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Volvo Penta MD5A, Instruction Book

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Volvo Penta MD5A Instruction Book Download Page 28

24 

 

 

 

TRACING FAULTS WITH INTERRUPTIONS IN OPERATION 

The fault tracing scheme given below lists only the most usual reasons for faults that give 
rise to interruptions in operation. 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. 

 

Engine does not start

 

Engine stops

 

Engine does not reach correct 

operating speed at full throttle

 

Engine runs unevenly or

 

vibrates abnormall

y

 

Engine becomes abnormally hot

 

Reason 
 

See 
 

X 

 

 

 

 

Main switch not switched on; flat 
battery, breakage in electric 
cables or blown fuse. 
 

pp 5, 12, 16, 
17, 27 

X 

X 

 

 

 

Empty fuel tank, closed fuel 
cock, blocked fuel filter 
 

pp 17, 18 

X 

X 

 

X 

 

Water, air or impurities in fuel 
 

pp 17, 18, 19 

X 

X 

X 

X 

 

Defective injector 

pp 18, 26 

 

X 

 

X 

 

Idling speed not properly 
adjusted 
 

p 25 

 

 

X 

 

 

Boat overloaded 
 

 

 

 

X 

 

 

Marine growth on boat bottom  
 

 

 

 

 

X 

 

Damaged propellor 
 

 

 

 

 

 

X 

Blockage in cooling water 
intake, cooling jackets, defective 
impeller, or thermostat 

p 15 

 

FAULT TRACING SCHEME 

Summary of Contents for MD5A

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Page 3: ...product will be met and that your engine will serve you faithfully on many pleasant cruises WARRANTY A warranty certificate is supplied with each engine It contains the warranty conditions for the engine and should be studied carefully Also included is a report card which is to be completed by the dealer or boat seller If our warranty is to apply however it is an absolute condition that the measur...

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Page 5: ...7 9 Checks and Service Scheme 10 Checks and Service 11 17 Check daily before starting Check every 14 days Service every 50 hours of operation Service every 100 hours of operation Laying up and launching 11 11 12 12 13 13 19 20 23 Fault Tracing Scheme 24 Technical Data 25 26 Wiring Diagram 27 Engine Component Guide 28 Index alphabetical order 29 CONTENTS ...

Page 6: ...ngle Control System For side mounting 1 Control lever 2 Disengaging button Push in the button when the control lever is in neutral and move the lever a bit forwards Release button The lever is now used only for engine speed control To use the lever for both engine speed control and gear changing push in the button and pull back the lever to neutral N Neutral F Control lever in position for running...

Page 7: ...ort periods Oil change Change the engine lubricating oil and the oil filter after the engine has been run for 20 hours See further under Checks and Service 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 s...

Page 8: ...eviated BOAT HOOK and paddle MOORING ROPES FOG HORN and whistle FLOATING ANCHOR TORCH PREPARATIONS BEFORE STARTING Make sure that There is no FUEL LEAKAGE There is no WATER LEAKAGE from engine and hull There is no OIL LEAKAGE There is no SMELL OF LP GAS in the deep cavities in the boat or elsewhere The OIL LEVEL is correct There is enough FUEL for the planned voyage The proper NAUTICAL CHARTS are ...

Page 9: ...e engine Release the key when the engine starts Hand starter If the engine is started with the starting crank the decompression handle on the rocker arm cover should first be folded up Fold down this handle for running when the cranking has got the engine up in speed Starting in cold weather is facilitated if the cold start control is pulled out Push it in again after a while Check immediately aft...

Page 10: ...The siren will sound and the respective warning lamp go on if the engine temperature becomes excessive or the oil pressure too low SHUTDOWN PROCEDURE After shutdown the engine should be allowed to idle for a couple of minutes or so with the control lever in neutral Stop the engine by pulling out the stop control when the engine is idling Then turn back the key switch to the initial position Switch...

Page 11: ...l pump prevents the oil pressure from becoming excessive ELECTRICAL SYSTEM The engine has a starter motor and alternator with built in rectifier Voltage regulation is taken care of by a transistorized regulator mounted on the alternator The alternator makes it possible to charge two battery circuits independent of each other if a charging distributor accessory is fitted on the alternator A main fu...

Page 12: ...STEM The engine is sea water cooled The cooling system includes a sea water pump as well as a water distributor housing with thermostat The sea water pump has an impeller of neoprene rubber driven by the camshaft via a rubber flange The thermostat installed in the water distributor housing regulates the water flow so that the water always flows through the exhaust manifold and out into the exhaust...

Page 13: ...s integrally built with the reverse gear Power transmission from the engine to the reverse gear is via a rubber flange The Volvo Penta patented cone clutch is used for Forward and Reverse operation and ensures smooth and quiet engagement Very small forces are required to operate the reverse gear TECHNICAL DESCRIPTION ...

Page 14: ... Change the oil in the engine Change the oil in the reverse gear Check and adjust the valve clearances 12 13 13 SERVICE EVERY 100 HOURS OF OPERATIONS OR AT LEAST ONCE EACH SEASON Change the oil filter Check the pulley belt Check tighten the cylinder head bolts Check the cooling system Check the electrical system fuses etc Fuel system filter strainer injector venting 13 14 15 15 16 17 19 SERVICE IN...

Page 15: ...ECKS every 14 days OIL LEVEL IN REVERSE GEAR Screw up the dipstick wipe it clean and insert it again without screwing it down Pull up the dipstick and check the oil level which should be between the marks If necessary top up with oil through the oil filler hole on the opposite side of the reverse gear Do not top up above the MAX mark Screw down the dipstick again Note that there is a sealing washe...

Page 16: ...tween the pulleys To tension the belt first slacken the alternator retaining points stretch the belts and tighten up the points again A well worn or crached belt should be replaced SERVICE EVERY 50 HOURS OF OPERATION CHANGE OIL IN ENGINE With a new or newly reconditioned engine the oil should be changed for the first time after 20 hours of operation and after that after every 50 hours of operation...

Page 17: ...NCE The valve clearance should be checked and adjusted by authorized personal See under Valves in Technical Data SERVICE EVERY 100 HOURS OF OPERATION OR AT LEAST ONCE EACH SEASON OIL FILTER The oil filter should be replaced for the first time after 20 hours of operation during the running in period and subsequently at every other oil change IMPORTANT Before removing the filter switch off the main ...

Page 18: ...heck the oil level and also for any leakage round the oil filter CHECK THE BELT Check the belt thoroughly for wear and cracks Replace it if there is any indica tion of such To remove the belt slacken the alternator retaining points in order to be able to slip the belt off Wipe clean the belt groove on the pulleys before fitting the new belt Tension the belt so that it can only be depressed 5 mm 3 ...

Page 19: ...defective impeller or flange in the sea water pump faulty thermostat or temp gauge sender Look out for water penetration during all work on the cooling system Check and replace the impeller The impeller can be damaged due to e g shortage of water Remove the cover on the water pump Pull out the shaft the length required in order to screw out the impeller lock bolt Hold against the shaft and pull of...

Page 20: ...harging distributor accessory on the alternator when more than one battery is connected up 4 Observe the following in the event the engine is started with an auxiliary battery Let the ordinary battery remain connected up Connect the auxiliary battery to the ordinary battery plus to plus and minus to minus When the engine has started remove the auxiliary battery but do not break the ordinary batter...

Page 21: ...y should he checked at cast once each season This is done by using a hydrometer which shows the specific gravity of the electrolyte this varying with the state of charge See the Technical Data FUEL SYSTEM Observe the greatest cleanliness when handling the fuel system IMPORTANT Try to avoid fuel splash Change fuel filter The filter element in the fuel filter should be changed at least once each sea...

Page 22: ...leaning and checking the opening pressure the spray pattern and for leakage To remove the injector unscrew the delivery pipe and the by pass oil line Fit protective caps over the openings Release both the nuts over the fork holding the injector to the cylinder head and lift up the injector If the injector feels stiff to remove due to gumming grip it with e g polygrip pliers and carefully rotate it...

Page 23: ...rimer until fuel free from air bubbles flows out Close the vent screw If the pumping effect is poor turn over the engine a bit so that the pump drive cam alters its position 3 If the fuel injection pump has been removed or when starting an entirely new engine for the first time the fuel injection pump must be vent To do this open the vent screw on the pump Pump with the hand primer until fuel free...

Page 24: ...gine for a long period acc To Inhibiting Schemes I and II A suitable procedure would be to test the compression SERVICE INSTRUCTION Inhibiting Scheme I Carried out with the boat in the water 1 Run the engine warm 2 Pump out all the oil from the engine and reverse gear Use an oil scavenging pump 3 Change the oil filter Fill the engine and reverse gear to the correct level with Volvo Penta oil which...

Page 25: ...rain cock in the reverse gear 7 Disconnect the reverse gear suction line from the reverse gear Connect a hose with inner diameter 1 2 and insert the free hose end in a container with fresh water Arrange to have water added to the container and run the engine at idle for about 5 10 minutes so that it is flushed throughout with fresh water Make sure that there is no dirt near the exhaust outlet Drai...

Page 26: ...er the engine several turns with the starter motor or the crank NOTE Prevent oil splash Fit the checked injector but do not final tighten it It will be removed again before launching 12 Clean the outside of the engine and reverse gear Touch up any bare patches on the paintwork with the same type of paint as the original Spray the electrical system components and all the controls with anti moisture...

Page 27: ...run the engine several turns so that the oil on the piston crowns is blown out Fit the injector See under Tightening torques Technical Data 18 Launch the boat Change the fuel filter cartridge Pump forward the fuel and vent the system See under Venting the fuel system 19 Start the engine See the instructions on page 5 Run the engine warm with the reverse gear engaged Check to make sure there is no ...

Page 28: ...ne does not reach correct operating speed at full throttle Engine runs unevenly or vibrates abnormally Engine becomes abnormally hot Reason See X Main switch not switched on flat battery breakage in electric cables or blown fuse pp 5 12 16 17 27 X X Empty fuel tank closed fuel cock blocked fuel filter pp 17 18 X X X Water air or impurities in fuel pp 17 18 19 X X X X Defective injector pp 18 26 X ...

Page 29: ...tion underway Rearwards max 15 To the sides max 20 Engine weight incl Reverse gear kg lb 111 244 Valves Valve clearance hot engine Inlet mm in 0 30 0 0012 Exhaust mm im 0 35 0 0014 Reverse Gear Type designation MSB Reduction ratio Forward and Reverse 1 91 1 Lubricating System Engine Oil Capacity engine litres Imp qts US qts excl filter 2 0 1 80 2 10 Incl filter 2 1 1 85 2 20 Oil quality Diesel lub...

Page 30: ...ction angle crankshaft degrees B T D C 25 28 Fuel quality Autodiesel Cet rating minimum 45 Electrical System Battery voltage 12v Battery capacity standard 60 Ah max 120 Ah Starter motor 0 8 kW 1 1 h p Alternator 35A 420W Battery electrolyte specific gravity Charging carried out at g cm 3 1 230 Fully charged battery g cm 3 1 275 1 285 Tightening Torques Cylinder head nuts Nm kpm lb ftf 70 7 0 50 Co...

Page 31: ...Blue Yellow 0 75 18 L White Red 0 75 18 M Blue Red 0 75 18 List of Components 1 Extra switch 2 Battery charging warning lamp 3 Excessive temp warning lamp 4 Low oil pressure warning lamp 5 Key switch 6 Siren 7 Alarm unit 8 Battery charging warning lamp for battery circuit opt equipment 9 Place for instruments opt equipment 10 Rapid connector 11 Starter motor 12 Alternator 13 Fusebox 14 Main switch...

Page 32: ...everse gear oil filler 11 Cooling water pump 12 Reverse gear oil dipstick 13 Fuel filter 14 Vent screw 15 Fuel hand primer 16 Engine oil dipstick 17 Oil filter The tool kit supplied with the engine contains the following tools US spanner 10 12 UP spanner 14 16 screwdriver Phillips screwdriver flat end pliers oil scavenging pump with hose and suction pipe as well as Allen spanners for the drive ENG...

Page 33: ...check 11 De inhibiting 22 Preparations before starting 4 Drain cocks 28 Running 6 Electrical system 16 Engine assembly 7 Safety equipment 4 Sea water pump 8 15 28 Fault tracing scheme 24 Starter motor 17 Fuel 3 Starting 5 Fuel filters 17 Fuel pump 8 Technical data 25 26 Fusebox 7 17 Thermostat 8 26 Hand primer 8 17 23 28 Valve clearances 13 25 Hand starter 5 28 Venting the fuel system 19 Impeller ...

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