Volvo D5 series Installation Manual
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Volvo D5 series Installation Manual

Marine propulsion diesel engines
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Installation
D E
Marine Propulsion
1(1)
Diesel Engines
D5 - D16 series

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Summary of Contents for Volvo D5 series

  • Page 1 Installation Marine Propulsion 1(1) Diesel Engines D5 - D16 series...

  • Page 3: Table Of Contents

    Installation Marine Propulsion Diesel Engines D5, D7, D9, D11, D12, D16 Contents Safety precautions ..........3 Engine installation ..........56 General information ..........6 Preparing the engine ........56 Engine application ratings ........9 Flexible engine mounting ........ 58 Marine engine environment ......12 Rigid engine mounting ........
  • Page 4 Dimension of air intakes and ducts....70 Location of ventilators and air intakes ..74 Soundproofing ..........75 Belt guards and protections ......178 © 2007 AB VOLVO PENTA All rights to changes or modifications reserved. Printed on environmentally-friendly paper...

  • Page 5: Safety Precautions

    Take precautions to avoid hot surfaces This Installation Manual contains the information you (exhaust pipes, turbochargers, charge air mani- will need to install your Volvo Penta product correctly. folds, starting elements etc.) and hot liquids in Check that you have the correct Installation Manual.
  • Page 6 Safety precautions Always wear protective goggles if there is a risk Ensure that the battery compartment is de- of splinters, grinding sparks and splashes from signed according to current safety standards. acid or other chemicals. Your eyes are extreme- Never allow an open flame or electric sparks ly sensitive and an injury to them can result in near the battery area.
  • Page 7 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.

  • Page 8: General Information

    The manufacturer of engines certified for national case the Volvo Penta organisation will be glad to of- and local environmental legislation (Lake Constance fer assistance in finding a solution for your particular for example) pledges that this legislation is met by installation.
  • Page 9 EU principles. For information and erly and that Volvo Penta approved parts as used. detailed descriptions of the safety requirements that Certain systems (components in the fuel system for...
  • Page 10 General information Conversion factors Metric to U.S. or IMP. conversion factors: U.S. or IMP. to metric conversion factors: To convert To convert from Multiply by from Multiply by Length inch 0.03937 inch 25.40 inch 0.3937 inch 2.540 foot 3.2808 foot 0.3048 Area mm²...

  • Page 11: Engine Application Ratings

    Engine application ratings Rating 3 The engines covered by this manual are mainly used for five different operating conditions, Rating 1 – Rat- Light Duty Commercial ing 5, as described below. For commercial boats with high demands on speed Even at a very early stage, the output requirements and acceleration, planing or semi planing hulls in cy- and operating conditions for the installation con- clical operation.
  • Page 12 Engine application ratings Examples of boats for medium and heavy duty commercial operation, Rating –2. Examples of boats for light and medium duty commercial operation, Rating 2–3.
  • Page 13 Engine application ratings Examples of boats for light duty and special light duty commercial operation, Rating 3–4. Examples of pleasure crafts, Rating 5.

  • Page 14: Marine Engine Environment

    Marine engine environment The marine engine and its environment Power Marine engines, like engines for cars and trucks, are rated according to one or more power norms. The Power losses due to atmospheric conditions output is indicated in kW, usually at maximum engine speed.
  • Page 15 When the prototype and first production boat is built, affecting boat speed. Increased boat weight has a a Volvo Penta representative and a boat manufactur- major effect on boat speed, especially on planing and er should undertake a fully loaded trial of the vessel semi-planing hulls.
  • Page 16 All Volvo Penta engines have an operating speed range where the engine develops its rated horsepower, this is titled "Full Throttle Operating Range". A propeller...
  • Page 17 Marine engine environment Typical sample of a planing hull and how displacement and engine output tolerances effects performance Thrust/ power Engine output / Thrust Displacement / hull resistance Speed Knots Max. tolerance range Nominal engine output Nominal displacement 3 tons Engine output ±3% Displacement ±...

  • Page 18: General Information About Classification

    • Det norske Veritas (DnV) fied it must be stated clearly when addressing inquir- • Lloyd’s Register of Shipping (LR) ies and quotation requests to AB Volvo Penta. • Bureau Veritas (BV) • American Bureau of Shipping (ABS) Special rules for different operational •...
  • Page 19 To be able to classify an engine, the type of engine carried out for the complete installation of the engine must first be type approved. In such cases, where Volvo Penta is concerned, an application for type in the vessel and approved by the Classification So- ciety.

  • Page 20: Installation Tools And Literature

    3838621 Docking station for the VODIA tool*. Con- 885164 Flange D7. For measuring exhaust backpres- nects the VODIA tool to the engine. sure and temperature. *Order via VODIA WEB on Volvo Penta Partner Network 9812519 Multimeter. 9988452 Digital probe tester. 9996065 Manometer. For measuring fuel feed pres- sure, not D9/D/D2.
  • Page 21 Installation instructions and templates are included in the kits. Chemicals A wide range of chemical products are available from Volvo Penta. Some examples are: • Oil and coolant • Sealant and grease • Touch-up paint • Refer to "Volvo Penta Accessories & Maintenance Parts"...

  • Page 22: Design Concepts Of Propulsion Systems

    There are different types of engines, reverse gears and front drive systems, depending on the available space and other requirements during the installation. Follow the manufacturer’s instructions when installing components and equipment not supplied by Volvo Penta. Reverse gear, various types...
  • Page 23 Design concepts of propulsion systems Remote reverse gear Then the couplings are fitted and the engine is The reverse gear is separated from the engine and aligned to the reverse gear. For final location and to mounted on the engine bed or on a separate bed. prevent possible shock loads, lugs must be welded in Torque is transferred via a flexible coupling through front of and behind the brackets on each side.

  • Page 24: V-Drive, Various Types

    Design concepts of propulsion systems V-drive, various types Remote V-drive The reverse gear is separated from the engine and mounted on a separate bed. Torque is transferred via the propeller shaft, as illustrated in the diagram, or via a flexible coupling. The axial forces from the propeller are absorbed by an axial bearing in the reverse gear.

  • Page 25: Twin Engine Package - Twin Gear

    Twin engine package - Twin gear The twin engine package over one marine gear is a Volvo Penta does not market these gears as a marine concept used by Volvo Penta over a period of time. engine package. If this application concept is consid-...

  • Page 26: Controllable Pitch

    Design concepts of propulsion systems Controllable pitch Controllable pitch is used as an alternative to a fixed regulated by means of a built-in function in the re- propeller. The pitch of the propeller blade is normally verse gear. Water Jet Water Jet drives work according to principles of jet There are different types of water jets, a direct drive propulsion.

  • Page 27: Torsional Vibrations And Tvc Calculations

    In classified installations, a TVC must be performed. Torsional analysis data Volvo Penta will do a torsional analysis on receipt of Torsional vibrations occur due to forces on the crank- the necessary details from the customer. The follow-...

  • Page 28: Routines For Handling Tvc

    2. Pump, compressor 6. Reduction gear, reverse gear The Drive package, i.e. engine, flexible coupling, and reverse gear, supplied by Volvo Penta has as one unit the lowest possible torsion vibration level in terms of standard propeller systems. A Torsional Vibration Calculation (TVC) must be conducted by Volvo Penta if other combinations are to be used.

  • Page 29: General Arrangement And Planning

    Consult Volvo Penta ate the information shown in the illustration below. literature and computer programs or contact the Volvo Trial and error is often needed to finally find the es- Penta organisation for assistance.

  • Page 30: Installation Example

    General arrangement and planning Installation example...
  • Page 31 Use of an engine/reverse gear is installed on flexible mounts. incorrect propeller can result in cavitation, which also Volvo Penta offers flexible mounts for a large variety causes noise and vibrations. of engine/reverse gear combinations.
  • Page 32 General arrangement and planning 5. Cooling system 10. Controls and steering Determine the type of cooling system. Chose where Plan for the routing of control cables, steering sys- to place seawater intakes and seawater filters. Plan tems, Dual station units (DS–units), etc. Allow acces- the routing of hoses.

  • Page 33: Propeller Theory

    General arrangement and planning Propeller theory The angle of the propeller shaft should be as small To get the best performance out of your boat, you as possible. Shaft angles of less than 2° do not usu- need to select the propeller and gearing that will suit ally cause any major problems, but shaft angles of your particular boat, engine and speed range.
  • Page 34 0.7 m (0.26 in ) per ton of thrust. Over the last year, Volvo Penta has been developing computer programs for calculating speed, gear ratios As described above, a large, slow-moving propeller and propellers. This is excellent for predicting speed is preferable.

  • Page 35: Propeller Selection

    For the best propeller efficiency, the angle of the pro- The combination of ratio, shaft diameter and propel- ler size can be calculated by using the Volvo Penta peller shaft in relation to the water line should be as computer program. Calculation of the correct pro- small as possible.
  • Page 36 General arrangement and planning Ensure that there is sufficient space between the propeller, hull, keel, skeg and the 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.
  • Page 37 General arrangement and planning Propeller rotation D5/D7 engine revolution range 1900–2300 rpm with conversional shaft/propeller system Ratio, Main type of Speed approx. operation range Work boats, 4:–3: Displacem. boats, 4–8 kn. High pulling power, Towing, Trawling Work boats, 3:–2.0: Displacement boats, 6–0 kn.

  • Page 38: Engine Inclination

    General arrangement and planning Engine inclination To ensure that the engine is sufficiently lubricated Each engine type has a maximum permitted en- and cooled, it is important that the maximum engine gine inclination while the boat is under way. This in- inclination is not exceeded.

  • Page 39: Weight Distribution

    General arrangement and planning Weight distribution Engine centre distance, twin installation 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.

  • Page 40: Accessibility For Maintenance And Repairs

    General arrangement and planning Accessibility for checking, maintenance and repairs When designing the engine room always pay atten- tion to the accessibility needed to allow proper serv- ice and repairs to the engine. Also ensure that the complete engine can be removed without damage to the boat structure.

  • Page 41: Selection Of Engine Suspension

    2 hours before the height is adjusted. excessive for the rubber mounts. Always follow the recommendations of Volvo Penta One condition for rubber mounts to be effective when selecting the engine suspension. The use of dampers is that the engine bed is sufficiently rigid.
  • Page 42 General arrangement and planning V-drive Vertical Propeller component thrust Axial component Engine rubber mount In all installations with a down angle propeller shaft This will create a lifting force to the engine mounts there will be a lifting force transmitted from the pro- fitted at the same end as the gear box.
  • Page 43 General arrangement and planning Rigid mounting Support bracket for front power take-off Sheet steel shims (about 0.4" = 0 mm thick) Steel bed frame (U-member or L-member, Rear mounting brackets (about 0" = 250 mm high) thickness 0.47–0.6" = 2-5 mm) Adjustment bolts (4 pcs) for engine heightwise position.
  • Page 44 General arrangement and planning Engine suspension vs propeller shafting NOTE! A flexible shaft coupling must never be fitted together with a flexible mounted stuffing box. This can cause vibration problems. Stainless steel propeller shafts are available in differ- ent diameters. The shaft dimension should be chosen based on the engine power output, gear ratio and propeller shaft material.
  • Page 45 Axial thrust bearing Flexible coupling Thrust bearing All reverse gears from the genuine Volvo Penta range a flexible coupling must always be fitted between the are fitted with built-in axial bearings for axial forces reverse gear and the thrust bearing so as to eliminate from the propeller shaft.

  • Page 46: Engine Foundation

    Engine foundation Aligning the boat Plane requirements, rigid mounting It is very important that the engine bed is dimension- ally stable when the engine has a rigid mounting. The maximum height deviation (movement) between the engine’s attachment plane must be within 3 mm (0.2").
  • Page 47 Engine foundation Fibreglass hull Example of an engine bed in a fibreglass hull. . Flat bar 2. Spacer material 3. Fibreglass The engine bed in fibreglass should be designed so The engine bed can be built up separately and then that it is rigid, both vertically, longitudinally and trans- carefully measured and bonded to the hull, or be built versely, to distribute the load as far as possible to the...
  • Page 48 Engine foundation Steel, aluminium or wooden hull Example of engine bed in a steel or aluminium hull. The bed frame in a steel or wooden boat should be If the engine has an extra PTO in the front end that designed as a welded steel structure.

  • Page 49: Building The Engine Bed

    Engine foundation Building the engine bed The engine bed position is determined by the posi- tion of the shaft. After measuring carefully, cut a hole in the stern large enough for the stern bearing to be put loosely in place. Alternative 1 The engine can be used as a fixture to determine the position of the engine bed.
  • Page 50 Engine foundation Flexible mounting 20 mm (3/4") 20 mm (3/4") When designing the engine bed, make sure that the space for the flywheel housing, the bottom and sides of the sump, etc. have a recommended clearance of at least 20 mm (3/4"). Fibreglass engine bed Rigid mounting •...
  • Page 51 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 M6. Check engine bed parallelity.

  • Page 52: Propeller Shaft Systems

    0.3 mm per metre (0.0036" per foot). be applied. The maximum bearing distance has a major influence for the calculation of shaft dimension- ing. To determine the propeller shaft dimension and bear- ing distance, use the Volvo Penta computer program or consult the shaft supplier.

  • Page 53: Flexible Propeller Shaft Coupling

    Propeller shaft systems Flexible propeller shaft coupling Together with a flexible mounted engine and a fixed stuffing box, the propeller shaft must be fitted with a flexible propeller shaft coupling. See combinations in chapter Selection of engine suspension. NOTE! The alignment of the engine is just as im- portant with the above propeller equipment as for a rigid shaft connection.
  • Page 54 NOTE! For D6, the oil cooler is delivered separately. too much water in a boat with wet exhaust system. If For installation instructions, contact Volvo Penta. too much water is lost through the outlet to the shaft seal, the exhaust hose might be overheated. A guide- line is to install a 0 mm (3/8") hose from the reverse...

  • Page 55: Shaft Bearings

    Propeller shaft systems Shaft bearings There are different types of shaft bearings. Choose the type which suits the application and use. The shaft bearings could be fitted in a propeller shaft bracket, front and/or rear end of the stern tube or in a separate support bearing.

  • Page 56: Installation Of Stern Tube And Shaft Bearing

    Propeller shaft systems Installation of stern tube and shaft bearing The fix point (A) is determined by required propeller size etc.The 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.
  • Page 57 Propeller shaft systems Push the propeller shaft into place and align the shaft and the stern bearing with the reverse gear’s output shaft (reverse gear’s flange). 4 mm (0.6") To prevent the shaft from bending in the stern shaft tube, the shaft can be centred as follows: The clearance between the propeller shaft and tube for a •...

  • Page 58: Engine Installation

    Engine installation Preparing the engine NOTE! Installations in the engine room for the cool- NOTE! All engines are delivered from Volvo Penta ing system, exhaust system, electrical system etc. without engine oil and coolant. Check that the oil plug should be as complete as possible before the engine and draining cocks for coolant, hot water cocks etc.
  • Page 59 Engine installation If the engine is flexible mounted: 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 the rubber mounts on the engine brackets.

  • Page 60: Flexible Engine Mounting

    Engine installation Flexible engine mounting Installing the engine on the engine bed with mounts of type 1 Before adjustments can be made, the engine must rest on the rubber mounts for at least twelve hours but prefferrably more than two days. Never use rubber mounts other than those intended for each particular engine type.
  • Page 61 Engine installation Align the engine to the propeller shaft. See chapter Alignment. Compare front and rear mounts sidewise in pairs. Adjust as necessary. NOTE! Make sure that the rubber mounts are in- stalled so that no pre-load or side forces occur after the engine has been installed and aligned with the propeller shaft.
  • Page 62 Engine installation Installing the engine on the engine bed with mounts of type 2 Before installation, check that the engine bed is flat, Re-measure distances B and B2. The difference as described in the applicable installation manual. must not exceed 3 mm (0.2") in any anchorage. The engine must have rested on the rubber mount- ings for at least twelve hours before any adjustments can be made.
  • Page 63 Engine installation 300 Nm (220 lbf-ft) NOTE! Check that the rubber mountings are installed Tighten the top nut on each engine bed after align- so that they are not left under tension or side forces ment in relation to the propeller shaft. Check paral- when the engine has been installed and aligned in lelism of the engine bed and check the loading of the relation to the propeller shaft.

  • Page 64: Rigid Engine Mounting

    Engine installation Rigid engine mounting Support bracket for front power take-off Steel bed frame Front mounting bracket Inspection covers Rear mounting brackets Adjustent bolts (4 pcs) for engine vertical position. To be removed after completed installation Bolt to adjust engine lateral position Make a rough alignment of the engine to the propel- Check that the engine is standing on all four height ler shaft with adjusting bolts (7, 8).
  • Page 65 Engine installation Fixing positions After final control and possible alignment and adjust- ment, the engine and reverse gear must be fixed in their correct locations with the aid of either wedges or tapered guide pins. Holes are drilled through diago- nally opposed engine and reverse gear brackets and the bed.

  • Page 66: Alignment

    Engine installation Alignment When the bed frame is finally in position, the propel- NOTE! Make sure that the flanges are pressed ler shaft installed and other preparatory work com- against each other throughout the entire check. pleted, the engine and reverse gear can be installed. When the engine is fitted on rubber mountings, align- Engines with a closed coupled reverse gear are ment must be carried out with the same care as in...
  • Page 67 Engine installation Remote reverse gear, alignment Drill all the holes for the brackets, fit the shims or spacers and then tighten the 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.

  • Page 68: Fuel System

    Fuel system General Fuel tanks Installation of the fuel system components - fuel If possible, the tanks should be located so that they tanks, cocks, fuel piping and extra fuel filters, etc., are at the same level or somewhat higher than the must be carried out very carefully to assure the en- engine.
  • Page 69 Fuel system Example of fuel system, D5/D7 . Feed pump 2. Fuel injection pump 3. Fuel tank 4. Shut-off valve (optional, se section 'Fuel tanks') 5. Primary filter and water separator 6. Fuel fine filter 7. Injector 8. Leak off line 9.
  • Page 70 Double tanks as shown in the figure should be con- nected at bottom by means of pipelines fitted with be installed for all Volvo Penta engines. shut-off cocks. The lower connecting pipe should If a day tank is installed, then it is advisable to con- have an internal diameter of at least "...
  • Page 71 Fuel system A shut-off valve must be installed in the suction line as close to the tank as possible. The 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...

  • Page 72: Piping

    Fuel system Piping All fuel lines should be led and properly clamped near bottom of the boat to avoid heat radiation. NOTE! The D5 and D7 has a high fuel flow and therefor must the fuel lines have a large diameter. To small piping will reduce the power output.

  • Page 73: Priming Pump For D5/D7

    Fuel system Priming pump for D5/D7 Copper piping D5/D7 has no engine mounted priming pump. To be able to vent the fuel 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.

  • Page 74: Fuel Pre-Filters

    Fuel system Fuel pre-filters Filtration Three progressive stages – separation, coagulation Single or double filters and filtration ensure that fuel arrives at the engine free from contamination. Water and other impurities The filter shall be installed on the suction side of the are collected in the bowls beneath, from where they feed pump, between the feed pump and the fuel tank, can be simply drain off by means of a drain valve.

  • Page 75: Checking Feed Pressure

    Fuel system Checking feed pressure The pressure is measured after the fuel has passed the filter cartridge. When checking, engine speed is first increased, after which the speed is reduced so that the pressure can 9998494 be read off at low idling speed. The feed pressure 9998339 must not be less than 280 kPa (40.6 psi) for D5/D7 &...

  • Page 76: Fuel Cooler For D5/D7

    Fuel system Fuel cooler for D5/D7 Increasing the fuel temperature above 40°C (meas- Theses kind of fuel coolers are integrated into the ured at the inlet to the injection pump) leads to a cooling system of the engine (air side) and are flowed decrease in power of approx.

  • Page 77: Cooling System

    Lines with an ex- the cooling system. cessively small bore, unsuitable routing, incorrect Always use Volvo Penta coolant in a mixture of anti- connections etc will cause restrictions and lead to freeze or anti-rust agent. The coolant used affects the abnormal engine temperatures.

  • Page 78: Seawater System

    Cooling system Seawater system A standard feature of Volvo Penta diesel engines is NOTE! The greatest permitted suction head for the a closed cooling system, with freshwater circulating pumps are 2 m (6.6") for D5/D7 and 3 m (0') for all in the cooling ducts and heat exchanger(s) of the en- other engines.
  • Page 79 Cooling system Flow area of the seawater intake Dimensions of hoses Dimensions of hoses and pipes for seawater to and from the engine, see drawings for each engine type. 200 mm (8") 500 mm (20") 200 mm (8") Minimum flow area of seawater intake = .5 x hose inner cross section area.
  • Page 80 Cooling system D5/D7 max =  bar (4.5 psi) max = 32°C (90°F) ∆t B–E min = -0.2 bar (2.9 psi) max = .0 bar (4.5 psi) . Strainer 2. Seawater valve 3. Seawater filter 4. Sea water pump 5. Charge air cooler, D5/D7 TA Seawater temperature max 32°C (90°F) 6.
  • Page 81 Cooling system max = 2.5 bar (36.3 psi) max = 32°C (90°F) ∆t B–E min = –0.3 bar (–4.4 psi) max = .0 bar (4.5 psi) . Strainer 2. Seawater valve 3. Seawater filter 4. Extra seawater pump 5. Sea water pump Seawater temperature 8.
  • Page 82 Cooling system Where a genuine Volvo Penta seawater pump is re- IMPORTANT! To ensure there are no leaks in placed with a different type of pump, the flow must be the cooling system, carry out a simple pressure measured. test before bringing the installation into service.
  • Page 83 Cooling system ∆ Temperature increase ( ) across the seawater circuit B – E of the engine including reverse gear oil cooler at nominal power. ∆ Engine Rating according to figure on pages 78 - 79 B – E °C (°F) D5A T, 900 rpm 8–0...

  • Page 84: Freshwater System

    (-8°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 protection.

  • Page 85: Filling With Coolant

    Cooling system Filling with coolant NOTE! Coolant should be filled with the engine stopped and cold. NOTE! For filling D2D-B MP with coolant, see Op- erator's Manual. External systems: When external systems are con- D5/D7: The coolant level should reach the lower nected to the engine’s cooling system, the valves to edge of the filler pipe.

  • Page 86: Venting Nipples

    Cooling system Venting nipples D5/D7/D9/D11/D16 D5/D7/D9/D/D6 has no venting nipples. The cool- ing system is automatically vented. D12D-A MP, D12D-B MH D12D-B MP All cooling systems All cooling systems Cooling pipe, turbo Cooling pipe, turbo...

  • Page 87: External Cooling

    It is important to use the correct materials in the cool- If using power take-off under 0 knot ers. Use Volvo Penta coolant, a mixture of anti-freeze. condition, what are the power and rpm at which the engine will be loaded?

  • Page 88: Central Cooling System

    See chapter Function diagrams. The parameters given for Volvo Penta marine engines under the heading External cooling also apply when the engine is connected to a central cooling system.
  • Page 89 Cooling system Keel cooling (Pipe cooling system) Pipe cooling (detail) Keel cooling (Skin cooling system) Skin cooling (detail)

  • Page 90: Engines Adapted For External Cooling

    Cooling system Coolant flow and connections for engines adapted for exter- nal cooling Engines adapted for external cooling differ from sea- 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.
  • Page 91 Cooling system D5/D7 Two circuit system with one keel cooler ∅ 38 mm (.5") ∅ 42 mm (.6") . To keel cooler 2. From keel cooler D5/D7 Two circuit system with two keel coolers ∅ 38 mm (.5") ∅ 50 mm (2") .
  • Page 92 Cooling system Two circuits keel cooler ∅ 50 mm (2") ∅ 50 mm (2") ∅ 50 mm (2") ∅ 50 mm (2") To the keel cooler, charge air cooler circuit From keel cooler, charge air cooler circuit To keel cooler, engine coolant circuit From keel cooler, engine coolant circuit...
  • Page 93 Cooling system One circuit keel cooler Port side ∅ 57 mm (2 /4") . From keel cooler 2. To keel cooler 3. Standard expansion tank 4. Extra expansion tank 5. Reverse gear oil cooler Starboard side ∅ 57 mm (2 /4")
  • Page 94 Cooling system Two circuit keel cooler Starboard side ∅ 45 mm (.8") Port side ∅ 42 mm (.7") ∅ 38 mm (.5") To the keel cooler, charge air cooler circuit From keel cooler, charge air cooler circuit ∅ 50 mm (2") To keel cooler, engine coolant circuit From keel cooler, engine coolant circuit...
  • Page 95 Cooling system Max. capacity of the freshwater system in keel cooled engines This table shows engine volume excluding heat exchanger and the max. permitted total cooling system volume with standard expansion tank, including keel cooler and other circuits such as an engine heater circuit or a cabin heater circuit.
  • Page 96 Cooling system ∆ Max. temperature increase, - across the engine circuit, T1–T2 (T5–T6 on D12C) - across the charge air cooler circuit, T3–T4 See also chapter Function diagrams, external cooling for each engine type. ∆ ∆ Engine Rating engine circuit charge air cooler circuit T1–T2 (T5–T6 D12) T3–T4...

  • Page 97: Measuring Pressure In Kc Systems

    /4" NPTF The T-nipple is used when measuring both pressure and temperature in the cooling circuit. The tool is not stocked by Volvo Penta. Locally manufactured Note that it is important to place the probe correctly adapter pipe for measuring in the coolant flow.

  • Page 98: Measuring Temperature In Kc Systems

    Cooling system 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 Coolant temperature from keel cooler...

  • Page 99: Function Diagrams, External Cooling

    Cooling system Function diagrams, external cooling Components, such as oil coolers for reversing gear, expansion tank etc. are not always supplied by Volvo Penta. These components are not the responsibility of Volvo Penta. The border of Scope of supply from Volvo Penta/Volvo Penta responsibility is marked in the diagrams by —...
  • Page 100 Cooling system D5/D7 -TA External cooling. Two circuit system with one keel cooler External system Internal system Scope of supply Volvo Penta responsible from Volvo Penta P2 T2 P T . Engine Engine oil 2. Expansion tank cooler 3. Keel cooler, engine circuit...
  • Page 101 Cooling system D5/D7 -TA External cooling. Two circuit system with two keel coolers External system Scope of supply Internal system from Volvo Penta Volvo Penta responsible P3 T3 03 P2 T2 P4 T4 P T . Engine 2. Expansion tank Engine oil 3.
  • Page 102 Cooling system External cooling. Two circuit system with two keel coolers Note! Note! Internal system Volvo Penta responsible Engine-circuit: CAC-circuit: 40% coolant / Scope of supply 20% coolant / from Volvo Penta 60% water. 80% water. External system External system .
  • Page 103 Cooling system External cooling. One circuit system P T Q P2 T2 External system Internal system Scope of supply Volvo Penta responsible from Volvo Penta Engine Expansion tank Engine oil Keel cooler cooler Restriction Charge air Coolant filter cooler Reverse gear...
  • Page 104 Cooling system External cooling. Two circuit system NOTE! Dearation must be moved to the extra expansion tank. For temperatures, max pressure drop and flow, see * LT exp tank is not incl. in delivery. Size should be Technical data in Sales Guide Marine Propulsion adapted to circuit volume Diesel Engines.

  • Page 105: Thermostats, External Cooling

    Cooling system Thermostats, external cooling Two different types of thermostats are used in Volvo Penta marine engines - disk thermostats and piston thermostats. D5/D7, D9, D2 and D6 have piston thermostats. NOTE: If an engine is connected to a central cool-...

  • Page 106: Expansion Tank, Function Diagram

    Cooling system Expansion tank, function diagram Correctly designed system A Coolant level before start up. Max. filling level with cold engine. Coolant level is not to pass below the MIN mark with cold engine. Coolant level is not to pass the MAX mark with warm engine.
  • Page 107 Cooling system Recovery tank incorrectly connected. Unacceptable system, fatal to the engine 0–75 kPa IMPORTANT! 75 kPa (0– psi) ( psi) • If there is too little expansion volume (E) an un- derpressure will be created when charged after an idling period, thus causing cavitation of the •...

  • Page 108: Extra Expansion Tank

    7.0 – 0.0 m (23.0 – 33.0') Open system NOTE! If you select an in-house manufactured expansion tank, you should use a Volvo Penta pressure cap. Choose the type of cap in accordance with table above. Heat exchanger cooled engines.
  • Page 109 Cooling system When an extra expansion tank is installed the en- gine’s expansion tank must be completely filled with coolant. NOTE! The keel cooled version of D9 and D6 must always have an extra expansion tank. The expansion tank volume in the extra tank should be 5% of the total capacity of the cooling system.

  • Page 110: Engine Heater

    Cooling system Engine heater Components: . Engine heater 2. Outlet 3. Inlet 4. Connector with protective cap 5. Appliance plug with protective cap Cold starting is one of the most important determin- The heater should have its own circulation pump and ing factors regarding the service life of an engine.
  • Page 111 Cooling system D5/D7 An engine mounted engine heater can be provided for the D5 and D7 engines. D9/D11 Engine heater connections From engine heater M6x,5 To engine heater ∅ 9,5 mm...
  • Page 112 Cooling system From engine heater Engine heater connections Thermostat housing /2"R To engine heater /2"R Engine heater connections From engine heater To engine heater /2"R /2"R...

  • Page 113: Hot Water Connections

    Shut-off valves venting nipple (4) at its highest point. The system is vented once pressurized. Volvo Penta recommends that shut-off valves (2, 3) are installed in the extra cooling circuit on both the In large heating systems, a hose thermostat (5)
  • Page 114 Cooling system D5/D7 D9/D11 Hot water connections Hot water connections Inlet and outlet - from hot water circuit Hot water inlet Hot water outlet /2"R, Inlet /2"R, Outlet Hot water connections M26x1.5 Outlet - to hot water circuit M30x2 D5/D7 When dimensioning the heat exchanger for heating, it must be observed that the coolant tap on the engine only can allow a limited water flow and temperature...

  • Page 115: Hot Water Connections

    Cooling system Hot water connections Inlet - from hot water circuit Outlet - to hot water circuit /2" R /2" R Inlet Engine coolant Outlet pump...

  • Page 116: General

    Dry exhaust line, insulated gine and so that there is no risk of overheating Most of the boats/vessels in Volvo Penta power range any adjacent parts of the boat. The demand for with inboard engines are equipped with wet exhaust silencing must also be met and the system ar- systems.
  • Page 117 CFR part 94 regulations. could make it unlawful to sell or place the ves- sel into service. Where Volvo Penta have not added a sam- ple port, for example when an inadequate Instructions to comply with this requirement amount of the exhaust system is supplied to can be provided by Volvo Penta upon request.

  • Page 118: Wet Exhaust Line

    Usually the marine engine manufacturers do not Engine Volvo Penta standard exhaust market complete wet exhaust systems. The OEM, elbow connection diameter shipyard, boat manufacturers etc. are the ones who design, chose components and experiment to de- 3"/ 68 mm...
  • Page 119 Exhaust system Exhaust elbow angle (α) relative to water line, fig. A should be min: 5° α 0° D9/D elbow angle is fixed 5° The elbow angle is important to obtain a water spray all around the outlet. This is to avoid overheating of the top of the exhaust hose.
  • Page 120 Exhaust system Water by-pass for D5 A water by-pass hose must always be installed on D5 to obtain allowed back pressure. The hose should be installed on the exhaust elbow and the water outlet through the hull. water by-pass Principal system for sailing yachts Anti siphon valve D min...
  • Page 121 Exhaust system Silencers There are various types of silencers depending on the type of installation. Two very common types are: • Aqua-lift silencers • In-line silencers Aqua-lift silencers, principle outlines of various types Alt. inlet Alt. inlet Inlet Inlet Single room Twin room Exhaust system Aqua-lift silencer, wet exhaust line in motor boats ∅...
  • Page 122 Exhaust system In-line silencers Round In-line silencer Oval In-line silencer Exhaust system In-line silencer, wet exhaust line ∅ Cmin ∅ Recommended hose diameter (innerdiameter) ∅ An in-line silencer is most suitable when the exhust and ∅ outlet is located high in relation to the water line so see table on the following page.
  • Page 123 Figure B α Figure A Figures A and C show a Volvo Penta multi-purpose riser fitted on a D2 engine. This riser can be used on both port and starbord engine in a twin engine installation. The riser is continuosly adjustable in the...
  • Page 124 Exhaust system Exhaust outlet through boat bottom – concept design Principle sketch, exhaust outlet through bottom In some installations an exhaust outlet through the bottom of the boat might be the prefered alternative. 350 mm (4") Exhaust hose Exhaust pipe (Full strength pipe) Exhaust outlet By-pass outlet...
  • Page 125 Volvo Penta has considerable know-how in the ap- forms in the boat and the exhaust fumes are drawn plication of custom-made exhaust boots, and can towards it.

  • Page 126: Dry Exhaust Line

    Exhaust system Dry exhaust line Introduction The line must also be provided with a flexible com- pensator () to absorb heat expansion and vibration The exhaust system should be planned at the layout from the engine. The compensator is fitted on the stage of the installation.
  • Page 127 Exhaust system Condensation water collector 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.
  • Page 128 Exhaust system Flexible exhaust compensator Exhaust pipes are isolated from the engine move- ments usually via a flexible compensator. The compensator should be fitted to the exhaust elbow. In special cases the compensator can be in- stalled up to max.  m (3.3 ft) from the exhaust outlet. Flexible exhaust compensators have three functions: •...

  • Page 129: Installation Data

    Exhaust system Measurements mm (in) Pos. Description Compensator type in fig. 4" (short) 4" (long) 5" 6" 7" Hose length 85 (7.3) 500 (9.7) 500 (9.7) 500 (9.7) 250 (9.8) Total nominal length 45 (5.7) 590 (23.2) 590 (23.2) 590 (23.2) 280 (.0) Screw circle diam.
  • Page 130 Calculation of HD silencer backpressure To calculate the backpressure for Volvo Penta HD silencers use the following formulas: See Sales Guide Marine Propulsion Diesel Engines Technical Data. Exhust gas flow (m /min)
  • Page 131 Exhaust system Velocity/Resistance curve at 400 °C Resistance in inches Wc Resistance in mm Wc Backpressure - exhaust pipe - calculation Using the value of the exhaust gas flow and having For equivalent straight length see the table below: calculated the backpressure for a certain silencer (HD) you will be able to determine the resistance to Pipe diameter Bend 45 deg.
  • Page 132 Exhaust system Example: Engine: D2MH Power: 294 kW / 800 rpm Silencer: 7" HD Calculation of pressure loss through the silencer. Q (m /min) Bore velocity (m/s) = Pipe area (m ) x 60 2952 m 2952 Q (flow) = 2952 m /h = = 0.82 m 3600...
  • Page 133 Exhaust system Exhaust elbows Standard system size ∅ For dimensions of exhaust elbows see current Sales Exhaust system diameter (∅) Guide Marine Propulsion Diesel Engines. Engine Dry exhaust line Multiple exhaust outlets 3"/68mm If more than one engine is being installed, the ex- 4"/07mm haust from the engines must not be taken into the same flue.

  • Page 134: Backpressure

    Exhaust system Backpressure The exhaust system will produce 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 •...
  • Page 135 Exhaust system Measuring procedure D9/D11 Wet exhaust system Wet exhaust line (picture with riser) • Remove the exhaust pipe from the turbocharger exhaust output. Clean the mating surface. • Install the measuring flange () to the turbine housing flange (only if measuring flange is need- ed).
  • Page 136 Exhaust system Measuring procedure Dry exhaust system Dry exhaust line 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. 2 mm Alternatively, connect a transparent plastic hose (0.08") with a suitable nipple to the exhaust elbow.

  • Page 137: Measuring Exhaust Temperature

    Exhaust system Measuring exhaust temperature Dry exhaust line Dry and wet exhaust line Control measuring of the exhaust temperatue is sometimes needed to ensure the thermal conditions of the installation and in some cases the engine. It is important that the measurements are accurate. One important factor when taking these measurements is to position the probe correctly in the gas flow.

  • Page 138: Electrical System

    Electrical system Electrical installation Batteries General Battery terminology The electrical installation has to be planned very Capacity carefully and carried out with the utmost care. Seek Capacity is measured in Ampère-hours (Ah). The simplicity when designing the electrical system. starter battery capacity (Ah) is usually stated as the The wires and connectors used in the installation 20 hour capacity of the battery, i.e.
  • Page 139 Electrical system Connecting batteries Series connection: Two 2 V batteries are connected in series so that If a boat has more than one battery, observe the fol- the system voltage in the boat is 24 V. lowing for each connection method: WARNING! Always check the boat’s system Parallel connection: voltage before connecting.

  • Page 140: Battery Installation

    Battery The battery sizes listed below are recommended for gas is easily ignited and highly volatile. Sparks Volvo Penta engines at a temperature down to +5°C. or open flames can cause explosion or fire. Battery voltage is 2V.

  • Page 141: Accessory Battery

    The use of a separate battery group for accessories The use of a cross-over switch between the acces- is mandatory. sory battery and the starter battery is recommended. Volvo Penta recommends using a charge distributor to feed the accessory batteries. Cross over switch...

  • Page 142: Starting Battery Cable Area

    (0–4.4) (4.4–2.0) (2.0–27.6) (27.6–36.0) ) AWG (American Wire Gauge) ) Values based on battery capacity 40 Ah Comparison cable core area (mm²) / diameter (mm) according to Volvo standard Cable core area, mm² Cable core diameter, mm Cable diameter, mm...

  • Page 143: Power Supply

    How to calculate the cable area is described in the installation instruction included in the charging dis- tributor kit. Recommended single installation Alternator Sensor cable 3-way charge distributor. (Not a Volvo Penta accessory) Accessories Cross over switch Accessories Accessory Start Bow thrusters, anchor...
  • Page 144 Electrical system Recommended twin installation Two accessory battery groups (single failure tolerant system) Alternator Accessory battery Alternator Accessories (normal starboard port Navigation equipment, loads) except naviga- other type of loads tion equipment Sensor Sensor cable cable Charge Charge distributor distributor Start Start Cross over...

  • Page 145: Power Module D9/D

    Electrical system Power module D9/D11/D12/D16 The power module monitors power supply to the con- NOTE! If the engine is stopped the starter motor trol unit, the EVC system (on D2, also exhaust tem- does not automatically switch over to backup battery perature sensor and sea water pressure sensor).

  • Page 146: Accessories

    Electrical system Accessories – – – Junction box for ground lead (–) Fuse box (+) Junction box, navigation lamps Before installing optional accessories, such as navi- gation instruments, extra lighting, radio, echo sound- er etc., carefully calculate the total electrical power consumption of these extras in order to be sure that Calculating the supply cable area the charging capacity in the boat is sufficient.
  • Page 147 Electrical system 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. Length Area Load Length Area Load (meters)

  • Page 148: Extra Alternators

    Electrical system Battery charging Relationship between AWG, inch, mm and mm IMPORTANT! Always connect the battery Diameter Area charger directly to the battery positive (+) and inches mm negative (–) poles. 0,0253 0,6438 0,3255 When a battery charger is used in a 2 V system, the 0,0285 0,7229 0,404 battery voltage rises quickly to around 2.9 V, and...

  • Page 149: Instruments Non Evc Engines

    Electrical system Instruments Charge state Non EVC engines The charge state is the level to which the battery is charged. This state can be measured either by mea- suring the specific gravity of the battery acid in each cell or by measuring the off-load voltage of the cell. The latter cannot be done on modern batteries since the cells’...
  • Page 150 Electrical system Complete instrument panels for one or two stations Flybridge Flybridge Oil pressure sensor Coolant temp. sensor Tachometer NOTE! When two Full instrumentation panels, full instru- (not D5/D7) mentation are used, make sure an electri- cal system with oil pressure sender and coolant temperature Main...
  • Page 151 Electrical system Instrument kits for customised dashboards NOTE! When two panels, full instru- Oil pressure sensor mentation are used, make sure an electrical system with oil pressure sender and coolant temperature Coolant temp. sensor sender for two instruments is used. Flybridge, start/stop buttons Flybridge, key switch Tachometer or full instrumentation...
  • Page 152 Electrical system Instrument kit – key switch . Panel kit Available as option: 2. Instrument kit (temperature, oil, volt) 3. Tachometer kit 4. Instrument kit (boost pressure, oil pressure reverse gear) Harness lengths: A → B 80 mm A → C 760 mm A →...
  • Page 153 Electrical system Universal tachometer, 12V/24V. Instructions–how to set the code Before you start using the tachometer, the correct code for the respective engine must be set. Setting steps Shown on display A Descriptions Important! For ta- Connected to sys- chometers that are COdE tem voltage already coded pin B...
  • Page 154 Water in fuel filter alarm Additional instruments are available to monitor en- Volvo Penta offers the option of installing an indica- gine boost pressure () and oil pressure (2) in the tion for water in the fuel pre-filter. The sender can be gearbox.
  • Page 155 D12D-A MP The auxiliary stop can be controlled remotely by installing two relays in series with the auxiliary stop wiring. The function can be used for a third party fire extinguishing system. Please contact Volvo Penta for further infor- mation.

  • Page 156: Fire Extinguishing System

    Electrical system Fire extinguishing system 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.

  • Page 157: Classified Electrical Systems, Mcc

    The Volvo Penta Marine Commercial Control pro- • On screen alarm list indication On screen alarm list indication tects the engine using the Volvo Penta shutdown unit • Event and time driven engine history for back tra- Event and time driven engine history for back tra- (SDU).
  • Page 158 Electrical system MCC system overview Terminology MCC ............Marine Commercial Control, name of the over all system. MCU ............Marine Control Unit, the central control unit of the system. SDU ............Shudown Unit, for engine protection. Activates a fuel shut-off valve to shut down the engine.
  • Page 159 Electrical system Technical data MCU General Power supply Voltage range ............8-36V DC Consumption ............0,34A at 8VDC ................. 0,2A at 24VDC Battery voltage measurement tolerance ....2 % at 24V Real Time Clock (RTC) battery life-cycle ..... 0 years NOTE! RTC battery flat causes wrong Date&Time information only.
  • Page 160 Electrical system Group  AI – AI4 Number of inputs ............. 4 unipolar Resolution ..............0 bits Jumper selectable range ......... V, W, mA Maximal resistance range ........2500 W Maximal voltage range ..........4,0 V Maximal current range ..........0 –...

  • Page 161: Electrochemical Corrosion

    Electrochemical corrosion General Galvanic corrosion A boat that lies in the water constitutes a galvanic NOTE! Please refer to the Marine Electrical Sys- element, since different metals (or metal alloys) such tems Part 1 manual, chapter Electrochemical cor- as steel and bronze are in electrical contact with rossion for more detailed information.

  • Page 162: Definitions

    Electrochemical corrosion Definitions Metals susceptible to corrosion All metals can be physically listed in a galvanic po- One-pole system tential series. This indicates the metal’s normal po- tential (voltage) in relation to a reference electrode In a -pole system the engine block itself is used as when each material is immersed in a particular elec- a negative return for all electrical components on the trolyte.

  • Page 163: Protection Electrochemical Corrosion

    Electrochemical corrosion Protection against electrochemical corrosion It is important that components submerged in the wa- ter such as through-hull fittings, swim ladders etc. are protected from galvanic corrosion. Our recommenda- tion is to bond all of them to a transom mounted, pro- tective anode, normally made of zinc.

  • Page 164: Stray Current And Shore Power Corrosion

    Electrochemical corrosion Protection against electro- static discharge and lightning For advice on the prevention of hazards due to electrostatic discharge or lightning, please refer to relevant publications by national and international standardization bodies such as the International Electrotechnical Commission and the American Boat and Yacht Council.

  • Page 165: Shore Power And Generator Installation

    Electrochemical corrosion Shore power and generator installation Recommended installations Shore power cable Encapsulated single phase connector : isolation transformer Branch circuit Power inlet (electrically with metal case breaker (typical) insulated from boat) Shore Transfer switch connection shore-off-gen Main shore power 20/230 VAC Disconnect circuit device...

  • Page 166: Shore Power And Battery Charging

    Electrochemical corrosion Shore power and Taking into account considerations of personnel safe- ty and care of the equipment, Volvo Penta gives the battery charging following recommendations regarding shore power alternating current (AC) installations: When shore power is connected (20V–230V), the...
  • Page 167 Electrochemical corrosion Prevention of stray currents during installation A proper installation will reduce the risk of stray cur- rent problems later in the boat’s service life. • All DC circuits must have an insulated return ca- ble. Consequently, a metal keel must not be used as a return conductor.

  • Page 168: Checking Electrochemical Corrosion

    The result should lie between (minus) -900 mV and -00 mV. Volvo Penta has produced a method for measuring To check individual components, move the electrode galvanic currents and stray currents using a calomel so that the tip is directed towards the surface, ap- electrode.
  • Page 169 Electrochemical corrosion Checking for leakage from the electrical system A simple way of testing the boat’s electrical integrity is Set the multimeter to Ohms. Connect the black test to employ the following procedure: lead to the loosened negative connector, and the red test lead to the loosened positive connector.

  • Page 170: Eng. Room, Ventilation And Soundproofing

    Engine room, ventilation and soundproofing Introduction Engine performance Engine power is affected by a number of different Two main conditions must be fulfilled: factors. Among the most important ones are air pres- A. The engine must get enough air (oxygen) to allow sure, air temperature and exhaust backpressure.
  • Page 171 NOTE! Electronic controlled engines are not suitable for running at altitudes exceeding: Rating 5 500 m (4920 ft) Rating -4 2500 m (8200 ft) NOTE! Emission certificates have not been verified by Volvo Penta for altitudes above 500 m (4920 ft)

  • Page 172: Dimension Of Air Intakes And Ducts

    Engine room depression Fans Volvo Penta recommends that the depression in the To ventilate the engine room more effectively and engine room does not exceed 0.5 kPa (0.07 psi) at thus keep the engine room temperature at a low full speed.

  • Page 173: Engine Room Ventilation

    Engine room, ventilation and sound proofing Engine’s air consumption The engine consumes a certain amount of air in the The ambient air temperature (outdoor air tempera- combustion process. This requires a minimum inter- ture) is assumed to be +30°C (86°F). Correction fac- nal area of air supply ducting.
  • Page 174 Engine room, ventilation and sound proofing Calculation of air ducts, example 1, Calculation of air ducts, example 2, two diesel engines, 294 kW (400 hp) diesel engine, 441 kW (600 hp) Calculation of areas for two engines at 294 kW each Calculation of areas for one engine with 2 m (6.6 ft) with a non-restricted air supply and an ambient air duct length, 2 bends and an ambient air temperature...
  • Page 175 Engine room, ventilation and sound proofing Fig. 1 Calculation of areas Area, cm² (square inch) 400(27) 200(86) 000(55) 800(24) 600(93) 400(62) 200(3) Ex. 1 (34) (268) (402) (536) (670) (804) (939) (Hp) Ex. 1. Engine power = 294 kW (400 hp) Combustion ducting Ventilation air, inlet /outlet...

  • Page 176: Location Of Ventilators And Air Intakes

    Engine room, ventilation and sound proofing Location of ventilators and air intakes Inlet duct, engine room Air inlet duct, open end in engine room Suction fan Outlet air duct Intermediary partition Water trap Draining holes Engine air filter NOTE! Air intakes or outlet holes must never be in- stalled in the transom.

  • Page 177: Soundproofing

    Engine room, ventilation and sound proofing Soundproofing Location of air ducts The channels or ducts for the engine air supply The drive package must be installed in such a way should be routed up as close as possible to the air as to minimise noise and vibration.
  • Page 178 Engine room, ventilation and sound proofing Above you can see an example of the build-up of an insulation sheeting. This type of insulation material is glued to the frame. NOTE! The insulation sheeting is turned differently, owing to the type of the material in the frame, i.e. GRP or wood.
  • Page 179 Engine room, ventilation and sound proofing Other cables, electrical wires, battery leads etc can be drawn through a rubber hose or through a special PVC-tube (electrical), being built onto the bulkhead of GRP. Possible clearance between the tubing and the wires can be sealed off with some kind of insulation material or sealing compound.

  • Page 180: Belt Guards And Protections

    Belt guards which can be fitted on the engine, are Unless the engine is protected by a cover or its own available as optional equipment from Volvo Penta. enclosure, exposed moving or hot parts of the engine that could cause personal injury must be effectively Protections can also be built in the engine room by shielded.

  • Page 181: Controls

    Controls General If the boat is to be manoeuvred and operated in a The control could be either a single lever control or convenient and safe manner, then the operating sta- two lever control. On a single lever control both shift- tion should be arranged in such a way that the con- ing and speed is operated with the same lever.

  • Page 182: Alternative Operating Stations

    Electrical control systems In fully electrical systems, the control communicates with the engine via electrical signals and can only be used on electrically governed engines, as the Volvo Penta EVC engines. It offers very simple installation as well as smooth handling with long cables and several control sta- tions.

  • Page 183: Controls

    Controls Controls Location of the controls These controls are for top mounting. Side mounted The following must be considered before cutting controls are available but not so common in vessels holes for the controls. or boats of this size. NEUTRAL Radius FORWARD REVERSE...

  • Page 184: Connecting

    Controls Connecting Connecting the speed control cable Gear cable connection To increase of the engine speed, the speed control Always connect the cable to the reverse gear lever cable must have a pulling movement on all engines. so that the neutral position is obtained on the reverse gear when the control is set to NEUTRAL.
  • Page 185 Controls In the case of twin installations, the starboard propel- ler must rotate to the right and the port propeller to the left in forward gear. Install the shifting cable and make sure the cable is connected for the required rotation of the propeller shaft.

  • Page 186: Final Check

    Controls Final check DS-unit, gear shift If two single lever controls are installed in parallel in Check, without starting the engine, after final connec- a mechanical control system and connected to one tion of cabling that the lever on the pump is at idling reverse gear, a DS-unit or similar must be installed.

  • Page 187: Trolling Valve

    For operating a trolling valve, a single-acting control with a pushing movement shall be used. Position A: Maximum slipping Position B: Trolling fuction off Verify that the required travel (C) is achived. For correct measurements consult Volvo Penta or- ganisation or the gearbox manufacturer.

  • Page 188: Power Take-Off

    Always see the current Sales Guide for the PTO op- power take-off on the starboard side at the front. tions Volvo Penta is marketing for each engine size and rating. If greater outputs are needed, a mechanical power...

  • Page 189: Disconnectable Power Take-Off, Crankshaft

    If direct drive is used without a belt transmission or if some output consumer is to be connected directly to the crankshaft, TVCs must always be made first. Calculations are carried out by AB Volvo Penta on request. Determine the output requirement, the maximum torque and the engine speed required for the driven equipment.
  • Page 190 Power take-off Front mounted, disengagable PTO. The clutches are of disengagable design, intended for driving winches, bilge pumps or other optional equipment. Engine PTO connecting Clutch Output Max torque flange size make, type Nm (lbf. ft.) SAE3 Twin Disc SP 2-.5" Stub-shaft () 000 (738)
  • Page 191 Power take-off Flywheel and flywheel housing, SAE standard Engine Standard Option Engine Standard Option SAE 3 SAE , 2 D9 R3-R5 SAE 2 — D7A T SAE 3 SAE , 2 SAE 2 — D7A/C TA SAE 2 SAE , 3 SAE  —...

  • Page 192: Power Take-Off Positions

    Power take-off Power take-off positions V-belt transmissions V-belt transmissions are easily adaptable for different ratios (by using differently sized pulleys). This type of transmission provides a flexible transmission, it has a low noise level and is relatively free of maintenance. The alignment, however, must be done carefully and the V-belt tension must be easy to adjust.

  • Page 193: Belt Tension

    Power take-off Belt tension Idler pulleys Idler pulleys used for tensioning the V-belts should be The correct tension must be applied to any PTO belt on the slack side of the belt, and not smaller than the driving arrangement, as insufficient installation ten- minimum diameter recommended by the manufac- sion could cause belt slippage at high powers and turer for a particular belt.
  • Page 194 Power take-off Power output from front end of Torsional vibration crankshaft Power can be taken out, for in-line duty, from the front The diesel engine, plus its driven equipment (driven end of the crankshaft. The limit for this power is the from either front or rear) is made up of rotating bolted joint between the damper/pulley and polygon masses connected by a series of shafts.

  • Page 195: Extra V-Belt Pulleys

    . The engine specification end of the crankshaft. 2. A drawing of the drive arrangements which should Information regarding Volvo Penta standard front end include the following: pulleys is published with its dimensions in the Sales a. the effective diameter of all pulleys in the system.

  • Page 196: In-Line Power Take-Off

    The figure shows one concept of how to utilise the crankshaft power in-line when all side thrusts are taken up by the bearings (). The torque figures are maximum levels. Flexible coupling (2) must be calcu- lated by Volvo Penta. D x 2 D9/D16 D5/D7...
  • Page 197 PTO D9 including flexible coupling PTO D16 including flexible coupling The PTO system that include flexible coupling gives Please contact Volvo Penta for verifications of the possibility to gain, under the normal circumstances, PTO that include flexible coupling other than VKE max torque at the engines front end.

  • Page 198: Stub Shafts And V-Belt Pulleys

    Stub shafts and V-belt pulleys Stub shaft system D5/D7 If a flexible joint is to be used, it must be preceded by a torsion vibration calculation done by Volvo Penta. Bolt to stub shaft 2 . Cover Intermediate cylinder. Will be cut to proper length...
  • Page 199 Power take-off Stub shaft 75 (Pos 2) 90° 25.5 (Pos ) 35° 45° 0° Stub shaft F(N) x ∅d (m) x (rpm) P(kW) = 3.2 x 0 D9-300 R1 D9A-355 R1 D9A-355 R1 D9A-425 R2/R3 D9-500 R4 22 kW/800 rpm 26 kW/800 rpm 26 kW/2200 rpm 33 kW/2200 rpm...
  • Page 200 Power take-off Stub shaft 64 (Pos 2) 90° 96.5 (Pos ) 35° 45° 0° Stub shaft F(N) x ∅d (m) x (rpm) P(kW) = 3.2 x 0 D16-500 - 750 368 kW - 559 kW Angle Pos Pos2 0°-80° 300 2500 PTO with stubshaft For the system with the stubshaft torque amplitude...

  • Page 201: Auxiliary Drives

    800 x 0.909 = 636 rpm. IMPORTANT! Any power take-off equipment at- tached directly to timing case must be approved π x 636 by Volvo Penta. 5300 = M x M = 89.3 Nm Example: What is the max permissible power for the servo...
  • Page 202 30 (22) *) PTO occupied or not applicable. NOTE! PTO application to timing gears requires cor- rect material combination of the gears. Use only by Volvo Penta approved gear wheels. Ratio Driven (wheel) speed = crankshaft/ratio number. Example: A = 800 rpm, ratio = 0.9...
  • Page 203 Power take-off Transmission wheel positions Power take-off on engine auxiliary drive gear casing FRONT Power take-off on auxiliary drive gear casing Drive gear for PTO connection Power take-off front, starboard side. (Drive gear B) Drive gear for feed pump, alternator or extra equipment Power take-off port (Drive gear C)

  • Page 204: Flush And Bilge Pumps

    Power take-off Flush and bilge pumps Different types of pumps can be fitted to dispose of Disengageable 2" bilge pumps and 2" flushing pumps bilgewater and for flushing purposes. Furthermore, can be fitted on the engines. The pumps are mounted when changing oil in the reverse gear and the en- to a power take-off at the back of the timing gear cas- gine, it can be convenient to have an electrically pow-...

  • Page 205: Oil And Coolant Drain Systems

    Oil and coolant drain systems General Waste fluid Pump Valve block Coolant drain connection Engine oil drain connection Engine installations in boats and vessels, carry the Reverse gear oil drain connection potential for negative impact on the environment. The Pipe to drain the bilge liquids necessary are harmful and should be handled in a safe way.

  • Page 206: Launching The Boat

    Launching the boat Check before launching: Starting the engine • Install the batteries in their compartment and at- • Starting procedures: tach the battery leads. See Operators’s Manual for each engine. • Check that all valves at through hull fittings are closed.

  • Page 207: Sea Trial

    Launching Sea trial Check when test running the boat: Check over the whole speed range: • Instruments • That the engine room temperature is kept at an Check engine rpm, oil pressure, coolant tem- acceptable level. perature and charging voltage. See Operators’s •...

  • Page 208: References To Service Bulletins

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

  • Page 209: Notes

    Notes ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 210 Notes ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 211 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...

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