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Volvo D11 series User Manual

Volvo D11 series
212 pages
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Marine Propulsion
Diesel Engines
Installation
1(1)
D E
D5 - D16 series

Table of Contents

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Volvo D11 series Specifications

General IconGeneral
Engine ModelD11
Cylinders6
ConfigurationInline
Engine TypeDiesel
Displacement10.8 liters
Fuel SystemCommon rail injection
AspirationTurbocharged
Cooling SystemLiquid-cooled
Bore123 mm
Stroke152 mm
Power Output242-313 kW (330-430 hp) depending on variant

Summary

Installation Marine Propulsion Diesel Engines D5 - D16 series

Safety Precautions

Important Warnings

Discusses dangers of personal injury, damage to property, or mechanical malfunction.

Safety Precautions (continued)

Battery Safety and Handling

Details precautions for battery compartments, avoiding sparks, and correct connection.

Engine Application Ratings

Rating 1: Heavy Duty Commercial

Describes commercial use with displacement hulls in heavy operation, unlimited hours.

The Marine Engine and Its Environment (continued)

Propeller Selection Criteria

Details factors and procedures for selecting the correct propeller for optimal performance.

Torsional Vibrations and TVC Calculations

Torsional Vibrations Explained

Defines torsional vibrations, frequency, amplitude, and critical speed.

Torsional Vibration Approvals

Explains the object of TVC and the consequences of ignoring torsional compatibility.

General Arrangement and Planning

Engine Selection Considerations

Outlines factors for choosing the right engine to meet performance requirements.

General Arrangement and Planning (continued)

Propeller Theory and Design

Explains propeller design principles, blade surface, shaft angles, and pitch/diameter relations.

Propeller Selection Criteria and Hull Interaction

Details propeller selection based on engine load curves and hull interaction for efficiency.

Engine Inclination Limits and Checks

Details maximum permitted engine inclination and the importance of checking it for lubrication.

Accessibility for Checking, Maintenance, and Repairs

Emphasizes ensuring adequate space for servicing, repairs, and engine removal.

Selection of Engine Suspension Types

Discusses choices between flexible and rigid engine mounting systems.

Rigid Mounting Installation Details

Explains rigid mounting procedures, including shims and moulding compound.

Engine Foundation

Engine Bed Design Principles (Rigid Mounting)

Covers design requirements for engine beds, focusing on dimensional stability and torque absorption.

Engine Foundation (continued)

Building the Engine Bed: Methods and Positioning

Explains methods for building engine beds, including using the engine as a fixture.

Propeller Shaft Systems (continued)

Installation of Stern Tube and Shaft Bearing

Illustrates the process of installing stern tubes and shaft bearings, and determining fix points.

Engine Installation

Preparing the Engine for Installation

Lists tasks to complete before installing the engine, such as closing cocks and filling fluids.

Engine Installation (continued)

Engine Mounting: Flexible vs. Rigid

Details lifting the engine onto the bed for both flexible and rigid mounting types.

Flexible Engine Mounting: Type 1 Adjustments

Explains procedures for adjusting engine height and lateral position for flexible mounts.

Aligning Engine with Propeller Shaft and Bed Parallelity

Covers engine alignment, bed parallelity checks, and tightening engine mounts.

Flexible Engine Mounting: Type 2 Adjustments

Details height and lateral adjustments for flexible engine mounts of type 2.

Checking Rubber Mounts and Tightening Torque

Guides on checking rubber mount loading and applying correct tightening torque.

Rigid Engine Mounting Procedures

Explains alignment, bolt tightening, and checking parallelity for rigid engine mounting.

Fixing Positions and Alignment Checks

Details securing engine locations with wedges or pins and checking alignment after hull changes.

Alignment Procedure: Checking Flanges (Method 1 & 2)

Describes two methods for checking flange alignment using feeler gauges or dial indicators.

Remote Reverse Gear Alignment and Fixing

Details alignment steps for remote reverse gears and securing brackets with shims or bolts.

Fuel System

General Fuel System Installation Guidelines

Covers careful installation of fuel components, planning tank location, and using quality parts.

Fuel System (continued)

Fuel Pre-Filters and Filtration Stages

Explains the three-stage filtration process and proper installation of pre-filters.

Checking Fuel Feed Pressure

Describes how to measure fuel feed pressure after the filter cartridge.

Cooling System

General Cooling System Installation Responsibility

Outlines the installer's responsibility for ensuring the cooling system operates correctly.

Cooling System (continued)

Seawater System Pressure and Flow Conditions

Lists required pressure conditions for seawater suction and discharge sides of the pump.

Filling with Coolant Procedures

Details the process for filling coolant, including venting procedures for different engine types.

Coolant Flow and Connections for Engines Adapted for External Cooling

Shows connections and hose diameters for engines adapted for external cooling systems.

Measuring Pressure in Keel Cooling Systems: Gauge Connections

Details gauge connections and T-nipple usage for measuring pressure in keel cooling systems.

Measuring Temperature in Keel Cooling Systems: Gauge Connections

Explains how to connect temperature meters to measure coolant temperature in keel cooling systems.

Thermostats and External Cooling Settings

Discusses thermostat types and opening temperatures, including forced full opening for central cooling.

Expansion Tank Function Diagram (Correctly Designed System)

Explains the function of an expansion tank and its correct connection and pressure settings.

Expansion Tank Function Diagram (Incorrectly Connected System)

Illustrates an incorrectly connected expansion tank and the resulting fatal system issues.

Extra Expansion Tank Requirements and Capacity

Details requirements for extra expansion tanks based on height and system volume.

Extra Expansion Tank Installation and Venting

Explains how to install and vent extra expansion tanks, including hose routing and temperature considerations.

Engine Heater: Function and Installation Points

Describes the function of engine heaters for cold starting and their connection points.

Seawater Intake, Sea Cock, Filter, and Circuit

Details positioning of seawater intake, valves, strainers, and the importance of filters.

Coolant Mixture Guidelines and Water Quality

Provides instructions for mixing coolant and specifies water quality requirements.

Exhaust System

General Exhaust System Design Principles

Covers basic principles for exhaust system design, including wet vs. dry systems and advantages.

Exhaust System (continued)

Dry Exhaust Line: Introduction and Design Objectives

Covers planning dry exhaust systems, objectives, material selection, and insulation requirements.

Flexible Exhaust Compensator Functions

Details the functions of flexible exhaust compensators for isolation, expansion, and lateral movement.

Measuring Exhaust Backpressure Procedure

Details the procedure for measuring exhaust backpressure using a transparent hose or manometer.

Measuring Exhaust Backpressure: Wet Exhaust Line Procedures

Provides specific measurement procedures for wet exhaust lines on D5/D7, D9/D11, and D12 engines.

Measuring Exhaust Backpressure: Dry Exhaust Line Procedures

Outlines procedures for measuring exhaust backpressure on dry exhaust lines for D9/D11/D12 and D16 engines.

Measuring Exhaust Temperature: Dry and Wet Exhaust Lines

Explains how to control and accurately measure exhaust temperatures for installation and engine conditions.

Electrical System

General Electrical Installation Guidelines

Covers careful planning and execution of electrical installations, wire routing, and joint minimization.

Electrical System (continued)

Connecting Batteries: Parallel vs. Series Configurations

Details the procedures and considerations for connecting batteries in parallel and series.

Battery Dimensioning: Cranking Current and Battery Size Selection

Provides guidelines for calculating cranking current and selecting appropriate battery sizes.

Battery Installation Safety and Ventilation

Emphasizes safe battery installation, box ventilation, and securing batteries to prevent movement.

Accessory Battery System and Charge Distributor

Mandates a separate accessory battery group and recommends a charge distributor.

Starting Battery Cable Area Calculation (Volvo Standard)

Provides tables for calculating starting battery cable area based on length and engine system.

Recommended Twin Installation Wiring Diagram

Shows wiring for twin installations, including separate batteries and a single failure tolerant system.

Calculating Supply Cable Area for Accessories

Guides on calculating cable area based on accessory load and total cable length.

Calculating Cable Area for Power Loads

Provides a method for calculating cable area for power loads based on length and consumption.

Battery Charging Procedures and Safety Warnings

Details battery charging safety, risk of explosion, and parameters affecting charge duration.

Universal Tachometer: Setting the Code

Provides instructions on setting the correct code for universal tachometers based on engine type.

External Stop Relay Functionality and Wiring

Explains the function of the external stop relay for remote engine shutdown, including wiring.

Fire Extinguishing System Integration

Details recommended and alternative installations for integrating fire extinguishing systems with engine shutdown.

Main Switch Installation Requirements

Specifies requirements for installing a main battery switch, including positioning and bulkhead transitions.

Electrochemical Corrosion

General Introduction to Electrochemical Corrosion

Introduces electrochemical corrosion, its causes, and types relevant to boats.

Electrochemical Corrosion (continued)

Protection Against Electrochemical Corrosion

Recommends bonding submerged components to anodes and discusses bonding system connections.

Shore Power and Generator Installation Recommendations

Presents recommended shore power and generator installations for safety and corrosion prevention.

Shore Power and Battery Charging Safety Guidelines

Provides safety recommendations for shore power connection and battery charging.

Prevention of Stray Currents During Installation

Offers advice on preventing stray current issues through proper installation practices.

Checking for Leakage from the Electrical System

Describes methods for checking electrical system integrity and identifying current leaks.

Checking Galvanic Electricity and Stray Currents in Water

Explains how to measure galvanic currents and stray currents using a calomel electrode and multimeter.

Stray Current and Shore Power Corrosion

Explains stray current corrosion, its causes, and how it differs from galvanic corrosion.

Engine Room, Ventilation and Soundproofing (continued)

Dimension of Air Intakes and Ducts for Engine Supply

Guides on dimensioning air intake and outlet ducts for proper engine air supply and heat dissipation.

Soundproofing Principles and Material Application

Covers soundproofing strategies for engine rooms, including structural and airborne noise reduction.

Belt Guards and Protections

Installation Requirements for Engine Protections

Emphasizes shielding exposed moving or hot engine parts to prevent personal injury.

Controls

Controls (continued)

Location of Controls: Considerations for Mounting

Details factors to consider when selecting the location for control levers and mechanisms.

Connecting the Speed Control Cable

Explains how to connect the speed control cable to the fuel injection pump for engine speed control.

Final Check of Control System Connections

Outlines final checks of control system connections, lever positions, and stops before starting the engine.

Power Take-Off

Power Take-Off (continued)

Sea Trial

Checks When Test Running the Boat

Lists critical checks during test running, including instruments, leaks, and exhaust backpressure.

Checks Over the Whole Speed Range

Covers checks for engine room temperature, noise, vibrations, and control system functionality across speed ranges.

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