INSTRUCTION BOOKMD2010, MD2020, MD2030, MD2040

CaliforniaProposition 65 WarningDiesel engine exhaust and some of its constituents are known to theState of California to cause cancer, birth defects, and other reproduc-tive harm.

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Welcome aboardCongratulations 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 enginedesign, coupled with revolutionary new ideas and concern for the environment,where traditional Volvo Penta qualities such as first class performance, reliabilityand durability have been upheld. We believe that this also reflects what you requireand expect from your new marine engine.

To help you fulfill your expectations, we want you to read through this instructionmanual carefully, and take our advice about operating and maintaining the engine,before you cast off on your maiden voyage.

Best regards

AB VOLVO PENTA

CALIFORNIAProposition 65 Warning

Diesel engine exhaust and some of its constituents are known tothe State of California to cause cancer, birth defects, and other re-productive harm.

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Safety Precautions ..............................................3–7

Introduction .........................................................8–9

Running-in ................................................................ 8

Fuel and oils ............................................................ 8

Certified engines ...................................................... 8

Warranty .................................................................. 9

Presentation .................................................... 10–12

MD2010, MD2020 .................................................. 10

MD2030, MD2040 .................................................. 11

Identification number ............................................. 12

Instrumentation .............................................. 13–15

Controls ................................................................ 16

Starting the engine .......................................... 17–19

Before starting ....................................................... 17

Starting using auxiliary batteries ............................ 19

Operation ......................................................... 20–21

Checking instruments ............................................ 20

Cruising speed....................................................... 20

Maneuvering .......................................................... 21

When sailing .......................................................... 21

Stopping the engine ............................................. 22

After stopping the engine ....................................... 22

Laying up ............................................................... 22

Cold weather precautions ...................................... 22

Maintenance schedule ......................................... 23

Maintenance .................................................... 24–45

Engine, general ...................................................... 24

Lubrication system ................................................ 26

Cooling system ...................................................... 27

Fuel system ........................................................... 32

Electrical system ................................................... 34

Wiring Diagrams ..................................................... 39

S drive and reverse gear ........................................ 43

Foldingpropeller ..................................................... 45

Laying up and launching ................................ 46–48

Inhibiting ................................................................ 46

Bringing out of storage ........................................... 47

Painting the drive and underwater hull ................... 48

Fault-tracing ......................................................... 49

Technical Data ................................................. 50–51

General .................................................................. 50

Lubrication system ................................................ 50

Fuel specification ................................................... 50

S drive and reverse gear ........................................ 51

© 1997 AB VOLVO PENTAAll rights to changes or modifications reserved.

Printed on environmentally-friendly paper

Contents

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Safety PrecautionsRead this chapter carefully. It concerns your safety. This section describes how safety information is presentedin the Instruction Manual and on the engine. It also gives a general account of basic safety precautions to be tak-en when operating the boat and maintaining the engine.

Check that you have the correct Instruction Manual before you read on. If this is not the case please con-tact your Volvo Penta dealer.

If operations are performed incorrectly it could result in personal injury, or damage to property orthe engine. 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.Always read these safety precautions very carefully.

In the Instruction Manual warning texts have the following priority:

WARNING! If these instructions are not followed there is a danger of personal injury, exten-sive damage to the product or serious mechanical malfunction.

IMPORTANT! Used to draw your attention to something that can cause damage, productmalfunction or damage to property.

NOTE! Used to draw your attention to important information that will facilitate work or opera-tions.

This symbol is used in certain cases on our products and refers to important information inthe Instruction Manual. Ensure that warning and information symbols on the engine and trans-mission are always visible and legible. Replace symbols that have been damaged or paintedover.

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Safety precautions to be taken when operating the boat

Your new boatRead Instruction Manuals and other information sup-plied with your new boat. Learn to operate the engine,controls and other equipment safely and correctly.

If this is your first boat, or is a boat type with whichyou are not familiar, we recommend that you practicecontrolling the boat in peace and quiet. Learn how theboat behaves at different speeds, weather conditionsand loads before casting off for your “real” maidenvoyage.

Remember that the person driving a boat is legally re-quired to know and follow the current rules regardingtraffic and safety at sea. Make sure you know therules that apply to you and the waters you are sailingin by contacting the relevant authorities or organiza-tion.

A good piece of advice is to take a course in sea-manship. We recommend that you contact your localboating organization to find a suitable course.

AccidentsStatistics show that poor maintenance of boats andengines and a lack of safety equipment are often thecause of accidents at sea.

Ensure that your boat is maintained in accordancewith the relevant Instruction Manual and that the ne-cessary safety equipment is on-board and is service-able.

Daily checklistMake a habit of checking the engine and engine com-partment visually before operating the boat (beforethe engine is started ) and after operating the boat(after the engine has been stopped ). This will helpyou to quickly detect fuel, coolant and oil leaks andspot anything else unusual that has or is about tohappen.

ManeuveringAvoid violent and unexpected changes in course andgear engagement. There is a risk that someoneaboard will fall down or overboard.

A rotating propeller can cause serious injury. Checkthat nobody is in the water before engaging ahead orastern. Never drive near bathers or in areas wherepeople could be in the water.

Avoid trimming an outboard drive too much, as steer-ing will be severely reduced.

RefuelingWhen refueling there is always a danger of fire andexplosion. Smoking is forbidden and the engine mustbe switched off.

Never overfill the tank. Close the fuel tank filler capproperly.

Only use the fuel recommended in the InstructionManual. The wrong grade of fuel can cause operatingproblems or cause the engine to stop. On a dieselengine poor quality fuel can cause the control rod toseize and the engine to overrev with a resultant risk ofdamage to the engine and personal injury.

Safety breakerWe recommend that you install and use a safetybreaker (accessory), especially if you boat can travelat high speeds. The safety breaker stops the engineif the driver falls down and loses control over theboat.

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Carbon monoxide poisoningWhen a boat moves forward through the water a va-cuum is created behind it to a greater or lesser extent.In some circumstances this vacuum effect can be sogreat that the boat’s own exhaust gases are suckedinto its cockpit or cabin. This poses a risk of carbonmonoxide poisoning to those on-board.

This problem is greatest for high, wide beamed boatswith a vertical stern. However, it can be a problem forother types of boat in certain conditions (running withthe cover up for example). Other factors that exacer-

bate the problem are wind conditions, load distribu-tion, sea conditions, trim, open hatches and ventil-ators etc.

Most modern boats are designed so that vacuum ef-fect problems are very rare. If a vacuum forms behindthe boat do not open ventilators or hatches at thefront of the boat. Strangely enough this leads to an in-crease in the vacuum effect. Instead, try changingspeed, trim or load distribution. Try also to takedown, open or in some other way change the configu-ration of the cover. Contact your boat dealer to find asolution for your particular boat.

Remember● Safety equipment: Life jackets for everybody on board, communication equipment, distress

flares, approved fire extinguishers, life-buoys, anchors, paddles, torches etc.

● Replacement parts and tools: impeller, fuel filter, fuses, tape, hose clamps, engine oil, propellerand the tools for jobs that may be necessary.

● Get out up-to-date charts for the planned route. Calculate distance and fuel consumption. Listento weather reports.

● Tell friends or relatives about your planned route when undertaking longer journeys. Remember totell people about changes to your plans.

● Teach those on-board the location of safety equipment and how to use it. Ensure that there ismore than one person on-board who can start and drive the boat safely.

This list should be added to if the type of boat requires extra safety equipment. We recommend thatyou contact your local boating organization to find a suitable course.

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Safety precautions for maintenance and service

PreparationsKnowledge baseThe Instruction Manual contains instructions on howto carry out the commonest maintenance and serviceoperations safely and correctly. Read them carefullybefore starting work.

Service literature for more extensive work can be ob-tained from your Volvo Penta dealer.

Never undertake an operation if you are not complete-ly sure how to do it. Contact your Volvo Penta dealerfor assistance instead.

Stopping the engineStop the engine before the engine compartment coveris opened or removed. Unless otherwise specified allmaintenance and service must be carried out with theengine stopped.

Immobilize the engine by removing the ignition key,turning off the power supply with the main switch andlocking it in the OFF position. Fix a warning that workis being undertaken to the control position.

Approaching a running engine is dangerous. Looseclothing, long hair, fingers or tools can get caught inrotating parts and cause serious personal injury.Volvo Penta recommend that all servicing with theengine running be undertaken by an authorized VolvoPenta workshop.

Lifting out the engineUse the lifting eyes mounted on the engine/reversegear when lifting the drive unit. Always check that lift-ing equipment is in good condition and has sufficientload capacity to lift the engine (engine weight includ-ing reverse gear and any extra equipment installed).For safety reasons the engine should be lifted with anadjustable lifting beam. All chains and cables shouldrun parallel to each other and as perpendicular aspossible to the top of the engine. Note that extraequipment mounted on the engine can change itscenter of gravity. Special hoists may be necessary tobalance the engine and make handling it safe. Nevercarry out work on an engine suspended on a hoist.

Before starting the engineReinstall all protective components that have beenremoved before starting the engine. Check that notools or other objects have been left on the engine.

Never start a turbocharger engine without installingthe air cleaner (ACL). The rotating compressor in theturbocharger (TC) can cause serious personal injury.Foreign objects may be sucked into it causing me-chanical damage.

Fire and explosionFuel and lubricating oilAll fuels, most lubricating oils and many chemicalspose a fire hazard. Read and follow the instructionson packaging.

Work on the fuel injection system must be carried outon a cold engine. A fuel leak or spill onto a hot sur-face or an electrical component can cause a fire.

Store oil and fuel soaked rags and other flammablematerial in fireproof conditions. In certain circum-stances oil soaked rags can spontaneously combust.

Never smoke when refueling, changing the oil or closeto filling stations or in the engine compartment.

Non-original componentsThe components in the fuel injection system, ignitionsystem (petrol engines) and electrical system in VolvoPenta products are designed and manufactured tominimize the risk of fire and explosion.

Using non-original Volvo Penta parts which do notmeet the above standards, can result in fire or explo-sion on board.

BatteriesBatteries contain and produce oxyhydrogen, espe-cially when they are being charged. This gas is easilyignited and highly volatile.

Never allow a naked flame or sparks near the bat-teries or battery compartment.

Incorrect connection of a battery lead or jump leadcan cause a spark which is sufficient to cause thebattery to explode.

Start sprayNever use start spray or similar agents to start an en-gine with pre-heating (glow plugs/start element). Thestarter element may cause an explosion in the intakemanifold. Danger of personal injury.

Hot surfaces and liquidsWhen the engine is at operating temperature there isalways a danger of burns. Avoid hot surfaces. For ex-ample: exhaust manifold, turbocharger (TC), oil sump,start element, hot coolant and hot lubricating oil inpipes and hoses.

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Carbon monoxide poisoningOnly start the engine in a well-ventilated area. If oper-ating the engine in an enclosed space, ensure thatexhaust gases and crankcase emissions are ventilat-ed out of the working area.

ChemicalsMost chemicals such as glycol, rustproofing agents,inhibiting oils and degreasing agents are hazardous tohealth. Read and follow the instructions on packag-ing.

Certain chemicals such as inhibiting oils are inflam-mable and also hazardous to health if inhaled. Ensurethat ventilation in the workplace is good and use aprotective mask when spraying. Read and follow theinstructions on packaging.

Store chemicals and other hazardous material awayfrom children. Deposit excess or used chemicals at aproperly designated disposal site.

Cooling systemThere is a risk of water penetration when working onthe seawater system. Turn off the engine and closethe sea cock before starting work on the system.

Avoid opening the coolant filler cap when the engineis hot. Steam or hot coolant can spray out and causeburns.

If work must be carried out with the engine at operat-ing temperature and the coolant filler cap or a cockopen or a coolant hose disconnected, open the cool-ant filler cap carefully and slowly to release pressurebefore removing the cap completely. Note that thecoolant may still be hot and can cause burns.

Lubrication systemHot oil can cause burns. Avoid skin contact with hotoil. Ensure that the lubrication system is not underpressure before commencing work on it. Never startor operate the engine with the oil filler cap removed,otherwise oil could be ejected.

Fuel systemAlways use protective gloves when tracing leaks.Liquids ejected under pressure can penetrate bodytissue and cause serious injury. There is a danger ofblood poisoning.

Always cover the generator if it is located under thefuel filter. The generator can be damaged by spilledfuel.

Electrical systemCutting off powerAlways stop the engine and break the current usingthe main switches before working on the electricalsystem. Isolate shore current to the engine blockheater, battery charger, or accessories mounted onthe engine.

BatteriesThe batteries contain an extremely corrosive electro-lyte. Protect your skin and clothes when charging orhandling batteries. Always use protective gogglesand gloves.

If battery electrolyte comes into contact with unpro-tected skin wash off immediately using plenty of wa-ter and soap. If battery acid comes into contact withthe eyes, flush immediately with plenty of water andobtain medical assistance without delay.

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IntroductionThis Instruction Manual has been compiled to help you get the most from your Volvo Penta engine. It contains allthe 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.

Always have the Instruction Manual available. Keep it in a safe place and do not forget to give it to the newowner if you sell your boat.

Responsibility for the environmentWe all want to live in a clean environment. Where wecan breathe clean air, see healthy trees, have cleanwater in our lakes and oceans and enjoy the sunshinewithout worrying about our health. Unfortunately thisis no longer something we can take for granted, wemust work hard together for the environment.

As a manufacturer of marine engines Volvo Penta hasa particular responsibility. This is why concern for theenvironment is one of the cornerstones of our productdevelopment. Today great advances have beenmade in reducing exhaust emissions, fuel consump-tion and engine noise in Volvo Penta’s wide range ofengines.

We hope that you will take care to maintain theseproperties. Always follow the advice in the InstructionManual about fuel grades, operation and maintenanceand you will avoid unnecessary negative impact onthe environment. If you notice changes such as in-creased fuel consumption or exhaust smoke, pleasecontact your Volvo Penta dealer.

Adapt speed and distance so that swell and noisegenerated by the boat do not disturb or harm wildlife,moored boats, landing stages etc. Leave islands andharbors in the same condition you would like to findthem. Always dispose of environmentally harmfulwaste such as engine and transmission oil, coolant,old paint, degreasing agents, cleaning residue andold batteries at proper disposal areas.

Together we can work to make a valuable improve-ment to the environment.

Running-inThe engine must be run in for its first 10 operatinghours as follows: Operate the engine normally. Do notoperate it at full load except for short periods. Neverrun the engine at a constant engine speed for longperiods during the running-in period.

The engine can be expected to use more engine oilduring the running-in period than would otherwise benormal. Check the oil level more often than is normal-ly recommended.

A First Service Inspection must be carried out after20–50 running hours. For further information: See theWarranty and Service Book.

Fuel and oilsOnly use the fuel and oils recommended in the chap-ter Technical Data. Other grades of fuel and oil cancause operating problems, increased fuel consump-tion and, in the long-term, a shorter engine servicelife.

Always change oil, oil filters and fuel filters at the re-commended intervals.

Service and replacement partsVolvo Penta engines and are designed for maximumservice life and reliability. They are built to survive ina tough marine environment, but also to cause as lit-tle environmental impact as possible. Regular serviceand the use of Volvo Penta Genuine parts will main-tain these properties.

Volvo Penta have built up a world wide network ofauthorized dealers. They specialize in Volvo Pentaproducts and can help you to maintain your engine intop condition. They have the accessories, genuine re-placement parts, test equipment and special toolsnecessary to provide high-quality service and repairwork.

Always follow the maintenance intervals contained inthe Instruction Manual. Remember to state the en-gine/transmission identification number when orderingservice and replacement parts.

Certified enginesIf you own an engine certificated for Lake Con-stance and Switzerland or for any other areawhere exhaust emissions are regulated by law,the following is important:

In some countries and regions environmental legisla-tion requires that the engines in use there be certified.

Certification means that an engine type is tested andapproved by the authorities, and that the engine man-ufacturer guarantees that all engines of that typemanufactured thereafter, correspond to the certifiedengine. The manufacturer is also responsible for en-suring that all engines of that type in operation fulfill

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the statutory environmental regulations. This placesspecial requirements on maintenance, service and re-placement parts as follows:

● The maintenance and service intervals recom-mended by Volvo Penta must be observed.

● Only Volvo Penta genuine replacement parts, in-tended for the certificated engine, may be used.

● The servicing of ignition, timing and fuel injectionsystems (gasoline) or injector pumps, pump set-tings and injectors (diesel) must always be carriedout be an authorized Volvo Penta workshop.

● The engine must not be modified in any way apartfrom with accessories and service kits developedfor it by Volvo Penta.

● No modifications to the exhaust pipes and airsupply ducts for the engine room (ventilationducts) may be undertaken as this may effect ex-haust emissions.

● Seals may only be broken by authorized person-nel.

Otherwise the general instructions contained in the In-struction Manual concerning operation, service andmaintenance must be followed. Always contact yourVolvo Penta dealer if you are not sure about the oper-ation or maintenance of your engine.

IMPORTANT! Use only Volvo Penta GenuineParts. Use of non-original AB Volvo Penta spareparts will result in AB Volvo Penta being unableto assume liability for the engine meeting enginecertification requirements. Any type of damageand/or costs resulting from the use of non-ori-ginal Volvo Penta replacement parts for theproduct will not be covered under any warrantyprovided by AB Volvo Penta.

WarrantyYour new Volvo Penta marine engine is covered by a limited warranty according to the conditionsand instructions contained in the 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 informationabout warranty cards, service and maintenance which you, the owner, must be aware of, checkand carry out. Liability covered in the warranty may otherwise be refused by AB Volvo Penta.

* Contact your Volvo Penta dealer if you have not received a Warranty and Service Book.

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Presentation

MD2010 with reverse gear MS2L–D MD2010 with reverse gear MS2L–D

MD2020 with sailing boat drive 120S–D MD2020 with sailing boat drive 120S–D

6 4 5 4

1 2 3 7 8 9 10 11

17 16 15 14 13

1 2 3

6 4 5 20

19

4

18

7 8 9 10 11 12

15 16 14 13

22 21

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MD2040 with reverse gear MS2L–D MD2040 with reverse gear MS2L–D

MD2030 with reverse gear MS2A–D MD2030 with reverse gear MS2A–D

1. Coolant filler cap

2. Expansion tank

3. Relay box with fuses

4. Flexible mounting

5. Starter motor

6. AC generator

7. Dipstick, reverse gear/S-drive

8. Oil filler cap, reverse gear/S-drive

9. Fine fuel filters

10. Oil filler cap, engine

11. Dipstick, engine

12. Air cleaner (ACL)/Air intake

13. Seawater pump

14. Injection pump

15. Lubricating oil filter

16. Fuel pump

17. Oil cooler, reverse gear

18. Folding propeller

19. Cooling water intake, S-drive

20. Sea cock, S-drive

21. Oil drain plug, S-drive

22. Sacrificial anode

6 4 5 4

1 2 3

17 16 15 14 13

7 8 9 11 10 12

6 4 5 4

1 2 3 7 8 12 9 10 11

17 16 15 14 13

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Identification numberYour 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 boatand its equipment. Make a note of the details below, make a copy of the page and keep it so that you have acopy should the boat be stolen.

The appearance and location of identification plates is shown below. The figures in brackets refer to the locationof the identification numbers on the identification plate.

Engine

Product designation (1) ..........................................................................

Serial number (2) ...................................................................................

Product number (3) ................................................................................

Certification number (4) .........................................................................

Key codeThe key code is on a disc secured to the ignition keys. This code is usedwhen ordering extra keys and should not be available to unauthorizedpersons.

S-drive/Reverse gear:

Product designation (5) ..........................................................................

Serial number (6) ...................................................................................

Product number (7) ................................................................................

Gear ratio (8) .........................................................................................

Propeller designation ............................................................................

Location of identification plates:

xxx (5) (8) xxxxxx (7)

No. xxxxxxxxxx (6)

EMISSION APPROVED IN ACCORDANCE TO THEBODENSEE SCHIFFAHRTS ORDNUNG ANLAGE C.APPROVAL NO: xxxxxxxxxx (4)

XXXX (1) XXX XXX (3)

XXXXXXXXXX (2)

Engine plateEngine and transmission decal

S-drive and reverse gear

EMISSION APPROVED IN ACCORDANCE TO THEBODENSEE SCHIFFAHRTS ORDNUNG ANLAGE C.APPROVAL NO: xxxxxxxxxx (4)

XXXX (1) XXX XXX (3)

XXXXXXXXXX (2)

xxx (5) (8) xxxxxx (7)

No. xxxxxxxxxx (6)

Engine plate

Engine and transmission decal

S-drive and reverse gear

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This chapter only describes the instrument panels available as standard for your engine from Volvo Penta. Notethat 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.

Instrument panel with ignition switch1. Tachometer and hour counter (accessory). Dis-

plays engine speed. Multiply this value by 100 forrevolutions per minute. The hour counter displaysengine operating time in hours and tenths of anhour.

2. Siren for acoustic alarm.

3. Warning display. See 16–19.

4. Switch for instrument lighting.

5. Alarm test/acknowledgment switch.

To test alarm : Press the switch. All warning lightslight and the acoustic alarm sounds.

Alarm acknowledgment: Press the switch if thereis an alarm. The acoustic alarm stops but the rel-evant warning lamp continues to flash until themalfunction is corrected.

6. Temperature gauge. Displays the engine coolanttemperature.

7. Oil pressure gauge. Displays the oil pressure inthe engine.

8. Voltmeter. Displays the charge voltage from thegenerator.

9. Ignition switch. See description in the next sec-tion.

Ignition switchThe starter keys are tagged with a key code. Thiscode must be quoted when ordering extra keys.Keep the code where it is not available to un-authorized persons.

Instrumentation

6 7 3 8

1 5 2 4 9

3 9 4

1 5 2

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12 14 13

10 15 11

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.

III = Starting position. The starter motor is engaged.

IMPORTANT! Read the starting instructions inthe chapter: Starting the engine.

Instrument panel without ignition switchThe instrument panel does not have an ignitionswitch. To stop unauthorized persons starting the en-gine the wheelhouse should have a lock or a lockablemain switch should be used.

10. Tachometer and hour counter (accessory). Dis-plays engine speed. Multiply this value by 100 forrevolutions per minute. The hour counter displaysengine operating time in hours and tenths of anhour.

11. Siren for acoustic alarm.

12. Warning display. See 16–19.

13. Switch for connecting and disconnecting instru-ment panel.

14. Starter button. The starter motor is engaged whenthis button is pressed.

15. Alarm test/acknowledgment and glow plug rockerswitch.

Glow plugs active: When the rocker switch is inthe up position the glow plugs are activated.

To test alarm: Move the rocker switch down. Allwarning lights light and the acoustic alarmsounds.

Alarm acknowledgement: If there is an alarm therocker switch is moved down and the alarm isacknowledged. The acoustic alarm stops but therelevant warning lamp continues to flash until themalfunction is corrected.

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20 21 22 23

17 18

16 19

Warning displayIf the acoustic alarm sounds, one of the three warninglamps (16-18) on the instrument panel starts to flashto indicate the source of the alarm.

16. Engine coolant temperature too high.

IMPORTANT! If the alarm sounds: Reduce en-gine speed to idle (neutral). Stop the engine ifthe temperature does not drop. Investigate andcorrect the malfunction.

17. Low oil pressure.

IMPORTANT! If the alarm sounds: Stop the en-gine immediately and investigate.

18. Generator not charging.

19. Indicator lamp Comes on when the glow plugs areactivated.

Check that the warning lamps are operating beforestarting the engine according to the description of therelevant instrument panel.

Extra warning displayIf the acoustic alarm sounds, one of the four warninglamps starts to flash to indicate the source of thealarm. The extra warning display is an accessory.

20. Not used.

21. Low coolant level. Top up to correct level beforestarting.

22. Water in extra fuel pre-filter. Drain off water in fil-ter. See instructions in the chapter Maintenance.

23. Extra alarm for an optional function.

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ControlsThe shift function and engine speed control are combined in one lever. If necessary the shift function can beeasily disengaged so that only the engine speed (rpm) is affected by the lever. The control lever has an adjust-able friction brake. A neutral position switch is available as an accessory, this will only permit the engine to bestarted with the drive/reverse gear disengaged.

Control lever for tip mounting

Adjusting the friction brakeThe friction brake only affects the engine speed control move-ments.

● Lift the cover over the control. For side-mounted controls thelever must first be removed.

● Set the lever to the half-open throttle/reverse position.

● Adjust the friction brake. Turning the screw clockwise (+) makesthe lever movement stiffer, while turning counterclockwise (–)makes it easier to move the lever.

● Reinstall the cover and lever.

ManeuveringShifting and engine speed are controlled with the same lever (1).

N = Neutral position. Drive/reverse gear disengaged.

F = Drive/reverse gear engaged for movement ahead.

R = Drive/reverse gear engaged for movement astern.

T = Engine speed control

Disengaging the shift functionMove lever (1) to the neutral position (N). Press in button (2), movethe lever slightly forward and release the button. The shift functionis now disengaged and the lever affects only engine speed.

When the lever is moved back to the neutral position it will auto-matically re-engage.

IMPORTANT! Take care not to engage the drive/reverse gearby mistake.

Control lever for side mounting

2

1

TT

1

2

TT

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Starting the engineMake a habit of checking the engine and engine compartment visually before operating the boat. This will helpyou 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.

Before starting● Open the cooling water intake sea cock.

● Open fuel cock.

● Check that there are no fuel, engine coolant or oil leaks.

● Check oil and engine coolant levels in the engine. See chapter:Maintenance.

● Switch on the main switch.

IMPORTANT! Never break the circuit with the main switchwhile the engine is running. This could damage the generator.

● Start the engine compartment fan if one is fitted and let it run for atleast four minutes.

● Check that there is sufficient fuel.

● Push in the stop control.

Starting. Instrument panel with ignition switchWARNING! Never use start spray or similar to start the engine.Danger of explosion!

1. Move the control lever to the neutral/idle position.

2. Insert the key in the ignition switch. Turn key to the “I” position. Thethree warning lamps come on and can be checked.

Check that the acoustic alarm is operating by pressing the “AlarmTest” button.

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3. Turn key to the “II” position. The indicator light comes on and theglow plugs are connected to pre-heat the engine. Let the glowplugs remain activated for 10 seconds (max. 30 seconds).

IMPORTANT! Always pre-heat the engine (even when it is atoperating temperature).

4. Turn the key to position “III” to start. Release the key as soon asthe engine has started, the key will automatically spring back tothe “I” position. If the engine did not start the key must first beturned to the “0” position before trying again.

IMPORTANT! If the starter motor is engaged for its maximumengagement time (20–30 seconds) let it cool down for fiveminutes before trying to start the engine again.

5. Warm up the engine at low speed and low load.

IMPORTANT! Do not race the engine while it is cold.

Starting. Instrument panel without ignitionswitch

WARNING! Never use start spray or similar to start the en-gine. Danger of explosion!

1. Move the control lever to the neutral/idle position.

2. Activate the instrument panel by pressing the “Power ON/OFF”switch. The three warning lamps come on and can be checked.

Check that the acoustic alarm is operating by pushing the rockerswitch to the “Alarm Test” position.

3. Push the rocker switch to the “Glow” position. The indicator lightcomes on and the glow plugs are connected to pre-heat the engine.Let the glow plugs remain activated for 10 seconds (max. 30 sec-onds).

IMPORTANT! Always pre-heat the engine (even when it is atoperating temperature).

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4. Press the starter button. Release the starter button as soon as theengine starts.

IMPORTANT! If the starter motor is engaged for its maximumengagement time (20–30 seconds) let it cool down for fiveminutes before trying to start the engine again.

5. Warm up the engine at low speed and low load.

IMPORTANT! Do not race the engine while it is cold.

Starting using auxiliary batteries

WARNING! Batteries produce oxyhydrogen. This gas is easily ig-nited and highly volatile. A short-circuit, naked flame or spark cancause a large explosion. Ensure that the ventilation is good.

Never mix up battery positive and negative terminals. This maycause sparks and an explosion.

1. Check the auxiliary batteries have the same rated voltage as theengine’s system voltage.

2. First connect the red jump lead to the discharged battery’s + termi-nal (A) and then to the auxiliary battery’s + terminal (B) .

3. First connect the black jump lead to the auxiliary battery’s – termi-nal (C) and then to a site (D) where there is good contact with thecylinder block as far away from the discharged battery as possible.

4. Start the engine and run it at a fast idle for approximately ten min-utes to charge the battery.

WARNING! Approaching a running engine is dangerous. Watchout for rotating components and hot surfaces.

Do not touch the connections while trying to start the engine: Thismay cause sparks. Do not lean over the batteries.

5. Stop the engine. Remove the jump leads in exactly the oppositeorder to which you put them on.

C B

A

D

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OperationAvoid violent and unexpected changes in course and gear engagement. There is a risk that someone aboard willfall over or overboard.

WARNING! A rotating propeller can cause serious injury. Check that nobody is in the water before engagingahead or astern. Never drive near bathers or in areas where people could be in the water.

Checking instrumentsCheck the instruments and warning display directly after starting theengine and then at regular intervals while driving the boat. Stop the en-gine if there is an abnormal reading or any warning lamp comes on andthe alarm sounds. For engines with measuring instruments the follow-ing standard values apply:

Oil pressure (A)Normal operating oil pressure is between 150–500 kPa (21–71 psi). Atengine idle this is normally lower. The acoustic alarm will automaticallygo off if the oil pressure is too low.

IMPORTANT! If the alarm sounds: Stop the engine immediately.Investigate and correct the malfunction.

Engine coolant temperature (ECT) (B)Normal operating temperature is between 75–90°C. The acoustic alarmwill automatically go off if the engine coolant temperature (ECT) is toohigh.

IMPORTANT! If the alarm sounds: Reduce engine speed to idle(neutral). Stop the engine if the temperature does not drop. Inves-tigate and correct the malfunction.

Charging (C)The operating charge current is approx. 14 V. When the engine isstopped battery voltage is approx. 12 V.

Cruising speedOperating the engine at wide open throttle (WOT) should be avoidedsince 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, loadand conditions etc. the maximum engine speed at top speed canvary, but it should be within the WOT range.

Wide Open Throttle (WOT) range:

MD2010-2040 .................... 3,200–3,600 rpm

B A C

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ManeuveringAll shifting between ahead and astern must be done at engine idlespeed. Shifting at higher speeds may damage the drive or reversegear and will also be uncomfortable for those on board.

1. Reduce engine speed to idling and, if possible, let the boat losemost of its speed.

2. Move the reverse gear control lever quickly and firmly into the neu-tral position. Wait for a moment.

3. Move the gear control lever quickly and firmly into astern, then in-crease the speed.

When sailingIf the boat has a fixed propeller the control lever must be in the neu-tral position when sailing. If the boat has a folding propeller the con-trol lever must be in the astern position.

IMPORTANT! If you are sailing far, run the engine every 10hours if the boat has a fixed propeller. This is to ensure thedrive/reverse gear is lubricated and cooled. If this is not pos-sible then a propeller shaft brake must be installed.

1.

2.

3.

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

StoppingPull and hold out the stop control until the engine has stopped. Push inthe stop control. Turn the key to stop position “S”. The key will auto-matically spring back to the “0” position when it is released and canthen be removed.

After stopping the engine● Inspect the engine and engine compartment for any leaks.

● Close the fuel cock and sea cock for the cooling water intake.

IMPORTANT! Do not forget to open the cocks before the engineis started again.

● Switch off the main switch if the boat is not to be used for sometime.

IMPORTANT! Never break the circuit with the main switcheswhile the engine is running. This could damage the generator.

Laying upIf the boat is not going to be used for some time but is being left in thewater, the engine must be run to operating temperature at least onceevery 14 days. This prevents the corrosion in the engine. If the boat willnot be used for more than two months then inhibiting should be carriedout: See chapter on Laying up/Launching.

Cold weather precautionsTo prevent freezing damage, the seawater system must be drained andthe freshwater system coolant must have sufficient antifreeze protec-tion. See chapter Maintenance “Cooling systems”.

IMPORTANT! A poorly charged battery may burst as a result offreezing.

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Maintenance scheduleYour Volvo Penta engine and its transmission is designed for maximum service life and reliability. They are built tosurvive 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 withoutproblems.

WARNING! Read the chapter on Maintenance carefully before starting work. It contains instructions on how tocarry out the most common maintenance and service operations safely and correctly.

IMPORTANT! Service operations marked must be carried out by an authorized Volvo Penta Service work-shop.

First Service inspection:

A first Service Inspection must be carried out inaccordance with the instructions in the Warrantyand Service Book.

Daily before starting first time:

● Engine oil. Checking level

● Coolant. Checking level

Every 14 days:

● Fuel pre-filter. Drain water

● Drive belt. Check

● Seawater filter. Clean

● Battery. Check electrolyte level

● Reverse gear. Check oil level

● S-drive. Check oil level

Every 100 operating hours or at least once a year:

● Engine oil. Change

● Oil filter. Replace

Every 200 operating hours or at least once a year:

● Fuel filter. Replace

● Fuel pre-filter. Replace

● Idling speed. Check

● Coolant 1). Change

● Seawater pump. Check impeller

● Vacuum valve. Clean

● Reverse gear. Oil changel

● Reverse gear. Lubricate propeller shaft seal.

● S-drive. Oil change

● S-drive. Checking corrosion protection

● S-drive. Check rubber seal (hull/drive)

Every 400 operating hours or at least once everytwo years:

● Air Cleaner (ACL). Clean

● Coolant 1). Change

● Heat exchanger. Clean

Injectors. Test pressure

Valve clearance. Adjustment

Every four years:

● Folding propeller. Replace tab washer and lockingscrew.

Every 500 operating hours or at least every fifthyear:

Reverse gear. Replacing propeller shaft seal

Every seven years:

S-drive. Replacing rubber seal between drive andhull

1) If the freshwater system is filled with an anti-corrosion agent mixture it must be changed every year. If the freshwater system is filledwith an antifreeze (glycol) mixture it must be changed every other year.

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MaintenanceThis chapter describes how to carry out the above maintenance. Read the instructions carefully before startingwork. 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.

WARNING! Unless otherwise specified all maintenance and service must be carried out with the enginestopped. Stop the engine before the engine compartment cover is opened or removed. Immobilize the en-gine by removing the ignition key, turning off the power supply with the main switch and locking it in theOFF position.

Engine, general

Air Cleaner (ACL)*. CleaningRemove air cleaner (ACL). Carefully blow clean usingcompressed air. Take care that no contaminants enterthe engine.

* Applies to the 2040 and later versions of the 2020 and 2030.

Idling. AdjustmentIdling speed should be 850 ± 25 rpm. A lower idlingspeed can cause the engine to stall and a higherspeed increases the stresses on the drive/reversegear when shifting.

Adjust with the engine at operating temperature asfollows:

1* Set the control lever in the neutral position. Checkthat gap (1) is approx. 3 mm. Adjustment: Slackenoff the locknut (2) and adjust until the correct gapis obtained with screw (3). Tighten locknut.

* This point does not apply to boats with double controlpositions.

2 Start engine and allow to idle with gear selector inneutral.

WARNING! Approaching a running engine isdangerous. Watch out for rotating componentsand hot surfaces.

3 Slacken off locknut (4). Adjust engine speed withadjustment screw (5). Tighten locknut. Repeatstep 1.

1

2

4

3

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Drive belt. CheckThe belt drives both the circulation pump and thegenerator. A belt that is too loose can result in slip-page, poor cooling and poor charging. A belt that istoo tight can damage the bearings in the circulationpump and damage the generator.

Check the tension of the belt regularly. Adjust if nec-essary. Check that the belt is not cracked or dam-aged. Replace a worn belt. Keep a spare belt on-board.

Drive belt. Adjusting and replacingWARNING! Always turn the engine off beforestarting maintenance work.

IMPORTANT! Tighten screw (1) to 50–60 Nm.

AdjustingCheck and adjust as necessary after operating theengine when the belts are warm.

It should be possible to depress a correctly ten-sioned belt approx. 10 mm between the pulleys withyour thumb. To adjust slacken off screws (1 and 2)and if necessary screw (3) on the 2010 and 2020.Tension belt, adjust tension and tighten screws.Check the tension.

ReplacingTo replace the belt slacken off screws (1 and 2) and ifnecessary screw (3) on the 2010 and 2020. Press thegenerator in towards the cylinder block so that thebelt can be removed. Clean off the pulley grooves. In-stall the new belt. Adjust as above. Check belt ten-sion again after a few hours’ operation.

1

23

MD2010, MD2020

MD2030, MD2040

2

1

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Lubrication system

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

Oil level. Checking and topping upThe oil level should be within the marked area on thedipstick (1). It should be checked every day beforethe engine is started. Topping up is done through thevalve cover (2). Top up oil slowly. Wait a few minutesbefore checking the oil level again to give the oil timeto run down to the oil pan. Then check the levelagain. Use only the recommended grades of oil: Seethe chapter “Technical Data”.

IMPORTANT! Do not fill the oil above the MAXlevel.

Oil and oil filters. ChangingRun the engine to operating temperature so that theoil is easier to suck out. Stop the engine. Suck out theoil using an oil drain pump through oil drain pipe (1).

WARNING! Hot oil and hot surfaces can causeburns.

Unscrew the old filter. (To avoid oil spills put a plasticbag over the filter before it is unscrewed). Check thatthe engine mating surface is clean. Moisten the filterrubber gasket with a little oil. Screw on the new filterby hand until it is in contact with the mating surface.And then a further half turn but no more!

Top up oil to correct level. Start the engine and let itidle. Check that the warning lamp for low oil pressuregoes out. Stop the engine. Check the oil level and topup if necessary. Check that there are no leaks roundthe oil filter.

NOTE! Collect up the old oil and filter for deposit at aproper disposal site.

2

1

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Coolant. GeneralThe freshwater system must be filled with a coolantthat protects the engine against internal corrosion andfrom freezing (if the climate requires it). Never usefreshwater alone.

WARNING! Anti-corrosive agents and antifreezeproducts are harmful to health (do not drink!)

When there is a risk for freezing the engine coolantsystem must be filled with a mixture of 50% VolvoPenta antifreeze and 50% clean water. This mixtureprevents corrosion and protects against freezingdown to approx. –40°C. It should be used all yearround. NOTE! There should be at least 40% anti-freeze in the system for complete protectionagainst corrosion.

Where there is no risk of damage from freezing theengine coolant can be fresh water with of Volvo Pentaanti-corrosion fluid added. Mix according to the in-structions on the packaging.

IMPORTANT! Never mix the anti-corrosiveagent with antifreeze as this could result in foamgeneration and greatly reduced cooling proper-ties.

Cooling system

The cooling system is divided into a freshwater and a seawater system. The seawater pump sucks water intothe seawater system through the drive/reverse gear. Seawater is then pumped through the heat exchanger andinto the exhaust elbow pipe where it is mixed with the exhaust gases. The freshwater system is the internal en-gine coolant system. It is a closed system driven by the circulation pump. The freshwater system engine cool-ant is cooled in the heat exchanger by the seawater.

WARNING! Risk for water penetration when working with the cooling system. Close the sea cock.

Coolant. FillingWARNING! Do not open the engine coolant sys-tem filler cap when the engine is still hot exceptin an emergency. Steam or hot coolant mayspray out.

Turn the filler cap to the first stop and let any pres-sure escape from the system before removing thecap. Top up coolant if necessary. The level should bejust under the neck of the filler pipe or between theMIN and MAX marks on the separate plastic expan-sion tank (accessory) if installed. Reinstall the fillercap.

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Coolant. ChangingThe corrosion-proofing additives become less effec-tive with time and the coolant must be changed. If thefreshwater system is filled with antifreeze mixture itmust be changed every other year. If the system isfilled with anti-corrosion agent mixture it must bechanged every year.

Drain the coolant and clean the heat exchanger as fol-lows. Close the drain cock and fill with fresh coolant.

Heat exchanger. CleaningCooling performance is reduced by scaling in the heatexchanger. It should therefore be flushed when thecoolant is changed.

1. Drain the coolant as above.

2. Insert a hose into the filler pipe on the heat ex-changer. Flush the fresh water until the waterwhich runs out of the drain cocks is clean. Allowall the water to run out.

3. Close the drain cock. Fill with new coolant to cor-rect level. Reinstall the filler cap.

Coolant. DrainingPosition a container under the drain cock on the star-board side of the cylinder block. Remove the fillercap on the heat exchanger (this lets the coolant runout faster). Open the drain cock and drain coolant.Clean the heat exchanger as follows before fillingcoolant.

NOTE! Deposit old coolant at a properly designateddisposal site.

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Seawater system. DrainingTo prevent freezing damage the seawater systemmust be drained in cold weather where there is a riskof frost.

WARNING! Risk for water penetration. Close thesea cock if the boat is in the water. If the boat islaid up then the sea cock can be open.

1. Drain seawater filter (accessory). Remove thecover and sealing plate on the sea water filter.Disconnect hoses and drain them.

2. Remove the cover from the seawater pump andlet the water run out.

3. Engine with drive: Disconnect seawater pumphose by the drive and bend down so that thewater runs out.

4. Engine with reverse gear Disconnect seawaterpump hose (A) by the drive and bend down sothat the water runs out. Disconnect hose (B) by thesea cock and empty it of water.

5. Connect and tighten all hoses. Reinstall the coveron the seawater pump* and the cover and seal onthe seawater filter.

* When laying up the boat, remove the impeller from theseawater pump and store it in a cool place in a plasticbag. Reinstall the impeller when bringing the boat out ofstorage.

Impeller. Checking/Replacing

WARNING! Risk for water penetration. Close thesea cock.

Close the sea cock. Remove cover (1) on the seawa-ter pump. Remove impeller (2). If there are cracks orother defects the impeller must be replaced. Lubri-cate the pump housing and the inside of the coverwith a little waterproof grease for rubber . Reinstallthe impeller using a clockwise rotating movement. In-stall the cover together with a new gasket. Open thesea cock.

IMPORTANT! Always carry a spare impeller onboard.

1. 2.

3.

2

1

4.

AB

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Seawater system. Cleaning and inhibitingTo prevent the build up of deposits and salt crystalsin 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 systemshould be carried out with the boat on land.

1. Open the sea cock.

2. Secure a container by the exhaust outlet.

3. Disconnect seawater hose (from the sea cock) onthe reverse gear or on the seawater pump if theengine has an S-drive.

4. Connect a hose* which is long enough to reach thecontainer so that the freshwater can be circulated.

* Internal diameter = 19 mm.

5. Fill the container with freshwater. Check that thereis nothing that will get splashed behind the ex-haust outlet.

IMPORTANT! The impeller will be damagedif it runs dry.

6. Set the gear control lever in the neutral position.Check that nobody is near the propellers. Start en-gine. Let it run at fast idle a few minutes. Stop theengine.

WARNING! Approaching a running engine isdangerous. Watch out for rotating compo-nents and hot surfaces.

7. To inhibit the seawater system repeat points 5and 6 but replace the freshwater with antifreeze.

8. Reconnect the seawater hose

9. The system is now inhibited. The antifreeze mix-ture should be left in the system while the boat islaid up. Drain the mixture just before the boat islaunched. Reuse the antifreeze mixture next sea-son or deposit it at a properly designated disposalsite.

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Vacuum valve. CleaningSome engines have a vacuum valve installed in theseawater piping.

WARNING! Risk for water penetration. Close thesea cock.

Close the sea cock. Disassemble the valve. Unscrewthe hexagonal cover. In the cover there is a mem-brane and a gasket. Clean all the parts. Turn thecover upside down. Install the membrane first andthen the gasket. Turn the valve housing upside downas well. Screw the cover into position, but not toohard (0.2 kpm), or the valve may stop working.

Seawater filter. CleaningThe seawater filter is an accessory. Screw off cover(1) and remove seal plate (2). Lift out and clean the in-sert (3).

IMPORTANT! If the boat is used in water thathas a lot of contaminants, seaweed etc. the filtermust be checked more frequently than indicatedin the maintenance schedule. Otherwise there isa risk the filter will clog and the engine will over-heat.

2

3

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Fuel system

All work on the engine injection pump or injectors must be carried out at an authorized workshop. Use only therecommended 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 spillonto a hot surface or an electrical component can cause a fire. Store fuel soaked rags and other flammablematerial in fireproof conditions.

Venting the fuel systemThe fuel system must be vented after the fuel filtershave been replaced or after refilling the fuel tank after ithas been run dry.

1. Open vent screw (1) on the filter mounting approx.three turns. Avoid fuel spillage. Use rags aroundthe venting point.

2. Pump the fuel using hand pump (2) until there areno more air bubbles visible in the fuel. Continuepumping and at the same time tighten the ventingscrew. If the pump effect is poor, turn the engineover slightly so that the pump drive cam changesposition.

3. Slacken off the injector delivery line nuts and setthe engine speed control to wide open throttle(WOT). Turn the engine over at WOT with the start-er motor until fuel comes out of the delivery lines.Avoid fuel spillage. Tighten delivery line nuts.

4. Start the engine and check for leaks.

WARNING! Approaching a running engine isdangerous. Watch out for rotating componentsand hot surfaces.

Fuel filter ReplacingClean the filter mounting. To avoid fuel spills put aplastic bag over the filter before it is unscrewed.Unscrew the filter. Moisten the rubber filter gasket witha little oil. Screw on the new filter by hand until it is incontact with the mating surface. And then a furtherhalf turn but no more! Vent fuel system. Deposit theold filter at a properly designated disposal site.

Start the engine and check for leaks.

WARNING! Approaching a running engine isdangerous. Watch out for rotating componentsand hot surfaces.

3

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Fuel pre-filter. DrainingThe fuel pre-filter is an accessory.

Position a container under the fuel filter. Drain off waterand contaminants using the cock/plug at the bottom ofthe glass.

IMPORTANT! Wait a few hours after the enginehas been turned off before draining the filter.

Fuel pre-filter. Replacing filter insertClose fuel cock at the fuel tank. Position a containerunder the fuel filter.

Remove the glass by slackening off screw (1). Emptyand clean glass. Replace insert and reinstall glass.Open fuel cock. Vent fuel system. Deposit the oldfilter insert at a properly designated disposal site.

Start the engine and check for leaks.

WARNING! Approaching a running engine isdangerous. Watch out for rotating componentsand hot surfaces.

1

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Electrical system

WARNING! Always stop the engine and break the current using the main switches before working on theelectrical system. Isolate shore current to the engine block heater, battery charger, or accessories mountedon the engine.

Main switchThe main switch must never be turned off before theengine has stopped. If the circuit between thegenerator and the battery is cut off when the engine isrunning the generator can be seriously damaged. Forthe same reason charging circuits must never beswitched over while the engine is running.

FusesThe engine has a fuse holder with four 15 A fuses.This is located on the relay box to the left at the rearof the engine. One fuse protects the system and cutspower in the event of an overload, the others arespares.

If a fuse blows the system can be reconnected bymoving the cable to the next fuse. Always investigatethe cause of an overload before resetting the fuse!

IMPORTANT! Make sure that you always havespare fuses on board.

Electrical connectionsAlso check that all electrical connections are dry andfree of oxidation and that there are no loose connec-tions. If necessary, spray these connections with awater-repellent spray (Volvo Penta Universal oil).

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Starting using auxiliary batteriesSee instructions for starting the engine with anauxiliary 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 thebattery or batteries.

WARNING! Never mix up battery positive andnegative terminals. This may cause sparks andan explosion.

WARNING! The battery electrolyte contains ex-tremely corrosive sulfuric acid. Protect your skinand clothes when charging or handling batteries.Always use protective goggles and gloves. Ifbattery electrolyte comes into contact with un-protected skin wash off immediately usingplenty of water and soap. If battery acid comesinto contact with the eyes, flush immediatelywith plenty of water and obtain medical assist-ance without delay.

Connecting and disconnectingFirst connect the red battery lead + to the battery +terminal. Then connect the black battery lead – to thebattery – terminal.

When disconnecting the battery, disconnect the -lead(black) first and then the + lead (red).

CleaningKeep batteries dry and clean. Oxidation or dirt on thebattery and battery terminals can cause short-circuits, voltage drop and discharge especially indamp weather. Clean the battery terminals and leadsto remove oxidation using a brass brush. Tighten thecable terminals well and grease them with terminalgrease or petroleum jelly.

Topping upThe electrolyte should be 5–10 mm over the plates inthe battery. Top up using distilled water if neces-sary. Charge the battery after topping up for at least30 minutes by running the engine at fast idle. NOTE!Certain maintenance-free batteries have specialinstructions which must be followed.

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Battery. Charging

WARNING! Danger of explosion! The batteriesgive off hydrogen gas during charging whichwhen mixed with air can form an explosive gas– oxyhydrogen. A short-circuit, naked flame orspark can cause a large explosion. Ensure thatthe ventilation is good.

WARNING! The battery electrolyte contains ex-tremely corrosive sulfuric acid. Protect your skinand clothes when charging or handling batteries.Always use protective goggles and gloves. Ifbattery electrolyte comes into contact with un-protected skin wash off immediately usingplenty of water and soap. If battery acid comesinto contact with the eyes, flush immediatelywith plenty of water and obtain medical assist-ance without delay.

If the battery has discharged it must be charged. Ifthe boat has not been used for some time charge thebattery and then trickle charge it (see manufacturer’srecommendations). A poorly charged battery will bedamaged and may burst in cold weather.

IMPORTANT! Follow the instructions suppliedwith the battery charger carefully. To avoid elec-trolytic corrosion when an external charger isconnected, always disconnect the battery leadsbefore connecting the charger.

When charging, unscrew filler plugs but leave them intheir holes. Ventilation should be good, particularly ifthe batteries are being charged in an enclosed area.

WARNING! Always switch off the charging cir-cuit before removing the battery charger con-nectors. Never mix up battery positive and ne-gative terminals. This may cause sparks and anexplosion.

Special instructions apply when boost charging thebatteries. Avoid boost charging the batteries as it willshorten their service life.

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Electrical installationsLeakage current from the electrical system can becaused by incorrect installation of electrical equip-ment. Leakage current can knock out the galvanicprotection of components such as the drive, propel-ler, propeller shaft, rudder stock and keel and causedamage by electrolytic corrosion.

IMPORTANT! Work on the boat’s low tensioncircuit should only be carried out by qualified orexperienced persons. Installation or work on theshore power equipment must only be carriedout by electricians authorized to work with high-voltage installations.

The following should always be observed:

1. If shore power is connected, the protector groundshould be ashore, never in the boat. Shore powershould always have a ground fault circuit breaker.

Shore power units (transformer, rectifier, batterychargers etc.) must be intended for marine usageand the high tension circuit must be galvanical-ly separated from the low tension circuit.

2. Route and clamp electric cables so that they willnot be exposed to rubbing, damp or bilge water inthe keelson.

3. The drive/reverse gear and flywheel cover areelectrically insulated (A) from the engine and mustnever be used as a ground.

IMPORTANT! The drive/reverse gear andflywheel cover must never be used as aground or be electrically connected to otherequipment such as the radio, navigationalequipment, the rudder, bathing steps etc.

Protective grounds for the radio, navigationalequipment, rudder, bathing steps or otherequipment with separate ground leads must beconnected to a common ground terminal (B).

4. There must be a main switch (C) connected to thestarter battery positive (+) terminal. The mainswitch should cut off power to all power consum-ing equipment and should be switched off whenthe boat is not in use.

A

B

C

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D

5. If an auxiliary battery is in use, a main switch (D)should be connected between its + terminal andthe fuse block. The main switch for the auxiliarybattery must cut off all power consuming equip-ment connected to that battery and be turned offwhen power is no longer needed.

All equipment connected to the auxiliary batteryshould have separate switches.

To simultaneously charge two independent batterycircuits, fit a Volvo Penta charge distributor (ac-cessory) to the regular generator.

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Wiring DiagramsEngine 2010, 2020, 2030, 2040

Cable color

BL = Blue OR = OrangeLBL = Light-blue R = RedBN = Brown SB = BlackLBN = Light-brown W = WhiteGN = Green Y = YellowGR = Gray

1. Battery

2. Main switch

3. Starter motor

4. Generator

5. Glow plugs. MD2010: x 2. Others x 3.

6. Starter relay

7. Glow plug relay

8. Fuses, max. 15A (+)

9. Excitation resistor

10. Oil pressure switch, engine

11. Oil pressure sensor

12. Coolant temperature switch

13. Engine coolant temperature sensor

14. Connector, 16-pin.

Cable areas in mm 2 are indicated after the color codes inthe wiring diagrams.

Areas not indicated = 1.0 mm 2.

A broken line indicates a non-Volvo Penta cable.

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Wiring DiagramsInstrument panel without ignition switch

1. Instrument lighting2. Tachometer with built-in hours

run meter (accessory)Dummy plug

3. Connector for connecting ex-tra warning display (accesso-ry)

4. Electronics module (alarm)5. Engine coolant temperature

warning lamp6. Oil pressure warning lamp7. Charge warning lamp

8. Glow plug indicator lamp9. Starter button

10. Button. Instrument panel Off/On

11. Connector for neutral positionswitch, if fitted (accessory)

12. Semiconductor diode13. Alarm14. Rocker switch. Glow plug –

Alarm test/acknowledge15. 16-pin connector

Cable color

BL = BlueBN = BrownGN = GreenGR = GrayOR = OrangePU = PurpleR = RedSB = BlackW = WhiteY = Yellow

Cable areas in mm 2 are indicated after the colorcodes in the wiring diagrams.

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Wiring DiagramsInstrument panel with ignition switch (Alt. 1)

1. Instrument lighting2. Tachometer with built-in hours

run meter (accessory)Dummy plug

3. Connector for connecting extrawarning display (accessory)

4. Electronics module (alarm)5. Engine coolant temperature

warning lamp6. Oil pressure warning lamp7. Charge warning lamp

8. Glow plug indicator lamp9. Switch, instrument panel ligh-

ting10. Alarm test/acknowledgment

switch11. Ignition switch12. Alarm13. Connector for neutral position

switch, if fitted (accessory)14. 16-pin connector

Spring back

Spring back

Cable color

BL = BlueBN = BrownGN = GreenGR = GrayOR = OrangeR = RedSB = BlackVO = VioletW = WhiteY = Yellow

Cable areas in mm 2 are indicated after the color codes in thewiring diagrams.

Areas not indicated = 1.0 mm 2.

Conversions mm 2/AWG** American Wiring Gauge

mm2 1.0 1.5 2.5 10 16AWG 16 (17) 15 (16) 13 7 5

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Wiring DiagramsInstrument panel with ignition switch (Alt. 2)

Cable areas in mm 2 are indicated after the color codes inthe wiring diagrams.

Areas not indicated = 1.0 mm 2.

Cable colorBL = BlueLBL = Light-blueBN = BrownLBN = Light-brownGN = GreenGR = Gray

OR = OrangeR = RedSB = BlackVO = VioletW = WhiteY = Yellow

1. Instrument lighting2. Voltmeter3. Oil pressure gauge4. Engine coolant temperature gauge5. Connector for extra

warning display (accessory)6. Electronics module (alarm)7. Engine coolant temperature warning lamp8. Oil pressure warning lamp9. Charge warning lamp

10. Glow plug indicator lamp11. Switch, instrument panel lighting12. Alarm test/acknowledgment switch13. Tachometer with built-in hours run meter

(accessory). Dummy plug14. Ignition switch15. Alarm16. Connector for connecting

neutral position switch, if fitted (accessory)17. 16-pin connector18. 2-pin connector (for additional control panel)

Spring back

Spring back

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S-drive and reverse gear

The S drive and in certain cases the propeller (reverse gear) is equipped with a sacrificial anode which preventsgalvanic 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 thechapter: “Electrical system”

IMPORTANT! Improperly applied paint or the wrong type of paint on the keel can put the corrosion protec-tion system out of action. For further information on painting see the chapter: Laying up/Launching

Oil level. Checking and topping upUnscrew (counter clockwise) and remove thedipstick. Wipe off oil. Reinsert the dipstick in thedrive/reverse gear without screwing it in . Removeagain and check that the oil level is between theMAX and MIN markings on the dipstick. Top up oilif necessary. For oil quality and capacity: See thechapter “Technical Data”.

IMPORTANT! The oil level should always bewithin the MAX and MIN range marked on thedipstick.

Oil change. Reverse gearRemove the oil dipstick. Suck up oil using an oilpump through the hole for the dipstick. Top up oil tocorrect level. For oil quality and capacity: See thechapter “Technical Data”.

Oil change. S-driveRemove the oil dipstick. Remove the plug on thepropeller gear housing and let the oil run out. Checkthat the plug o-ring is intact. Replace if necessary.Install the plug and o-ring. Top up oil to correct level.For oil quality and capacity: See the chapter“Technical Data”.

IMPORTANT! If oil is colored gray then waterhas entered the drive. Contact authorizedservice personnel.

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Rubber seal. S-driveCheck the rubber seal between the drive and the hullregularly for cracks and wear.

WARNING! The seal must be changed everyseven years or earlier if it is defective. This workshould be carried out by an authorizedworkshop.

Corrosion protection. Checking/ReplacingCheck the sacrificial anodes, if 50% of the materialhas been corroded replace the anode (also appliesto anodes on the propeller and reverse gear).Remove a folding propeller according to theinstructions on the next page. Remove anode byremoving the two screws. Scrape mating surface onthe drive really clean. Install and tighten the newanode so that there is a good metal contact. Cleanthe new anode to remove oxidation just before theboat is launched.

MPORTANT! Use emery paper. Do not use awire brush or other steel tools when cleaning, asthese may damage the galvanic protection.

IMPORTANT! Use zinc sacrificial anodes forsalt water and magnesium anodes forfreshwater.

Propeller shaft seal. Reverse gearIf the boat has a Volvo Penta shaft the shaft sealmust be vented and lubricated directly afterlaunching.

Vent the bushing by pressing it together while press-ing down on the shaft until water appears. Then pressin approx. 1 cc water repellent grease into the seal.

IMPORTANT! The seal must be replaced every500 running hours or every 5th year.

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1. Propeller hub

2. Shaft studs

3. Propeller blade

4. Cogs

5. Locking screws

6. Nut

7. Tab wascher

8. Locking screws

9. Protective anode

Folding propeller. Removing and installing

WARNING! Iimmobilize the engine before starting work. Remove the ignition key and turn off the powersupply with the main switch.

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 aVolvo Penta original locking screw (8) may be used.

Removing● Set the control lever in the “Ahead” position.

● Remove the propeller blade by first undoing thelocking screws (5) completely and then pressingout the shaft studs (2).

● Fold down the tabs on the tab washer (7). Removethe locking screw (8), tab washer and nut (6). Thenpull off the propeller hub (1) and line cutter (10).

● Clean the propeller shaft and propeller hub (1)carefully and grease with water repellent grease.

Installing● Clean the propeller shaft and propeller hub (1)

carefully and grease with water repellent grease.

● Set the control lever in the “Ahead” position.

● Install the line cutter (10) and propeller hub (1) onthe shaft. Locate one propeller blade in the hub.

Lock a wooden block between the propeller bladeand bottom of the boat. Tighten locknut (6) to70 Nm. Wrench = 24 mm.

● Locate the tab washer (7) on the nut so the tabsare easily accessible.

● Install locking screw (8) and tighten to 20 Nm.

● Bend one of the tabs against the screw head.

● Apply water repellent grease on the studs (2) andon the propeller blade cogs (4).

● Install one propeller blade in the propeller hub andpush in the stud in such a position so the groovein the stud is exactly centered in the hole for thelocking screw (5). Tighten locking screw to 20 Nm,use a 6 mm hex wrench.

● Reinstall the other blade in the same way. Checkthe blades are at the same angle to the propellershaft and that they move easily.

1

2

3

4

5

6

78

9

10

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Laying up and launchingBefore 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 thatyour boat is in top condition for the new season.

Inhibition should be carried out to ensure that the engine and transmission are not damaged while out of com-mission during the winter/off-season. It is important this is done properly and than nothing is forgotten. We havetherefore provided a checklist covering the most important points.

WARNING! Read the chapter on Maintenance carefully before starting work. It contains instructions onhow to carry out the most common maintenance and service operations safely and correctly.

InhibitingThe following are best carried out with the boat inthe water:

● Change engine oil and replace oil filter.

● Change oil in the reverse gear.

● Replace fuel filter. Replace fuel pre-filter if in-stalled.

● Run the engine to normal operating temperature.

● Take the boat out of the water:

The following should be carried out with the boatout of the water:

● Clean the hull and drive directly after taking up theboat (before it dries).

IMPORTANT! Be careful when cleaning with ahigh pressure water spray. Never direct the wa-ter jet at the propeller shaft seal, grommets etc.

● Change oil in the drive.

● Clean the vacuum valve and seawater filter (ac-cessory).

● Clean and inhibit the seawater system.

● Remove the impeller from the seawater pump.Store the impeller in a sealed plastic bag in a coolplace.

● Check the condition of the engine coolant anti-freeze. Top up if required.

IMPORTANT! An anti-corrosion mixture inthe engine coolant system provides no pro-tection against freezing. If there is any possi-bility the engine will be subjected to freezingtemperatures then the system must bedrained.

● Drain any water and contaminants from the fueltank. Fill the tank completely with fuel to avoidcondensation.

● Clean the outside of the engine. Do not use a highpressure spray to clean the engine. Touch up anydamaged areas of paintwork with Volvo Pentaoriginal paint.

● Check all control cables and treat with rust in-hibitor.

● Repair any damaged areas of paintwork withVolvo Penta original paint. NOTE! Read the specialinstructions on painting the drive under the head-ing: “Painting the drive and hull”.

● Disconnect battery leads. Clean and charge thebatteries. NOTE! A poorly charged battery mayburst as a result of freezing.

● Spray electrical system components with moisturerepellent spray.

● Remove the propeller for storage. Grease the pro-peller shaft using water repellent grease. Disas-semble folding propellers, clean and grease.

● Check the rubber seal between the drive and hullcarefully.

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Bringing out of storage● Check oil level in the engine and drive/reverse

gear. Top up if required. If there is inhibiting oil inthe system drain and fill with new oil, change oilfilter. For correct oil grade: See the chapter “Tech-nical Data”.

● Drain the antifreeze from the seawater system.

● Install the impeller in the seawater pump (replaceif the old one looks worn).

● Close/tighten drain cocks/plugs.

● Check drive belts.

● Check the condition of rubber hoses and tightenhose clamps.

● Check engine coolant level and antifreeze protec-tion. Top up if necessary.

● Connect the fully charged batteries.

● Paint the drive and hull: See following page.

● Check the sacrificial anode on the drive. If there isless than 50% of the anode left it must be re-placed. Clean with emery cloth just before theboat is launched.

IMPORTANT! Do not use a wire brush or othersteel tools when cleaning, as these may damagethe galvanic protection.

● Reinstall the propeller.

● Launch the boat. Check for leaks.

● Vent and lubricate the propeller shaft seal (reversegear).

● Start engine. Check that there are no fuel, enginecoolant or exhaust gas leaks and that all controlfunctions are operating.

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Painting the drive and underwaterhull

DriveBefore treating the drive with anti-fouling agent anydamaged paintwork must be repaired. Sand downmetal surfaces lightly using a 120 grade paper and afiner grade for painted surfaces. Wash off using thin-ners or similar. Any pores in the surface should befilled and sanded down. Paint using Volvo Penta orig-inal primer and topcoat. Let the paint dry. A furthertwo coats of Volvo Penta anti-fouling primer shouldthen be applied. Let them dry. A further two coats ofVolvo Penta anti-fouling should then be applied.

IMPORTANT! The sacrificial anodes on thedrive must not be painted or treated with Teflon.This also applies to stainless or bronze propel-lers.

Use of anti-fouling agents is not permitted in all coun-tries. Please make sure that it is permitted whereyour boat is to be used. If anti-fouling agents are notpermitted we recommend that a pure Teflon®* agentbe applied onto the original paintwork on the drivewithout sanding it down first.

*Teflon is the registered trademark of the Du Pont Corp.

Underwater hullAll types of paints with anti-fouling properties arepoisonous and cause damage to the marine environ-ment. Avoid the use of such agents. Most countrieshave introduced legislation controlling the use of anti-fouling agents. Always abide by these regulations.In some cases these agents are completely forbiddenfor use on leisure craft used in fresh water. If the boatis easy to take up on land then we recommend Teflontreatment combined with mechanical cleaning severaltimes during the season.For larger craft this is not practicable. If the boat is inan area where the water quickly produces foulingthen anti-fouling paints must probably be used. If thisis the case use a copper-based paint containing cop-per cyanate and not copper oxide .

IMPORTANT! Leave an area of 10 mm aroundthe drive unpainted.

Tin-based agents (TBT) must not be used. Check thelegislation that applies where the boat is to beused. Wait for the paint to dry before launching theboat.

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Fault-tracing

List of probable causes

1. Discharged battery

2. Loose connection/open-circuit

3. Fuse (in the relay box) blown.

4. Stop control pulled out

5. Inadequate pre-heating

6. Lack of fuel

7. Blocked fuel filter

8. Air in the fuel injection system

9. Water/contaminants in the fuel

10. Boat abnormally loaded

11. Fouling on underwater hull/drive/propeller

12. Limited speed control lever movement

13. Insufficient air supply

14. Engine coolant temperature is too high

15. Engine coolant temperature is too low

16. Lubricating oil level too low.

17. Blocked fuel filter

18. Defective/incorrect propeller

19. Defective engine mounting

20. Too little coolant

21. Blocked seawater intake/pipe/filter

22. Circulation pump drive belt slipping

23. Defective impeller

24. Defective/incorrect thermostat

25. Lubricating oil level too high

26. Generator drive belt slipping

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 14

Engine runs unevenly 6, 7, 8, 9, 13, 14

Engine vibrates 18, 19

High fuel consumption 10, 11, 13, 15, 18

Black exhaust smoke 5, 13, 15, 18

Blue or white exhaust smoke 15, 25

Low oil pressure 16, 17

Engine coolant temperature too high 20, 21, 22, 23, 24

No or poor charging 2, 26

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Technical Data

GeneralEngine designation .................................................. MD2010B MD2020B MD2030B MD2040BNo. of cylinders ....................................................... 2 3 3 3Cylinder bore ........................................................... 67 mm 67 mm 75 mm 84 mmCylinder stroke ........................................................ 64 mm 64 mm 72 mm 90 mmOverall cylinder displacement ................................ 0.45 liter 0.68 liter 0.95 liter 1.50 literPower, see sales literatureIdling speed ............................................................. 850 ± 25 rpm 850 ± 25 rpm 850 ± 25 rpm 850 ± 25 rpmRotation, viewed from in front ................................ Clockwise Clockwise Clockwise ClockwiseMax. permitted rake backwards while running ...... 20° 20° 20° 20°Max. list while running ............................................ 30° 30° 30° 30°Valve clearance (stopped, cold engine)

inlet and outlet ...................................................... 0.20 mm 0.20 mm 0.20 mm 0.20 mmWeight, dry engine .................................................. 98 kg 116 kg 129 kg 179 kg

Lubrication systemOil capacity incl. oil filter, approx.:

no engine inclination ............................................. 1.8 liters 3.4 liters 4.3 liters 6.4 litersOil grade (in accordance with API system) ............ CD CD CD CDViscosity at –5o – +50oC* ........................................ SAE 15W/40, SAE 15W/40, SAE 15W/40, SAE 15W/40,

SAE 20W/50 SAE 20W/50 SAE 20W/50 SAE 20W/50Oil drain plug tightening torque .............................. 30–40 Nm 30–40 Nm 30–40 Nm 30–40 Nm

(3.0–4.0 kpm) (3.0–4.0 kpm) (3.0–4.0 kpm) (3.0–4.0 kpm)

* Steady ambient temperature

Cooling systemThermostats, no. ..................................................... x 1 x 1 x 1 x 1The thermostat starts opening at ............................ 75o ± 2°C 75o ± 2°C 82o ± 2°C 82o ± 2°C

fully open at ....................................... 87°C 87°C 95°C 95°CFreshwater system capacity, approx. ................... 2.1 liters 3.0 liters 4.0 liters 6.9 liters

Electrical systemSystem voltage ........................................................ 12 V 12 V 12 V 12 VFuses ....................................................................... 15 A 15 A 15 A 15 ABattery capacity (starter battery) ............................ 70 Ah 70 Ah 70 Ah 70 AhAC generator voltage/max. current ........................ 14 V/60 A 14 V/60 A 14 V/60 A 14 V/60 A

output approx. ................................. 840 W 840 W 840 W 840 WStarter motor, output approx. ................................. 0.7 kW 0.7 kW 1.2 kW 2.0 kW

Fuel specificationFuel must meet national and international standards at least. For example:

EN 590 (with national environmental and cold standards)

ASTM D 975 No 1-D and 2-D

JIS KK 2204

Sulfur content: According to statutory requirements.

Fuels with extremely low sulfur contents (“urban diesel” in Sweden and “city diesel” in Finland) can cause a drop inoutput of 5% and an increase in fuel consumption of 2–3%.

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Reverse gearType designation ...................................................... MS2L–D, MS2A–DGear ratios:

MS2L-D ............................................................... 2.3:1MS2A-D ............................................................... 2.37:1; 3.0:1

Angle (output shaft):MS2L-D ............................................................... 0°MS2A-D ............................................................... 7°

Oil capacity, approx. ............................................... 0.8 litersOil grade (in accordance with API system) ............. CDViscosity ................................................................... SAE 15W/40Weight ....................................................................... 17 kgTightening torque:

oil drain plug........................................................ 20 ± 5 Nm (2 ±0.5 kpm)

Sailing boat driveType designation ...................................................... 120S–DGear ratio .................................................................. 2,48:1Oil capacity, approx. ............................................... 2.8 liter

volume difference min.-max. ................................ 0.07 literOil grade (in accordance with API system) ............. CDViscosity ................................................................... SAE 15W/40Weight ....................................................................... 28 kgTightening torque:

oil drain plug .......................................................... 10 ±5 Nm (1 ±0.5 kpm)

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________________________________________________

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Notes

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5E

nglis

h04

-199

7

AB Volvo PentaSE-405 08 Göteborg, Sweden

www.volvopenta.com