Volvo Penta D1-13 User manual

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

2
Installation
Marine Diesel Engines
D1-13, D1-20, D1-30
D2-40, D2-55, D2-75
Contents
Safety precautions ............................................. 2
General information ........................................... 5
Conversion factors ......................................... 7
Special tools ....................................................... 8
Installation drawings .......................................... 8
Engine installation ............................................. 9
Engine inclination ........................................... 9
Flexible shaft seal ........................................... 10
Rigid shaft seal ............................................... 10
Fitting of reverse gear and S-drive ................. 11
S-drive insulation ............................................ 11
Rubber mounts ............................................... 12
Propeller shaft system .................................... 13
Front end power take-off ................................ 15
Cooling system ............................................... 19
Exhust system ................................................ 24
Engine room ventilation .................................. 26
Soundproong ................................................ 28
Fuel system .................................................... 30
Electrical system ................................................ 32
Connection of battery cables .......................... 36
Controls ............................................................... 38
S-drive installation ............................................. 41
Preparation ..................................................... 41
Cutting and berglassing of engine bed ......... 43
Installation of drive and engine ....................... 46
Fitting of the rubber seal ................................. 48
Installation of propeller ................................... 49
Oil quality and lling .......................................... 50
References to Service Bulletins ........................ 52
©2007 AB VOLVO PENTA
All rights to changes or modications reserved.
Printed on environmentally-friendly paper

3
Safety precautions
Introduction
This Installation Manual contains the information you
will need to install your Volvo Penta product correctly.
Check that you have the correct Installation Manual.
Read the Safety precautions and the General
information in the installation manual carefully
before servicing or operating the engine.
Important
The following special warning symbols are found in
this manual and on the engine.
WARNING! Danger of personal injury, damage
to property or mechanical malfunction if the in-
structions are not followed.
IMPORTANT! Possible damage or mechanical
malfunction in products or property.
NOTE! Important information to facilitate work pro-
cesses or operation.
Below is a list of the risks that you must always be
aware of and the safety measures you must always
carry out.
Plan in advance so that you have enough room
for safe installation and (future) dismantling. Plan
the engine compartment (and other compart-
ments such as the battery compartment) so that
all service points are accessible. Make sure it is
not possible to come into contact with rotating
components, hot surfaces or sharp edges when
servicing and inspecting the engine. Ensure that
all equipment (pump drives, compressors for ex-
ample) has protective covers.
Make sure the engine is immobilized by not con-
necting the electrical system or turning off the
power supply to the engine at the main switch
(breakers), and locking the switch (breakers) in
the OFF position for as long as work continues.
Set up a warning notice at the engine control
point or helm.
As a rule, no work should be done on a running
engine. However, some 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, start-
ing elements etc.) and hot liquids in supply lines
and hoses in engines that are running or have
just been turned off. Reinstall all protective parts
removed during service operations before start-
ing work on the engine.
Ensure that the warning or information decals
on the product are always visible. Replace de-
cals which are damaged or painted over.
Turbocharged engines: Never start the engine
without installing the air cleaner. The rotating
compressor turbine in the turbocharger can
cause serious personal injury. Foreign objects
entering the intake ducts can also cause me-
chanical damage.
Never use start spray in the air intake. Use of
such products could result in an explosion in the
air intake pipe. There is a danger of personal in-
jury.
Do not open the ller cap for the engine coolant
(freshwater cooled engines) when the engine is
hot. Steam or hot engine coolant can be ejected
and any pressure in the system will be lost.
Open the ller cap slowly and release coolant
system pressure (freshwater cooled engines). If
the ller cap or drain cock must be opened, or if
a plug or engine coolant line must be removed
on a hot engine, steam or hot coolant can be
ejected.
Hot oil can cause burns. Avoid skin contact with
hot oil. Make sure that the oil system is released
before starting work on it. Never start or run the
engine without the oil ller cap in place because
of the risk of oil being ejected.

4
Safety precautions
If the boat is in the water, stop the engine and
close the sea cock before carrying out opera-
tions on the cooling system.
Only start the engine in an area that is well ven-
tilated. Beware, the exhaust gas is poisonous
to breathe in. When operating in an enclosed
space, use exhaust extraction to lead the ex-
haust and crankcase gases away from the work-
place.
Always wear protective goggles if there is a risk
of splinters, grinding sparks and splashes from
acid or other chemicals. Your eyes are extremely
sensitive and an injury to them can result in loss
of sight!
Avoid skin contact with oil! Long term or re-
peated skin contact with oil can lead to the loss
of natural oils from the skin. This leads to irrita-
tion, dry skin, eczema and other skin problems.
Old oil is more dangerous to your health than
new. Use protective gloves and avoid oil-soaked
clothes and rags. Wash regularly, especially
before meals. Use special skin creams to help
clean and to stop your skin drying out.
Most chemicals intended for the product (en-
gine and reverse gear oils, glycol, gasoline and
diesel), or chemicals intended for the workshop
(degreasing agent, paints and solvents) are
harmful to your health. Read the instructions on
the packaging carefully! Always follow protective
measures (using a protective mask, goggles,
gloves etc.). Make sure that other personnel are
not unknowingly exposed to harmful substances,
in the air that they breathe for example. Ensure
good ventilation. Dispose of used and excess
chemicals as directed.
Be extremely careful when tracing leaks in the
fuel system and when testing injectors. Wear
protective goggles. The jet from an injector is
under very high pressure and fuel can penetrate
deep into tissue, causing serious injury with a
risk of blood poisoning.
All fuels and many chemicals are ammable.
Keep away from naked ames or sparks. Gaso-
line, some solvents and hydrogen from batteries
in the correct proportions with air are very inam-
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 re extinguisher accessible in
the workplace.
Store oil and fuel-soaked rags and old fuel and
oil lters properly. Oil-soaked rags can ignite
spontaneously in certain circumstances. Old fuel
and oil lters are environmentally harmful and
should be sent for destruction to a proper refuse
station for environmentally harmful material for
destruction.
Ensure that the battery compartment is designed
according to current safety standards. Never
allow an open ame or electric sparks near the
battery area. Never smoke near to the batter-
ies. The batteries give off hydrogen gas during
charging which when mixed with air can form
an explosive gas. This gas is easily ignited and
highly volatile. Incorrect connection of the bat-
tery can cause sparks sufcient to cause an
explosion with resulting damage. Do not shift the
connections when attempting to start the engine
(spark risk) and do not lean over any of the bat-
teries.
Always ensure that the Plus (positive) and Minus
(negative) battery leads are correctly installed on
the corresponding terminal posts on the battery.
Incorrect installation can result in serious dam-
age to the electrical equipment. Refer to the wir-
ing diagrams.
Always use protective goggles when charging
and handling the batteries. The battery electro-
lyte contains extremely corrosive sulphuric acid.
If this should come in contact with the skin, im-
mediately wash with soap and plenty of water.
If battery acid comes in contact with the eyes,
ush immediately with water and obtain medical
assistance.
Turn the engine off and turn off the power at the
main switches (breakers) before carrying out
work on the electrical system.

5
Safety precautions
Clutch adjustments must be carried out with the
engine turned off.
Use the lifting eyes tted on the engine/reverse
gear when lifting the drive unit. Always check
that the lifting equipment used is in good condi-
tion and has the load capacity to lift the engine
(engine weight including reverse gear and any
extra equipment installed).
Use an adjustable lifting beam to ensure safe lift-
ing and avoid damage to components installed
on the top of the engine . All chains and cables
must run parallel to each other and as perpen-
dicular as possible to the upper side of the en-
gine.
If extra equipment is installed on the engine
which alters its center of gravity a special lifting
device is required to obtain the correct balance
for safe handling.
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/petrol engines) and
in the fuel system on Volvo Penta products are
designed and manufactured to minimize risks of
re and explosion. Engines should not run in en-
vironments containing explosive media.
Always use fuels recommended by VolvoPenta.
Refer to the Owner’s Manual. Use of lower qual-
ity fuels can damage the engine. On a diesel en-
gine poor quality fuel can cause the fuel control
rack to stick causing the engine to overspeed
with resulting risk of damage to the engine and
personal injury. Poor fuel quality can also lead to
higher maintenance costs.

6
General information
About the Installation Manual
This publication is intended as a guide for the instal-
lation of Volvo Penta D1 and D2 engines, inboard
and S-drive. The publication is not comprehensive
and does not cover every possible installation, but is
to be regarded as recommendations and guidelines
applying to Volvo Penta standards. Detailed Instal-
lation Instructions are included in most of the acces-
sory kits.
These recommendations are the result of many years
of practical experience of installations from all over
the world. Departures from recommended proce-
dures etc. can be necessary or desirable, however, in
which case the Volvo Penta organization will be glad
to offer assistance in nding a solution for your par-
ticular installation.
It is the sole responsibility of the installer to ensure
that the installation work is carried out in a satisfac-
tory manner, it is operationally in good order, the ap-
proved materials and accessories are used and the
installation meets all applicable rules and regulations.
This Installation Manual has been published for
professionals and qualied personnel. It is therefore
assumed that persons using this book have basic
knowledge of marine propulsion systems and are
able to carry out related mechanical and electrical
work.
Installation of electrical 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 product
data available at the time of print. Notication of
any important modications to the product causing
changes to installation methods after this date will be
made in Service Bulletins.
Plan installations with care
Great care must be taken in the installation of en-
gines and their components if they are to operate
perfectly. Always make sure that the correct speci-
cations, drawings and any other data are available
before starting work. This will allow for correct plan-
ning 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 Service Manual
with the original drawings showing the dimensions.
It is very important when installing engines that no
dirt or other foreign matter gets into the fuel, cooling,
intake or turbocharger systems, as this can lead to
faults or engine seizure. For this reason the systems
must be sealed. Clean supply lines and hoses before
connecting them to the engine. Only remove protec-
tive engine plugs when making a connection to an
external system.

7
General information
Certied engines
The manufacturer of engines certied for national
and local environmental legislation (Lake Constance
for example) pledges that this legislation is met by
both new and currently operational engines. The
product must compare with the example approved
for certication purposes. So that Volvo Penta, as a
manufacturer, can pledge that currently operational
engines meet environmental regulations, the follow-
ing must be observed during installation:
• Servicing of ignition, timing and fuel injection
systems (gasoline) or injector pumps, pump set-
tings and injectors (diesel) must always be car-
ried out by an authorised Volvo Penta workshop.
• The engine must not be modied in any way ex-
cept with accessories and service kits developed
for it by Volvo Penta.
• Installation of exhaust pipes and air intake ducts
for the engine compartment (ventilation ducts)
must be carefully planned as its design may af-
fect exhaust emissions.
• Seals may only be broken by authorised person-
nel.
IMPORTANT! Use only Volvo Penta Genuine
Parts.
Using non-genuine parts will mean that AB
Volvo Penta will no longer take responsibility
for the engine meeting the certied design.
All damage and costs caused by the use of non-
genuine replacement parts will not be covered
by Volvo Penta.
Seaworthiness
It is the boat builder’s duty to check that the security
requirements apply to the market in which the boat
is sold. In the USA for example, these are the US
Federal Regulations for pleasure boats described
in Title 46. The requirements described below apply
to the EU principles. For information and detailed
descriptions of the safety requirements that apply to
other markets, contact the authority for the country
concerned.
As of June 16 1998, pleasure boats and certain as-
sociated equipment marketed and used within the
EU must bear CE labels to conrm that they meet the
safety requirements stipulated by the European 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.
Certicates that grant the right for CE label use and
conrm that boats and equipment meet safety re-
quirements are issued by approved notied bodies.
In many Member States the classication societies
have become the notied bodies for pleasure boats,
e.g. Lloyd’s Register, Bureau Veritas, Registro Ital-
iano Navale, Germanischer Lloyd, etc.
In many cases completely new institutions have been
approved as notied bodies. The directive also allows
boat builders and component manufacturers to issue
assurances 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 activities are ap-
proved by classication societies or by the navigation
authority for the boat’s registered country.
Joint liability
Each engine consists of many components working
together. One component deviating from its techni-
cal specication can cause a dramatic increase in
the environmental impact of an engine. It is therefore
vital that systems that can be adjusted are adjusted
properly and that Volvo Penta Genuine Parts as
used.
Certain systems e.g.components in the fuel system
may require special expertise and special test equip-
ment. Some components are sealed at the factory for
environmental reasons. No work should be carried
out on sealed components except by authorised per-
sonnel.
Remember that most chemical products damage the
environment if used incorrectly. Volvo Penta recom-
mends the use of biodegradable degreasing agents
for cleaning engine components, unless otherwise
indicated in a Workshop Manual. Take special care
when working on board boats to ensure that oil and
waste are taken for destruction and not accidentally
pumped into the environment with bilgewater.

8
General information
Conversion factors
Metric to U.S. or IMP. conversion factors:
U.S. or IMP. to metric conversion factors:
To convert To convert
from To Multiply by from To Multiply by
Length mm inch 0.03937 inch mm 25.40
cm inch 0.3937 inch cm 2.540
m foot 3.2808 foot m 0.3048
Area mm² sq.in. 0.00155 sq. in. mm² 645.2
m² sq. ft. 10.76 sq. ft. m² 0.093
Volume cm³ cu. in. 0.06102 cu. in. cm³ 16.388
litre, dm³ cu. ft. 0.03531 cu. ft. litre, dm³ 28.320
litre, dm³ cu. in. 61.023 cu. in. litre, dm³ 0.01639
litre, dm³ imp. gallon 0.220 imp. gallon litre, dm³ 4.545
litre, dm³ U.S. gallon 0.2642 U.S. gallon litre, dm³ 3.785
m³ cu. ft. 35.315 cu.ft. m³ 0.0283
Force N lbf 0.2248 lbf N 4.448
Weight kg lb. 2.205 lb. kg 0.454
Power kW hp (metric) 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 0.430 BTU/lb kJ/kg 2.326
MJ/kg BTU/lb 430 BTU/lb MJ/kg 0.00233
kJ/kg kcal/kg 0.239 kcal/kg kJ/kg 4.184
Fuel g/kWh g/hph 0.736 g/hph g/kWh 1.36
consump. g/kWh lb/hph 0.00162 lb/hph g/kWh 616.78
Inertia kgm² lbft² 23.734 lbft² kgm² 0.042
Flow, gas m³/h cu.ft./min. 0.5886 cu.ft./min. m³/h 1.699
Flow, liquid m³/h US gal/min 4.403 US gal/min m³/h 0.2271
Speed m/s ft./s 3.281 ft./s m/s 0.3048
mph knots 0.869 knots mph 1.1508
Temp. °F=9/5 x °C+32 °C=5/9 x (°F–32)
1) All hp gures stated in the catalogue are metric.

9
Special tools
Engine bed tool
Engine bed tool for D1-series and D2-series can be
produced locally. Contact Volvo Penta organisation
for drawings of a suitable tool.
Installation drawings
Installation drawings regarding the D1 and D2 en-
gines are available at:
http://www.volvopenta.com.

10
Engine installation
Engine inclination
Flywheel down Flywheel up
Service accessability
When you design the engine installation,
always pay attention to the access needed
for correct engine service. Also ensure that
the complete engine can be removed without
damage to the boat structure.
There must also be sufcient space for the
sound proong 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°
D2-55/75 15° 0° 35° 10° 35°

11
Engine Instillation
Flexible shaft seal
Volvo ´Penta water lubricated rubber type
Grease lubricated shaft seal
When using a exible shaft seal and exible engine
suspension, a exible shaft coupling must not be t-
ted.
Rigid shaft seal
When using a rigid shaft seal and exible engine sus-
pension, a exible shaft coupling must be tted.
Flexible shaft
coupling Rigid
shaft seal
Max. 1500 mm (59")
Max. 1800 mm (71")

12
Engine installation
Fitting of reverse gear
and S-drive
Tightening torque:
40 Nm (29 ft/lb)
Tightening torque:
40 Nm (29 ft/lb)
NOTE! There is no insulation between engine and
transmission except on S-drives.
Tightening torque:
40 Nm (29 ft/lb)
C
S-drive insulation
The 130S/SR and 150S/SR has an insulation located
in the drive. Between the adapter plate and the upper
housing is a insulating gasket (C) installed.
One of the lower two bolts (A) has an insolating
bushing (B) tted. This bolt and bushing are secured
during transportation by a nut.
Electrical insulation between engine and ywheel
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 upper
housing and the grounding connection on the engine.
The result should be above 100 kW. If the measured
value is below 100kWthe installation needs to be re-
viewed. Please contact your Volvo Penta dealer.

13
Engine Instillation
Rubber mounts
A
70 Nm (52 lb.ft)
70Nm (52 lb.ft)
A- measurement, D1 and D2
Unloaded conditions
Transmission Front Rear
mm (") mm (")
Reverse gear 85±8 (3.3±0.3) 85±8 (3.3±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

14
Engine installation
Propeller shaft system
Dimensions
Engine Reverse gear ratio Shaft diameter,
min. mm
(")*
D1-13 2.4:1–2.7:1 Æ=25 (1.0)
D1-20 2.4:1–2.7:1 Æ=25 (1.0)
D1-30 2.4:1–2.7:1 –2.6:1 Æ=25 (1.0)
D2-40 2.1:1–2.6:1 Æ=30 (1.2)
D2-55 2.2:1–2.7:1 Æ=30 (1.2)
D2-75 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 ange
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)
* Female conguration
* With Volvo Penta standard material

15
Engine Instillation
Reverse gear ratios
Reverse gear Ratio RH Ratio LH
MS10L 2.35:1 2.26:1
MS10L 2.72:1 2.26:1
MS10A 2.35:1 2.70:1
MS10A 2.72:1 2.70:1
MS15L 2.14:1 1.95:1
MS15L 2.63:1 1.95:1
MS15A 2.14:1 1.95:1
MS15A 2.63:1 1.95:1
MS25L 2.27:1 2.10:1
MS25L 2.74:1 2.72:1
MS25A 2.23:1 2.74:1
MS25A 2.74:1 2.74:1
HS25A 2.29:1 2.29:1
HS25A 2.71:1 2.71:1
130S/SR 2.19:1
2.19:1
150S/SR 2.19:1
2.19:1
Alignment
Before the propeller shaft is connected to the reverse
gear ange, check to make sure that the anges are
parallel.
Move the anges together so that the guide engages.
Then, with the anges 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 anges 90°, 180° and 270° and repeat
this check at the new positions. Make sure that the
anges are well pressed together during the entire
check. If the deviation is greater than 0.10 mm
(0.004"), the alignment must be re adjusted.
Remove any aids being used and connect the shaft
to the reverse gear ange, or exible coupling.
IMPORTANT! The alignment should be re-
checked again a few days after the launch when
the boat is completed (extra critical with sail-
boats).
A

16
Engine installation
Front end power take-off
IMPORTANT! D1-13 engines only:
Power take-off is not allowed.
Front mounted universal bracket
This universal bracket, with adjustable attachments,
allows air conditioning compressors or hydraulic
pumps etc. to be installed and operated. The kit con-
tains the bracket and ttings.
The table below 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 included in a separate kit.
Top mounted extra alternator
Added installaltion length (A): 82 mm (3.2")
Added installaltion width (B): 18 mm (0.7")
W
L
A
B

17
Engine Instillation
Extra pulleys (power take-off)
IMPORTANT! D1-13 engines only:
Power take-off is not allowed.
Auxilliary equipment driven by the drive belt on the
crankshaft of the engine increase the load on the
crankshaft. Therefore it is important to review the po-
sition and power requirement of the power take-off.
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 the crankshaft nose.
W
B
D
1
2
3
Pulley 1 2 3
Engine kW/pulley*
D2-55 6.8 6.8 6.8
D2-75 6.8 6.8 6.8
D2-55 and D2-75

18
Engine installation
NOTE! The maximum permissable torque shown in
the gures can be applied for one pulley at a maxi-
mum distance from the cylinder block corresponding
to 4 pulleys or 3 spacers and one pulley. If several
pulleys are to be used the permissable torque has
to be divided so that torque limitations are not ex-
ceeded.
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° 7.8
120° 7.5
150° 8.7
180° 11.0
210° 14.7
240° 21.1
270° 24.0
300° 24.6
330° 24.1

19
Engine Instillation
The engine is a D1-30 and the direction of force for
two auxiliaries is A=10° and B=120°.
Maximum permissible torque for auxiliary A and B
depends on the vector sum of their directions of force
and their torque. The combination must end up within
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 principles as in the example.
Example - D1-30 - One pulley used
A
B

20
Engine installation
Cooling system
Seawater intake
Always install a shut-off valve on the water intake.
Two hose clamps for each connection should be
used.
Seawater inlet
If a scoop pickup is used on a sailing boat the water
intake should be facing 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 lter
The seawater lter 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 ow may be installed in the
cooling system.
WL
100–200 mm
(4–8")