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Volvo D11 series, Installation Manual

The Volvo D11 series Installation Manual is a comprehensive user guide for the renowned Volvo D11 series engine. This manual provides step-by-step instructions, ensuring hassle-free installation. Download the manual for free from our website, manualshive.com, to access all the invaluable information needed to install and operate this exceptional product.

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Safety precautions

5

  Never work alone when installing heavy com-

ponents, even when using secure lifting equip-
ment 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 
components do not get caught and damaged. 

  The components in the electrical system, the 

ignition system (gasoline/petrol engines) and 
in the fuel system on Volvo Penta products are 
designed and manufactured to minimise risks 
of fire and explosion. Engines should not run in 
environments containing explosive media.

  Always use fuels recommended by Volvo Penta. 

Refer to the Operators’s Manual. Use of fuels 
that are of a lower quality can damage the en-
gine. On a diesel engine poor quality fuel can 
cause the fuel control rack to stick causing the 
engine to overspeed with resulting risk of dam-
age to the engine and personal injury. Poor fuel 
quality can also lead to higher maintenance 
costs.

Summary of Contents for D11 series

Page 1: ...Marine Propulsion Diesel Engines Installation 1 1 D E D5 D16 series ...

Page 2: ......

Page 3: ... 50 Flexible propeller shaft coupling 51 Shaft seals 51 Shaft bearings 53 Installation of stern tube and shaft bearing 54 Engine installation 56 Preparing the engine 56 Flexible engine mounting 58 Rigid engine mounting 62 Alignment 64 Fuel system 66 General 66 Fuel tanks 66 Piping 70 Priming pump for D5 D7 71 Fuel pre filters 72 Checking feed pressure 73 Fuel cooler for D5 D7 74 Cooling system 75 ...

Page 4: ...rrosion 166 Eng room ventilation and soundproofing 168 Introduction 168 Dimension of air intakes and ducts 170 Location of ventilators and air intakes 174 Soundproofing 175 Belt guards and protections 178 Controls 179 General 179 Alternative operating stations 180 Controls 181 Location of the controls 181 Connecting 182 Final check 184 Trolling valve 185 Power take off 186 General 186 Disconnectab...

Page 5: ...rsonal injury If working in proximity of a running engine careless move ments or a dropped tool can result in personal injury Take precautions to avoid hot surfaces exhaust pipes turbochargers charge air mani folds starting elements etc and hot liquids in supply lines and hoses in engines that are run ning or have just been turned off Reinstall all protective parts removed during service opera tio...

Page 6: ... lubrication oil contaminated fuel paint solvents and de greasing agents to a proper refuse station for environmentally harmful material for destruc tion Ensure that the battery compartment is de signed according to current safety standards Never allow an open flame or electric sparks near the battery area Never smoke in proximity to the batteries The batteries give off hydrogen gas during chargin...

Page 7: ... engines and in the fuel system on Volvo Penta products are designed and manufactured to minimise risks of fire and explosion Engines should not run in environments containing explosive media Always use fuels recommended by Volvo Penta Refer to the Operators s Manual Use of fuels that are of a lower quality can damage the en gine On a diesel engine poor quality fuel can cause the fuel control rack...

Page 8: ...specifications drawings and any other data are available before starting work This will allow for correct planning and installation right from the start Plan the engine room so that it is easy to carry out routine service operations involving the replacement of components Compare the engine s Service Manu al with the original drawings showing the dimensions It is very important when installing eng...

Page 9: ...d as notified bodies The directive also allows boat build ers and component manufacturers to issue assur ances of compliance with the requirements of the directive This requires the manufacturer to store the prescribed product documentation in a place that is accessible to the monitoring authority for at least ten years after the last product is produced Life boats and boats for commercial activit...

Page 10: ... 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 11: ...short trips Full power could be utilised max 4 h per 12 h opera tion period Between full load operation periods en gine speed should be reduced at least 10 from the obtained full load engine speed Rating 3 Light Duty Commercial For commercial boats with high demands on speed and acceleration planing or semi planing hulls in cy clical operation Running hours less than 2000 h per year Typical boats ...

Page 12: ...Engine application ratings 10 Examples of boats for medium and heavy duty commercial operation Rating 1 2 Examples of boats for light and medium duty commercial operation Rating 2 3 ...

Page 13: ...Engine application ratings 11 Examples of boats for light duty and special light duty commercial operation Rating 3 4 Examples of pleasure crafts Rating 5 ...

Page 14: ...ent temperature humidity fuel thermal value fuel temperature not EDC engines and back pressure Deviation from normal values affects diesel and petrol engines differently Diesel engines use a large amount of air for combus tion If the mass flow of the air is reduced the first sign is an increase in black smoke The effect of this is especially noticeable at planing threshold speed where the engine m...

Page 15: ...cts marine engineers or other qualified people should choose the propeller The required en gine performance data to make the proper propeller selection is available in technical literature With regard to the propeller selection it is important to achieve correct engine RPM For this purpose we recommend Full Throttle Operating Range In order to achieve good all round performance the propeller shoul...

Page 16: ... Should the propeller load be less than the rated horsepower the engine will operate above the specified range A propeller load that is greater than the engines rated horsepower will result in the engine not being able to reach the rated rpm and will therefore overload the engine An engine in a newly launched vessel is likely to be exposed to the lightest loads This is because the to tal displacem...

Page 17: ...rformance of the ves sel and long engine life correct propeller size is es sential Selecting the correct propeller will enable the engine to develop its full power and provide the per formance that is expected There are a number of factors with their tolerances that can greatly affect the performance of the vessel These must be recognised for correct engine propel ler selection These factors are A...

Page 18: ...n Societies have established their rules so that the authorities requirements are cov ered The authorities however have requirements for lifeboats that are not included in the rules of the Classification Society In 1974 an International Convention for the Safety of life at sea SOLAS was adopted by the International Maritime Organisation IMO This document ratifies uniform rules for life saving equi...

Page 19: ...nitiated as a result of a re quest from a customer or dealer who has to deliver an engine in a classified installation For these orders Volvo Penta normally starts with a type approved engine During production of such an engine the surveyor checks the production if there is no quality assurance system agreement Separate certificates are issued for the following components Crankshaft connecting rod...

Page 20: ...e D7 For measuring exhaust backpres sure and temperature 9812519 Multimeter 9988452 Digital probe tester 9996065 Manometer For measuring fuel feed pres sure not D9 D11 D12 9996398 Manometer D9 D11 D12 D16 For measur ing fuel feed pressure 9996666 Connection D9 D11 D12 D16 For measur ing fuel feed pressure 9998494 Hose and nipple D9 D11 D12 D16 For measuring fuel feed pressure 3838620 VODIA tool Fo...

Page 21: ...es are Oil and coolant Sealant and grease Touch up paint Refer to Volvo Penta Accessories Maintenance Parts Publications Installation Electronic Vessel Control EVC Installation Marine Commercial Control MCC Marine Electrical Systems Part 1 Inboard propellers and speed calculation Installation Water Jet Sales Guide Marine Propulsion Diesel Engines Volvo Penta Accessories Maintenance Parts Workshop ...

Page 22: ...se gear s out put shaft are parallel The output shaft is on a lower level than the crankshaft The engine and reverse gear form one unit The com pressive forces from the propeller are absorbed by an axial bearing in the reverse gear Coaxial down angle The extension of the engine crankshaft centre line is angled in the reverse gear The angle of the propeller shaft deviates from the angle of the cran...

Page 23: ...ler shaft can deviate from the angle of the crankshaft The remote reverse gear must first be installed and carefully aligned nominated by the propeller shaft Then the couplings are fitted and the engine is aligned to the reverse gear For final location and to prevent possible shock loads lugs must be welded in front of and behind the brackets on each side Wedg es are then driven in and secured by ...

Page 24: ...es from the propeller are absorbed by an axial bearing in the reverse gear The remote V drive must first be installed and care fully aligned according to the propeller shaft Then the shaft and couplings are fitted and the engine is aligned to the reverse gear For final location and to prevent possible shock loads lugs must be welded in front of and behind the brackets on each side Wedg es are then...

Page 25: ...ine package If this application concept is consid ered attractive further information and support can be acquired from Volvo Penta Sales Organisation Another transmission concept is the multi belt utilis ing a number of diesel engines driving a common shaft to a remote marine gear The engines in this ap plication are normally disengagable by a clutch The concept is proven very functional to obtain...

Page 26: ...s used as an alternative to a fixed propeller The pitch of the propeller blade is normally regulated by means of a built in function in the re verse gear A number of surface piercing propeller systems are available on most markets These systems are aimed at high speed applications where the systems are highly efficient The systems are available with rud der arrangements or steerable drive unit At ...

Page 27: ...may fracture the crankshaft and flywheel bolts and overheat the vibration damper Since compatibility of the installation is the system designer s responsibility it is also his responsibility to obtain the theoretical torsional vibration analysis Volvo Penta standard propulsion packages would generally not require TVCs unless front end PTO is utilised TVCs are recommended for all heavy duty commerc...

Page 28: ...ommunication re garding the matter 2 All communication in TVC matters should be directed to the Quality System and Classifica tion Department The responsibility for internal handling is on Quality System and Classification Department at the production unit in Göteborg 1 Engine 2 Coupling disengagable 3 Pulley 4 Coupling 5 Pump compressor etc with the same rpm as engine 6 Reduction gear reverse gea...

Page 29: ...ften needed to finally find the es sential set of performance requirements the instal BOAT VESSEL REVERSE GEAR AND PROPELLER PERFORMANCE LIMITATIONS PROPULSION SYSTEM POWER REQUIREMENT ENGINE lation aims to fulfil Analysis of each contribution may vary depending on the dominating priorities such as top speed economy safety etc Consult Volvo Penta literature and computer programs or contact the Vol...

Page 30: ...er and exhaust boot The starboard propeller shaft is mounted with a wa ter lubricated stuffing box with water tapped off from the reverse gear oil cooler The port propeller shaft has a grease lubricated stuffing box The control is an electrical to mechanical system Installation example This illustration is also avail able as a four colour poster size 500 x 700 mm Publ no 7738092 1 ...

Page 31: ... consider international and local re quirements 1 Engine room layout Only use updated and approved dimensional draw ings Study the drawings carefully Consider sound proofing material the engine s movements when run ning and accessibility for servicing and repairs For twin installations the distance between the en gines should be sufficient to allow easy performance of inspection and service work 2...

Page 32: ...fficient duct area and pay attention to optimise the design of air inlet Plan the routing of the ducts hoses for the engine s air consumption and ventilation so that they do not impede installation of the batteries fuel tanks etc Sound insulation in the engine room is of great im portance to keep the sound level as low as possible Sufficient space for soundproofing material must also be planned fo...

Page 33: ... This means that if the propeller diameter is limited in size as is often the case it is better to select several narrower blades four or five rather than three wide ones for example The angle of the propeller shaft should be as small as possible Shaft angles of less than 12 do not usu ally cause any major problems but shaft angles of more than 14 15 should be avoided The distance between the bott...

Page 34: ...e whether the pro peller should be at its best when trawling e g with a pitch ratio of 0 7 or whether it should be better when not trawling with a slightly higher pitch ratio Adjustable propellers are an excellent solution for trawlers tugs and freighters As a very rough estimate the bollard pull thrust can be calculated using the formula Adjustable propeller N 95 105 x kW Fixed propeller N 80 90 ...

Page 35: ... flat The hull can be reinforced on the inside to reduce noise and vibrations caused by the propeller blade pulses A B C rpm kW For the best propeller efficiency the angle of the pro peller shaft in relation to the water line should be as small as possible The larger the shaft angle the low er the efficiency Shaft angles exceeding 12 should be avoided if possible This means that with the boat lyin...

Page 36: ...e rudder It should be possible to move the propeller shaft at least 200 mm 8 aft to allow the removal of the reverse gear or coupling Also make sure that any transverse bulk head does not impede its removal Sufficient clear ance approx 1 x the shaft diameter must be pro vided between the propeller and the stern bearing to prevent the propeller from pressing against the stern bearing Allowance shou...

Page 37: ...nti clockwise seen from the aft forward Otherwise there is a risk that air bubbles will be drawn down into the water between the two propellers which can cause ventilation Choice of reduction ratio The propeller shaft usually has lower speed than the engine This is normally achieved with the reduction in the reverse gear As a rule the largest possible ratio should be chosen for slow going displace...

Page 38: ...ine inclination while the boat is under way This in clination includes both the installation inclination and the trim angle that the boat engine has when going through the water A The engine s static inclination B The boat s trim angle under way C Total inclination of engine under way maximum permissible inclination A B Max engine inclination Static A Under way C Engine Flywheel Flywheel Flywheel ...

Page 39: ...A Weight distribution General The centre of gravity has a major influence on the boat s static and dynamic stability It is therefore im portant to consider this for the both when loaded and unloaded Planing and semi planing hulls For planing and semi planing hulls especially it is im portant that heavy equipment such as engines fuel tanks water tanks and batteries are positioned in a way as to obt...

Page 40: ...gine carefully Accessibility for maintenance Some areas that normally require access for mainte nance Oil change and refill Change of oil filters Change of fuel filters Venting fuel system Change of air filter Check of belt tension Change of belts Removal of valve cover Change of seawater impeller Cleaning of water filter Venting cooling system Accessibility for repairs Some areas that may require...

Page 41: ...the bed frame thus contributing to a low noise level Dimensions for flexible mountings see chapter Building the engine bed There are two types of rubber mounts mounts that are adjustable in the vertical plane and mounts with a fixed height that must be shimmed to the correct height Flexible engine suspen sion rubber mount Flexible engine suspen sion rubber mount The rubber mounts are compressed du...

Page 42: ...th a V drive this force could be higher than that from the weight of the engine and gear box Engine rubber mount Axial component Propeller thrust Vertical component 1 This will create a lifting force to the engine mounts fitted at the same end as the gear box Therefore all engines with a close coupled V drive must be equipped with mounts that are designed for this type of installation at the rear ...

Page 43: ...rive package is not particularly noticeable with a large hull It is very important that the bed is level where the engine mounts rest since otherwise there is a risk of building tensions into the suspension joint With rigid mounting the engine mounts are bolted to the engine bed with 10 mm 0 4 thick shims The shims need to be milled to the correct size in conjunction with the final alignment toget...

Page 44: ...mounts and flexible shaft seal In this case a flexible shaft coupling should not be installed 1 Flexible engine mountings 2 Fixed shaft coupling 3 Flexible mounted shaft seal 4 Water lubricated stern bearing L Maximum distance between support points For calculation see page 50 2 Engine with flexible mounts and fixed shaft seal 1 Flexible engine mountings 2 Flexible shaft coupling 3 Fixed front ste...

Page 45: ...le cou pling as an alternative 3 Fixed front stern bearing and shaft seal 4 Water lubricated stern bearing L Distance between support points For calculation L max see page 50 C Distance reverse gear flange sup port point Regarding C min see page 50 C max is calculated in the same way as L max C L 1 1 2 4 3 Flexible coupling as an alternative a flexible coupling must always be fitted between the re...

Page 46: ...t of move ments in the hull in rough sea or when the boat is put on shore or into the sea Design The bed should have a design basis that enables it to absorb by an adequate margin the engine torque the compressive force of the propeller and the dynamic forces mass forces that occur during movement in rough sea When designing the bed it is important that there is sufficient space under the engine f...

Page 47: ...d as far as possible to the hull The bed is often built as a box construction As much of possible of the engine bed including cross members should be attached to the hull to ensure the best possible noise and vibration insulation The engine bed can be built up separately and then carefully measured and bonded to the hull or be built up directly in the hull It is important that the bed con nects to...

Page 48: ...with bolts and nuts The length of the engine bed should be extended as far as possible to distribute the load If the engine has an extra PTO in the front end that requires extra support the bed should be designed to accommodate this support There must be space in front of the PTO so that it can be dismantled Take into consideration and calculate brackets and foundations etc for other systems fuel ...

Page 49: ...empo rary be installed and located in a correct position Alternative 2 parallel gearboxes only Another method to fix the engine bed without a fixture or the engine is to apply a line from the rear end 3 centered in the stern tube 2 to a fixed point 5 for ward of the engine bed The measurement A should be equal to the rulers 1 within 0 2 mm 0 0 08 See figure Ensure that the rulers are horizontal at...

Page 50: ...of layers of fibreglass Seal the surface with gelcoat To reduce noise and vibrations the engine bed should be filled with a material that does not absorb water Build up the engine bed with spacer material A so that the underside of the engine mounts engine rub ber mounts almost rest against the bed Divinycell for example can be used as spacer material There must be room for flat bars and fibreglas...

Page 51: ...he engine mounts rubber mounts should be drilled in conjunction with installing the engine in the boat See also chapter Engine installation Align the engine to the propeller shaft and mark up for the holes of the engine mounts Drill and thread the holes in the bed and flat bars Recommended bolt diameter for Volvo Penta elastic mounts is 5 8 alternatively M16 Align the engine to the propeller shaft...

Page 52: ...aft it is of great impor tance to protect the precision straightness and fine surface finish When lifting shafts it is best to use slings with spreaders to distribute weight more evenly to avoid straightness problems Always check the straightness of the propeller shaft The run out of the shaft from 100 straightness must not exceed 0 3 mm per metre 0 0036 per foot Shafts that are tapered at both en...

Page 53: ...ube The feed pipes should be designed to build up pres sure through the boats motion in water It is important to check that the water lubrication is adequate also at full speed while test running a new installation Make sure that the pipes 2 allow enough water to flow in 1 2 2 1 Shaft seal 2 Water pick up pipes Flexible propeller shaft coupling Together with a flexible mounted engine and a fixed s...

Page 54: ... a 10 mm 3 8 hose from the reverse gear oil cooler It is important to check that the water lubrication is adequate also at full speed while testing a new in stallation NOTE For D16 the oil cooler is delivered separately For installation instructions contact Volvo Penta The grease is injected either with a grease cup fitted to the seal assembly or from a remote greaser The bolt holding the seal sho...

Page 55: ...bearing is to create a film of water upon which the propeller shaft floats Normal play between shaft and bearing is 0 1 of the shaft diameter Bearings fitted in for example p brackets are normally self lubricated but for bear ings in stern tubes is it important to ensure the water supply Metal bearings Metal bearings are often fitted inside a stern tube or a separate support bearing and grease lub...

Page 56: ...e engine can be used as a fixture to de cide the location of the stern tube and bearing The engine must be adjusted to its nominal position In serial productio tailor made fixtures are often used instead of the engine to locate the stern bearing Installation of stern tube and shaft bearing A ...

Page 57: ...des 3 Check that the shaft is not bent in front of the tube support the shaft if necessary After alignment has carefully been done the stern bearing can be bolted or bonded in place 1 2 3 4 4 mm 0 16 The clearance between the propeller shaft and tube for a flexible mounted engine should be min 4 mm 0 16 If the stern bearing is to be bolted to the stern the contact surface for the bearing flange mu...

Page 58: ...uipment and accessories on the en gine such as extra alternator hot water outlet power take off etc before engine is installed The figure above shows a flexible mounted engine NOTE All engines are delivered from Volvo Penta without engine oil and coolant Check that the oil plug and draining cocks for coolant hot water cocks etc are closed Fill oil and coolant See chapters Coolant and Filling with ...

Page 59: ...ater on If the engine is rigid mounted Lift the engine into the boat and on to the bed The lifting device should also be available when making the alignment to the propeller shaft later on Install adjustment bolts for vertical adjustment 1 in the engine brackets Tighten the bolts until they are in contact with the bed plane Install adjustment bolts for lateral adjustment 2 1 2 Install the rubber m...

Page 60: ...r engine type This chapter explains the procedure using a mount which is adjustable in the vertical plane with a nut Mounts adjusted with shims follow in principle the same procedure but use shims to adjust the engine height A Nominal height D12 130 mm 8 mm 5 1 0 27 All other engines 117 mm 8 mm 4 6 0 31 V Lateral adjustment 8 mm 0 30 B To verify height adjustment 0 16 mm 0 0 62 Height adjustment ...

Page 61: ...gine is installed the load on the front pair of mounts as well as the load on the rear pair of mounts must be equal Measure the compression B of the mounts on all sides The difference between port and starboard mount must not exceed 2 mm 0 08 B Compare front and rear mounts sidewise in pairs Adjust as necessary After alignment to propeller shaft and verification of engine bed parallelity and loadi...

Page 62: ...eight 125 mm 4 9 may not be exceeded Side adjustment V 7 mm 0 28 Side adjustment is done by using the slotted holes H on the base plate of each anchorage To start off with the rubber anchorages should be placed in the center of the slots with the slots aligned parallel to the length of the engine bed Check whether there is any deviation from parallelism in the engine bed 2 A V V H B1 B2 Also measu...

Page 63: ...he two rear mountings be Measure the compression B of the engine mount ings on each side The difference between port and starboard mountings must not exceed 1 mm 0 04 Compare the sideways alignment of the front and mountings of the front and rear mountings as pairs Adjust as necessary Tighten the top nut on each engine bed after align ment in relation to the propeller shaft Check paral lelism of t...

Page 64: ...the engine to the propel ler shaft with adjusting bolts 7 8 Always attempt to have even load on the height adjustment bolts 8 on port and starboard side Make the final alignment see chapter Alignment Verify that there is some space clearance between the bed and the engine brackets for later alignments Check that the engine is standing on all four height adjustment bolts 6 using a 0 10 mm 0 04 file...

Page 65: ...he wedges must be welded and the surplus part cut off After the boat has been taken into use check at reg ular intervals to ensure that no change has occurred in alignment due to changes in the shape of the hull Poor alignment between the engine and the propeller shaft can cause vibrations in the hull reverse gear damage rapid wear of propeller shaft thrust bear ings propeller shaft bearing sleeve...

Page 66: ...flanges through 90 180 and 270 and repeat the check in the new positions NOTE Make sure that the flanges are pressed against each other throughout the entire check When the engine is fitted on rubber mountings align ment must be carried out with the same care as in the case of fixed mountings IMPORTANT The alignment should be re checked a few days after launch with the boat completed and rigged sa...

Page 67: ... engine and reverse gear in position Make sure that all adjuster bolts for the vertical position are unscrewed so that the brackets rest on the shims or spacers The adjuster bolts are then removed After the boat has been launched check alignment once again The boat should have been in the wa ter for some days and should be loaded with all the tanks full The hull is always flexible and does not hav...

Page 68: ...clamping intact on the engine Otherwise there will be a risk of broken pressure line and fire When working with the fuel system it is important to keep it free from dirt Fuel tanks If possible the tanks should be located so that they are at the same level or somewhat higher than the engine If they are placed lower due attention must be paid to the maximum suction height of the feed pump which is 1...

Page 69: ...Feed pump 2 Injector unit 6pcs 3 Fuel tank 4 Shut off valve optional se section Fuel tanks 5 Primary filter and water separator 6 Fuel fine filter and water separator 7 Leak off line 8 Return to tank 9 Electronic Control Module ECM Example of fuel system D9 4 2 x6 3 1 2 x6 4 5 6 3 9 8 7 1 Feed pump 2 Injector unit 6pcs 3 Fuel tank 4 Shut off valve optional se section Fuel tanks 5 Primary filter an...

Page 70: ... An extra fuel filter with water separator must be installed for all Volvo Penta engines If a day tank is installed then it is advisable to con nect the return line to this tank A shut off valve must be installed in the supply pipe between the tank and the filter This tap should be able to be shut from a location outside the engine room 1 5 5 11 9 7 2 3 8 9 13 10 1 4 4 6 14 14 12 1 Fuel tank 2 Fue...

Page 71: ...he shut off valve may have a remote controlled shut off function by means of a push pull cable for example Certain mar kets require electrically controlled shut off valves The fuel return line on diesel engines must be drawn back to the bottom of the tank in order to avoid air from entering the fuel system when engine is stopped Position the tank on some kind of soft bedding Do not position the ta...

Page 72: ...ubing at either end with at least 75 mm 3 0 and be locked with two hose clamps The hose clamps must be made of a corrosion resistant material Common ground for the fuel tank filling etc is not generally necessary for diesel installations Local authorities however could demand this on boats in general NOTE Install the filler and venting hoses preventing traps 3 being formed NOTE The fuel filler fit...

Page 73: ...system if the tank is located be low the engine a prime pump must be installed on a bulkhead or similar between fuel tank and prefilter NOTE It s important to install the pump with the ar row upwards according to the picture below 6 m 20 6 m 20 D5 D7 14 mm 16 mm D9 D11 D12 D16 10 mm 3 8 12 mm 1 2 From tank to fuel line connection point D5 D7 12 mm 1 2 12 mm 1 2 D9 D11 D12 D16 10 mm 3 8 10 mm 3 8 F...

Page 74: ...not done the stop fuction will not work be cause there will not be sufficient negative pressure in the injection pump Fuel pre filters Single or double filters The filter shall be installed on the suction side of the feed pump between the feed pump and the fuel tank and should be located at a height between the base of the fuel tank and the feed pump to reduce the re sistance in the supply pipe In...

Page 75: ... if necessary 9998339 9998494 Measure the feed pressure at the fuel inlet hollow screw on the front of the engine block P by using manometer 999 6398 with nipple 999 6066 and a long hollow screw 44 mm with a new copper wash er 969011 NOTE The feed pressure shold be min 280 kPa 40 6 psi P D5 D7 D9 D11 D12 D16 The hose and nipple 999 4894 and the manometer 999 8339 are connected to the air vent outl...

Page 76: ...ines with high pressure injec tion require a lower fuel temperature level Through design and material selection when building the fuel tank and its mounting position in the unit good vent ing avoiding additional heating the fuel temperature characteristics can be influenced Safe and defined heat dissipation can also ensured by an accordingly dimensioned fuel cooler Theses kind of fuel coolers are ...

Page 77: ...on instructions are to be treated as recommenda tions The only way to tell whether an installation is correct is to check pressures temperatures and flows with the engine running In case of doubt contact the Volvo Penta organisation To reduce corrosion to a miniumum use the correct combinations of materials in pipes valves etc plus a correctly sized and pressurized expansion tank Electrolytic corr...

Page 78: ... D5 D7 and 3 m 10 for all other engines The seawater intake valve and strainer must have sufficient flow area For planing crafts a sloted water intake is recommended To avoid the seawater becoming blocked when pass ing through ice the intake can be designed as shown in the illustration 1 Valve for seawater intake 2 Valve for flushing with hot water The sea cock must be easily accessible and in cer...

Page 79: ...id resistant stainless steel pipe Connections above the waterline are to be made with high quality rubber hose with several layers of fabric to resist hose collapse under suction Double stain less steel hoseclamps must be used at both ends of the hose Dimensions of hoses Dimensions of hoses and pipes for seawater to and from the engine see drawings for each engine type 200 mm 8 200 mm 8 500 mm 20 ...

Page 80: ...a water pump 5 Charge air cooler D5 D7 TA 6 Heat exchanger 7 Oil cooler reverse gear 8 Exhaust elbow 9 Bypass only D5 A B D E Seawater temperature max 32 C 90 F PB max 1 bar 14 5 psi t B max 32 C 90 F tE tB E 1 2 4 5 6 7 9 3 8 1 Strainer 2 Seawater valve 3 Seawater filter 4 Extra seawater pump 5 Sea water pump 6 Oil cooler reverse gear 7 Charge air cooler 8 Heat exchanger 9 Exhaust elbow PA min 0 ...

Page 81: ...3 bar 4 4 psi PA max 1 0 bar 14 5 psi 1 1 2 3 3 5 5 8 9 4 A B C D E D12 Seawater temperature max 32 C 90 F D12D B MP max 30 C 86 F D16 A Seawater temperature max 32 C 90 F PB max 1 1 bar 16 psi t B max 32 C 90 F TB E 1 Strainer 2 Seawater valve 3 Seawater filter 4 Extra seawater pump 5 Sea water pump 8 Heat exchanger 9 Oil cooler reverse gear 1 1 2 3 3 5 5 8 9 4 A B C D E A PA min 0 3 bar 4 4 psi ...

Page 82: ...ing must have sufficient flow area to avoid restriction losses Any bends in the line must be swept to avoid unnecessary restriction losses Copper pipe is recommended It should be ar ranged in a U bend to reduce stresses and must be connected with reinforced rubber hose To pre vent collapse the hose must have several layers of fabric E The temperature increase of the seawater tB E and the pressure ...

Page 83: ...1900 rpm 2 16 19 29 35 2300 rpm 2 16 19 29 35 D9 221 kW 1 10 12 18 22 D9 261 kW 1800 rpm 1 13 15 24 27 D9 261 kW 2200 rpm 1 12 14 22 26 D9 313 kW 2 3 15 18 27 33 D9 368 kW 4 17 19 31 35 D9 425 kW 5 20 24 36 44 D11 493 kW 5 21 25 38 45 D12 294 kW 1 11 13 20 24 D12 331 kW 1 13 15 24 27 D12 405 kW 2 17 20 31 36 D12 452 kW 3 15 18 27 33 D12 478 kW 4 16 19 29 35 D12 496 kW 5 16 19 29 35 D12 515 kW 5 13...

Page 84: ...lvo Penta Cool ant conc coolant and 80 water This mixture protects the engine against internal cor rosion cavitation and frost damage down to 28 C 18 F Using 60 glycol lowers the freezing point to 54 C 65 F Never mix more than 60 concentrate Volvo Penta Coolant in the cooling liquid this will give reduced cooling effect and increase the risk of over heating and will give reduced freezing protectio...

Page 85: ... Start the engine and let it run without load at 1000 1500 rpm for 15 20 minutes Check coolant level D12 Open all venting nipples when filling Fill at the rate of approximately 10 15 l min 2 5 4 0 US gal min Close the venting nipple s as no bubbles can be seen in the coolant Fill until the system is completely filled up including the expansion tank Start the engine and let it run without load at 1...

Page 86: ...nting nipples D5 D7 D9 D11 D16 D5 D7 D9 D11 D16 has no venting nipples The cool ing system is automatically vented D12D A MP D12D B MH All cooling systems D12D B MP All cooling systems Cooling pipe turbo Cooling pipe turbo ...

Page 87: ...he highest point of the engine cooling system The volume of the expansion tank should be equivalent to about 15 of the total volume of the keel cooling system See chapter Extra expansion tank for further details The extra expansion tank must be connected to the suction side of the circulation pump of the en gine via a static pressure line There must be means of venting inbetween the standard expan...

Page 88: ...ler 250 kPa 36 3 psi In cases where the maximum coolant pressure of the engine is exceeded a heat exchanger capable of handling the higher pressure must be connect ed in between the engine and the central cooling system An extra expansion tank for the engine must also be connected to the system For further details see un der chapter Extra expansion tank Depending on system temperatures in the cent...

Page 89: ...Cooling system 87 Keel cooling Pipe cooling system Pipe cooling detail Keel cooling Skin cooling system Skin cooling detail ...

Page 90: ...ea water cooled engines The seawater pump and the heat exchanger s have been removed The engines have been fitted with connections for the external cooling system The figures below show the connections on the en gines and the inner diameter of the hoses D5 D7 One circuit keel cooling 1 To keel cooler 2 From keel cooler 2 50 mm 2 1 50 mm 2 ...

Page 91: ...l coolers 1 To keel cooler charge air cooler circuit 2 From keel cooler charge air cooler circuit 3 To keel cooler engine coolant circuit 4 From keel cooler engine coolant circuit D5 D7 Two circuit system with one keel cooler 2 38 mm 1 5 1 40 mm 1 6 2 38 mm 1 5 1 42 mm 1 6 3 50 mm 2 4 50 mm 2 ...

Page 92: ...uits keel cooler 1 To the keel cooler charge air cooler circuit 2 From keel cooler charge air cooler circuit 3 To keel cooler engine coolant circuit 4 From keel cooler engine coolant circuit 2 50 mm 2 1 50 mm 2 4 50 mm 2 3 50 mm 2 ...

Page 93: ...stem 91 D12 One circuit keel cooler Port side 4 3 5 1 57 mm 2 1 4 1 From keel cooler 2 To keel cooler 3 Standard expansion tank 4 Extra expansion tank 5 Reverse gear oil cooler Starboard side 4 1 5 2 57 mm 2 1 4 ...

Page 94: ...r Starboard side 1 To the keel cooler charge air cooler circuit 2 From keel cooler charge air cooler circuit 3 To keel cooler engine coolant circuit 4 From keel cooler engine coolant circuit 1 45 mm 1 8 4 50 mm 2 3 42 mm 1 7 Port side 2 38 mm 1 5 ...

Page 95: ...3 D5A TA 11 2 9 63 16 6 D12 44 11 6 135 35 6 D7A T 14 3 7 63 16 6 D161 39 10 3 59 15 6 2 D7A TA 14 3 7 63 16 6 D7C TA 14 3 7 63 16 6 1 Volumes for engine circuit only 2 For D16 an extra expansion tank on the LT circuit should always be used Dimensioning of external cooling systems Heat rejection from freshwater system in kW For additional data on temperature pressure and coolant flow see Sales Gui...

Page 96: ...m 1 7 13 3 6 D5A TA 1900 rpm 2 9 17 2 4 D5A TA 2300 rpm 2 8 15 3 6 D7A T 1900 rpm 1 12 22 D7A T 2300 rpm 1 11 20 D7A T 1900 rpm 2 13 24 D7A T 2300 rpm 2 12 22 D7A TA 1900 rpm 1 11 20 2 4 D7A TA 2300 rpm 1 10 18 3 6 D7A TA 1900 rpm 2 12 22 2 4 D7A TA 2300 rpm 2 12 22 3 6 D7C TA 1900 rpm 1 12 22 2 4 D7C TA 2300 rpm 1 11 20 3 6 D7C TA 1900 rpm 2 13 24 2 4 D7C TA 2300 rpm 2 13 24 3 6 D9 Please refer t...

Page 97: ...ple for measuring pressure and temperature The T nipple is used when measuring both pressure and temperature in the cooling circuit The tool is not stocked by Volvo Penta Note that it is important to place the probe correctly in the coolant flow See figure above D5 D7 D9 D16 Pressure before and after keel cooler Connections for measuring pressure in the cool ing circuit on D5 D7 D9 D16 has to be b...

Page 98: ... NPTF Reverse gear oil cooler Measuring temperature in keel cooling systems Gauge connections NOTE Before installation is carried out the internal freshwater temperature to and from the keel cooler must be checked The temperature gauge connections of the engines are shown in the illustrations below D5 D7 D9 D16 Temperature before and after keel cooler Connections for measuring temperature in the c...

Page 99: ...T2 and the charge air cooler circuit keel cooler 2 T3 T4 see table on page 94 for each engine type D5 D7 T External cooling One circuit system 1 Engine 2 Expansion tank 3 Keel cooler engine circuit Engine oil cooler Charge air cooler Reverse gear oil cooler Connection flange or thread for valve Thermostatic valve Circulation pump Seawater pump Air vent nipple Restriction Cooler Turbo External syst...

Page 100: ...e Thermostatic valve Circulation pump Seawater pump Air vent nipple Restriction Cooler Turbo External system Internal system Volvo Penta responsible Scope of supply from Volvo Penta D5 D7 TA External cooling Two circuit system with one keel cooler P1 T1 P2 T2 For temperatures max pressure drop and flow see Technical data in Sales Guide Marine Propulsion Diesel Engines ...

Page 101: ...ead for valve Thermostatic valve Circulation pump Seawater pump Air vent nipple Restriction Cooler Turbo External system Internal system Volvo Penta responsible Scope of supply from Volvo Penta D5 D7 TA External cooling Two circuit system with two keel coolers P3 T3 03 P1 T1 P2 T2 P4 T4 For temperatures max pressure drop and flow see Technical data in Sales Guide Marine Propulsion Diesel Engines ...

Page 102: ...ion Diesel Engines D9 External cooling Two circuit system with two keel coolers Engine oil cooler Charge air cooler Reverse gear oil cooler Connection flange or thread for valve Thermostatic valve Circulation pump Seawater pump Air vent nipple Restriction Cooler Turbo External system Internal system Volvo Penta responsible Scope of supply from Volvo Penta 1 2 4 3 5 CAC EOC GOC External system Note...

Page 103: ...oler Connection flange or thread for valve Thermostatic valve Circulation pump Seawater pump Air vent nipple Restriction Cooler Turbo External system Internal system Volvo Penta responsible Scope of supply from Volvo Penta For temperatures max pressure drop and flow see Technical data in Sales Guide Marine Propulsion Diesel Engines 4 5 2 1 3 4 4 4 4 P2 T2 P1 T1 Q1 CAC GOC T3 T4 T5 T6 ...

Page 104: ...ust be installed when system volume exceeds 20 ltr Not incl in delivery Size should be adapted to circuit volume NOTE Dearation must be moved to the extra expan sion tank refer to schematic For temperatures max pressure drop and flow see Technical data in Sales Guide Marine Propulsion Diesel Engines NOTE Dearation must be moved to the extra expansion tank ...

Page 105: ...open The following table shows opening temperatures for the various thermostats and the gap of the opening when fully open IMPORTANT Do not run an engine without thermostats Thermostats external cooling Engine D5 D7 D9 D12 D16 No of thermostats 1 1 1 1 Opening temp C F 83 181 86 187 76 169 86 187 Fully open C F 95 203 96 205 86 185 96 205 84 183 Opening with fully open therm mm inch 8 0 32 16 0 63...

Page 106: ...row out if an undesired quick stop occurs With a correctly designed cooling system the pressure cap prevents ventilation Avoid opening the pressure cap If necessary always open cap when the engine is cold Connection B is to be connected before the ther mostat with the hose continuously inclining in or der to ensure deairing when filling up coolant after the system has been drained In the case of a...

Page 107: ...g period thus causing cavitation of the jacket pump During idling the thermostats close the coolant is cooled off and contracting The pressure cap has a low pressure relief valve C which opens up around 15 kPa 2 2 psi It is not healthy for a jacket pump to operate with an inlet pressure of 0 kPa 0 psi and below since cavitation is likely to occur 75 kPa 11 psi 0 75 kPa 0 11 psi 15 70 kPa 2 2 10 2 ...

Page 108: ...ra circuit IMPORTANT When the volume is further increased the cooling system has to be equipped with a larger expansion tank Please contact the Volvo Penta organisation for more information Extra expansion tank All engines Type of pressure cap and opening pressure depending on height Height H Type of pressure cap engine valve cover MIN mark 2 0 m 6 5 75 kPa 10 9 psi 2 0 5 0 m 6 5 16 5 50 kPa 7 3 p...

Page 109: ... MIN 3 4 1 2 The expansion tank of the engine must have a sepa rate vent 3 to the extra tank connected below MIN level NOTE If there are no manual venting nipples the hose 3 must be continously inclining The hoses must be able to withstand temperatures up to 115 C 240 F The engine s pressure cap is replaced with a sealed cap The standard engine venting hose from the thermostat housing can be conne...

Page 110: ...h the engine block It is important that the en gine heater is of the right type is correctly connected and maintains the engine coolant at the right tem perature The heater should have its own circulation pump and be located in a protected area The figures on the following two pages show for each engine model connecting points for a separately mounted heater An engine mounted engine heater can be ...

Page 111: ...Cooling system 109 D5 D7 An engine mounted engine heater can be provided for the D5 and D7 engines D9 D11 Engine heater connections From engine heater To engine heater M16x1 5 19 5 mm ...

Page 112: ...Cooling system 110 D16 Engine heater connections D12 Engine heater connections 1 2 R 1 2 R Thermostat housing To engine heater From engine heater From engine heater To engine heater 1 2 R 1 2 R ...

Page 113: ...neral A cabin heater and or a calorifier can be connected to the freshwater circuit of the engine When a cabin heater is installed it must always have a manual venting nipple 4 at its highest point The system is vented once pressurized In large heating systems a hose thermostat 5 should be mounted in the line of the hot water cir cuit This ensures that the engine quickly reaches its operating temp...

Page 114: ...water flow and temperature drop Max allowed water flow 18 l min Max allowed temperature drop 30 C 86 F The external circuit must be designed to restrict the flow to not exceed the allowed flow The external cir cuit is by passing the engine cooling circuit to great flow may cause engine overheating If the heating is designed so that it can dissipate more heat whit the available quantity of coolant ...

Page 115: ...Cooling system 113 D16 Hot water connections Inlet from hot water circuit Outlet to hot water circuit Engine coolant pump 1 2 R 1 2 R Outlet Inlet ...

Page 116: ...designed and installed in such a way that the exhaust emissions are taken out of the boat without any harmful backpressure for the en gine and so that there is no risk of overheating any adjacent parts of the boat The demand for silencing must also be met and the system ar ranged in such a way as to prevent the gases from entering the boat All exhaust systems must be installed in such a way that w...

Page 117: ...cturers should note that U S federal regulations applicable to U S vessels require the installation of an ex haust sampling port in the exhaust system that could be used for connection to an exhaust emissions measuring device This applies to engines certified according to U S EPA 40 CFR part 94 regulations Where Volvo Penta have not added a sam ple port for example when an inadequate amount of the...

Page 118: ...s with silencers especially the Aqua lifts contribute to the system s total backpressure The contribution of each silencer must be carefully esti mated and calculated as well as sea trialed and veri fied by measurements NOTE U S federal regulations applicable to U S vessels require the installation of an exhaust sam pling port in the exhaust system See chapter Gen eral under Exhaust system Wet exh...

Page 119: ...supported 1 to avoid a sack see figure A Inclination angle β figure B from elbow to silencer should be min Longitudinal inclination 4 according to figure B Longitudinal inclination systems without silencer 10 Transverse inclination 10 according to figure C Fig B β Transverse inclination β figure C The inclination should be minimum 10 This presumes that the coolant can be collected in the silencer ...

Page 120: ...nd D min The height of exhaust elbow above water line C min see fig D should be 200 mm 8 If less a vacuum valve is needed in the cooling system to avoid siphon action that could result in water ingress through the exhaust system The height of anti siphon valve above water line D min should be at least 500 mm 20 A suitable position of the valve is as close as possible to the centre line of the boat...

Page 121: ...haust backpressure See table on in this chapter under section Recom mended hose diameters for dimensioning hoses for and after the silencer The minimum height between the lower edge of the silencer exhaust outlet and the water line is at least 350 mm 14 See figure above A A B B Min 350 mm 14 A B Silencers There are various types of silencers depending on the type of installation Two very common ty...

Page 122: ... and silencer outlet B Aqua lift and in line systems Engine Exhaust hose Exhaust hose inner diameter A inner diameter B D5 4 102 mm 5 127 mm D7 5 127 mm 6 152 mm D9 D11 6 150 mm 8 200 mm D12 8 200 mm 8 200 mm NOTE As a rule of thumb multiply A x 1 4 to estimate B Rounding to rubber hose standard diameters Recommended hose diameter innerdiameter A and B see table on the following page NOTE An in li...

Page 123: ...ion The riser is continuosly adjustable in the vertical and the horizontal plane for each installation purpose A riser is also available for D9 D11 engines It is of dry type and is shown in figure B 1 together with the wet exhaust elbow NOTE The dry part of the riser see figure B and C 1 should be insulated with proper heat insulation material see figure C 2 1 2 WL α Wet exhaust elbow D9 D11 The e...

Page 124: ...boat is towed or running with one en gine only Position the outlet in the bottom in a way so the ex haust gases will not create negative turbulance flow ing into the propeller or trim tabs not even when the boat is turning as this will affect the performance of the boat A by pass outlet should be installed from the exhaust pipe above the water line to an outlet above the wa ter line to avoid high ...

Page 125: ...xhaust fumes far from the boat transom The outlets of the boots are prefer ably positioned in line with the propeller shaft just behind the propeller and rudder This way the exhaust emissions are carried into the currents of water aft of the propeller See Wagon back effect in chapter Exhaust system General This slipstream system can be profiled to meet the requirements of individual boat builders ...

Page 126: ...lexible com pensator 1 to absorb heat expansion and vibration from the engine The compensator is fitted on the engine exhaust pipe flange as straight and stress re lieved as possible The exhaust line must be insulated throughout its whole length Note that the movements of the com pensator must not be obstructed After the compen sator the exhaust line including silencer 4 must be suspended by flexi...

Page 127: ... must be fitted with a cock or drain plug at the bottom 1 Exhaust elbow 2 Condensation water collector for D5 D7 D9 D12 1 2 Insulated exhaust systems Due to the high temperatures that arise in a dry ex haust pipe 400 500 C it is sometimes necessary to insulate it Thereby the temperature in the engine room can be kept low and personal injuries can be avoided The insulation also helps to keep the no...

Page 128: ...ial movements but no twisting movements It must not be bent The flexible compensator can be fitted in different positions but should preferably be fitted vertically The fixture for the exhaust line should be designed to prevent that radial movements generated by pres sure pulses in the line are transfered into the com pensator Thermal growth of exhaust piping must be planned to avoid excessive loa...

Page 129: ...nge 4 4 4 4 8 E Diam holes in flange 17 0 67 18 0 71 18 0 71 18 0 71 18 0 71 F Flange thickness 16 0 63 14 0 55 14 0 55 14 0 55 15 0 61 G Inner diameter 100 4 0 100 4 0 128 5 0 150 6 0 195 7 7 Measurements mm in Installation data Compensator 7 Compensator 4 long 5 and 6 A B F E D C G Compensator 4 short A B D G C F E F E A B G C D Compensator type Total nominal length Flexibility mm in B Radial Ax...

Page 130: ...ilencer There are generally two types of silencers described as either absorptive or reactive Absorptive type These work on the principle of absorbing noise by means of an absorbent lining inside the silencer and normally provide attenuation over a broad frequency range An absorptive silencer is generally designed as a straight through and would only create a marginally greater backpressure than s...

Page 131: ...Bend 90 deg inches m bend m bend 3 5 0 57 1 33 4 0 65 1 52 5 0 81 1 90 6 0 98 2 28 7 1 22 2 70 Backpressure exhaust pipe calculation Using the value of the exhaust gas flow and having calculated the backpressure for a certain silencer HD you will be able to determine the resistance to flow in a straight exhaust pipe The following formula is recommended where P is backpressure through the exhaust p...

Page 132: ...ce in mm Wc The resistance is approx 99 mm Wc The pressure loss will be calculated according to the formula Pressure loss mm Wc 118 mm Wc T Exhaust gas Temperature T 293 C See Technical Data in Sales Guide Marine Propulsion Diesel Engines Pressure loss will be Ploss 118 mm Wc 1 157 kPa The pressure loss through the silencer is 1 873 kPa NOTE Check that the total backpressure silencer backpressure ...

Page 133: ... of the stopped engine and then into the engine cylinders which can cause corrosion If a flap valve of good quality is fitted in each exhaust line near the intersection multi engine installations on one exhaust line can sometimes be acceptable To calculate the total diameter of a common exhaust pipe use the following formula D total D x K where D is exhaust pipe diameter for one engine K is a fact...

Page 134: ...a certain resistance to the exhaust gas flow This resistance or backpres sure must be kept within specified limits Excessive backpressure can cause damage and will lead to Loss of power output Poor fuel economy High exhaust temperature These conditions produce overheating and excessive smoke from the installation and reduce the service life of the valves and turbocharger No performance losses Rela...

Page 135: ... the turbocharger exhaust output Clean the mating surface Install the measuring flange 1 to the turbine housing flange only if measuring flange is need ed Install the exhaust elbow pipe 2 on the measur ing flange or the nipple Use V clamps or bolts de pending on the engine type and exhaust system Connect a transparent plastic hose 3 to the measuring flange or the nipple as illustrated Alternativel...

Page 136: ...artly filled with water see previous page position 3 Exhaust backpressure in mm wc A See figures for wet exhaust line 2 1 Measuring procedure Dry exhaust system Connect a manometer calibrated to 24 kPa 3 5 psi 2440 mm wc with pressure hose and a suit able nipple to the exhaust elbow Alternatively connect a transparent plastic hose with a suitable nipple to the exhaust elbow Run the engine at full ...

Page 137: ...important that the measurements are accurate One important factor when taking these measurements is to position the probe correctly in the gas flow See figure With an accurate measurement 2 comparison can be made with the technical data for verification provided that compensation is made for atmospheric conditions Exhaust monitoring guages are normally less accurate Wet exhaust line 0 75 x DI Dry ...

Page 138: ...ll cable joints should be lo cated higher up than the alternator Batteries Battery terminology Capacity Capacity is measured in Ampère hours Ah The starter battery capacity Ah is usually stated as the 20 hour capacity of the battery i e the battery can be discharged at a constant current for 20 hours to a final voltage of 1 75 V cell For example If a battery can produce 3 A for 20 hours its capaci...

Page 139: ...l the nominal system voltage will be approx 10 V Series connection Two 12 V batteries are connected in series so that the system voltage in the boat is 24 V WARNING Always check the boat s system voltage before connecting A particular engine type may be available for 12 V and 24 V con figurations The batteries must be similar same capacity and voltage The batteries must be the same age since the c...

Page 140: ... the breakaway current can be calcu lated as 2 2 5 times cranking current Selecting battery size When selecting battery size it is vital to look at both momentary and long term capacity The rating norm for long term capacity batteries marked with Ah the C20 norm is used C20 means the amount of current able to take out from the battery during 20 h Ex 1 60Ah 20 h X 3A Ex 2 100Ah 20 h X 5A The batter...

Page 141: ...cessories is mandatory Volvo Penta recommends using a charge distributor to feed the accessory batteries Start battery Accessory battery I Cross over switch Starter Cross over switch The use of a cross over switch between the acces sory battery and the starter battery is recommended ...

Page 142: ... to provide sufficient power from the battery to the start er motor Measure the total cable length from the battery positive terminal via the main switch to the starter motor positive terminal and from the starter motor negative terminal back to the battery negative terminal Thereafter select the recommended cable area ac cording to the table on the next page for both the negative cable and the po...

Page 143: ...cted directly to the accessory battery positive terminal All other equipment lamps fans refrigerators etc navigation instruments excepted can be con nected either to accessory battery I or II On D9 D11 D12 and D16 the sensor cable is factory mounted on the starter motor If accessory batteries are used re route the cable according to the picture B Sensor cable Start battery Accessory battery I Acce...

Page 144: ...erminal All other equipment lamps fans refrigerators etc except navigation instruments can be connected either to the port or starboard accessory battery On D9 D11 D12 and D16 the sensor cable is factory mounted on the starter motor If accessory batteries are used re route the cable according to the picture Single failure tolerant system If a short circuit appears in one of the drivelines this wil...

Page 145: ...the main switch outside the en gine room but as close to the engine as possible to reduce cable length Requirements main switch Normal Nominal capacity Working temp Dimension Standard Protection voltage Contin During and storage terminal spade tags degree CEI529 uous 5 sec Min Max standard 48V 300A 3000A 40 C 85 C M10 SAE J1171 IP 68 40 F 185 F NOTE If the engine is stopped the starter motor does ...

Page 146: ...der to be sure that the charging capacity in the boat is sufficient The above diagram indicates how this extra equip ment can be installed in the boat Clamp the leads at close intervals and preferably mark the leads at the fuse and junction boxes 1 3 with the purpose of each lead i e communication radio refrigerator navigation lamps etc Position the electrical system control panel in a place free ...

Page 147: ...needed area 2 5 mm2 Calculating the cable area for power loads Measure the distance from the terminal block to the accessory Multiply the distance by two Calculate the area in accordance with the table below The calculation is based on the max permissible total voltage drop in all cables between the positive terminal to the load and the load back to the negative terminal Total voltage drop when us...

Page 148: ... is normal Towards the end of charging the voltage rises quickly to 15 16 V This value is not exceeded even if charging is continued Risk of explosion Gas is formed in the battery during charging A short circuit naked flames or sparks in the vicinity of the battery can cause a powerful explosion Ensure proper ventilation especially if the battery is charged in a closed area WARNING Always disconne...

Page 149: ...ith tropical acid is fully charged when the acid specific gravity is 1 24 g cm3 at 25 C 77 F Instruments Non EVC engines This manual covers normal instruments Special in struments and senders might be required for some installations for example classified systems Select a position where the instruments will be unob structed and easily readable NOTE The safe distance for the compass location to avo...

Page 150: ...onal instruments audio etc NOTE Maximum current outlet for both instrument panels together 5 Amps Oil pressure sensor Coolant temp sensor Main Y connector Flybridge Flybridge Full instrumentation not D5 D7 Full instrumentation Tachometer NOTE When two panels full instru mentation are used make sure an electri cal system with oil pressure sender and coolant temperature sender for two instru ments i...

Page 151: ...her 5 Amps Main key switch Flybridge start stop buttons Flybridge key switch Coolant temp sensor Oil pressure sensor Full instrumentation Tachometer or full instrumentation D5 D7 not two oil pressure and temperatur gauges Tachometer or full instrumentation D5 D7 not two oil pressure and temperatur gauges NOTE When two panels full instru mentation are used make sure an electrical system with oil pr...

Page 152: ...it 4 Instrument kit boost pressure oil pressure reverse gear Instrument kit flybridge start stop buttons 1 Panel kit Available as option 2 Instrument kit temperature oil volt 3 Tachometer kit Harness lengths A B 500 mm A C 580 mm A D 1600 mm A B C C C C D 1 3 1 4 2 C C C 1 1 1 1 3 2 Harness lengths A B 180 mm A C 760 mm A D 3280 mm ...

Page 153: ...ncluded in the tachometer kit Press in pin B Remove pin B when the correct code is displayed Shown on display A Descriptions Cd1 Important For ta chometers that are already coded pin B must be pressed in when the voltage is turned on Codes are scrolled at 1 second intervals This is your code Compare with code table Switches to hours counting COdE Cd3 Cd4 Cd5 0 0 Cd3 IMPORTANT Wait for 10 seconds w...

Page 154: ...nstruments On D5 D7 the senders have to be ordered separately for fitting on the engine Other instruments such as water and fuel tank gauges and senders etc are also available as ac cessories Water in fuel filter alarm Volvo Penta offers the option of installing an indica tion for water in the fuel pre filter The sender can be connected to an indicator or to a second alarm panel Code Code shown Si...

Page 155: ...B MP and D16 engines are equipped with a relay that can be remotely controlled by third party equipment e g a fire extinguishing system The engine shuts down when the relay is energized NOTE Leave the external stop connector unconnected if the functionality is not to be used Fault codes presented on Vodia when external stop relay is activated D9 D11 D12D B MP and D16 MID128 PPID 6 FMI 11 Connectin...

Page 156: ...em Before the fire extinguishing system deploys it should turn off the engine s By connecting the engine shut down functionality of the fire extinguishing system to the external stop relay the engine can be shut down in case of fire Pin 1 R Pin 2 SB 30 87a 87 85 86 Main switch Do not use EVC aux relay Accessory cabel kit 3 m 10 ft Fire extinguishing system Engine 30 87 87a 86 85 Main switch Do not...

Page 157: ... wire detection Broken wire reset button Test button for overspeed shutdown test DIN 35 rail mounting MCU The MCU communicates with Engine Management System via the CAN serial line using standard J1939 and J1587 communication protocols and controls and monitors the engine in 4 different applications Pro pulsion emergency auxiliary and combined Equipped with a powerful graphic display with icons sy...

Page 158: ...engine control system all functions hard wired COM Communication Module for J1708 J1587 and CAN2 bus for RP and other extension modules RP Remote Panel additional display panel for remote monitoring EMS Engine Management Systemmonitors engine status and handles engine speed and torque governing and overall control of fuel injection and emission control algorithms PM Power Module handles power dist...

Page 159: ...0 70 C Storage temperature 30 80 C Humidity 95 without condensation Flash memory data retention time 10 years Protection front panel IP65 Dimensions and weight Dimensions 180x120x50mm Weight 800g Binary inputs Number of inputs 14 Input resistance 4 7 kW Input range 0 36 VDC Switching voltage closed contact indication 0 2 V Max voltage for open contact indication 8 36 V Binary open collector output...

Page 160: ...ent measurement tolerance 1 0 5mA out of measured value Group 2 AI5 AI8 Number of inputs 4 bipolar Resolution up to 16 bits Jumper selectable range V ohm mA thermocoupler Maximal resistance range 2500 W Maximal voltage range 1000 mV or 100mV Maximal current range 0 20 mA active 0 20 mA passive Resistance measurement tolerance 0 5 2 W out of measured value Voltage measurement tolerance 0 5 1mV out ...

Page 161: ...ectrical Sys tems Part 1 manual chapter Electrochemical cor rossion for more detailed information Electrochemical corrosion Electrochemical corrosion of metals can cause very serious and expensive damage to propellers propel ler shafts rudders keels and other equipment fitted to the boat The types of corrosion that are particularly significant for boats are Galvanic corrosion Crevice and deposit c...

Page 162: ... is not present in an active state Still water From the table we can see that steel has about 0 65 V and aluminum around 0 85 V in the voltage se ries The higher up in the voltage series the greater potential the more noble the metal If these metals are connected together in a galvanic element the less noble metal will be consumed by the more noble metal galvanic corrosion arises In our case the a...

Page 163: ...s may have their own protection NOTE This bonding system with its individual com ponents should normally have no contact with the negative circuit of the boat s electrical system Local recommendations e g ABYC may state that the battery negative terminal should be connected to the bonding galvanic circuit If you decide to connect the bonding galvanic circuit to the battery negative terminal you mu...

Page 164: ...urrent and shore power corrosion Stray current corrosion is similar to galvanic corrosion in the way it acts but differs in the way it is caused In galvanic corrosion it is the potential differences on the metal that initiates corrosion As the name implies stray current corrosion is caused by stray currents Stray currents can arise as a result of faults in the boat s electrical system such as conn...

Page 165: ... breaker Transfer switch shore off gen AC generator optional 2 pole 3 wire grounding type plug and receptacles To DC negative bus and boat ground plate GFCI Live Neutral Grounding Live conductor Neutral conductor Grounding conductor Shore side Boat side Shore connection Shore power cable Shore power cable connector Power inlet electrically insulated from boat Main shore power Disconnect circuit br...

Page 166: ...s 8 and 11 but require a ground fault circuit interrupter and an isolation transformer Figures 1 and 2 are considered best practice and are in harmonywith recommendations from ABYC and ISO and provide protection against electrochemical corrosion and electrical shock The safety related components are important for the following reasons Isolation transformer The isolation transformer galvanically se...

Page 167: ...n please refer to the Electrical System chapter Engines and drivelines must not be used as a ground earth for radio navigation or other equip ment where separate ground cables are used All separate ground earth cables ground con nections for radio navigation equipment echo sounder etc must be linked to a common ground earth point i e a cable that does not normally act as a return for equipment If ...

Page 168: ...such as magnesium anodes in salt water Volvo Penta has produced a method for measuring galvanic currents and stray currents using a calomel electrode The calomel electrode Ag AgCl 885156 is a refer ence electrode which shall be connected to the mul timeter 9812519 The multimeter is used to measure potential differences NOTE If other multimeters are used accuracy is re quired to 1 mV Depending on t...

Page 169: ...e red test lead to the battery positive terminal and the black lead to the loosened connector The meter will now show how much current is leaking If you do not get a reading change to the DC mAmps scale 3 Double check to see the resistance in the circuit Set the multimeter to Ohms Connect the black test lead to the loosened negative connector and the red test lead to the loosened positive connecto...

Page 170: ...ot pass through the planing threshold For the engine to function properly and give full power it is absolutely necessary that both the inlet and outlet air ducts are sufficiently dimensioned and installed correctly Two main conditions must be fulfilled A The engine must get enough air oxygen to allow for the combustion of the fuel B The engine room must be ventilated so that the temperature can be...

Page 171: ... not adjusted de rated despite high air tempera ture the result will be very smoky exhaust in creased thermal load and greatly increased en gine wear and consequently greatly increased operating costs Engine power output at high altitudes above sea level In most cases marine engines are run at or near sea level There are however some lakes that are situ ated at high altitudes above sea level There...

Page 172: ...om temperature at a low level a suction fan must normally be installed in the outlet air duct Fans must never be installed in the inlet air ducts as this could lead to overpressure in the engine room with the risk of gas or air leaking out into other parts of the boat For diesel engines the fan can very well be ther mostat controlled and should start at approx 60 C 140 F engine room temperature me...

Page 173: ... minimum inter nal area of air supply ducting The area can be calcu lated by using the formula A 1 9 engine power output A Area in cm Engine output in kW The value applies for non restricted intake and up to 1 m 3 3 ft duct length with only one 90 degree bend The bending radius should be at least twice the dia If longer ducts or more bends are used the area is corrected by multiplying by a coeffic...

Page 174: ...allation figures have to be doubled Calculation of air ducts example 2 diesel engine 441 kW 600 hp Calculation of areas for one engine with 2 m 6 6 ft duct length 2 bends and an ambient air temperature of 20 C 68 F Area for engine s air consumption 1 1 9 441 838 cm 130 sq in Correction for air temperature 0 7 from Table 2 and correction for duct length and bends 1 41 from Table 1 This gives 838 0 ...

Page 175: ... power 294 kW 400 hp Cross section area cm square inch 0 100 3 9 50 2 0 150 5 9 200 7 9 250 9 8 300 11 8 350 13 8 ø mm ø inch Ex 1 Fig 2 Conversion of area to diameter 1000 155 800 124 600 93 400 62 200 31 800 124 600 93 400 62 200 31 600 804 700 939 1000 155 400 15 7 450 17 7 1 2 Ex 1 Ex 1 Air consumption duct diameter 265 mm 10 4 Ventilation duct diameter 250 mm 9 8 1200 186 1400 217 1200 186 50...

Page 176: ...ransom The air in this area is mixed with water and exhausts and must therefore never be allowed to enter the boat Function of air intakes Air intakes and outlets must function well even in bad weather and must therefore have efficient water traps Soundproofing must usually be built in The air intake and outlet should be placed as far away from each other as possible so that a good through flow is...

Page 177: ...ch a way as to minimise noise and vibration The noise that oc curs is airborne noise and structural noise vibration Structural noise Vibration from the engine is transmitted via the en gine mountings and the engine bed to the hull Other routes are via the transmission and propeller sys tems exhaust pipe coolant pipes fuel pipes electri cal cables and control cables Pressure pulses from the propell...

Page 178: ... differently owing to the type of the material in the frame i e GRP or wood Insulation material being applied on wood plywood 1 Wood plywood 2 Flame proof absorption sheeting 3 Flame proof reflecting soundproofing foil Make sure the necessary room is available for serv ice and repair Also make sure that all hatches are properly sealed off Greatest possible care must be given to the task of screeni...

Page 179: ...n be sealed off with some kind of insulation material or sealing compound Shift cables throttle cables and electrical wires coming through bulkheads can perferably 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 rest in a grommet where they pass through the bulkhead The grommet seals off and...

Page 180: ...over or its own enclosure exposed moving or hot parts of the engine that could cause personal injury must be effectively shielded Belt guards which can be fitted on the engine are available as optional equipment from Volvo Penta Protections can also be built in the engine room by the boat builder ...

Page 181: ... be either a single lever control or two lever control On a single lever control both shift ing and speed is operated with the same lever In a two lever control there is one lever for shifting and one for speed Example showing different control systems 1 Single lever control mechanical 2 Single lever control two stations mechanical DS unit 3 Two lever control two stations mechanical serial connect...

Page 182: ... actuators usually located in the engine room via electrical wires The actuator transforms the electrical signal to a mechan ical movement From the actuator a push pull cable runs to the engine reverse gear and there installation is done the same way as with a mechanical control system Hydraulic and pneumatic controls The principle behind communication between control and engine reverse gear is to...

Page 183: ...cient space underneath the panel for the control mechanism There must be enough room for full stroke of the control lever for FORWARD and sufficient space for operating REVERSE The lower part of the control must not come so close to the steering control or other components that they are affected in any way There must be sufficient space under the control to permit installation of the control cable...

Page 184: ...o the pump lever Gear cable connection Always connect the cable to the reverse gear lever so that the neutral position is obtained on the reverse gear when the control is set to NEUTRAL Install the shifting cable and make sure the cable is connected in the control for the required rotation of the propeller shaft See table on the following page 1 Connection 2 Bracket 3 Control cable 1 2 3 N 1 4 3 2...

Page 185: ...ropeller rotation Right hand propeller rotation ZF45 Pulling Clockwise Pushing Anticlockwise ZF220 ZF220A Pulling Clockwise Pushing Anticlockwise ZF220IV Pushing Anticlockwise Pulling Clockwise ZF280 ZF280A Pushing Anticlockwise Pulling Clockwise ZF280IV Pulling Clockwise Pushing Anticlockwise ZF301A Pulling Anticlockwise Pushing Clockwise ZF302IV Pushing Anticlockwise Pulling Clockwise ZF350A Pul...

Page 186: ...s preferred A DS unit is not needed when two lever controls are installed in series Final check Check without starting the engine after final connec tion of cabling that the lever on the pump is at idling and the lever for the reverse gear is in the neutral po sition when the control is in NEUTRAL Then move the control to full speed and FORWARD position Check that the pump lever is against the ful...

Page 187: ...e can be used A larger oil cooler is some times fitted to keep the oil temperature stable It is highly recommended to use a thermostat on the gear box oil cooler The benefit of the trolling valve is reduction of the idling speed of the boat or the option of increasing engine rpm at low boat speed for example in order to use pumps etc during fishing For operating a trolling valve a single acting co...

Page 188: ...nd of the crank shaft Either via a common standard over centre clutch or an extra shaft connection in line 1 Front end power take off 2 In line power take off 3 Extra V belt pulleys 4 Side located power take off 5 Auxiliary pumps 1 3 5 2 4 Various configurations of PTO can be built The most common are described in this chapter Always see the current Sales Guide for the PTO op tions Volvo Penta is ...

Page 189: ...fitted with a reduction gear must be fitted with a support device See figure Disconnectable power take offs are required if the load is on from start or if it is required to disengage the load while the engine is running Volvo Penta offers a range of power take offs The over centre toggle action assures smooth and progressive engagement locking the PTO securely into the driving position If direct ...

Page 190: ...PTO The clutches are of disengagable design intended for driving winches bilge pumps or other optional equipment 2 1 Engine PTO connecting Clutch Output Max torque flange size make type Nm lbf ft D12 SAE3 Twin Disc SP 211 11 5 Stub shaft 1 1000 738 ...

Page 191: ...am mm in 00 787 4 31 00 850 9 33 50 882 7 34 75 16 13 5 17 32 0 647 7 25 75 679 5 26 75 711 2 28 00 16 13 5 17 32 1 2 584 2 23 00 619 1 24 38 647 7 25 50 12 13 5 17 32 1 511 2 20 12 530 2 20 87 552 5 21 75 12 11 9 15 32 2 447 7 17 62 466 7 18 38 488 9 19 25 12 10 3 13 32 3 409 6 16 12 428 6 16 87 450 8 17 75 12 10 3 13 32 4 361 9 14 25 381 0 15 00 403 2 15 87 12 10 3 13 32 5 314 3 12 38 333 4 13 1...

Page 192: ...on the distance of the PTO pulley from the face of the cylinder block and the direction of the resultant loads acting on the pulley It also depends on the pulley diameter and engine speed Crank pulleys are available for each engine type some with an integral PTO groove and some accept ing a bolt on PTO pulley Tightening Torque If the crankshaft pulley type is changed it must be ensured that the co...

Page 193: ...re belts are used between two pulleys belts matched in length must be used to ensure correct load sharing and best possible life Idler pulleys Idler pulleys used for tensioning the V belts should be on the slack side of the belt and not smaller than the minimum diameter recommended by the manufac turer for a particular belt The use of too small a pulley will severely reduce belt life A suitable sp...

Page 194: ... D7C TA 0 26 kgm2 0 19 kgm2 Below you can find a guidline for the moment of iner tia for some additional equipment Pulley for 140A extra alternator0 1514 kgm2 3 belt pulley 0 0334 kgm2 Pulley on stub shaft 0 040 kgm2 estimated weight 8 kg Power output from front end of crankshaft Power can be taken out for in line duty from the front end of the crankshaft The limit for this power is the bolted joi...

Page 195: ...d if possible so that the driven equipment is below the crankshaft centre line F F F If two or more belt drives are required and can be ar ranged in opposite directions the effects will tend to cancel each other out and minimise the overall side load on the crankshaft Unsupported power take off pulley When it is essential to have an unsupported power take off pulley the design can be checked and a...

Page 196: ...o utilise the crankshaft power in line when all side thrusts are taken up by the bearings 1 The torque figures are maximum levels Flexible coupling 2 must be calcu lated by Volvo Penta 1 Bearings 2 Flexible coupling 3 Belt pulley D5 D7 B A C E D x 9 D12 E A B C D x 12 2 1 3 D9 D16 ...

Page 197: ...TO system that include flexible coupling gives possibility to gain under the normal circumstances max torque at the engines front end Vibratory torque limit that is set up by values that can be carrying out by the bolt connection is satisfied with this PTO sys tem Both the dynamical and the statical part of the torque amplitude is possible to transmit over the bolt connection The flexible coupling...

Page 198: ... 5 1 Bolt to stub shaft 2 Cover 3 Intermediate cylinder Will be cut to proper length 4 Bolt to crankshaft 5 Stub shaft 180 Stub shaft D5 D7 141 106 95 5 27 50H8 28H13 Depth 40H13 32H8 0 06 0 5 Depth 0 06 0 5 Depth 0 06 0 5 10H7 14H7 68 5 F N x d m x rpm P kW 3 2 x 104 0 45 90 135 F1 F2 FMAX Stub shaft Fmax N Angle Pos1 Pos2 0 5900 5200 45 3100 2800 90 3100 2800 135 3100 2800 180 5400 4800 ...

Page 199: ...0 135 1700 1350 1700 1350 1480 1170 1480 1170 690 550 180 3210 2540 3210 2540 3160 2500 3160 2500 2270 1800 PTO with stubshaft For the system with the stubshaft torque amplitude values are delimited in relation to the added lumped inertia J1 on the engine s front end Corresponding power that is possible to deliver at the engine s front end is limited to values that are below engine s full load cur...

Page 200: ...n relation to the added lumped inertia J1 on the engine s front end Corresponding power that is possible to deliver at the engine s front end is limited to values that are below engine s full load curve for some of the values for J1 J1 0 1 0 6 Engines working according the propeller load excitation curve J1 kgm2 P kW P kW R1 R2 368 479kW 1800rpm 551kW 1900rpm 0 1 551 551 0 2 551 551 0 3 551 551 0 ...

Page 201: ...pecifications must be appropriate for the power take off equipment to be fitted Weight The weight of the extra equipment to be bolted on to the timing cases must be considered A support bracket from the cylinder block should be used for heavy equipment Cyclic torque Some equipment i e hydraulic pumps impose high cyclic torque variations on the timing gears This means that max torque in accordance ...

Page 202: ... A 1800 rpm ratio 0 91 Driven wheel speed 1800 0 91 1978 rpm NOTE PTO application to timing gears requires cor rect material combination of the gears Use only by Volvo Penta approved gear wheels Timing gear wheel ratio and maximum torque PTO occupied or not applicable Transmission wheel positions D5 D7 Timing gear positions seen from flywheelside A Crankshaft gear B Drive gear for seawater pump im...

Page 203: ...sion wheel positions D12 A C D B Power take off on engine auxiliary drive gear casing Power take off on auxiliary drive gear casing B Drive gear for PTO connection 1 Power take off front starboard side Drive gear B C Drive gear for feed pump alternator or extra equipment 2 Power take off port Drive gear C D Drive gear for hydraulic pump Extra equipment 3 Power take off hydraulic pump CL Crankshaft...

Page 204: ...ansferred through an electromag netic clutch The connection time of the bilge pump is monitored by a vacuum switch At start the switch is held down for approx 20 seconds The vacuum switch breaks the current to the magnetic coupling when the pump ing medium is finished The flushing pump is used for many service purposes such as deck flushing fish washing etc The Sales Guide Marine Propulsion Diesel...

Page 205: ...isk of accidental draining Oil and coolant drain systems General Engine installations in boats and vessels carry the potential for negative impact on the environment The liquids necessary are harmful and should be handled in a safe way The figure above shows a concept of how this could be solved via a central waste pump connected to the important positions in the engine room The systems must compl...

Page 206: ...rrect rotation right or left Launch the boat Check before starting the engine Open valves at through hull fittings one by one Check for leakages in hull and through hull fittings Open valves for external systems keel cooling hot water circuit etc That all drain cocks are closed and all drain plugs are installed Engine oil The oil capacity oil quality and viscos ity See Operators s Manual Reverse g...

Page 207: ...t might be loaded in a way that results in a bad running attitude position in the water Exhaust backpressure See chapter Exhaust sys tem Backpressure Keel cooling system for leakages and coolant circulation temperature and pressure inlet and outlet See Cooling system External cooling Grease propeller shaft bearings and seals These should be at a low temperature and without leakes Check over the wh...

Page 208: ...206 References to Service Bulletins Group No Date Concerns ...

Page 209: ...207 Notes ...

Page 210: ...208 Notes ...

Page 211: ... this page write your comments down and post it to us The address is at the bottom of the page We would prefer you to write in English or Swedish From Refers to publication Publication no Issued Suggestion reasons Date Name AB Volvo Penta Technical Information Dept 42200 SE 405 08 Göteborg Sweden ...

Page 212: ...7748655 English 11 2007 ...

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