INSTRUCTION BOOK

MD2010, 2020, 2030, 2040

Welcome on board! Maintenance Manual
You have chosen a boat with all the comfort you could ever This Owner’s Manual contains brief operating instructions
wish for, plus an engine with maximum safety which will be in the form of a maintenance schedule containing text and
extremely economical to run. We welcome you to our illustrations
worldwide service network. For the “Do-It-Yourselfer” we have put together a more
comprehensive Maintenance Manual which describes the
engine and its fuel, lubricating and cooling systems, etc. in
Read this before you cast off from shore more detail. The Maintenance Manual also provides hints
We advise you to read through this Owner’s Manual even if on the tools you will need.
you are used to the sea and have previously piloted
various types of boat. Some things may be different to what The Maintenance Manual can be bought from your VOLVO
you are used to. PENTA retailer.

Safety
Warranties and Service Preparations
Provided with each engine is a description of the warranty
we issue for our product. The warranty card you receive We have put together the checklist below (to which you
should be filled in and returned to VOLVO PENTA by your can, of course, add your own notes) in order that you may
sales representative: this is important both for us and for enjoy trouble-free running.
you. Make sure this is done, because we may refuse to It is, of course, important that the engine, its equipment and
undertake repairs on the warranty because the date of the boat in general are maintained according to the
delivery cannot be verified. instructions given in order to avoid breakdowns.
Some markets have other warranty conditions which
replace or supplement the VOLVO PENTA warranty. Travel plans
– Do you have a current nautical chart for the planned
Diesel fuel voyage?
Use “Autodiesel” diesel oil. An inferior fuel may cause – Have you taken note of the weather forecast for the
breakdowns. area in which you will be travelling?
– Have you calculated the distance?
– Have you calculated the amount of fuel you will need?
Lubricating oils – Where can you buy fuel on your journey?
Only use lubricating oils of the quality recommended in – Do your relatives know of your travel plans?
“Technical Data”.

The boat’s equipment

Maintenance – Rescue equipment such as lifejackets and distress
There are a number of maintenance instructions listed in rockets.
this Owner’s Manual. If these are not carried out in good Does everyone on board know where they are?
time, your engine may become less reliable and less – Spare parts on board, e.g. water pump wheel
economical to run afterwards. Contact an authorised (impeller) for the seawater pump.
VOLVO PENTA service workshop if you are unable to carry
– Tools which suit the equipment
out the prescribed maintenance yourself.
– Full fire extinguishers.
It is important that you always use original parts in order to
maintain VOLVO PENTA quality. It will be worth it in the
long run. The environment
VOLVO PENTA has developed an extensive network of We invest large amounts of money in ensuring that our
retailers in order to be able to provide services and spare engines are as environmentally friendly as possible. We
parts. hope, therefore, that you as a boat owner will continue to
help keep our environment clean.
Always state the complete type designation and serial
number when ordering spare parts As regards changes of oil and oil and/or fuel filters, it is
important that used oil or discarded filters do not make
their way into ordinary rubbish. Used filters always contain
Safety instructions a small amount of oil or fuel even when they have been
emptied.
When you see this symbol before an item of text, it
means that there is a danger of injury or damage Always hand in used filters and oil to a service or
unless the instructions are followed. environmental station which has special containers for
products which can be harmful to the environment.
Used batteries should also be handed in here.

AB VOLVO PENTA
Technical Information
Volvo Penta reserve the right to make changes
© AB VOLVO PENTA
 Instruction book

Marine Diesel Engines

MD2010, MD2020, MD2030, MD2040

Contents

Introduction Laying-up
Engine description ................................................... 2 Inhibiting ................................................................ 12
Number plate and engine designation ....................... 3 Recommissioning, launching .................................. 12

Operation Electrical system

Before starting ......................................................... 6 Electrical system ................................................... 14
Starting .................................................................... 6 Wiring diagrams ..................................................... 15
Stopping .................................................................. 7
Measures to be taken when freezing is imminent ..... 7
Technical data
Engine ................................................................... 18
Maintenance Reverse gear, S-drive ............................................ 19
Maintenance schedule ............................................. 8
Troubleshooting
General information Troubleshooting schedule – engine ........................ 20
Venting the fuel system ......................................... 11
Coolant .................................................................. 11

Important information
Standard instrument panels do not have a key switch. The engine is fluid-cooled. Drain the seawater system
The operator’s cabin should therefore be lockable and/ after the engine has stopped if there is a risk of freez-
or a lockable main switch should be used in order to ing. The freshwater system should be filled with an an-
prevent unauthorised persons from starting the engine. ticorrosion antifreeze solution.

Stop the engine before opening the door of the Note that siphoning may occur when work has been
engine room! There are rotating parts on an en- carried out on the seawater system. Close all cocks if
gine which is running which are dangerous to ap- the boat is not supervised constantly. Drainage which
proach. Bear in mind the risk of fire. All engine has been carried out incorrectly may lead to the boat
fuel is flammable. filling with water and sinking.

1
Introduction

MD2010 with reverse gear MS2L-D

MD2010 with reverse gear MS2L-D

MD2020 with 120S-drive MD2020 with 120S-drive

Illustrations for guidance (pages 2 and 3)

1. Coolant filler cap 13. MD2040: Air filter. Other engines: Air intake
2. Expansion tank 14. Seawater pump
3. Relay box with fuses 15. Injection pump
4. Rubber mount 16. Lubricating oil filter
5. Earthing relay (for starter motor and glow plugs) 17. Feed pump
6. Starter motor 18. Oil cooler, reverse gear
7. Alternator 19. Folding propeller
8. Oil dipstick, reverse gear/S-drive 20. Cooling water intake, S-drive
9. Oil filler cap, reverse gear/S-drive 21. Bottom cock (seawater), S-drive
10. Fuel fine filter 22. Oil drainage, S-drive
11. Oil filler cap, engine 23. Zinc ring*
12. Oil dipstick, engine * NB. A magnesium ring should be used when running in
freshwater.
2
Type designations (example) Approval No.
Engine: (Certifying)

Engine designat. Reverse gear designat.

(or drive designation)
Serial number Serial number

Product No.- Product number

Engine designation Serial number
Product No.

Reverse gear/S-drive:

Designation Ratio Product No.

Serial number

MD2030 with reverse gear MS2A-D MD2030 with reverse gear MS2A-D

MD2040 with reverse gear MS2L-D MD2040 with reverse gear MS2L-D
3
Instruments
There are three types of main panel (A, B and C). 1. Rev. counter/Blind plug*
The rev. counter shows the engine speed. Multiply the
Standard (alternatives “A” and “B”) value by 100 to calculate revolutions per minute. Full
throttle: operating range: 3200–3600 r/min.
* NB. Rev. counters come with instrument panels “A” and “C”. Blind
plugs come with instrument panel “B”.

2. Toggle switch - Heating/Alarm test

➡
Pos.: (up) = “Glow” position (glow plugs switched on).
(down) = Alarm test.

➡
3. Alarm (siren)

4. Pressure switch for switching instrument

panel On/Off (In/Out)

Instrument panel (standard), 5. Start button

(with or without rev. counter) The starter motor comes on as soon as this button is
pressed. Let the button go as soon as the engine has
started.
See also the starting instructions on the next page.

6. Warning display
The display has four ”windows”. If the acoustic alarm
comes on, one of windows “A–C” lights up (red) to show
the cause of the alarm.
A. Coolant too hot.* Reduce the speed to idling (in
neutral) until the temperature decreases. Investigate
Warning display the cause of the alarm (e.g. restricted water supply
to the engine). Stop the engine if the temperature
does not decrease.
B. Lubricating oil pressure too low. Stop the engine
immediately and locate the cause of the alarm.
De luxe (alternative “C”) C. Alternator not charging.
D. Heating (indicator lamp comes on when glow
plugs are on).
* NB. The light will come on even if there is a problem with
charging (no alarm sound).

7. Temperature gauge
The temperature gauge should normally show approx.
75-95°C (167-203°F) during normal operation. The acous-
tic alarm comes on when the coolant is too hot.
If an alarm is emitted, reduce the speed to idling (in neu-
tral) until the temperature decreases. Investigate the
cause (e.g. restricted water supply to the engine).
Stop the engine if the temperature does not decrease.

8. Oil pressure gauge

The oil pressure gauge should normally show approx.
150–500 kPa (1.5–5 kp/cm2 = 21–71 lbf/in2) during opera-
tion. It is normal for the gauge to show a lower value
when the engine is idling.
Instrument panel (De luxe)

4
 Control
The acoustic alarm comes on when the oil pressure is 9. Voltmeter
too low.
The voltmeter shows the voltage in the starter battery cir-
When the alarm sounds, stop the engine immediately cuit.
and locate the cause.
The voltage should be about 14V during operation. The
voltage is about 12V when the engine is off.

10. Key switch

The key switch has five positions, including 0:
Pos. 0 = Key can be inserted and removed.
S = The mechanical restart block disengages.
The key springs back automatically to 0.
I = Running position. Key springs automatically
back to running position after starting.
II = “Glow” position.
III = Start position (starter motor comes on). Let
the key go as soon as the engine has started.
See also the starting instructions on the next page.
A disc is provided with the keys which gives the key code.
This code must be stated when ordering new keys. Do not
keep the number disc on the boat. Do not allow unauthor-
ised persons access to the code.

11. Pressure switch – instrument lighting

12. Pressure switch – alarm test

Controls
The Volvo Penta single-lever control combines the throttle
and gear shift functions in one lever. When starting, for ex-
ample, the gear change function can easily be switched off
so only the engine speed is affected by the lever. When
manoeuvring the boat backwards or forwards, the control
mechanism makes the engine speed drop to idling speed
when the gears are changed.
The control lever has an adjustable friction brake. A neutral
position switch which allows the engine to be started only
when reverse gear is not engaged is available as an extra.
Manoeuvring takes place as follows:
Lever (1) for reverse gear/S-drive manoeuvres and engine
speed control.
Position N = neutral position.
From N to F – reverse gear engaged for forward running.
From N to R – reverse gear engaged for reversing.
T = affects engine speed.
Disengaging the reverse gear from the control:
Place the lever (1) in the neutral position “N”. Press the
button (2), push the lever forwards slightly and release the
button. The lever will now only affect the speed.
The lever automatically reconnects the reversing function
when it is moved back to the neutral position. The speed
can then be adjusted and forward/reverse manoeuvres ex-
VP single control ecuted. Ensure that the reverse gear/S-drive is not en-
gaged unintentionally.
5
Operation
Measures to be taken before starting
1. Open the bottom cock for the cooling water intake.
2. Open the fuel cocks.
3. Check that no leakage of water, fuel or oil occurs.
4. Check the level of coolant. The level should be just
below the filler neck, or between the MIN and MAX
marks on the separate expansion tank (extra).
Open the cap carefully if the engine is hot.

5. Check the engine oil level. This should be within the

area marked on the dipstick.
The oil level must never drop below the lower mark.
6. Engage the main switches.
7. Start the engine room blower (if fitted). Let it run for
at least four minutes before starting the engine.
8. Push in the stop control.
9. Check the amount of fuel.

Starting
Warning! Never use starting spray or similar prod-
ucts to help you start the engine. The glow plugs
may cause an explosion in the inlet manifold. Risk
of personal injury.

Standard instrument panel (“A” or “B”)

1. Disengage the control lever. Place the lever in the
full speed position.
2. Press the “Power ON/OFF” switch (instrument panel
comes on). Push the toggle switch down (“Alarm
test”) and check that the alarm sounds.
3. Push the toggle switch up to the “Glow” position and
hold it there for about 20-30 sec. (max. 60 sec.).
4. Press the start button at the same time. Let the but-
ton and the toggle switch go when the engine starts.*
Reduce the engine speed to idle.
*NB. Do not run the starter motor for more than 20 sec.

De luxe instrument panel (“C”)

1. Disengage the control lever. Place the lever in the
full speed position.
NB. Less throttle can be used when starting to re-
duce exhaust emissions.
2. Turn the key switch to position “I” (running position).
The warning lights come on in this position. Press
the “Alarm Test” button and check that the alarm
sounds.
3. Turn the key switch to position “II” (“glow” position)
and hold it there for about 20-30 sec. (max. 60 sec.).
4. Turn the key to position “III” to start. Release the key
immediately once the engine has started* (it will
spring back automatically to the running position).
Reduce the engine speed to idle.
* NB. Do not run the starter motor for more than 20 sec. The key
switch has a restart lock. Therefore, the starting procedure must
always begin from the “S” position when repeated attempts are
made to start the engine.
6
The following applies to all engines regardless of the NB. For maximum fuel economy, avoid running on full
type of instrument panel: throttle. The maximum cruising speed is the maximum
speed reached minus approx. 300 r/min.
NB: The starter motor must never be switched on
when the engine is running. The starter motor and When under sail, the control lever should be in the neu-
the flywheel ring gear may be seriously damaged. tral position if the propeller is a fixed propeller. If the pro-
peller is a folding propeller, the control lever should be in
5. Warm up the engine at low speed and under low the reverse position. Start the engine and run for five
load. Do not race the engine when it is cold. minutes every ten hours when on long-distance cruises.
6. Monitor the instruments/warning display during op- Warning! Manoeuvring of the reverse gear/S-
eration. Stop the engine and check the cause of any drive should be done at idling speed. Manoeu-
abnormal readings or if a warning light comes on. vring at higher engine speed can damage the
reverse gear/S-drive.
The engine must not be run if the oil pressure is
too low or the coolant temperature too high. NB: Never switch off the power using the main
switch when the engine is running. If you do,
the voltage regulator and alternator may be seri-
ously damaged.

Shutdown procedure
1. Let the engine run at idling speed for about 1 min after
operation (with reverse gear/S-drive in the neutral po-
sition). This will ensure an equalisation of temperature
in the engine and prevent “afterboiling”.
2. Pull out the stop control. Turn the key switch to the
“S” position and release it (the key will automatically
spring back into the “0” position). You may then re-
move the key.

Safety measures:
3. Disconnect the main switches if the boat is not to be
used for some time.
NB: Never disconnect the main switches
when the engine is running. If you do, the
voltage regulator and alternator may be seriously
damaged.
4. Check there are no leaks around the engine and that
everything in the engine room looks normal.
5. Close the sea cock (cooling water intake) and the fuel
cocks.
In cold weather, where there is a risk of freezing, it is
important that the coolant in the freshwater system has
sufficient antifreeze.
Drain the water in the seawater system (see next sec-
tion).
Check the battery’s charge. A battery with low charge can
easily burst when frozen.

Draining the seawater system:

Do not allow the ingress of water into the boat.

1. Close the bottom cock (sea cock). Release the cap

on the seawater pump and let the water run out.
2. Release the hoses from the seawater pump and
seawater filter at the reverse gear/S-drive and point
them downwards so that the water runs out.
3. Tighten the hoses and the cap on the seawater pump.
7
Maintenance
General description for MD 2010, MD 2020, MD 2030 NB: Stop the engine and cut the power using
and MD2040. the main switches before service work is be-
gun!

Check daily before starting

1. Check the coolant level.
Warning! Open the filler cap very carefully if the
engine is hot. Steam or hot liquid may spray
out.
Turn the cap to the first stop and wait a moment before
removing the cap.
The level should be just below the filler neck, or between
the MIN and MAX marks on the separate expansion tank
(extra). See the section entitled “Coolant” on page 11 for
information on coolants.
A solution which is the same as that already in the cool-
ing system should be used to replenish the system. NB.
Fill the cooling system slowly!

2. Check the engine’s lubricating oil level.

The level should be within the area marked on the dip-
stick.
Add more oil if necessary. See “Technical data” regard-
ing oil quality and viscosity. NB. Fill the system slowly!
The oil level must never fall below the lower mark.

Check every 14 days

3. Check the oil level in the reverse gear or S-drive.
The level should be within the area marked on the dip-
stick. NB. The dipstick should not be screwed in when
you check the oil level.
Add more oil if necessary. See “Technical data” regard-
ing oil quality and viscosity.
The oil level must never fall below the lower mark.

4. Drain water and any other impurities from the ex-

tra fuel filter (if applicable).
Drain water or impurities through the cock/plug (1).
NB. Wait a few hours after the engine has stopped be-
fore you drain the filter.

8
5. Check/tension the drive belt.
If the belt is too tight, it may damage the bearings. If the
belt is too loose, it may make the belt pulley slip.
Change the belt if it looks worn or is cracked.
After changing the belt: Re-check the tension of the
belt after about one hour’s running.

MD2010, MD2020 MD2030, MD2040

6. Check the level of electrolyte in the battery.

Warning! Use protective goggles. The batteries
contain oxyhydrogen gas and extremely corrosive
sulphuric acid. A spark or naked flame in the vicin-
ity of the battery can cause an explosion.

Service every 50 hours of operation

7. Check the seawater filter.*

Close the sea valve. Open the filter, clean it if neces-
sary.

Warning! Take care not to let in water.

* NB. When to check the seawater filter should be determined from
experience after running the boat for a time. Check the filter more
often should there be a danger that it will get blocked.

Service every 100 hours of operation, or at least once every 6 months

8. Change the engine oil.*
See “Technical data” regarding oil quality and viscosity.

Warning! Hot oil can cause burn injuries.

NB. Fill up slowly! Check that you are using the cor-
rect amount.
* NB: The oil should be changed after the first 20–40 operating
hours in a new or reconditioned engine.

9. Change the lubricating oil filter.*

Screw on the new filter by hand until the gasket is in
close contact. Then tighten it by another 1/2 turn. Check
for leaks.
* NB: The oil filter should be changed after the first 20–40 operating
hours for a new or reconditioned engine.

9
 Service every 200 hours of operation, or at least once a year
10.Drain the oil from the S-drive.
Use a collecting vessel. Contact an authorised Volvo
Penta Service Workshop if the oil looks grey.

Warning! Hot oil can cause burn injuries.

11.Refill the S-drive with new oil.

See “Technical data” regarding oil quality and viscosity.
NB. Do not screw down the dipstick when measuring
the oil level. If there is too much oil, the excess must be
drained off.
Check the tightening of the dipstick and the plug.

12.Change the oil in the reverse gear.

Warning! Hot oil can cause burn injuries.

See “Technical data” regarding oil quality and viscosity.

Check the level. Top up with oil if necessary.

13.Change the fuel fine filter.

Be careful not to spill fuel! Screw on the new filter by
hand until the gasket is in close contact. Then tighten it
by another 1/2 turn.
Vent the system. See Item 15. Check the tightness.

14.Change the insert in any extra fuel filter fitted.

Close the fuel cocks at the tank. Be careful not to spill
fuel!
Clean the filter bowl. Fit a new filter insert and tighten it.
Open the fuel cocks and vent the filter.
Check for leakage.

15.Vent the fuel system.

Open the venting screw (1) and pump using the hand
pump (2) until fuel comes out which does not contain air
bubbles. Close the screw while the fuel is flowing out.
Avoid spilling fuel.
NB. Rotate the engine slightly if the pump output is poor.

10
 Service every 400 hours of operation, or at least once every other year

16.Clean the air filter (MD2040).

Remove the filter.
Carefully blow the filter clean using compressed air.
NB. Impurities must not be allowed to enter the en-
gine.

MD2040

Other maintenance Cooling system

Some checks are best carried out in connection with in- Coolant
hibiting/recommissioning. These maintenance actions Use a mixture of 50% Volvo Penta antifreeze (glycol)
are marked “–“. and 50% clean water (as neutral as possible) for the en-
gine’s internal cooling system (freshwater system).
Some checks and maintenance actions require spe-
cialist knowledge, which is why we recommend that This mixture protects against freezing down to a
you consult an authorised service workshop. The fol- temperature of approx. -40°C (-40°F) and should be
lowing are of this type (marked “•”): used all year round.
NB. At least 40% antifreeze should be used in the sys-
every 200 hours, or at least once a year: tem in order to attain satisfactory anti-corrosion protec-
• Check/adjust idling speed. tion.
• General check of the engine and its equipment.
NB: Glycol is harmful to health (dangerous to
– Check the impeller in the seawater pump.*
consume).
– Check the S-drive’s zinc anode (zinc ring).*
• Take apart and clean the vacuum valve, if fitted.* Topping up shall use the same mixture as is already in
– Lubricate the rubber propeller shaft seal (inboard en- the system. Topping up using only water will adversely
gine).* affect the coolant’s properties as regards anti-corrosion
protection, antifreeze and boiling point.
every 400 hours, or at least once every other year:
NB. Fill slowly! Check that the correct amount is being
• Re-tighten the cylinder head bolts.
used.
• Check the valve clearance.
The cooling system normally operates at a temperature
• Check the injectors.
of 75–95°C (167–203°F).
– Clean the cooling system and change the coolant.*
– Check that the heat exchanger is not blocked. If nec- Too high coolant temperature (warning light comes on)
essary, flush and clean it using suitable brushes.* may can be caused by:
• A blocked seawater intake or seawater filter (op-
* NB. See the instructions under “Inhibiting” on the next tional).
page. • A defective seawater pump impeller.
• Low coolant level, air in the freshwater system.
• Slipping or broken circulation pump drive belt.
Fuel system • Faulty thermostat, temperature sender or instrumen-
Venting the fuel system tation.
The fuel system must be vented in the following cases Be careful not to allow the ingress of water when
in order for the engine to start: working with the cooling system.
• After the fuel filter has been changed.
Ensure that water is not able to leak in and sink
• After filling the tank with fuel if it has been run com-
the boat if it has to be left with the cooling sys-
pletely dry.
tem dismantled.
• After the fuel lines have been undone.
• After the boat has not been used for a long time.
NB. Refer to Item 15 in the maintenance schedule for
venting.

Maintain quality and safety.

Always use original VOLVO PENTA parts.

11
Inhibiting, Recommissioning
Inhibiting an engine to be out of Fill the reservoir with a mixture of 50% Volvo Penta glycol
operation and 50% freshwater, then repeat the same procedure.
The engine must be started and warmed up at least Alternatively, a mixture of freshwater and emulsifying oil
once every 14th day while the boat is in the water in can be used. However, this mixture has no anti-freezing
order to prevent corrosion. properties and must therefore be drained immediately af-
Check/top up the antifreeze in the freshwater system. ter stopping.
Hand the mixture in at a recycling plant. Never pollute
Should the boat not be used for more than 90 days,
the water. Or drain the mixture and keep it to use again
it should be put into long-term inhibiting as follows:
the next year.
NB. Let an authorised service workshop test the engine Remove the alternator/circulation pump drive belt.
and equipment before the boat is taken out of the water. Remove the seawater pump impeller. Rinse the impel-
Repairs can then be carried out while the boat is not be- ler in freshwater and keep it in a sealed plastic bag during
ing used. laying-up if it is in good condition. (Otherwise fit a new im-
Do the following while the boat is in the water: peller when launching the boat.)
1. Warm up the engine. Then stop it and drain or pump Clean the outside of the engine and reverse gear/S-drive.
off the lubricating oil from the engine and reverse Where necessary, touch up with original paint to avoid
gear, if any. corrosion.
2. Change the lubricating oil filter. Warning! Never direct the water at the propeller
3. Fill Volvo Penta lubricating oil* to the right level in shaft seal when cleaning the S-drive with high-pres-
the engine. sure jets.
4. Fill lubricating oil* to the right level in the reverse
gear. Remove the propeller for winter storage and lubricate the
*NB. See “Technical data” regarding oil quality and viscosity. propeller shaft with anti-corrosion oil.
Protect control parts, cables and electrical system
Do the following while the boat is on land: components against corrosion using moisture-repellent
Freshwater system spray.
Check/top up the antifreeze in the freshwater system. Remove the batteries from the boat. Clean them and
NB. The coolant should be changed at least once every store them in a cool, dry place. Check that the batteries
two years. are well charged. Trickle charge them according to the
Unscrew the filler cap and open the drain cock. Flush manufacturer’s instructions (a flat battery can easily be
through the drainage opening until clean water comes damaged as a result of freezing).
out. See under “Coolant” on page 11 regarding coolant. Drain any water or impurities in the fuel tank. Fill the
tank to prevent the formation of condensation.

Boat with S-drive:

Change the oil in the drive. See Items 10 and 11 in the
maintenance schedule.
Carefully check the rubber seal between the S-drive and
the bed plate.

NB. The seal should be changed every 7 years.

This should be done by an authorised service work-
shop.

S-drive with folding propeller: Remove the folding pro-

peller for winter storage.
Location of drain cock (freshwater system) Remove the blades’ mounting pin locking screws. Knock
out the pins and remove the blades. Remove the propeller
shaft nut and pull off the propeller hub. Clean and lubri-
Seawater system cate the propeller shaft with anti-corrosion oil.
Release the hose at the seawater pump intake. Connect
a hose to the pump and place the free end into a con-
tainer of freshwater. Check that nothing is in danger of Recommissioning – Launching
being splashed behind the exhaust discharge. Fill up the
Check the oil level in the engine and reverse gear or S-
reservoir and start the engine. Let it run at a fast idle
drive.
speed for a few minutes in neutral.
Change the engine fuel filter and any extra fuel
NB! The seawater pump should not be run dry pre-filter. Vent the fuel system. See Items 13–15 in the
(the impeller will be damaged). maintenance schedule.
12
 Recommissioning, Launching

Fitting the impeller in the seawater pump

Fit the impeller to the seawater pump. Check that the Fitting folding propeller to S-drive
impeller is in good condition. Change it if necessary.
1. Propeller blade 6. Locking nut
Lubricate the pump housing and the inside of the cover 2. Teeth 7. Locking screw
with a little lubricating grease. Press in the wheel while 3. Propeller hub 8. Pin
turning it (clockwise). Fit the grommet in the outer edge of 4. Zinc anode* 9. Grooves
5. Locking screw
the centre of the impeller. Fit the cover using a new gas-
ket. * NB: A magnesium anode should be used when running in fresh-
water.
Fit the alternator/circulation pump drive belt. Change
the belt if it is worn. See Item 5 in the maintenance
schedule.
Check the condition of the rubber hoses and the tight-
ening of all hose clamps. 1. Put the control in the “Forward” position.
Take apart the vacuum valve (where appropriate) for 2. Carefully clean the propeller shaft and propeller hub
cleaning. (3).
Fit the propeller. See the next section regarding fitting 3. Lubricate the shaft pivot and hub (grease pad
the propeller to the S-drive. 828250-1).
Check the batteries’ charge. Connect the batteries. 4. Fit the propeller hub to the shaft. Tighten the locking
Boat with inboard engine fitted with a propeller shaft nut (6) by 65-75 Nm (6.5-7.5 kpm = 47-54 lbf. ft).
seal of rubber: Socket spanner 24 mm.
Vent the tubular sleeve and seal after launching by press- 5. Fit the locking screw (5) and tighten it using a hex-
ing them together and pressing the seal down against the agonal key (4 mm).
shaft until water emerges. Then press approx. 1 cm3 of 6. Grease the pins (8) and the teeth (2) of the propeller
waterproof grease into the seal. blades.
7. Fit a propeller blade in the propeller hub and push the
Warning! The propeller shaft seal must be pin into a position such that the groove (9) in the pin
changed after 5 years or a maximum of 500 oper- end up right in the centre of the locking screw hole
ating hours. (7).
Tighten the locking screw using a hexagonal key (4
mm).
8. Fit the other blade in the same way. Check that the
Fitting a propeller to the S-drive blades form the same angle to the propeller shaft
and that they move freely.
Warning! Remove the key from the instrument
panel or cut the power using the main switches be-
fore starting work on the propeller. Painting
Check the zinc anode* (zinc ring “4”). Change the anode Check the painting of the S-drive. Touch up damaged ar-
if it is consumed more than 50%. eas using Genuine Volvo Penta drive Paint. Then coat
Otherwise clean the anode with an emery cloth to remove the drive with a Teflon®* agent for aluminium drives. We
the oxide layer. NB. This should be done shortly before recommend the Volvo Penta Anti-fouling Agents (part
launching. No. 1141593-2 or 1141594-0). These products are spe-
cially designed for the S-drive and are at the same time
NB: Do not use a wire brush or other steel tools when
as kind to the environment as possible.
cleaning, as these may damage the galvanic protection.
Check that there is good metallic contact between the an- Paint the bottom of the boat and the propeller using a
ode and the material. suitable anti-fouling paint or with a pure Teflon agent.
* NB: A magnesium anode should be used when running in * NB. Teflon is a registered trademark of Du Pont.
freshwater.
13
Launching, Electrical system
All anti-fouling paints are poisonous and by definition Warning! When charging, the batteries give off hy-
more or less harmful to our marine environment. Avoid drogen gas which forms oxyhydrogen gas with air.
such products. Most countries have a legislation which This gas is inflammable and extremely explosive.
controls the usage of anti-fouling boat bottom paints. Al-
Always use protective goggles and gloves when
ways make sure you follow these regulations! In
handling batteries.
some countries it is forbidden to use anti-fouling paints
on leisure crafts, e.g. in freshwater. The battery electrolyte contains strongly corrosive
acid. Should this acid come into contact with the
We recommend simple Teflon treatment in combination skin, wash with soap and plenty of water. Should
with mechanical cleaning a few times during the season, the battery acid come into contact with the eyes,
especially in the case of smaller boats which are easy to immediately rinse with copious amounts of water
lift. and contact your doctor immediately.
This may be impractical for larger boats. Also, if the boat
is in water which promotes fouling, an anti-fouling paint
may need to be used after all. In this case, use a pure
Fuses
copper-based anti-fouling paint which contains copper
thiocyanate (not copper oxide). Two blocks of fuses of four fuses each (15A) for plus (+)
and minus (-) are located on the relay box at the back of
Tin-based paints (TBT paints) must not be used! the lefthand side of the engine. The fuses break the cur-
Bear in mind the legislation in force for the area in rent in the event of overloading.
which the boat is used. Re-couple the electrical system if a fuse has burnt out
NB. Unsuitable bottom paints may cause great corrosion by moving the cable connection to the next contact.
damage to the S-drive. Always investigate the cause of the overload.
Warning! Do not paint the zinc anode (zinc Ensure that you always have spare fuses available.
ring) in front of the propeller. Leave a 10 mm
(0.4 in) margin without anti-fouling paint
around the S-drive.

Launch the boat when the paint has dried.

Electrical system
Stop the engine and cut the power using the
main switches before working on the electrical
system.

Batteries
NB: Follow the stipulated safety regulations when charg-
ing batteries. Always break the charging current before Fuses (15A)
the charging clamps are removed.

14
 Wiring diagrams
Standard instrument panels (“A” and “B”)

1. Instrument lighting 10. Connector for connecting neutral Wire colours

2. Rev. counter/blind plug* position switch, if applicable (extra
3. Warning light, coolant temperature equip.) BL = Blue
4. Warning light, oil pressure 11. Semiconductor diode LBL = Light blue
5. Warning light, charging 12. Alarm BN = Brown
6. Control light, heating 13. Toggle switch. Heating/Alarm test
7. Electronic unit (alarm) 14. 16-pole connection LBN = Light brown
8. Starter button * The blind plug is for instrument panel “B”. GN = Green
9. Pressure switch. Instrument panel GR = Grey
In/Out OR = Orange
PU = Purple
R = Red
SB = Black
W = White
Y = Yellow

15
 De luxe instrument panel (“C”)

1. Instrument lighting
2. Voltmeter
3. Oil pressure gauge
4. Coolant temperature gauge
5. Warning light, coolant temperature
6. Warning light, oil pressure
7. Warning light, charging
8. Control light, heating
9. Electronic unit (alarm)
10. Switch, instrument lighting
11. Switch, alarm test
12. Rev. counter
13. Key switch
14. Alarm
15. Connection for connecting neutral
position switch, if applicable (extra
equip.)
16. 2-pole connection (for additional panel,
if applicable)
17. 16-pole connection

Wire colours
BL = Blue
Re-springing LBL = Light blue
BN = Brown
LBN = Light brown
GN = Green
GR = Grey
Re-springing
OR = Orange
PU = Purple
R = Red
SB = Black
W = White
Y = Yellow
16
 Engines MD2010, MD2020, MD2030, MD2040

1. Battery 9. Glow relay 16. Coolant temperature switch

2. Main switch 10. Protective diode (normally open, closes at 95° ±3°C
3. Starter motor 11. Fuses (x 4), max. 15A = 203° ±5°F)
4. Earthing relay 12. Fuses (x 4), max. 15A 17. Coolant temperature sender
5. Earth rail 13. Junction 18. Connector, 16-pole
6. Glow plugs* 14. Oil pressure switch, engine (normally
7. Alternator open, closes at 0.3 ±0.1 bar)
8. Start relay 15. Oil pressure sender
* MD 2010: x 2. Other engines: x 3.

Cable colours
BL = Blue OR = Orange
LBL = Light blue R = Red
BN = Brown SB = Black
LBN = Light brown W = White
GN = Green Y = Yellow
GR = Grey
Cable areas in mm2 are stated after the colour code
in the wiring diagram. Where no area is stated 1.5
mm2 applies
Volvo Penta does not supply the dashed wires.
Relation mm2 /AWG* Proposal for connection of oil bilge pump
* American Wiring Gauge (draining and filling)
mm2 1.0 1.5 2.5 10 16 Wire area 1.5 mm2.
AWG 16 (17) 15 (16) 13 7 5 A. Fuse (15A).

17
Technical data
General
Engine designation ............................................. MD2010 MD2020 MD2030 MD2040
No. of cylinders .................................................. 2 3 3 3
Bore .................................................................... 67 mm 67 mm 75 mm 84 mm
(2.638 in) (2.638 in) (2.953 in) (3.307 in)
Stroke ................................................................. 64 mm 64 mm 72 mm 90 mm
(2.520 in) (2.520 in) (2.835 in) (3.543 in)
Swept volume, total ............................................ 0.45 litre 0.68 litre 0.95 litre 1.50 litres
(27.5 in3) (41.3 in3) (58.2 in3) (91.3 in3)
Output, see sales literature
Idling speed ........................................................ 850 ±25 r/min. 850 ±25 r/min. 850 ±25 r/min. 850 ±25 r/min.
Compression ratio .............................................. 23.5:1 23.5:1 23:1 22:1
Direction of rotation, seen from the front ........... Clockwise Clockwise Clockwise Clockwise
Max. permissible tilt backwards during operation 20° 20° 20° 20°
Max. side tilt during operation ............................ 30° 30° 30° 30°
Valve clearance, stationary cold engine:
inlet and outlet .................................................... 0.20 mm 0.20 mm 0.20 mm 0.20 mm
(0.008 in) (0.008 in) (0.008 in) (0.008 in)
Weight, engine without oil and water ................. 98 kg 116 kg 129 kg 179 kg
(216 lbs) (256 lbs) (285 lbs) (395 lbs)

Fuel system
Start of injection, crankshaft position ................ 25.5° ±1° BTDC 25.5° ±1° BTDC 22.5° ±1° BTDC 21° ±1° BTDC
Injectors, opening pressure (when checking) .... 11.3-12.3 MPa 11.3-12.3 MPa 11.3-12.3 MPa 15.2-16.2 MPa
(115-125 (115-125 (115-125 (155-165
kp/cm2 = 1639- kp/cm2 =1639- kp/cm2 = 1639- kp/cm2 =2205-
1784 lbf/in2) 1784 lbf/in2) 1784 lbf/in2) 2347 lbf/in2)
opening pressure (when setting) ........................ 11.8 MPa 11.8 MPa 11.8 MPa 15.7 MPa
(120 kp/cm2 (120 kp/cm2 (120 kp/cm2 (160 kp/cm2
1711 lbf/ in2) 1711 lbf/ in2) 1711 lbf/ in2) 2276 lbf/ in2)

Lubricating system
Oil capacity, inc. oil filter, approx.:
no engine tilt ....................................................... 1.8 litres 3.4 litres 4.3 litres 7.3 litres
(3.2 Imp. pints/ (6.0 Imp. pints/ (7.6 Imp. pints/ (12.8 Imp. pints/
1.9 US quarts) 3.6 US quarts) 4.5 US quarts) 7.7 US quarts)
Oil quality according to the API-system ............ CD CD CD CD
Viscosity at -5° - +50°C* .................................... SAE 15W/40 SAE 15W/40 SAE 15W/40 SAE 15W/40
SAE 20W/50 SAE 20W/50 SAE 20W/50 SAE 20W/50
Oil 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 =
21.7-28.9 lbf. ft) 21.7-28.9 lbf. ft) 21.7-28.9 lbf. ft) 21.7-28.9 lbf. ft)
*Note! The temperature values bear reference to a constant ambient temperature.

Cooling system
Thermostat, No. .................................................. 1 1 1 1
The thermostat begins to open at ...................... 75° ±2°C 75° ±2°C 82° ±2°C 82° ±2°C
(167° ±4°F) (167° ±4°F) (167° ±4°F) (167° ±4°F)
completely open at ............................................. 87°C (189°F) 87°C (189°F) 95°C (203°F) 95°C (203°F)
Freshwater system capacity, approx ................ 2.1 litres 3.0 litres 4.0 litres 6.9 litres
(3.7 Imp. pints/ (5.3 Imp. pints/ (7.0 Imp. pints/ (12.1 Imp. pints/
2.2 US quarts) 3.2 US quarts) 4.2 US quarts) 7.3 US quarts)

18
Electrical system
MD2010 MD2020 MD2030 MD2040
System voltage .................................................. 12 V 12 V 12 V 12 V
Fuses .................................................................. 15A 15A 15A 15A
Battery capacity (starter battery) ....................... 70 Ah 70 Ah 70 Ah 70 Ah
Alternator, voltage/max. amperage ................... 14V/60A 14V/60A 14V/60A 14V/60A
output approx. .................................. 840 W 840 W 840 W 840 W
Starter motor, output approx. ............................. 0.7 kW 0.7 kW 1.2 kW 2.0 kW

Reverse gear
Type designations .............................................. MS2L-D MS2A-D
Gear ratios .......................................................... 2.3:1 2.37:1; 3.0:1
Angle (output shaft) ............................................ 0° 7°
Oil capacity, approx. .......................................... 0.8 litre
(1.4 Imp. pints/
0.85 US quarts)
Oil quality in accordance with the API system . CD
Viscosity ............................................................. SAE 15W/40
Weight ................................................................. 17 kg (37.5 lbs)
Tightening torque:
oil drain plug .................................................... 20 ±5 Nm
(2 ±0.5 kpm
14.5 ±4 lbf.ft)

S-drive
Type designation ................................................ 120S-D
Gear ratio ............................................................ 2.48:1
Oil capacity, approx. .......................................... 2.8 litres (4.9 Imp pints/3.0 US quarts)
volume difference min.- max. ............................ 0.07 litre (0.12 Imp pints/0.07 US quarts)
Oil quality in accordance with the API system . CD
Viscosity ............................................................. SAE 15W/40
Weight ................................................................. 28 kg (61.7 lbs)
Tightening torque:
oil drain plug ....................................................... 10 ±5 Nm
(1 ±0.5 kpm = 7.2 ±4 lbf.ft)

19
Troubleshooting

Troubleshooting schedule – engine

Engine Engine Does not Runs Gets Cause of fault
does not stops reach full unevenly, abnormally
start speed vibrates hot
Check the batteries, electric wires, main
switches.

Check amount of fuel, fuel cocks,

fuel filter and fuel (for any impurities,
water, air).

Faulty injectors.

Boat abnormally loaded, fouling on the

bottom of the boat.

Blocked air filter.

Damage to propeller.

Blocked cooling water intake, blocked

seawater filter, coolant level too low, air in
the freshwater system, detective impeller
or thermostat.

20
Owner
Name: ......................................................................... Tel.: ...........................................

Address: ........................................................................................................................

Nearest Volvo Penta Service Dealer

Name: ....................................................................... Tel.: ...........................................

Address: ........................................................................................................................

Engine
Engine type: ..................................................................................................................

Serial No.: .....................................................................................................................

Reverse gear/S-drive
Type: ...................................................................... Ratio: ...........................................

Serial No.: .....................................................................................................................

7735333-2 English 08-1993