Volvo Penta D1-13, Installation Manual

Page 1: ...coming 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 Manua...

Page 2: ...ller shaft system 13 Front end power take off 15 Cooling system 19 Exhust system 24 Engine room ventilation 26 Soundproofing 28 Fuel system 30 Electrical system 32 Connection of battery cables 36 Controls 38 S drive installation 41 Preparation 41 Cutting and fiberglassing of engine bed 43 Installation of drive and engine 46 Fitting of the rubber seal 48 Installation of propeller 49 Oil quality and...

Page 3: ...e work e g adjustments requires a running engine Approaching an en gine that is running is a safety risk Loose cloth ing or long hair can fasten in rotating parts and cause serious personal injury If working in prox imity of a running engine careless movements or a dropped tool can result in personal injury Take precautions to avoid hot surfaces exhaust pipes turbochargers charge air manifolds sta...

Page 4: ...l fuels and many chemicals are flammable Keep away from naked flames or sparks Gaso line some solvents and hydrogen from batteries in the correct proportions with air are very inflam mable and explosive Do not smoke Maintain good ventilation and take the necessary safety measures before welding or grinding in the vicin ity Always keep a fire extinguisher accessible in the workplace Store oil and f...

Page 5: ...ndling Never carry out work on an engine suspended on a hoist Never work alone when installing heavy compo nents even when using secure lifting equipment such as a lockable block and tackle Most lifting devices require two people one to see to the lifting device and one to ensure that the compo nents do not get caught and damaged The components in the electrical system the ignition system gasoline...

Page 6: ...al systems shall only be carried out by a professional boat electrician Only components cables connections etc delivered or approved by the manufacturer may be used The manufacturer will accept no responsibility what so ever if this requirement is ignored Volvo Penta continuously upgrades its products and reserves the right to make changes All the informa tion contained in this manual is based on ...

Page 7: ...n Par liament and Council of Europe s directive for pleasure boats The normative requirements can be found in the standards drawn up to support the directive s objective of uniform safety requirements for pleasure boats in EU countries Certificates that grant the right for CE label use and confirm that boats and equipment meet safety re quirements are issued by approved notified bodies In many Mem...

Page 8: ...c 1 1 36 hp metric 1 kW 0 735 kW bhp 1 341 bhp kW 0 7457 kW BTU min 56 87 BTU min kW 0 0176 Torque Nm lbf ft 0 738 lbf ft Nm 1 356 Pressure Bar psi 14 5038 psi Bar 0 06895 MPa psi 145 038 psi MPa 0 006895 Pa mm Wc 0 102 mm Wc Pa 9 807 Pa in Wc 0 004 in Wc Pa 249 098 KPa in Wc 4 0 in Wc KPa 0 24908 mWg in Wc 39 37 in Wc mWg 0 0254 Energy kJ kWh BTU hph 0 697 BTU hph kJ kWh 1 435 Work kJ kg BTU lb 0...

Page 9: ...ed 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 http www volvopenta com ...

Page 10: ... the complete engine can be removed without damage to the boat structure There must also be sufficient space for the sound proofing material NOTE See installation drawing for space re quired to lift out engine NOTE Minimum recommended access two sides front and starboard Max inclination Static Under way Flywheel Flywheel Sideways Engine down up down up D1 ser 15 0 25 0 35 D2 40 15 0 25 0 35 D2 55 ...

Page 11: ...t seal When using a flexible shaft seal and flexible engine suspension a flexible shaft coupling must not be fit ted Rigid shaft seal When using a rigid shaft seal and flexible engine sus pension a flexible shaft coupling must be fitted Flexible shaft coupling Rigid shaft seal Max 1500 mm 59 Max 1800 mm 71 ...

Page 12: ...ed One of the lower two bolts A has an insolating bushing B fitted This bolt and bushing are secured during transportation by a nut Electrical insulation between engine and flywheel casing power transmission IMPORTANT The S drive must on no account be grounded Grounding the S drive may cause serious damage due to galvanic corrosion Check insulation Connect a measuring device to the bolt on the upp...

Page 13: ... 3 0 3 S drive Fixed Fixed Tightening torque Tightening torque rubber mounts all D1 and D2 engines 70 Nm 52 lb ft NOTE Make sure that the rubber mounts are in stalled so that no pre load or side forces occur when the engine has been installed and aligned with the propeller shaft Compare front and rear mounts sidewise in pairs Adjust if necessary A A D1 20 and D1 30 Inboard ...

Page 14: ...5 2 1 1 2 3 1 Æ 30 1 2 D2 75 2 4 1 2 8 1 Æ 35 1 4 Propeller shaft coupling Reverse gear flange Transmission D Pcd d T A 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 4x11 5 0 45 MS15 A L 102 4 02 80 3 15 60 2 36 H8 12 0 47 3 5 0 14 4x11 5 0 45 MS25 A L 102 4 02 80 3 15 60 2 36 H8 12 0 47 3 5 0 14 4x11 5 0 45 HS25A 127 5 00 108 4 25 63 5 2 50 H8 10 0 39 4 0 16 4x11 5 0 45 Fem...

Page 15: ...the flanges are parallel Move the flanges together so that the guide engages Then with the flanges pressed together check that they are parallel and that a 0 10 mm 0 004 feeler gauge cannot be inserted anywhere inbetween them A Then turn the flanges 90 180 and 270 and repeat this check at the new positions Make sure that the flanges are well pressed together during the entire check If the deviatio...

Page 16: ...ow shows the width and length of the mounting plate Engine Width Lenght W mm L mm D1 D2 40 582 22 9 140 5 5 D2 55 D2 75 634 25 0 170 6 7 The increase in length of the engine installation depends on how the bracket is installed Auxiliary equipment can increase the length further NOTE Additional rear brackets are required when installing a universal bracket on a S drive engine Rear brackets are incl...

Page 17: ...ke off Maximum power supplied depends on the alignment of the belt the belt type and the engine type Pulley groove alternatives HC50 Multi V Pulley HC50 Number of groves 1 Overall diameter D 120 0 5 mm 4 72 0 02 Width W 18 0 0 25 mm 0 71 0 01 Belt width B 12 7 mm 0 50 NOTE The following table only gives general advice about the power which can be taken via a maximum of three extra belt grooves on ...

Page 18: ...s to be divided so that torque limitations are not ex ceeded D1 20 D1 30 and D2 40 D1 20 D1 30 D2 40 Permissible torque a Nm 0 13 2 30 11 8 60 7 7 90 6 0 120 5 6 150 6 4 180 8 6 210 13 2 240 13 2 270 13 2 300 13 2 330 13 2 Permissible torque a Nm 0 21 7 30 21 7 60 21 7 90 21 2 120 20 8 150 21 7 180 21 7 210 21 7 240 21 7 270 21 7 300 21 7 330 21 7 Permissible torque a Nm 0 18 0 30 12 9 60 9 4 90 7...

Page 19: ...ithin the permissible torque range In this example the torque for the auxiliary is A 10 Nm 7 4 lbf ft and B 4 Nm 3 0 lbf ft The resultant force gives a torque C 10 1 Nm 7 4 lbf ft with direction of force 32 9 The resultant ends up within the permissible torque In every case Read off the resultant of two torques with different directions of force by drawing a parallelogram in the graph on the same ...

Page 20: ... backwards to avoid water to be pushed into the exhaust system during sailing Internal hose diameter MS10 15 19 mm 3 4 MS25 HS25 32 mm 1 1 4 130S 19 mm 3 4 150S 32 mm 1 1 4 Seawater filter The seawater filter should be installed minimum 100 mm and maximum 200 mm 4 8 above the static water line level NOTE At all load conditions IMPORTANT No valves or connections that could restrict water flow may b...

Page 21: ...e unless below criteria is fullfilled IMPORTANT If the distance from static water level to exhaust outlet 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 D2 55 D2 75 Æ 19 mm 3 4 ...

Page 22: ... 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 The hoses should be bent in gentle curves and in a way which avoids them being pinched or kinked D1 13 D1 20 D1 30 D2 40 The upper edge of the hot water heater should be placed min 50 mm 2 below the engine s expan sion ...

Page 23: ...t hot water heater defroster etc is routed higher than the engine the expansion tank the tank has to be moved according to figures Max mounting height above engine top 1 2 m 4 ft D2 55 D2 75 D2 75 IMPORTANT No valves or thermostats are al lowed in the circuit as this may cause engine overheating Replace existing hose between the turbo compressor and the engine oil cooler outlet Install two hoses a...

Page 24: ...taines 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 If the external cirquit hot water heater defroster etc is routed higher than the engine the expansion tank the tank has to be moved according to figures Max mounting height above engine top 1 2 m 4 ft ...

Page 25: ... inch A H 300 11 8 110 4 3 400 15 7 120 4 7 600 23 6 150 6 0 1300 51 2 180 7 1 Support needed to avoid water to stay in hose be fore silencer IMPORTANT If measurement H cannot be met an exhaust riser has to be installed Min 350 mm above water level in loaded conditions Min 100 mm 4 A H IMPORTANT Residual water must flow to si lencer or overboard when the engine is shut off ...

Page 26: ...1 series 20 2 9 2040 D2 40 20 2 9 2040 D2 55 15 2 2 1530 20 2 9 2040 D2 75 15 2 2 1530 20 2 9 2040 Exhaust riser D1 13 D1 20 D1 30 D2 40 Standard installation Engine B measurement mm D1 13 197 7 75 D1 20 197 7 75 D1 30 222 8 75 D2 40 222 8 75 Exhaust riser installation Engine B measurement mm D1 13 288 11 3 D1 20 288 11 3 D1 30 323 12 7 D2 40 323 12 7 The riser increases the overall engine install...

Page 27: ...s charging regulators and relays should there fore be fitted on bulkheads or elsewhere where the temperature is relatively low The maximum temperature for areas where electric components are fitted is 70 C 158 F The starter motor and alternator however have their given loca tions NOTE The total intake area can be calculated by us ing the formula Engine air consumption The engine consumes a certain...

Page 28: ...and duct length The ambient air temperature outdoor air tempera ture is assumed to be 30 C 86 F Correction fac tors as per Table 2 shall be used where applicable Ambient air temperature Correction C F factor 20 68 0 7 30 86 1 0 40 104 1 4 Table 2 Fan selection The fan must be dimensioned according to air flow volumes as follows Air flow 0 07 engine power output Air flow volume in m3 min Engine pow...

Page 29: ...ing sound traps for the air inlets The engine installation should be soundproofed in or der to obtain a noise level that is as low as possible Build the engine compartment with sound traps Vari ous types of sound traps can be selected The figure shows a type that is also provided with drainage Furthermore due consideration must be given to the thickness of the insulation material Prior to installi...

Page 30: ...orption sheeting 4 Flame proof reflecting soundproofing foil Shift cables throttle cables and electrical wires coming through bulkheads can preferably be drawn through a tube or a grommet sealing off properly At the same time the cables are protected against wear Fuel hoses going through a bulkhead should be pro tected by a grommet where they pass through the bulkhead The grommet seals off and pro...

Page 31: ...mp the fuel line Distance between clamps ap prox 300 mm 12 Make sure the hose cannot be damaged by sharp edges Inner diameter Required minimum inner diameter for feed line hose 10 mm 3 8 return hose 10 mm 3 8 NOTE Only use approved flexible hose Connections Min inner diameter 7 0 mm 0 28 Male thread 1 4 NPTF Volvo Penta part no 3825000 Inner diameter 10 mm 3 8 NOTE Legal requirements may demand fu...

Page 32: ...ale thread 1 4 NPTF Volvo Penta part no 3825000 Inner diameter 10 mm 3 8 Outer diameter 10 mm 3 8 1 2 A 3 4 16UNF 1 4 18NPTF Outer diameter Required minimum outer diameter for feed line pipe 10 mm 3 8 alt 12 mm 1 2 return pipe 10 mm 3 8 Fuel pre filter Use a fuel pre filter of correct size to avoid excessive resistance across the filter The recommended filtra tion is 10 micron 10m NOTE Fuel pre fi...

Page 33: ...engage or turn off the system NOTE The control panel must not be turned off while the engine is running B Multifunction button Alarm acknowledgement Dimmer background lighting Contrast tachometer LCD C Stop button The engine stop running when this button is pressed D Start button When this button is pressed the glow function is activated and the starter is engaged Control panel A B C D Multilink S...

Page 34: ...k Buzzer Instruments EVC sys tem display NMEA Interface Multisensor Aux switch input Fuel level sender Button panel ADU To neutral switch To power switch Aux relay MDI Button panel MDI EVC system tachometer EVC system tachometer NOTE Jumpers are mounted IMPORTANT The MDI system allows maximum one EVC system tachometer and or one EVC system display in the system Neutral switch Power switch 3 3 3 3 ...

Page 35: ...ter Button panel Buzzer Neutral switch Secondary helm station Main helm station NOTE Jumpers are mounted Neutral switch and power switch shall not be used Only buzz er on secondary helm station IMPORTANT Only one neutral switch and pow er switch input shall be installed to the MDI The neutral switch function shall be routed in serial to both helm stations controls for full functionality 1 1 1 IMPO...

Page 36: ...ruments gauges 3 0 10 3 Connection cable 2 pin 10 0 32 4 Tachometer cable 6 pin 1 5 5 For tachometer and multilink 5 Y split multilink 6 pin 6 Y connector 6 pin P N 874760 7 Cable harness For neutral switch power switch and buzzer 8 Auxiliary relay cable IMPORTANT Never cut or modify the Volvo Penta EVC cable harnesses IMPORTANT Never use any kind of grease in the EVC connectors ...

Page 37: ... 5 Starter 6 Main switch 7 Accessory batteries accessory 8 Start battery engine Another battery may be installed in parallel to and to to obtain more battery capacity for accesso ries cable cable B S B 8 7 1 3 2 4 5 5 6 NOTE Max tightening torque 10 Nm 7 4 lb ft NOTE Max tightening torque 10 Nm 7 4 lb ft Starter From battery Main switch Engine block From battery From alternator Cable area 25 mm2 N...

Page 38: ...min Engine D1 D2 25 35 50 70 Relation between mm sq in and AWG AWG mm std sq in 18 0 75 0 029 16 1 5 0 044 14 2 5 0 098 12 2 5 0 098 10 6 0 236 8 10 0 393 6 10 0 393 5 16 0 629 4 25 0 984 3 25 0 984 2 35 1 378 1 0 50 1 969 Recommended start battery capacity Engine Ah CCA SAE standard D1 70 540 D2 88 700 CCA Cold Cranking Amp Total cable length and cable area battery to starter For cables that carr...

Page 39: ...ear shift cable routing is very important for control functionality The shift cable must attach to the reverse gear lever in a straight and unstrained way Sail boat drive 130S SR 150S SR Left hand propeller Standard recommendation is propeller with left hand rotation for forward FORWARD posi tion left hand ro tating propeller ...

Page 40: ...ropeller Right hand propeller Standard recommendation is propeller with right hand rotation for forward The bracket may be turned 90 for cable installation from above The bracket can be mounted for cable installation from astern and from port side From astern From port side A 25 30 mm 1 0 1 2 A A ...

Page 41: ...Bracket Reverse gear HS25 with trolling valve Shifting lever Trolling lever A A Position A Maximum slipping Position B Trolling fuction off Lever travel for the outer pivot point from position B A 51 mm 2 Lever travel for the inner pivot point from position B A 44 mm 1 7 Reverse gear HS25 A B Engine 51 2 44 1 7 A 30 35 mm 1 2 1 4 NOTE Loose fit required NOTE Loose fit required ...

Page 42: ... boat so the expected waterline is horizon tal both length and sidewise Necessary space for drive to be installed taken out NOTE Make sure it is enough space to mount and dismount the drive for future maintenance and repair 665 690 26 1 27 1 454 480 17 9 18 9 230 9 0 115 4 5 100 3 9 230 9 0 115 4 5 310 12 2 800 31 4 100 3 9 Alternative 2 Alternative 1 ...

Page 43: ...inimum 20 mm 0 8 130S 130SR 150S 150SR Formula C D A B This gives at different propeller diameters D D 18 C 140 5 5 A B D 19 C 128 5 0 A B D 20 C 115 4 5 A B D 21 C 103 4 0 A B D 22 C 91 3 6 A B C Measure distance B B Drilled hole position a 295 mm 11 6 D 4 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 A 425 m...

Page 44: ...nded distance 40 mm 1 6 Adjust a pair of compasses to the distance be tween the hull and the marking made at fig 10 Make a line around the complete bed at this height Cut the bed according to this line Grind off the gelcoat on the surface of the bed where there will be covered with fibre glass Put the bed back in the hull position it correctly and make a marking around it 10 11 12 13 14 Min 40 mm ...

Page 45: ...he inside of the hull Grind off the gelcoat on the hull where it will be covered with fibre glass Protect the surface of the bed where the mounts and clamp ring diaphragm will be positioned Make sure the bed is positioned correctly Make a few markings to make sure it does not move during the bonding 130S 130SR 150S 150SR A 125 4 92 B 62 5 2 46 ...

Page 46: ...46 S drive installation 22 23 21 Fibre glass the bed to the hull Clean off the extra fiberglass Protect the surface with top coat Drill a drain hole diameter approximately 30 mm 1 2 ...

Page 47: ...c on the diaphragm Tighten the rear mount to the clamp ring 3 20 Nm 15 lb ft 20 Nm 15 lb ft 40 Nm 30 lb ft A NOTE D2 55 D2 75 only Mount distance plate A 4 2 Install the S drive to the engine Lift the engine and the drive onto the boat WARNING Always use both lifting eyes when lifting the engine 40 Nm 30 lb ft D2 55 D2 75 70 Nm 52 lb ft Install the front mounts NOTE D2 55 and D2 75 has two washers...

Page 48: ...e grease silicon etc on the diaphragm Tighten the rear mount to the engine bed NOTE D2 55 D2 75 only Mount distance plate A Connect the engine to the S drive 20 Nm 15 lb ft 20 Nm 15 lb ft 40 Nm 30 lb ft A Water resistant grease Volvo Penta part no 828250 20 Nm 15 lb ft NOTE Apply water resistant grease on output shaft splines WARNING Always use both lifting eyes when lifting the engine Tighten the...

Page 49: ...pe off with acetone Glue the rub ber seal to the hull Glue is not included in the kit We recommend a good quality contact glue for plastic and rubber NOTE Carefully follow the clue manufacturer s in structions on the package 40 Nm 30 lb ft D2 55 D2 75 70 Nm 52 lb ft Install the front mounts NOTE D2 55 and D2 75 has two washers between mount and engine bracket 6 40 Nm 30 lb ft ...

Page 50: ...50 on the propeller shaft NOTE Use zinc sacrificial anodes for salt water and magnesium anodes for freshwater Zinc anodes are fitted as standard Mount the propeller according to instruction Thread sealant Volvo Penta part no 1161056 70 Nm 52 lb ft 20 Nm 15 lb ft 10 Nm 7 lb ft Thread sealant Volvo Penta part no 1161056 20 Nm 15 lb ft 70 Nm 52 lb ft 10 Nm 7 lb ft ...

Page 51: ... D2 55 10 5 11 0 D2 75 10 5 11 0 NOTE Always check oil dipstick for final topping up Oil quality S drive ATF Automatic Transmission Fluid Dexron II III Type Volumes liters US qts 130S SR 2 9 3 0 150S SR 3 0 3 1 Fill engine and S drive with oil Also see Operator s manual Oil quality reverse gear ATF Automatic Transmission Fluid Dexron II III Reverse gear Volumes liters US qts MS10 0 35 0 37 MS15 0 ...

Page 52: ...52 Notes ...

Page 53: ...53 References to Service Bulletins Group No Date Concerns ...