Volvo Penta D1-13 Installation Manual
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Volvo Penta D1-13 Installation Manual

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Welcome Aboard
Polar DC Generators and Volvo Penta marine engines are used all over the world to-
day. They are used in all possible operating conditions for professional as well as lei-
sure purposes.
Polar DC Marine is becoming a symbol of reliability, technical innovation, performance
and long service life. We also believe that this is what you demand and expect of your
Polar DC Marine generator .
Please read this operator's manual thoroughly and consider the advice we provide on
operation and maintenance before you cast off on your voyage so that you will be en-
sured of fulfilling your expectations.
Installation
Manual
Volvo Penta - Engine

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Summary of Contents for Volvo Penta D1-13

  • Page 1 Manual Volvo Penta - Engine Welcome Aboard Polar DC Generators and Volvo Penta marine engines are used all over the world to- day. They are used in all possible operating conditions for professional as well as lei- sure purposes. Polar DC Marine is becoming a symbol of reliability, technical innovation, performance and long service life.

  • Page 2: Table Of Contents

    Installation Marine Diesel Engines D1-13, D1-20, D1-30 D2-40, D2-55, D2-75 Contents Safety precautions ..........2 General information ........... 5 Conversion factors ......... 7 Special tools ............8 Installation drawings .......... 8 Engine installation ..........9 Engine inclination ........... 9 Flexible shaft seal ........... 10 Rigid shaft seal ..........

  • Page 3: Safety Precautions

    This Installation Manual contains the information you requires a running engine. Approaching an en- will need to install your Volvo Penta product correctly. gine that is running is a safety risk. Loose cloth- Check that you have the correct Installation Manual.
  • Page 4 Safety precautions the workplace. If the boat is in the water, stop the engine and close the sea cock before carrying out opera- Store oil and fuel-soaked rags and old fuel and tions on the cooling system. oil filters properly. Oil-soaked rags can ignite spontaneously in certain circumstances.
  • Page 5 The components in the electrical system, the ignition system (gasoline/petrol engines) and Use an adjustable lifting beam to ensure safe lift- in the fuel system on Volvo Penta products are ing and avoid damage to components installed designed and manufactured to minimize risks of on the top of the engine .

  • Page 6: General Information

    This publication is intended as a guide for the instal- Great care must be taken in the installation of en- lation of Volvo Penta D1 and D2 engines, inboard gines and their components if they are to operate and S-drive. The publication is not comprehensive perfectly.
  • Page 7 Council of Europe’s directive for pleasure product must compare with the example approved boats. The normative requirements can be found in for certification purposes. So that Volvo Penta, as a the standards drawn up to support the directive’s manufacturer, can pledge that currently operational...

  • Page 8: Conversion Factors

    General information Conversion factors Metric to U.S. or IMP. conversion factors: U.S. or IMP. to metric conversion factors: To convert To convert from Multiply by from Multiply by Length inch 0.03937 inch 25.40 inch 0.3937 inch 2.540 foot 3.2808 foot 0.3048 Area mm²...

  • Page 9: Special Tools

    Special tools Engine bed tool Engine bed tool for D1-series and D2-series can be produced locally. Contact Volvo Penta organisation for drawings of a suitable tool. Installation drawings Installation drawings regarding the D1 and D2 en- gines are available at:...

  • Page 10: Engine Installation

    Engine installation Engine inclination Flywheel down Flywheel up Max. inclination Static Under way Flywheel Flywheel Sideways Engine down down D1-ser. 15° 0° 25° 0° 35° D2-40 15° 0° 25° 0° 35° D2-55/75 15° 0° 35° 10° 35° Service accessability When you design the engine installation, always pay attention to the access needed for correct engine service.

  • Page 11: Flexible Shaft Seal

    Engine Instillation Flexible shaft seal Volvo ´Penta water lubricated rubber type Max. 1500 mm (59") Grease lubricated shaft seal Max. 1800 mm (71") When using a flexible shaft seal and flexible engine suspension, a flexible shaft coupling must not be fit- ted.

  • Page 12: Fitting Of Reverse Gear And S-Drive

    Connect a measuring device to the bolt on the upper housing and the grounding connection on the engine. The result should be above 100 k If the measured value is below 100k the installation needs to be re- viewed. Please contact your Volvo Penta dealer.

  • Page 13: Rubber Mounts

    Engine Instillation Rubber mounts 70 Nm (52 lb.ft) 70Nm (52 lb.ft) D1-20 and D1-30, Inboard Tightening torque Tightening torque, rubber mounts, all D1 and D2 engines: 70 Nm (52 lb.ft) A- measurement, D1 and D2 Unloaded conditions Transmission Front Rear mm (") mm (") Reverse gear...

  • Page 14: Propeller Shaft System

    D2-55 2.2:1–2.7:1 =30 (1.2) D2-75 2.1:1–2.3:1 =30 (1.2) D2-75 2.4:1–2.8:1 =35 (1.4) * With Volvo Penta standard material Propeller shaft coupling Reverse gear flange Transmission N x Hd mm (inch) MS10 A/L 102 (4.02) 80 (3.15) 60 (2.36) H8 12 (0.47) 3.5 (0.14)
  • Page 15 Engine Instillation Reverse gear ratios Alignment Before the propeller shaft is connected to the reverse gear flange, check to make sure that the flanges are Reverse gear Ratio RH Ratio LH parallel. MS10L 2.35:1 2.26:1 MS10L 2.72:1 2.26:1 MS10A 2.35:1 2.70:1 MS10A 2.72:1...

  • Page 16: Front End Power Take-Off

    Engine installation Front end power take-off IMPORTANT! D1-13 engines only: Power take-off is not allowed. Front mounted universal bracket This universal bracket, with adjustable attachments, allows air conditioning compressors or hydraulic pumps etc. to be installed and operated. The kit con- tains the bracket and fittings.
  • Page 17 Engine Instillation Extra pulleys (power take-off) D2-55 and D2-75 IMPORTANT! D1-13 engines only: Power take-off is not allowed. Auxilliary equipment driven by the drive belt on the crankshaft of the engine increase the load on the crankshaft. Therefore it is important to review the po- sition and power requirement of the power take-off.
  • Page 18 Engine installation D1-20, D1-30 and D2-40 NOTE! The maximum permissable torque shown in the figures can be applied for one pulley at a maxi- mum distance from the cylinder block corresponding to 4 pulleys or 3 spacers and one pulley. If several pulleys are to be used the permissable torque has to be divided so that torque limitations are not ex- ceeded.
  • Page 19 Engine Instillation Example - D1-30 - One pulley used The engine is a D1-30 and the direction of force for two auxiliaries is A=10° and B=120°. Maximum permissible torque for auxiliary A and B depends on the vector sum of their directions of force and their torque.

  • Page 20: Cooling System

    Engine installation Cooling system Seawater intake 100–200 mm (4–8") Seawater filter The seawater filter should be installed minimum 100 mm and maximum 200 mm (4–8") above the static water line level. Internal hose diameter: MS10,15 19 mm (3/4") NOTE! At all load conditions. MS25, HS25 32 mm (1 1/4") 130S...
  • Page 21 (A) is less than 200 mm (7.9") a vacuum valve must be installed. Install the vacuum valve in an accessible place not less than 500 mm (19.6") above loaded water line level (B). D1-13, D1-20, D1-30, D2-40 19 mm (3/4")
  • Page 22 Engine installation Hot water circuit D2-55 NOTE! Maximum external circuit volume: Outlet to hot water circuit D1-13, D1-20, D-30, D2-40 3.0 l (3.2 US qts) D2-55, D75 1.6 l (1.7 US qts) Larger volumes require additional expansion tank. NOTE! All hose connections for hot water outlets are intended for a hose inner diameter of 16 mm (5/8").
  • Page 23 Engine Instillation Expansion tank D2-75 D1-13, D1-20, D1-30, D2-40 Return from hot water circuit The expansion tank can also be remote mounted for easy access. Outlet to hot water circuit 7.5 mm (0.3") 16 mm (5/8") Max 1.2 m (4 ft)
  • Page 24 Engine installation The loose standard expansion tank must be bulk- head mounted. If an external cirquit (hot water heater, defroster, etc) Max 1.2 m (4 ft) containes a larger water quantity than 1.6 liters (1.7 US qts) or the cirquit is routed higher than the engine a larger or extra expansion tank must be installed.

  • Page 25: Exhust System

    Engine Instillation Exhaust system Routing of exhaust hose between silencer and exhaust bend Min. 100 mm (4") Min. 350 mm above water level in loaded conditions IMPORTANT! Residual water must flow to si- lencer or overboard when the engine is shut off. Highest position of silencer in relation to exhaust hose length, all engines mm (inch)
  • Page 26 Engine installation Exhaust hose dimensions Exhaust riser D1-13, D1-20, D1-30, D2-40 Engine Hose inner diameter mm(") Exhaust riser D1-series 45 mm (1 3/4) D2-40 45 mm (1 3/4) D2-55 57 mm (2 1/4) D2-75 90 mm (3 1/2) Exhaust back pressure measurements,...

  • Page 27: Engine Room Ventilation

    Engine Instillation Engine room ventilation Engine air consumption The engine consumes a certain amount of air in the combustion process. This requires a minimum inter- nal area in the air supply ducting. The area can be calculated by using the formula: A = 1.9 ×...
  • Page 28 Engine installation Engine room ventilation Fan selection A great deal of the radiant heat must be transported The fan must be dimensioned according to air flow out of the engine room to keep the engine room tem- volumes as follows: perature down to the permitted values, in other words the heat must be ventilated away .

  • Page 29: Soundproofing

    Engine Instillation Soundproofing The greatest possible care must be given to the task of screening the sound source as well as possible. The drive package must be installed in such a way Screen all the way down to the hull but leave a small as to minimize noise and vibration.
  • Page 30 Engine installation Insulation material installed on wood (plywood): 1. Wood (plywood) 2. Flame-proof absorption sheeting. 3. Flame-proof, reflecting soundproofing foil. Above you can see an example of the construction of an insulation material. This type of insulation material is glued to the frame. NOTE! The insulation sheeting faces differently, ow- Fuel hoses going through a bulkhead should be pro- ing to the type of the material in the frame, i.e.

  • Page 31: Fuel System

    Inner diameter Required minimum inner diameter for Min. inner diameter: 7.0 mm (0.28") feed line hose: 10 mm (3/8"). Male thread : 1/4" NPTF return hose: 10 mm (3/8"). Volvo Penta part no.: 3825000 NOTE! Only use approved flexible hose.
  • Page 32 Connections Min. inner diameter: 7.0 mm (0.28") Male thread : 1/4" NPTF Volvo Penta part no.: 3825000 Use a fuel pre-filter of correct size to avoid excessive resistance across the filter. The recommended filtra- tion is 10 micron (10m) .

  • Page 33: Electrical System

    Electrical system The MDI is located at the engine and is connected to a number of nearby components, such as sensors, control panel and instruments. A data link (CAN bus) links the MDI to the tachom- eter/display and other optional equipment such as NMEA2000 interface and multisensor.
  • Page 34 Engine installation Minimum instrumentation EVC system tachometer Button panel Optional instrumentation IMPORTANT! The MDI system allows maximum one EVC system tachometer and/or one EVC system display in the system. EVC sys- EVC system tem display Instruments tachometer NMEA Interface Aux relay Button Buzzer neutral...
  • Page 35 Secondary helm station IMPORTANT! The MDI system allows maximum one EVC system tachometer and/or one EVC system display in the system. EVC system tachometer Instruments NMEA Interface Multisensor Aux relay Main helm station Button Neutral panel switch Power Fuel switch level sender switch...
  • Page 36 Electrical system Cables and cable harnesses Pos. in figure 1. Extension cable, 6-pin 11.0 2. Extension cable, 3-pin For Easylink instruments (gauges) 3. Connection cable, 2-pin 10.0 4. Tachometer cable, 6-pin For tachometer and multilink 5. Y-split, multilink, 6-pin 6. Y-connector, 6-pin (P/N 874760) 7.

  • Page 37: Connection Of Battery Cables

    Electrical system Connection of battery cables NOTE! Max tightening torque: 10 Nm (7.4 lb.ft) With charge distributor NOTE! Remove the 25 mm² cable between alternator and starter when a charge distributor is installed. Connection of diod/sensor cable sys- tem to standard alternator, principle drawing 1.
  • Page 38 Electrical system Total cable length and cable area, battery to starter For cables that carry starting current, for systems with and without charge distributor. Cable length in meter (ft) –1.3 1.3–1.8 1.8–2.6 2.6–3.7 3.7–4.8 (–4.2) (4.2–5.9) (5.9–8.5) (8.5–12.1) (12.1–15.7) Cable area in mm (min) Engine D1 Total power cable length and cable area, alternator–battery...

  • Page 39: Controls

    Controls Connecting the Connecting the speed control cable gear shift cable IMPORTANT! The gear shift cable routing is very important for control functionality. The shift IMPORTANT! cable must attach to the reverse gear lever in a To be counter straight and unstrained way. locked.
  • Page 40 Controls Reverse gear MS10, MS15, MS25 REVERSE position FORWARD position, right hand rotating propeller From astern Right-hand propeller Standard recommendation is propeller with right hand rotation for forward. The bracket may be turned 90° for cable installation from above. From port side The bracket can be mounted for cable installation from astern and from port side.
  • Page 41 Controls Reverse gear HS25 Reverse gear HS25 Alternative connection 1 NOTE! Loose fit required. A = 30–35 mm (1.2–1.4") Reverse gear HS25 with trolling valve Alternative connection 2 Bracket Trolling lever Shifting lever 51 (2) 44 (1.7) NOTE! Loose fit required. In order to install the cable according to alternative 2, Engine a bracket is available as an accessorie.

  • Page 42: S-Drive Installation

    S-drive installation Preparations step 1–8 Alternative 1 800 (31.4) 100 (3.9) (4.5) 310 (12.2) 230 (9.0) Alternative 2 Engine mounting The engine may be installed with the flywheel facing forward or backwards. 100 (3.9) (4.5) 454–480 (17.9–18.9) 230 (9.0) Necessary space for drive to be installed/taken out.
  • Page 43 S - drive installation Drilled hole, position (a) 295 mm (11.6") Measure distance (B). Position point "a" in hull Make a line along the center line of the boat. Make sure there is space for bonding the engine bed to the hull. Calculate distance (C), clearence between propel- ler and hull.

  • Page 44: Cutting And Fiberglassing Of Engine Bed

    S-drive installation Cutting and fiberglassing of engine bed, step 9–23 Cut the bed according to this line. Put the bed in its position and align it so it is hor- isontal. Min. 40 mm (1.6") Grind off the gelcoat on the surface of the bed where there will be covered with fibre glass.
  • Page 45 S - drive installation 130S, 130SR 150S, 150SR A= 125 (4.92") B= 62.5 (2.46") Grind off the gelcoat on the hull where it will be Mark up the position of the hole covered with fibre glass. according to dimensions above. Cut the hole.
  • Page 46 S-drive installation Fibre glass the bed to the hull. Drill a drain hole, diameter approximately 30 mm (1.2"). Clean off the extra fiberglass. Protect the surface with top coat.

  • Page 47: Installation Of Drive And Engine

    S - drive installation Installation alternative A. Drive and engine as one unit 40 Nm 20 Nm (30 lb.ft) 20 Nm (15 lb.ft) (15 lb.ft) Tighten the clamp ring to the bed. NOTE! Use no chemicals like grease, silicon etc. on the diaphragm.
  • Page 48 NOTE! D2-55, D2-75 only: Mount distance plate (A). Connect the engine to the S-drive. Put the S-drive through the hull. Water resistant grease, Volvo Penta part no. 828250 20 Nm (15 lb.ft) Tighten the clamp ring to the bed. NOTE! Apply water resistant grease on output shaft NOTE! Use no chemicals like grease, silicon etc.

  • Page 49: Fitting Of The Rubber Seal

    S - drive installation Fitting of the rubber seal 40 Nm (30 lb.ft) Glue Acetone 70 Nm (52 lb.ft) D2-55 D2-75 Grind the surface of the hull where the rubber seal shall be attached and the rubber seal with 40 Nm sandpaper.

  • Page 50: Installation Of Propeller

    Volvo Penta part no. 1161056 10 Nm (7 lb.ft) Put water resistant grease, Volvo Penta part no. 828250, on the propeller shaft. NOTE! Use zinc sacrificial anodes for salt water and 70 Nm magnesium anodes for freshwater. Zinc anodes are (52 lb.ft)

  • Page 51: Oil Quality And Filling

    Also see Operator's manual. Oil quality engine: VDS–2, ACEA E5, API CH–4 Viscosity (at –5° – +50°C constant ambient air temperature) : SAE 15W/40, SAE 20W/50 Engine Approx. volumes liters (US qts) D1-13 (2.0) D1-20 (3.0) D1-30 (3.7) D2-40 (6.3) D2-55 10.5...
  • Page 52 Notes...

  • Page 53: References To Service Bulletins

    References to Service Bulletins Group Date Concerns ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

This manual is also suitable for:

D1-20D1-30D2-40D2-55D2-75

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