Volvo Penta IPS D4, D6 Aquamatic DPH, DPR Installation Manual_39118794 – PDF DOWNLOAD

Volvo Penta IPS D4, D6 Aquamatic DPH, DPR Installation Manual_39118794 – PDF DOWNLOAD

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Volvo Penta IPS D4, D6 Aquamatic DPH, DPR Installation Manual_39118794 – PDF DOWNLOAD

Language : English
Pages : 236
Downloadable : Yes
File Type : PDF
Size: 3.64 MB

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Volvo Penta IPS D4, D6 Aquamatic DPH, DPR Installation Manual_39118794 – PDF DOWNLOAD

General information :About the Installation Manual :

This publication is intended as a guide for the installation of Volvo Penta marine diesel engines for inboard use. 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 Installation Instructions are included in most of the accessory kits. These recommendations are the result of many years’ practical experience of installations from all over the world. Departures from recommended procedures etc. can be necessary or desirable however, in which case the Volvo Penta organization will be glad to offer assistance in finding a solution for your particular installation.
• It is the sole responsibility of the installer to ensure that the installation work is carried out in a satisfactory manner, it is operationally in good order, the approved materials and accessories are used and the installation meets all applicable rules and regulations. This Installation Manual has been published for professionals and qualified personnel.
• It is therefore assumed that persons using this book have basic knowledge of marine drive systems and are able to carry out related mechanical and electrical work. Volvo Penta continuously upgrades its products and reserves the right to make changes. All the information contained in this manual is based on product data available at the time of going to print. Notification of any important modifications to the product causing changes to installation methods after this date will be made in Service Bulletins.

TABLE OF CONTENTS:

Volvo Penta IPS D4, D6 Aquamatic DPH, DPR Installation Manual_39118794 – PDF DOWNLOAD

Safety precautions……………………………………….. 3
General information……………………………………… 6
Engine application ratings…………………………….. 9
Marine engine environment…………………………. 10
Installation tools and literature……………………. 13
Design concepts of propulsion systems……… 16
Aquamatic Duo Prop (DP)® drive………………… 16
Aquamatic drive with jack shaft………………….. 16
Volvo Penta IPS……………………………………….. 16
Volvo Penta IPS with jack shaft………………….. 16
Reverse gear, various types………………………. 17
Water Jet………………………………………………… 17
Surface drive…………………………………………… 17
AQUAMATIC APPLICATIONS
Accessibility……………………………………………….. 18
Transom……………………………………………………… 19
General…………………………………………………… 19
Water level at maximum load ……………………. 20
Transom cutout………………………………………… 21
Single engine installation…………………………… 23
Twin engine installation…………………………….. 25
Installing the transom shield………………………. 29
Installing gear shift actuator and cable………… 31
Engine foundation………………………………………. 32
Steering system………………………………………….. 34
Installation procedure……………………………….. 40
Filling and purging the system……………………. 45
Troubleshooting guide………………………………. 49
Controls……………………………………………………… 51
Engine installation………………………………………. 52
Preparing the engine………………………………… 52
Installing the exhaust pipe…………………………. 53
Installing the engine…………………………………. 53
Sterndrive installation…………………………………. 58
Preparations……………………………………………. 58
Assembling the sterndrive on the transom
shield……………………………………………………… 59
Tie bar installation……………………………………. 64
Rudder indicator and autopilot interface………. 65
Propeller installation…………………………………. 66
Jack shaft installation…………………………………. 67
General…………………………………………………… 67
VOLVO PENTA IPS APPLICATIONS
General………………………………………………………. 69
Accessibility……………………………………………….. 70
Maximum water levels…………………………………. 72
Hull inserts and engine foundations……………. 74
Hull mold integrated inserts……………………….. 74
Pre-molded hull insert………………………………. 75
Building the engine bed…………………………….. 80
Hull plugs and engine foundations………………. 83
Hull mold plug………………………………………….. 83
Positioning and fitting of hull plug,
Twin installation……………………………………….. 84
Positioning and fitting of hull plug,
Triple installation………………………………………. 86
Positioning and fitting of hull plug,
Quadruple installation……………………………….. 88
Building the engine bed…………………………….. 90
Propulsion unit and engine installation……….. 93
Fitting the propulsion unit to the hull……………. 94
Installing the inlet and outlet sea water cocks 96
Installing the exhaust outlet……………………….. 96
Transom mounted anode…………………………… 96
Installing the engines………………………………… 97
Installing exhaust line and water
by-pass and inlet hoses…………………………….. 99
Cooling system………………………………………. 101
Propeller installation……………………………….. 102
Jack shaft installation……………………………….. 103
Controls and steering……………………………….. 105
Drive leg calibration………………………………….. 106
Calibration, drive leg positions…………………. 106
Calibration, drive leg factory setting …………. 107
Calibration, drive leg parallelism……………….. 107
Steering angle, setting…………………………….. 108
INBOARD APPLICATIONS
General arrangement and planning……………. 109
Choice of engine……………………………………. 109
Propeller theory……………………………………… 113
Propeller selection………………………………….. 116
Engine inclination…………………………………… 116
Weight distribution………………………………….. 117
Selection of engine mountings…………………. 119
Engine suspension and propeller shafts……. 121
Engine bed……………………………………………….. 122
Building the engine bed…………………………… 125
Propeller shaft systems…………………………….. 127
Propeller shafts……………………………………… 127
Reverse gear flange……………………………….. 129
Flexible propeller shaft coupling……………….. 129
Shaft seals…………………………………………….. 130
Installation of stern tube and shaft bearing… 131
Engine installation…………………………………….. 133
Preparing the engine………………………………. 133
Installing the engine on the engine bed……… 134
Alignment……………………………………………… 137
Exhaust system………………………………………… 138
General…………………………………………………. 138
Wet exhaust line…………………………………….. 140
Dry exhaust line……………………………………… 147
Steering system………………………………………… 150
Mechanical system…………………………………. 150
Hydraulic system……………………………………. 150
Mechanical steering,
location of steering head ………………………… 151
Hydraulic steering,
location of steering pump ……………………….. 151
Controls……………………………………………………. 152
Propeller rotation, Inboard applications……… 153
Fuel system………………………………………………. 154
General…………………………………………………. 154
Fuel tanks……………………………………………… 155
Piping…………………………………………………… 157
Fuel flow……………………………………………….. 159
Cooling system…………………………………………. 161
Seawater system, Aquamatic…………………… 162
Seawater system, Volvo Penta IPS…………… 162
Seawater system, Inboard applications……… 163
Freshwater system…………………………………. 167
Hot water connections…………………………….. 168
Extra expansion tank………………………………. 169
Electrical system………………………………………. 171
General…………………………………………………. 171
Batteries……………………………………………….. 172
Battery installation………………………………….. 173
Starting group battery capacity………………… 174
Accessory battery…………………………………… 175
Cross-over switch…………………………………… 175
Mixed voltage systems……………………………. 175
Starting battery cable area………………………. 176
Alternator ……………………………………………… 177
Main switch……………………………………………. 178
Charge distributor 12 V and 24 V,
engine and boat……………………………………… 178
Single installation, D4/D6 12 V or 24 V,
Aquamatic and Inboard…………………………… 179
Single installation, D4/D6 12 V or 24 V,
Aquamatic and Inboard…………………………… 180
Twin installation, D4/D6 12 V or 24 V,
two accessory battery groups,
Aquamatic, Inboard and Volvo Penta IPS…… 181
Twin installation, D4/D6 12 V or 24 V,
one common accessory battery group,
Aquamatic, Inboard and Volvo Penta IPS…… 182
Twin installation, D4/D6 12 V or 24 V,
Aquamatic and Inboard…………………………… 183
Twin installation, D4/D6 12 V or 24 V,
Aquamatic and Inboard…………………………… 184
Extra alternator, single and twin installations,
D4/D6 12 V or 24 V,
Aquamatic, Inboard and Volvo Penta IPS…… 185
Connections to starter motor……………………. 186
Power supply,
PowerTrim pump, Aquamatic……………………. 187
Power supply,
Volvo Penta IPS Servo Unit Steering (SUS).. 188
EVC–Electronic Vessel Control ……………….. 188
Accessories…………………………………………… 189
Extra alternators…………………………………….. 191
Battery charging…………………………………….. 191
Instruments……………………………………………. 192
Fire extinguishing system…………………………. 193
Electrochemical corrosion…………………………. 195
General…………………………………………………. 195
Definitions……………………………………………… 196
Protection against electrochemical
corrosion……………………………………………….. 197
Protection against electro-static
discharge and lightning…………………………… 198
Stray current and shore power corrosion…… 198
Painting the Volvo Penta IPS propulsion unit 199
Shore power and generator installation……… 200
Prevention of stray currents
during installation…………………………………… 201
Checking electrochemical corrosion………….. 202
Engine room, ventilation and
soundproofing………………………………………….. 205
Introduction……………………………………………. 205
Dimension of air intakes and ducts…………… 206
Location of ventilators and air intakes……….. 210
Soundproofing……………………………………….. 211
Power take-off…………………………………………… 213
Extra alternator………………………………………. 213
Front end power take-off………………………….. 213
In-line power take-off………………………………. 217
Draining of oil and coolant ……………………….. 218
Launching and starting……………………………… 219
Sea trial…………………………………………………….. 227
References to Service Bulletins…………………. 229
Notes………………………………………………………… 230