gear by removing the plugs under the
reverse and reduction gears respectively
(see Engine Component Guide), or by
sucking up the oil through the dipstick
hole with the help of an oil scavenging
pump.
Fill with oil through the filler hole to the
correct level. NOTE. Do not fill above the
Max. mark on the dipstick. Concerning
choice of oil, see “Technical Data”.
CHECKS AND SERVICE

16
OIL CHANGE IN S-DRIVE (every 200 hours of operation or at
least once per season)
Remove the oil dipstick. Remove the plug
underneath the propeller gear housing
and let the oil drain off. Install the plug
with its O-ring. Fill oil through the dipstick
hole. The oil level shall be within the
dipstick marks. NOTE! Do not fill oil above
the upper oil dipstick mark. Concerning
the choice of oil, see “Technical Data”,
Page 30.
VALVE CLEARANCE
Checking and adjusting the valve
clearance should be done by an authorized
Volvo penta Service Workshop. See further
under “Valves-Technical Data”.
CHECKS AND SERVICE