Volvo Penta MD2010 Instruction Book
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Volvo Penta MD2010 Instruction Book

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INSTRUCTION BOOK
MD2010, MD2020, MD2030, MD2040

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Summary of Contents for Volvo Penta MD2010

  • Page 1 INSTRUCTION BOOK MD2010, MD2020, MD2030, MD2040...
  • Page 2 California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproduc- tive harm.
  • 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 boating pleasure. Your new marine engine is the result of 90 years experience in marine engine...

  • Page 4: Table Of Contents

    Warranty ..............9 Technical Data ..........50–51 General ..............50 Presentation ............ 10–12 Lubrication system ..........50 MD2010, MD2020 ..........10 Fuel specification ........... 50 MD2030, MD2040 ..........11 S drive and reverse gear ........51 Identification number ..........12 Instrumentation ..........

  • Page 5: Safety Precautions

    Read the Instruction Manual carefully before operating or servicing the engine. If any- thing 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 Your new boat Refueling Read Instruction Manuals and other information sup- When refueling there is always a danger of fire and plied with your new boat. Learn to operate the engine, explosion.
  • Page 7 Carbon monoxide poisoning bate the problem are wind conditions, load distribu- tion, sea conditions, trim, open hatches and ventil- When a boat moves forward through the water a va- ators etc. cuum is created behind it to a greater or lesser extent. In some circumstances this vacuum effect can be so Most modern boats are designed so that vacuum ef- great that the boat’s own exhaust gases are sucked...
  • Page 8 Never undertake an operation if you are not complete- Store oil and fuel soaked rags and other flammable ly sure how to do it. Contact your Volvo Penta dealer material in fireproof conditions. In certain circum- for assistance instead.
  • Page 9 Carbon monoxide poisoning Fuel system Only start the engine in a well-ventilated area. If oper- Always use protective gloves when tracing leaks. ating the engine in an enclosed space, ensure that Liquids ejected under pressure can penetrate body exhaust gases and crankcase emissions are ventilat- tissue and cause serious injury.

  • Page 10: Introduction

    Introduction This Instruction 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 In- struction Manual carefully and learn how to operate the engine, controls and other equipment safely.

  • Page 11: Warranty

    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: Presentation

    Presentation 9 10 16 15 MD2010 with reverse gear MS2L–D MD2010 with reverse gear MS2L–D 10 11 12 14 13 MD2020 with sailing boat drive 120S–D MD2020 with sailing boat drive 120S–D...

  • Page 13: Md2030, Md2040

    11 10 MD2030 with reverse gear MS2A–D MD2030 with reverse gear MS2A–D 8 12 10 11 MD2040 with reverse gear MS2L–D MD2040 with reverse gear MS2L–D 9. Fine fuel filters 17. Oil cooler, reverse gear 1. Coolant filler cap 10. Oil filler cap, engine 18.

  • Page 14: Identification Number

    Identification number Your engine and transmission has identification plates with identification numbers. This information should al- ways 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

    Instrumentation This chapter only describes the instrument panels available as standard for your engine from Volvo Penta. Note that in certain boats instruments, alarm panels, key switches etc. may be installed separately without the instru- ment panels shown here. If you want to install additional instrumentation, or your boat is equipped with instruments not described here, please contact your Volvo Penta dealer.
  • Page 16 S = The mechanical restart inhibitor is disengaged. The key springs back automatically to the 0 po- sition. 0 = The key can be inserted and removed. I = Operating position. II = Glow plug position. The glow plugs are connect- ed 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 en- gine 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 adjust- able 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 warn- ing 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 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 its transmission is designed for maximum service life and reliability. They are built to survive in a tough marine environment, but also to cause as little environmental impact as possible. Regular main- tenance according to the following schedule is necessary if the engine and transmission are to operate without problems.

  • Page 26: Maintenance

    Maintenance This chapter describes how to carry out the above maintenance. 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 27 Clean off the pulley grooves. In- stall the new belt. Adjust as above. Check belt ten- sion again after a few hours’ operation. MD2010, MD2020 MD2030, MD2040...

  • Page 28: 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 29: Cooling System

    Where there is no risk of damage from freezing the engine coolant can be fresh water with of Volvo Penta anti-corrosion fluid added. Mix according to the in- structions on the packaging.
  • Page 30 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 31 Seawater system. Draining To prevent freezing damage the seawater system must be drained in cold weather where there is a risk of frost. WARNING! Risk for water penetration. Close the sea cock if the boat is in the water. If the boat is laid up then the sea cock can be open.
  • Page 32 Seawater system. Cleaning and inhibiting To prevent the build up of deposits and salt crystals in the seawater system it must be flushed with fresh- water. When the boat is laid up it must also be inhib- ited. WARNING! There is a risk of water penetration. Cleaning and inhibiting the seawater system should be carried out with the boat on land.
  • Page 33 Vacuum valve. Cleaning Some engines have a vacuum valve installed in the seawater piping. WARNING! Risk for water penetration. Close the sea cock. Close the sea cock. Disassemble the valve. Unscrew the hexagonal cover. In the cover there is a mem- brane and a gasket.

  • Page 34: 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. Work on the fuel injection system must be carried out on a cold engine. A fuel spill onto a hot surface or an electrical component can cause a fire.
  • Page 35 Fuel pre-filter. Draining The fuel pre-filter is an accessory. Position a container under the fuel filter. Drain off water and contaminants using the cock/plug at the bottom of the glass. IMPORTANT! Wait a few hours after the engine has been turned off before draining the filter. Fuel pre-filter.

  • Page 36: Electrical System

    IMPORTANT! Make sure that you always have spare fuses on board. Electrical connections 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).
  • Page 37 Starting using auxiliary batteries See instructions for starting the engine with an auxiliary battery in the chapter: Starting the engine. Battery. Maintenance WARNING! Risk of fire and explosion. Never al- low an open flame or electric sparks near the battery or batteries. WARNING! Never mix up battery positive and negative terminals.
  • Page 38 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 ex- tremely corrosive sulfuric acid.
  • Page 39 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, propel- ler, propeller shaft, rudder stock and keel and cause damage by electrolytic corrosion.
  • Page 40 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 41: Wiring Diagrams

    Glow plug relay Starter motor Fuses, max. 15A (+) Engine coolant temperature sensor Generator Excitation resistor Connector, 16-pin. Glow plugs. MD2010: x 2. Others x 3. Oil pressure switch, engine Cable color Blue OR = Orange LBL = Light-blue = Red...
  • Page 42 Wiring Diagrams Instrument panel without ignition switch Instrument lighting Glow plug indicator lamp Cable color Tachometer with built-in hours Starter button Blue run meter (accessory) Button. Instrument panel Off/ Brown Dummy plug Connector for connecting ex- Connector for neutral position Green tra warning display (accesso- switch, if fitted (accessory)
  • Page 43 Wiring Diagrams Instrument panel with ignition switch (Alt. 1) 1. Instrument lighting 8. Glow plug indicator lamp Spring back 2. Tachometer with built-in hours 9. Switch, instrument panel ligh- run meter (accessory) ting Dummy plug Alarm test/acknowledgment 3. Connector for connecting extra switch warning display (accessory) Ignition switch...
  • Page 44 Wiring Diagrams Instrument panel with ignition switch (Alt. 2) Spring back 1. Instrument lighting 2. Voltmeter 3. Oil pressure gauge Spring back 4. Engine coolant temperature gauge 5. Connector for extra warning display (accessory) 6. Electronics module (alarm) 7. Engine coolant temperature warning lamp 8.

  • Page 45: 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. For further information see the chapter: “Electrical system”...
  • Page 46 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.

  • Page 47: Foldingpropeller

    The line cutter (10) has very sharp edges and must be handled with care. IMPORTANT! The locking screw (5) and the tab washer (7) must be replaced every fourth year. Only a Volvo Penta original locking screw (8) may be used. 1. Propeller hub 2.

  • Page 48: Laying Up And 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. Have any necessary repairs or service work carried out so that your boat is in top condition for the new season.

  • Page 49: Bringing Out Of Storage

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

  • Page 50: Painting The Drive And Underwater Hull

    Wash off using thin- ners or similar. Any pores in the surface should be filled and sanded down. Paint using Volvo Penta orig- inal primer and topcoat. Let the paint dry. A further two coats of Volvo Penta anti-fouling primer should then be applied.

  • Page 51: Fault-Tracing

    Fault-tracing Problem Probable cause Starter motor not turning (or slow) 1, 2, 3 Engine fails to start 4, 5, 6, 7, 8, 9 Engine starts but stops again 6, 7, 8, 9 Engine is difficult to start 6, 7, 8, 9 Engine does not reach correct speed at wide open throttle (WOT) 7, 8, 9, 10, 11, 12, 13, 18 Engine knocks...

  • Page 52: Technical Data

    Technical Data General Engine designation ..........MD2010B MD2020B MD2030B MD2040B 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 liter 0.68 liter 0.95 liter 1.50 liter...

  • Page 53: S Drive And Reverse Gear

    Reverse gear Type designation ............MS2L–D, MS2A–D Gear ratios: MS2L-D ............... 2.3:1 MS2A-D ............... 2.37:1; 3.0:1 Angle (output shaft): MS2L-D ............... 0° MS2A-D ............... 7° Oil capacity, approx..........0.8 liters Oil grade (in accordance with API system) ..... CD Viscosity ..............
  • Page 54 Notes ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________...
  • Page 56 AB Volvo Penta SE-405 08 Göteborg, Sweden www.volvopenta.com...

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Md2020Md2030Md2040

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