Volvo D series MDI box still an issue

L

lproulx

Well-known member
Joined
Apr 14, 2018
Messages
199
Fluid Motion Model
C-24 C SE
Vessel Name
Red Owl
Hi All,

This has been discussed before, but the thread sort of died out, implying that Volvo has solved the MDI box problem. I'm starting a new thread on the subject because my box failed after 140 hrs on a 1-1/2 year old MD1-30. Volvo replaced it under warranty. (The engine was new under the emissions recall.) I urge anyone with one of these boxes to install the "emergency" start button described in a you tube video. It's easy - basically just connect a push button switch from the "bat" to the "starter" terminals on the box. It allows you to start the engine if the box malfunctions. You lose the tach, alarms and stop function, but it sure beats being towed. You can shut the engine down using the manual lever. (Also - the tach starts over at zero with the new box.)

Larry
 
Larry,
Thanks for reminding us about the MDI issue. My engine is within the serial number range and when I called Volvo Penta they said that there was no recall for the MDI with my specific engine serial number. I guess I can only keep my fingers crossed.

In the mean time I will install an emergency start switch. One question, what gauge wire did you use for your switch, 16, 14 or larger?

Thanks again,
Harry
 
I must have one of the good MDI boxes. I have a 2014 R21-EC with 2070 hrs with lots of starts and stops and no issues so far. (Knock on wood) Only last week I was discussing with another member that I wanted to install the emergency switch. Did you just add connectors onto the two posts on the MDI box or tie into the wiring with another method? Another option I was considering was to buy one of those remote/portable start switches that comes with wiring and clips that you would only clip on when and if it was needed. I do however like the idea of having it hardwired in so it's there for immediate use should I have a failure.
 
It's not a very high current situation - Electrically, 14 Ga would probably be fine. I used short lengths of 8 Ga because it is stronger and helps to support the switch without having to mount it. Just cable tie it to something convenient. The terminals involved are very hard to reach with any kind of clips.
 
Newf - yes, just add the switch wiring to the existing MDI box studs.
 
All good info on the emergency start switch, thanks. I plan on installing one tomorrow.
One additional question regarding testing the switch.
Should I test it with the helm switch OFF or ON? Or does it matter?
Don't want to harm the MDI box.
Thanks
Harry
 
This is truly an invaluable resource for Ranger Tug owners, such a great group willing to share their insights.

So, I installed an emergency start switch as many have recommended here on TugNuts.
In doing this I didn’t want to introduce any new problems by making this modification and I wanted it to look professional, equal to what Ranger would have done if they offered this feature.

Diesel engines lend themselves readily to this modification by simply adding a switch connecting the start and battery terminals on the starter solenoid wires which lead to the MDI box. I presume a switch like this would be appropriate on any Ranger diesel model.

In thinking about the project I became concerned that this switch could be inadvertently pressed while the engine is running and thereby potentially damaging the starter. Accordingly I added a toggle switch ahead of the main emergency start button along with a light that shows when the start button is “armed”.

I then put all of this into a switch box. On the R21 EC there is a partition separating the engine and the batteries. That is where the switch was mounted. I used 12 gauge marine wire.

Finally, connecting the wire with heat shrink crimp ring terminals at the MDI box was made easier by temporarily unbolting the box from the engine for better access.

I hope this will be of help to others. Photos of the emergency start switch are in my photo gallery.
 
Looks like a quality job - nicely done. I’m still learning my diesel engine and wonder if this solution is Volvo/MDI-specific, or if it’s something I should be contemplating for my Yanmar 3YM30AE as well? Thanks!
 
My understanding is this type of switch is applicable to other brands as well. YouTube has some examples. Maybe others who have different brands will weigh in on this.
 
Yes, it can be used on other models. I got the idea after seeing it on YouTube with the Volvo D-1 -30 model with the MDI box removed but then saw a photo in Bob Daily's photo gallery where he has it on the Yanmar.

I installed the simple push button on mine today (2014 D-1 30 Volvo Penta) and when I first tested the switch with the 3 plugs pulled on the MDI box, the engine would turn over but wouldn't start. I plugged the wires back into the box and it started no problem. Then I pulled the 3 sets of wires on the MDI box again and used the new push botton switch and this time it fired up and I shut it down with the kill lever on the starboard side of the engine. Not sure why the engine didn't start on the first attempt but did on the second with the wires pulled out of the box.?? I pulled the wires because I wanted to simulate a failed box. In any case it now seems to work as I envisioned.
 
Newf Remember that the emergency switch bypassed the glow plugs, so if engine is colder than 120 degrees, the engine will be hard to start! This can be jumped too but usually not needed just a few more cranks on the engine will start it. In extremely cold conditions you'll need a way to heat engine or activate the glow plugs (jumper). Usually the emergency switch is used after the boat will not start after being shut down while underway and the engine is already preheated !
Hope this explains why your engine did not start the first time you tried your new emergency switch, but worked the second time after engine had been wormed up.
Good luck Bob
 
Thanks Bob. Definitely not 120F during my test. More like 50F. Normally the engine fires up on the first couple of revolutions but this is as you said with the glow plugs working.

Thanks again
Newf
 
Newf,
I agree with Bob's assessment of the starting issue. I would like to know how to jump the heating circuit and make it a part of the emergency start switch. I can see a situation in a cold weather emergency where that would be handy.
Has anyone looked at the schematic for the Volvo Penta engine to see how the pre-heat circuit operates?
Harry
 
Hwhayes, the glow plug relay only comes on when engine temperature is below abt 120 degrees, the voltage is battery voltage,So a simple line from the battery to the glow plugs is all that is needed! I would recommend a spring loaded toggle switch next to the emergency start button, a 5 to 10 second is all that is needed to worm enough for starting in cold environment. I recommend a spring loaded switch so it can't be left on and burn out the glow plugs.
The volvo Pentax D1-30 electrical manual can be downloaded and info on MDI box and glow plug relay and starting system is not to complicated to understand.
Good luck and let us know how your modification goes! Bob
 
Bob,
Thanks for the explanation. That helps.
I will keep you posted on my progress.
You and the others are very much appreciated.
Harry
 
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