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Volvo Penta MD2010 Operator's Manual

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OPERATOR'S MANUAL
MD2010, MD2020, MD2030, MD2040

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Summary of Contents for Volvo Penta MD2010

  • Page 1 OPERATOR’S MANUAL MD2010, MD2020, MD2030, MD2040...
  • Page 2 This operator’s manual is also available in the following languages: Diese Betriebsanleitung ist auch auf Dit instructieboek kan worden besteld Deutsch erhältlich. in het Nederlands. Ein Bestellcoupon ist am Ende der Betriebs- De bestelcoupon vindt u achter in het instruc- anleitung zu finden.
  • Page 3 Welcome aboard Congratulations on your new boat and your choice of a Volvo Penta marine engine. A choice that will give you many years of sailing pleasure. Your new marine engine is the result of over 90 years experience in marine engine...

  • Page 4: Table Of Contents

    Fuel system ............34 Warranty information ..........9 Electrical system ..........36 Introduction ............. 10–12 Wiring diagram ........... 41 MD2010, MD2020 ..........10 S drive and reverse gear ........45 MD2030, MD2040 ..........11 Laying up/Launching ........49–51 Identification numbers ........12 Inhibiting ............

  • Page 5: Safety Information

    Read the operator's manual carefully before operating or servicing the engine. If anything is unclear please contact your Volvo Penta dealer for assistance. This symbol is used in the book and on the engine to make you aware of safety information.

  • Page 6: Safety Precautions To Be Taken When Operating The Boat

    Safety precautions to be taken when operating the boat Your new boat Refueling Read Instruction Manuals and other information When refueling there is always a danger of fire and supplied with your new boat. Learn to operate the explosion. Smoking is forbidden and the engine must engine, controls and other equipment safely and be switched off.
  • Page 7 Carbon monoxide poisoning When a boat is moving forward backwash is caused Most modern boats are designed in such a way that behind the boat. Sometimes this backwash can be so problems with backwash are extremely unusual. powerful that exhaust gases can be sucked into the Should a backwash problem occur do not open cabin or seating well on the boat with the resulting risk hatches or valves in the forward part of the boat.
  • Page 8 Volvo Penta Using non-original Volvo Penta parts can result in fire recommend that all servicing with the engine running or explosion on board.
  • Page 9 Hot surfaces and fluids Fuel system There is always a risk of burns when working with a Always use protective gloves when tracing leaks. hot engine. Beware of hot surfaces. For example: the Liquids ejected under pressure can penetrate body exhaust pipe, turbocharger (TC), oil pan, charge air tissue and cause serious injury.

  • Page 10: Introduction

    Introduction This operator's manual has been compiled to help you get the most from your Volvo Penta engine. It contains all the information you need in order to operate and maintain your engine safely and correctly. Please read the operator's manual carefully and learn how to operate the engine, controls and other equipment safely.

  • Page 11: Certified Engines

    Warranty and Service book. Note that AB Volvo Penta’s liability is limited to that contained in the Warranty and Service Book. Read this book as soon as you take delivery of the engine. It contains important information about warranty cards, service and maintenance which you, the owner, must be aware of, check and carry out.

  • Page 12: Introduction

    Presentation MD2010 with reverse gear MS10L MD2010 with reverse gear MS10L MD2020 with sailing boat drive MS25S MD2020 with sailing boat drive MS25S...

  • Page 13: Md2030, Md2040

    MD2030 with reverse gear MS10A MD2030 with reverse gear MS10A MD2040 with reverse gear MS15A MD2040 with reverse gear MS15A 1. Coolant filler cap 9. Oil filler cap, engine 17. Folding propeller 10. Dipstick, engine 2. Expansion tank 18. Cooling water intake, S-drive 11.

  • Page 14: Identification Numbers

    Identification number Your engine and transmission has identification plates with identification numbers. This information should always be quoted when ordering service and replacement parts. There are probably similar plates on your boat and its equipment. Make a note of the details below, make a copy of the page and keep it so that you have a copy should the boat be stolen.

  • Page 15: Instrumentation

    If you want to install additional instrumentation, or your boat is equipped with instruments not described here, please contact your Volvo Penta dealer. Instrument panel with ignition switch 1. Tachometer and hour counter (accessory). Dis- plays engine speed.
  • Page 16 S = The mechanical restart inhibitor is disengaged. The key springs back automatically to the 0 position. 0 = The key can be inserted and removed. I = Operating position. II = Glow plug position. The glow plugs are connected and pre-heating the engine.
  • Page 17 Warning display If the acoustic alarm sounds, one of the three warning lamps (16-18) on the instrument panel starts to flash to indicate the source of the alarm. 16. Engine coolant temperature too high. 17 18 IMPORTANT! If the alarm sounds: Reduce engine speed to idle (neutral).

  • Page 18: Controls

    Controls The shift function and engine speed control are combined in one lever. If necessary the shift function can be easily disengaged so that only the engine speed (rpm) is affected by the lever. The control lever has an adjustable friction brake.

  • Page 19: Starting The Engine

    Starting the engine Make a habit of checking the engine and engine compartment visually before operating the boat. This will help you to quickly detect anything unusual that has or is about to happen. Also check that instruments and the warning display are indicating normal values when you have started the engine.
  • Page 20 3. Turn key to the ”II” position. The indicator light comes on and the glow plugs are connected to pre-heat the engine. Let the glow plugs remain activated for 10 seconds (max. 30 seconds). IMPORTANT! Always pre-heat the engine (even when it is at operating temperature).

  • Page 21: Starting The Engine Using Auxiliary Batteries

    4. Press the starter button. Release the starter button as soon as the engine starts. IMPORTANT! If the starter motor is engaged for its maximum engagement time (20-30 seconds) let it cool down for five minutes before trying to start the engine again. 5.

  • Page 22: Operation

    Cruising speed Operating the engine at wide open throttle (WOT) should be avoided since it is both uneconomical and uncomfortable. Volvo Penta recom- mends a cruising speed in the range 300 - 500 rpm lower than maxi- mum rpm at WOT. Depending on hull type, choice of propeller, load and conditions etc.

  • Page 23: Maneuvering

    Maneuvering All shifting between ahead and astern must be done at engine idle speed. Shifting at higher speeds may damage the drive or reverse gear and will also be uncomfortable for those on board. 1. Reduce engine speed to idling and, if possible, let the boat lose most of its speed.

  • Page 24: Stopping The Engine

    Stopping the engine The engine should be run for a few minutes at idle (in neutral) before turning it off. This will avoid boiling and even out the temperature. This is especially important if the engine has been operated at high engine speeds and loads.

  • Page 25: Maintenance Schedule

    Maintenance schedule Your Volvo Penta engine and associated equipment is designed to provide high operational reliability and long service life. They are constructed to withstand the marine environment while also affecting it as little as possi- ble. Preventive maintenance in accordance with the maintenance schedule will ensure that it retains these qualities and avoid unnecessary operational disturbances.
  • Page 26 Every 200 operating hours or at least once a year Fuel filter. Replace ..................page 35 Fuel pre-filter. Replace ................page 35 Idling speed. Check ..................page 26 Coolant . Replace ..................page 30 Seawater pump. Check impeller ..............page 31 Vacuum valve.

  • Page 27: Maintenance And Care

    Maintenance This chapter contains instructions regarding how the above maintenance points should be carried out together with general technical information. Read the instructions carefully before starting work. Maintenance intervals are contained in the chapter above. Maintenance schedule WARNING! Read the safety precautions for maintenance and service in the chapter: Safety Precautions, before starting work.
  • Page 28 (1 and 2) and if necessary also screw (3) on 2010, 2020. Tension the belt, adjust to the correct MD2010, MD2020 tension and tighten the screws. Check the tension. To replace the belt slacken off screws (1 and 2) and if necessary screw (3) on the 2010 and 2020.

  • Page 29: Lubrication System

    Lubrication system IMPORTANT! With a new or reconditioned engine, the oil and oil filters must be changed after 20-50 hours of operation. After that they should be changed every 100 operating hours or at least once a year. Use only the recommended grades of oil: See the chapter ”Technical Data”.

  • Page 30: Cooling System

    In event of risk of freezing Use a mixture of 50% Volvo Penta antifreeze (glycol) and 50% pure water. This mixture will protect against freezing to a temperature of approx. -40ºC (-40ºF) and should be used all year round.
  • Page 31 In there is no of risk of freezing When there is never a risk of freezing water may be used as coolant with addition of Volvo Penta anti corrosion agent. Mix according to the instructions on the packaging. Warm up the engine after filling to allow the additive to work as efficiently as possible.
  • Page 32 Coolant. Changing The corrosion-proofing additives become less effec- tive with time and the coolant must be changed. If the freshwater system is filled with antifreeze mixture it must be changed every other year. If the system is filled with anti-corrosion agent mixture it must be changed every year.
  • Page 33 Impeller. Checking/Replacing WARNING! Risk for water penetration. Close the sea cock. Close the sea cock. Remove cover (1) on the seawater pump. Remove impeller (2). If there are cracks or other defects the impeller must be re- placed. Lubricate the pump housing and the inside of the cover with a little waterproof grease for rubber.
  • Page 34 Let the engine run at fast idle for a few minutes. Stop the engine. 6. Fill the bucket with an anti-freeze mixture (50% Volvo Penta glycol and 50% fresh water). Collect the mixture from the system in a suitable contai- ner.
  • Page 35 Seawater system. Draining If it is not possible to keep the engine compartment free of frost, the seawater system must be drained to prevent freezing damage. Note that all the seawater must be drained. The type of drainage must be adapted to the way in which the engine is installed and any additional equipment that is connected, for example sea water filter (2), vacuum valve (5), exhaust riser with drain cock (6),...

  • Page 36: Fuel System

    Fuel system All work on the engine injection pump or injectors must be carried out at an authorized workshop. Use only the recommended grade of fuel: See the chapter ”Technical Data”. WARNING! Fire risk. When carrying out work on the fuel system make sure the engine is cold. A fuel spill onto a hot surface or an electrical component can cause a fire.
  • Page 37 Fuel filter. Changing Clean the filter mounting. To avoid fuel spills put a plastic bag over the filter before it is unscrewed. Unscrew the filter. Moisten the filter rubber gasket with a little oil. Screw on the new filter by hand until it is in contact with the mating surface.

  • Page 38: Electrical System

    Also check that all electrical connections are dry and free of oxidation and that there are no loose connec- tions. If necessary, spray these connections with a water-repellent spray (Volvo Penta Universal oil). Fuses The engine has a fuse holder with four 15 A fuses.
  • Page 39 Battery. Maintenance WARNING! Risk of fire and explosion. Never allow an open flame or electric sparks near the battery or batteries. WARNING! Never mix up battery positive and negative terminals. This may cause sparks and an explosion. WARNING! The battery electrolyte contains extremely corrosive sulfuric acid.
  • Page 40 Battery. Charging WARNING! Danger of explosion! The batteries give off hydrogen gas during charging which when mixed with air can form an explosive gas - oxyhydrogen A short-circuit, naked flame or spark can cause a large explosion. Ensure that the ventilation is good. WARNING! The battery electrolyte contains extremely corrosive sulfuric acid.
  • Page 41 Electrical installations Leakage current from the electrical system can be caused by incorrect installation of electrical equip- ment. Leakage current can knock out the galvanic protection of components such as the drive, propeller, propeller shaft, rudder stock and keel and cause damage by electrolytic corrosion.
  • Page 42 All equipment connected to the auxiliary battery should have separate switches. To simultaneously charge two independent battery circuits, fit a Volvo Penta charge distributor (ac- cessory) to the regular generator.

  • Page 43: Wiring Diagram

    3. Starter motor 8. Fuses, max. 15A (+) 13. Engine coolant temperature sensor 4. Generator 9. Excitation resistor 14. Connector, 16-pin. 5. Glow plugs. MD2010: 2 x. Others 3 x. 10. Oil pressure switch, engine Cable color Blue Orange LBL =...
  • Page 44 Wiring Diagrams Instrument panel without ignition switch 1. Instrument lighting 8. Glow plug indicator lamp Cable color 2. Tachometer with built-in hours 9. Starter button Blue run meter (accessory) 10. Button. Instrument panel Off/ Dummy plug Brown 3. Connector for connecting extra 11.
  • Page 45 Wiring Diagrams Instrument panel with ignition switch (Alt. 1) 1. Instrument lighting 9. Switch, instrument panel Spring loaded 2. Tachometer with built-in hours lighting run meter (accessory) 10. Alarm test/acknowledgment Dummy plug switch 3. Connector for connecting extra 11. Ignition switch warning display (accessory) 12.
  • Page 46 Wiring Diagrams Instrument panel with ignition switch (Alt. 2) Spring loaded 1. Instrument lighting Spring loaded 2. Voltmeter 3. Oil pressure gauge 4. Engine coolant temperature gauge 5. Connector for extra warning display (accessory) 6. Electronics module (alarm) 7. Engine coolant temperature warning lamp Cable color 8.

  • Page 47: S Drive And Reverse Gear

    S drive and reverse gear The S drive and in certain cases the propeller (reverse gear) is equipped with a sacrificial anode which prevents galvanic corrosion. Faulty electrical installation can also cause the break down of the galvanic protection. Damage due to electrolytic corrosion occurs rapidly and is often extensive.
  • Page 48 Corrosion protection. Check Check the sacrificial anode (1) on the drive and the three sacrificial anodes (2) on the propeller. Replace with a new anode if 50% of the material has perished or at least once per season. IMPORTANT! Use zinc sacrificial anodes for salt water and magnesium anodes for freshwa- ter.
  • Page 49 IMPORTANT! The tab washer (3) must be re- placed if necessary. Use only Volvo Penta ori- ginal locking screws (4). 4. Install one propeller blade in the propeller hub and...
  • Page 50 Propeller shaft seal. Reverse gear If the boat has a Volvo Penta shaft the shaft seal must be vented and lubricated directly after launching. Vent the bushing by pressing it together while press- ing down on the shaft until water appears. Then press in approx.

  • Page 51: Laying Up/Launching

    Laying up and launching Before taking the boat out of the water for winter/out-of-season storage have an authorized Volvo Penta work- shop inspect the engine and other equipment. Inhibition should be carried out to ensure that the engine and transmission are not damaged while out of commis- sion during the winter/off-season.

  • Page 52: Bringing Out Of Storage

    Bringing out of storage Check oil level in the engine and drive/reverse Paint the drive and hull: See next page. gear. Top up if necessary. If there is inhibiting oil Check the sacrificial anode on the drive. If there is in the system drain and fill with new oil, change oil less than 50% of the anode left it must be re- filter.

  • Page 53: Painting The Drive And Underwater Hull

    Most countries have introduced legislation controlling the use of anti-fouling agents. In some cases these agents are completely forbidden for use on leisure craft. In these cases ask your Volvo Penta dealer for advice about alternative methods. IMPORTANT! Find out what regulations apply to the use of anti-fouling agents.

  • Page 54: Fault-Tracing

    A number of symptoms and possible reasons for engine problems are described in the table below. In case of faults or mishaps which you cannot solve, always contact the Volvo Penta dealership. WARNING! Read the safety precautions for maintenance and service in the chapter: Safety Precautions, before starting work.

  • Page 55: Technical Data

    Technical Data General Engine designation ..........MD2010-D MD2020-D MD2030-D MD2040-D No. of cylinders ............2 Cylinder bore ............67 mm 67 mm 75 mm 84 mm Cylinder stroke ............64 mm 64 mm 72 mm 90 mm Overall cylinder displacement ......... 0.45 liters 0.68 liters...

  • Page 56: Fuel Specification

    Reverse gear Type designation ............MS10L, MS10A MS15L, MS15A Gear ratios ..............2.35:1, 2.72:1 2.14:1, 2.63:1 Angle (output shaft): MS10L, MS15L ........... 0 MS10A, MS15A ..........8 Oil capacity, approx..........0.35 liters 0.56 liters Oil grade ..............CD SAE 15W/40* CD SAE 15W/40* ATF (Dexron II, III)* ATF (Dexron II, III)*...
  • Page 57 Notes ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________...
  • Page 58 ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________...
  • Page 59 ✂ Yes please, I would like an operator’s manual in English at no charge. Publication number: 774 1986-9 Post or fax this coupon to: Document & Distribution Center Name Order Department ARU2, Dept. 64620 Address SE-405 08 Göteborg Sweden Fax: +46 31 545 772 Orders can also be placed via the Internet: http://www.volvopenta.com/...
  • Page 60 ✂ Sí gracias, deseo recibir gratuitamente un libro de instrucciones en español. Número de publicación: 774 1989-3 Franquear o enviar fax a: Document & Distribution Center Nombre Order Department ARU2, Dept. 64620 Dirección SE-405 08 Göteborg Suecia Fax: +46 31 545 772 El pedido puede hacerse tam- bién por internet: http://www.volvopenta.com/...
  • Page 61 ✂ Ja graag, Ik wil kosteloos een instructieboek in het Nederlands ontvangen. Publicatienummer: 7741994-3 Stuur of fax de coupon naar: Document & Distribution Center Naam Order Department ARU2, Dept. 64620 Adres SE-405 08 Göteborg Zweden Fax: +46 31 545 772 U kunt ook bestellen via internet: http://www.volvopenta.com/...
  • Page 62 ✂ Sim, obrigado(a)! Gostaria de receber gratuitamente um manual de instruções em português. Número de publicação: 774 1995-0 Envie o talão pelo correio ou um fax para: Nome Document & Distribution Center Order Department Endereço ARU2, Dept. 64620 SE-405 08 Göteborg Suécia Fax: +46 31 545 772 A encomenda também pode...

  • Page 64: Ab Volvo Penta

    AB Volvo Penta SE-405 08 Göteborg, Sweden www.volvopenta.com...

This manual is also suitable for:

Md2020Md2030Md2040

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