Installation Manual
The manual provides instructions
for the installation of Volvo Penta industrial engines. The publication is not
exhaustive and does not cover every conceivable installation; the contents
should be considered as recommendations and guidance for normal installations.
The recommendations are the
result of many years' practical experience from all over the world. If it is
necessary or desirable to deviate from recommended procedures, your Volvo Penta
dealer will be happy to offer help in finding a solution for your particular
installation. It is the responsibility of the installer to ensure that
installation works are carried out in a satisfactory manner, that the
installation is in good operable condition, that approved materials and
accessories are used and that the installation fulfills all applicable
legislation and regulations. This installation manual is intended for use by
professionally qualified and skilled personnel. The user of this manual is
expected to have fundamental knowledge of the drive systems and be able to
carry out related mechanical and electrical work. Volvo Penta continually
improves it products and reserves the right to make changes. All the
information in this manual is based on product specifications available at the
time of publication. Plan the installation carefully Great care must be taken
when installing engines and their components if they are to function perfectly.
Make sure that the correct specifications, drawings and other data are
available before work is begun.
This allows planning and
installation to be carried out correctly right from the start. Plan the engine
compartment so that it will be easy to perform routine service that involves
changing components.
When installing engines, it is
extremely important that no dirt or foreign objects enter the fuel, cooling,
inlet or turbocharger systems, as this may cause faults to arise or the engine
to seize. Blow pipes and hoses clean with compressed air before they are
connected to the engine. Only remove the protective caps from the engine when
an external system is connected.
Certified Engines
A certified engine means that the
engine manufacturer guarantees that not only new engines but also those in
operation fulfill legislation and regulations. The product must be comparable
to the engine that was approved at certification. In order for Volvo Penta to
be able to declare that engines fulfill environmental legislation, the
following must be observed during
installation:
• Service to
injection pumps, injectors or pump settings must always be carried out by an
authorized Volvo Penta workshop.
• The engine
may not be modified in any way except with accessories and service kits
developed
for the purpose by Volvo Penta.
• The
installation of exhaust pipes and air intakes (ventilation ducts) in the engine
compartment
must be carefully planned as
their design may influence exhaust emissions.
• Seals may
only be broken by authorized personnel.
IMPORTANT!
The use of replacement parts not
approved by AB Volvo Penta will render Volvo Penta unable to assume responsibility for engine
compliance with the certified version. Volvo Penta is not responsible for
damages or costs arising as a result of this.
Mutual responsibility
Every engine consists of a large
number of components working in unison. If one component deviates from its
technical specification, it may cause a dramatic increase in the engine's
environmental impact. It is therefore essential that adjustable systems are set
correctly and that replacement parts approved by Volvo Penta are used. Certain
systems (e.g. the fuel system) may require special professional expertise and
test equipment. For environmental reasons, some components are factory sealed.
Only authorized personnel may carry out work on sealed components. Remember
that most chemical products can harm the environment if they are used in the
wrong manner. Volvo Penta recommends the use of biodegradable degreasing agents
for cleaning engine components, unless the service manual states otherwise.
Hand in old oil and other waste to a recycling station.
Introduction
In order for engines to deliver
the expected performance, mechanical reliability is of great importance. The
engines must be installed correctly in an acceptable environment in order for
each engine system and the installation as a whole to be satisfactory. The
purpose of this summary is to pass on our knowhow and experience regarding the
installation of Volvo Penta industrial diesel engines. This summary is in no
way a complete installation manual, but hopefully it can act as a starting point
for the installer to avoid the most usual problems that occur when installing
diesel engines.
SALES ENGINEERING INDUSTRIAL AB
VOLVO PENTA
Engine Characteristics
Engine Performance
Engine Power Ratings for
Versatility Engines
ICFN power rating ISO standard
power for continuous operation. It is intended for applications with constant
loads that operate continually at full load for long periods. The average load
factor may not exceed 70 % of the continuous rating when the application is run
at continuous rpm and loads.
IFN power rating corresponding to
ISO overload power. It is intended for applications where intermittent power is
used for less than 1 hour within a 12-hour period of continual operations. The
average load factor may not exceed the continual rating. For further
information refer to general information in the Sales Support Tool, Partner
Network.
Power standards
Engine performance corresponds to
ISO 3046, BS 5514 and DIN 6271. Technical data refer to an engine without a
cooling fan running on a fuel with a heating value of 42.7 MJ/kg (18,360
BTU/lb) and a density of 0.84 kg/liter (7.01 lb/US gal, 8.42 lb/Imp gal). The
data are also applicable where there is a standard deviation.
Reference conditions:
Total barometric pressure: 100
kPa (15 psi)
Air temperature: 25 °C (77 °F)
Relative humidity: 30 %
Engine power codes according to
ISO standard 8528
I = ISO power corrected to
reference conditions for ISO 3406/1 standard.
C = Continuous power.
X = Continuous power may be
exceeded by 10 %.
F = Fuel stop power. This power
cannot be exceeded.
N = Net power expressed with and
without power losses from the radiator fan.
Rating Guidelines on Gen Set
Engines
Prime Power: rating corresponding
to ISO standard power for continuous operation. This relates to electrical
power supply at a variable load with a 70 % load factor for an unlimited number
of hours as opposed to commercially purchased power. There is an overload
capacity of 10 % available with this rating. Maximum standby power: ratings
that correspond to ISO fuel stop power. This relates to the supply of standby
electrical power at variable loads at locations with well-established
electrical grids during a normal power outage. No overload capacity is
available with this rating. For further information refer to: Sales Support
Tool, Partner Network
Power standards
Engine performance corresponds to
ISO 3046, BS 5514 and DIN 6271.
Technical data refer to an engine
without a cooling fan running on a fuel with a heating value of 42.7 MJ/kg
(18,360 BTU/lb) and a density of 0.84 kg/liter (7.01 lb/US gal). It is also
applicable where there is a standard deviation.
Engine speed governing in
accordance with ISO 3046/IV, class A1 and ISO8528 G2
(G3 with electronic engine speed
governor)
Reference conditions:
Total barometric pressure: 100
kPa (15 psi)
Air temperature: 25 °C (77 °F)
Relative humidity: 30 %
Fuel temperature: 40 °C (104 °F)
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