Volvo Penta MD5A Instruction Book
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Volvo Penta MD5A Instruction Book

Volvo Penta MD5A Instruction Book

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Summary of Contents for Volvo Penta MD5A

  • Page 3 FOREWORD Before you start running your new Volvo Penta marine engine, you would be 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.

  • Page 5: Table Of Contents

    CONTENTS Presentation 3 - 4 General Information 5 - 6 Running Instructions Starting the engine Running instructions Shutdown procedure 7 - 9 Technical Description Checks and Service Scheme 11 - 17 Checks and Service Check daily before starting Check every 14 days 11 - 12 Service every 50 hours of operation 12 - 13...

  • Page 6: Presentation

    Warning lamp, “No oil pressure” Switch, optional equipment Warning lamp, “No battery charging” Siren, “No oil pressure, excess temp.” Key switch Volvo Penta Single Control System CONTROL SYSTEM For side mounting Control lever Disengaging button Push in the button when the control lever is in neutral and move the lever a bit forwards.

  • Page 7: General Information

    ENGINE SPEED Max. speed: 41.7 rev/sec (2500 rev/mm). 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, greater than 41.7 rev/sec (2500 rev/mm).

  • Page 8: General Information 3

    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.

  • Page 9: Running Instructions

    RUNNING INSTRUCTIONS STARTING 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 the 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.
  • Page 10 RUNNING INSTRUCTIONS 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.

  • Page 11: Technical Description

    TECHNICAL DESCRIPTION The MD5A is a single-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. Cylinder angle 45 . The cylinder liner is replaceable. The engine has overhead valves.

  • Page 12: Fuel System

    TECHNICAL DESCRIPTION FUEL SYSTEM The fuel system contains a feed pump with pre-filter, fine filter, injection pump and injector. The feed pump, which is of the diaphragm type, has also a hand priming lever. Also fitted is a cold-start device with lever for connection of the push-pull control. COOLING S YSTEM The engine is sea-water cooled.

  • Page 13: Technical Description 7

    TECHNICAL DESCRIPTION REVERSE GEAR The Volvo Penta reverse gear, type Mono Shift (MSB) has a reduction ratio of 1.91:1. The reduction gear is integrally built with the reverse gear. Power transmission from the engine to the reverse gear is via a rubber flange.

  • Page 14: Checks And Service Scheme

    CHECKS AND SERVICE SCHEME Checks and service should be regularly carried out according to 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...

  • Page 15: Checks And Service

    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.

  • Page 16: Service Every 50 Hours Of Operation

    CHECKS AND SERVICE 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. IMPORTANT. Observe great care when doing this since the electrolyte is abrasive and the gas which is formed is explosive.

  • Page 17: Change The Oil In The Reverse Gear

    CHECKS AND SERVICE CHANGE OIL 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.

  • Page 18: Check The Pulley Belt

    CHECKS AND SERVICE Coat the new filter rubber gasket with oil. Check the area on the engine in contact with the filter and screw on the filter by hand until it just touches the engine. Then screw the filter a further half turn, but not more.

  • Page 19: Check-Tighten The Cylinder Head Bolts

    CHECKS AND SERVICE CHECK-TIGHTEN THE CYLINDER HEAD BOLTS Authorized personal should check-tighten the bolts with a torque wrench before starting a new or newly reconditioned engine for the first time and again after it has been in operation for 20 hours. Check the valve clearance after tightening up the bolts.

  • Page 20: Check The Electrical System (Fuses, Etc.)

    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 up. Observe the following in the event the engine is started with an auxiliary battery: Let the ordinary battery remain connected up.

  • Page 21: Fuel System, Filter, Strainer, Injector, Venting

    CHECKS AND SERVICE Change Fuse A fusebox is mounted on the cylinder. A fuse breaks the electrical system when the system is 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 shoold be done by an authorized service shop.
  • Page 22 CHECKS AND SERVICE Extra fuel filter If an extra fuel filter is fitted together with a water separator, check the transparent bowl to see if there is any water in the fuel. If necessary, drain the filter via the cock in the bottom of the bowl.
  • Page 23 CHECKS AND SERVICE Venting the fuel system In order for the engine to be able to start, the fuel system must be vented on the following occasions: When changing the fine filter. With leakage and work on the fuel lines. When draining through the drain hole.

  • Page 24: Service In Conjunction With Laying-Up And Launching The Boat

    Use an oil scavenging pump. Change the oil filter. Fill the engine and reverse gear to the correct level with Volvo Penta oil, which also has rustproofing properties, to the correct level. The lubricating system is thereafter ready for operation the next season.

  • Page 25: Inhibiting Scheme Ii. Inhibiting Measures Carried Out With Boat On Land

    LAYING-UP AND LAUNCHING Drain the fuel filter. Disconnect the fuel pump flexible suction hose from the fuel system and insert the free end in a can filled with 1/3rd Volvo Penta oil or preservative oil and 2/3rds diesel fuel oil. Bleed the fuel system.

  • Page 26: Service In Connection With Launching

    Service in connection with launching If Volvo Penta oil has been used, only the oil level in the engine and reverse gear needs to be checked. If another type of preservative oil has been used, both oil and filter must be replaced.
  • Page 27 . Check that all the controls, etc., are functioning properly. If necessary, contact authorized Volvo Penta service shops and let them service the engine and reverse gear according to the...

  • Page 28: Fault Tracing Scheme

    With the help of the instructions given in this handbook, the owner can generally remedy most of the reasons for the faults listed below. When in doubt always contact the nearest Volvo Penta service shop. Reason Main switch not switched on;...

  • Page 29: Technical Data

    2.1 (1.85 = 2.20) Oil quality Diesel lubricating oil Service CD (DS) Viscosity: Above +10°C (14°F) - Volvo Penta CD Double Grade oil SAE 20W/30 Below +10°C (14°F) - Volvo Penta CD Single Grade oil SAE 10W Oil pressure, hot engine...
  • Page 30 TECHNICAL DATA Reverse Gear Oil quality/Viscosity See under “Engine” Oil capacity, litre (qt.) 0.55 (0.5) Cooling System Thermostat, starts to open at °C (°F) 60°±2 (140±2) fully open at °C (°F) 90° (195) Fuel System Fuel injection pump, make & type Bosch PFR1K Feed pressure, MPa (kp/cm = lbf/in...

  • Page 31: Wiring Diagram

    WIRING DIAGRAM Cable Colour Code Marking Colour A.W.G. White Black B’ Black B” Black 0.75 C’ C” Yellow Brown H’ Blue Green/Red I’ Green/Red 0.75 Green J’ Green J” Green 0.75 Blue/Yellow 0.75 White/Red 0.75 Blue/Red 0.75 Place for instruments, opt. equipment) List of Components Rapid connector Extra switch...

  • Page 32: Engine Component Guide

    ENGINE COMPONENT GUIDE Connection for manual starting crank Fusebox Thermostat housing Decompression handle Injector Oil filler cap, engine Reverse gear water drainage Reverse gear oil drainage Engine water drainage 10. Reverse gear oil filler 11. Cooling water pump 12. Reverse gear oil dipstick 13.
  • Page 33 INDEX Alternator 7, 14, 16, 27 Lubricating oil 3, 25 Battery Main Switch 5, 6 Belt tensioning 12, 14 Oil change 12, 13 Charging regulator 7, 16 Oil dipstick, engine Controls 2, 6 Oil dipstick, reverse gear Cooling system Oil filter 14, 20, 28 Cylinder head bolts Oil level check...

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