Volvo Penta KAMD300 Installation Manual Download Page 21

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Installation tools and literature

Templates

- Instrument panels.
- Controls.

All 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

See "Volvo Penta Accessories & Maintenance Parts"

Summary of Contents for KAMD300

Page 1: ...Inboard Marine Diesel Engines TAMD31 41 42 KAMD43 44 300 Installation 1 1 B ...

Page 2: ......

Page 3: ...ilding the engine bed 39 Propeller shaft systems 41 Propeller shafts 41 Propeller shaft couplings 43 Shaft seals 44 Installation of stern tube and shaft bearing 45 Engine installation 47 Preparing the engine 47 Installing the engine on the engine bed 49 Alignement 50 Contents Fuel system 51 General 51 Fuel tanks 52 Piping 54 Checking feed pressure 55 Cooling system 58 General 58 Seawater system 59...

Page 4: ... 112 Steering 113 General 114 Cable routing 115 Hyraulic hose routing 115 Controls 116 General 116 Alternative operating stations 118 Location cable routing 118 Connecting the speed control cable 119 Installing the gear shift control cable 120 Trolling valve 122 Power take off 124 Extra V belt pulleys 124 Power take off positions 124 Recommendations to front power take off with drive shaft 125 Ext...

Page 5: ...p a warning notice at the engine control point or helm As a rule no work should be done on a running engine However some work e g adjustments requires a running engine Approaching an engine that is running is a safety risk Loose clothing or long hair can fasten in rotating parts and cause serious personal injury If working in proximity of a running engine careless movements or a dropped tool can r...

Page 6: ...t from an injector is under very high pressure and fuel can penetrate deep into tissue causing serious injury with a risk of blood poisoning All fuels and many chemicals are inflammable Keep away from naked flames or sparks Gaso line some solvents and hydrogen from batteries in the correct proportions with air are very inflam mable and explosive Do not smoke Maintain good ventilation and take the ...

Page 7: ... is required to obtain the correct balance for safe handling Never carry out work on an engine suspended on a hoist Never work alone when installing heavy compo nents even when using secure lifting equipment such as a lockable block and tackle Most lifting devices require two people one to see to the lifting device and one to ensure that the compo nents do not get caught and damaged The components...

Page 8: ...ect specifications drawings and any other data are avail able before starting work This will allow for correct planning and installation right from the start Plan the engine room so that it is easy to carry out routine service operations involving the replacement of components Compare the engine s Service Manual with the original drawings showing the dimensions It is very important when installing...

Page 9: ...proved as noti fied bodies The directive also allows boat builders and component manufacturers to issue assurances of compliance with the requirements of the directive This requires the manufacturer to store the prescribed product documentation in a place that is accessible to the monitoring authority for at least ten years after the last product is produced Life boats and boats for commercial act...

Page 10: ...c 1 1 36 hp metric 1 kW 0 735 kW bhp 1 341 bhp kW 0 7457 kW BTU min 56 87 BTU min kW 0 0176 Torque Nm lbf ft 0 738 lbf ft Nm 1 356 Pressure Bar psi 14 5038 psi Bar 0 06895 MPa psi 145 038 psi MPa 0 006895 Pa mm Wc 0 102 mm Wc Pa 9 807 Pa in Wc 0 004 in Wc Pa 249 098 KPa in Wc 4 0 in Wc KPa 0 24908 mWg in Wc 39 37 in Wc mWg 0 0254 Energy kJ kWh BTU hph 0 697 BTU hph kJ kWh 1 435 Work kJ kg BTU lb 0...

Page 11: ...d Between full load operation periods engine speed should be reduced at least 10 from the ob tained full load engine speed Rating 3 Light Duty Commercial For commercial boats with high demands on speed and acceleration planing or semiplaning hulls in cycli cal operation Running hours less than 2000 h per year Typical boats Fast patrol rescue police light fishing fast passenger and taxi boats etc F...

Page 12: ...ings 10 Examples of boats for light duty commercial operation Rating 3 4 Examples of boats for medium and heavy duty commercial operation Rating 1 2 Examples of boats for light and medium duty commercial operation Rating 2 3 ...

Page 13: ...Engine application ratings 11 Examples of pleasure crafts Rating 5 ...

Page 14: ...mbient temperature humidity fuel thermal val ue fuel temperature not EDC engines and backpres sure Deviation from normal values affects diesel and petrol engines differently Diesel engines use a large amount of air for combus tion If the mass flow of the air is reduced the first sign is an increase in black smoke The effect of this is especially noticeable at planing threshold speed where the engi...

Page 15: ...hitects marine engineers or other qualified people should choose the propeller The required en gine performance data to make the proper propeller selection is available in technical literature With regard to the propeller selection it is important to achieve correct engine rpm For this purpose we rec ommend Full Throttle Operating Range In order to achieve good all round performance the propeller ...

Page 16: ...al performance of the vessel and long engine life correct propeller size is essential Selecting the correct propeller will enable the engine to develop its full power and provide the performance that is expected There are a number of factors with their tolerances that can greatly affect the performance of the vessel These must be recognised for correct engine propeller selection These factors are ...

Page 17: ...on Societies have established their rules so that the authorities requirements are cov ered The authorities however have requirements for lifeboats that are not included in the rules of the Clas sification Society In 1974 an International Convention for the Safety of life at sea SOLAS was adopted by the International Maritime Organisation IMO This document ratifies uniform rules for life saving eq...

Page 18: ...initiated as a result of a re quest from a customer or dealer who has to deliver an engine in a classified installation For these orders Volvo Penta normally starts with a type approved en gine During production of such an engine the survey or checks the production if there is no quality assur ance system agreement Separate certificates are issued for the following com ponents Crankshaft connectin...

Page 19: ...ure 9510060 8 Multimeter 9812410 0 Temperature gauge Measuring exhaust temperature Used together with multimeter 9510060 8 9988452 0 Digital probe tester Checking electro chemical corrosion Used together with 885156 9996065 0 Manometer Measuring fuel feed pressure and exhaust back pressure 9996666 5 Nipple Cecking fuel supply presssure and exhaust back pressure 9998496 5 Pressure gauge Used togeth...

Page 20: ...uide Dimension drawings Drawings for current program leisure and commercial applications are available at http www penta volvo se Other special equipment 18817 7 Washer x 4 Checking the fuel feed pressure 25167 8 Hollow screw M14x1 TAMD31 with locally made threaded hole Checking the fuel feed pressure 861079 2 Banjo nipple x 2 Checking the fuel feed pressure 18817 861079 25167 947043 969299 969299...

Page 21: ...Controls All 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 See Volvo Penta Accessories Maintenance Parts ...

Page 22: ...vo Penta Reverse gear various types Drop centre parallel The engine s crankshaft and the reverse gear s output shaft are parallel The output shaft is on a lower level than the crankshaft The engine and reverse gear form one unit The com pressive forces from the propeller are absorbed by an axial bearing in the reverse gear Drop centre down angle The engine s crankshaft and the reverse gear s outpu...

Page 23: ...es See Installation and application guide for Water Jet Surface drive A number of surface piercing propeller systems are available on most markets These systems are aimed at high speed applications where the systems are highly efficient The systems are available with rudder arrangements or steerable drive unit At planing speed the propeller operates with half of its diameter sub merged At lower sp...

Page 24: ...often needed to finally find the essential set of performance requirements the installation BOAT VESSEL REVERSE GEAR AND PROPELLER PERFORMANCE LIMITATIONS PROPULSION SYSTEM POWER REQUIREMENT ENGINE aims to fulfil Analysis of each contribution may vary depending on the dominating priorities such as top speed economy safety etc Consult Volvo Penta lit erature and computer programs or contact the Vol...

Page 25: ...seal The port propel ler shaft has a grease lubricated stuffing box as the seal On both shafts there is an vane just outside the through hull which reinforces the water stream into the stuffing box The engines are equipped with the Volvo Penta EDC system Electronic Diesel Control and the boat has a hydraulic steering system with a Volvo Penta steer ing pump hydraulic cylinder and tie bar This illu...

Page 26: ... Only use updated and approved dimensional drawings Study the drawings carefully Consider soundproofing material the engine s movements when running and accessibility for servicing and repairs For twin installations the distance between the en gines should be sufficient to allow easy performance of inspection and service work 2 Weight distribution Consider the weight distribution of the boat so th...

Page 27: ...e room is of great impor tance to keep the sound level as low as possible Suf ficient space for soundproofing material must also be planned for A condition for good sound insulation is a sealed engine room with ducts as the only openings 9 Controls and steering Plan the routing of control cables steering systems Dual station units DS units etc Allow accessibility for servicing and replacement When...

Page 28: ... performance out of your boat you need to select the propeller and gearing that will suit your particular boat engine and speed range Below you will find a brief description of how propeller systems are designed It is not just the engine capaci ty determines the speed of the boat it depends just as much on the efficiency of the reverse gear and the propeller system Using the right propeller system...

Page 29: ...ler shaft at least 200 mm 8 aft to allow the removal of the reverse gear or coupling Also make sure that any transverse bulk head does not impede its removal Sufficient clear ance approx 1 x the shaft diameter must be provid ed between the propeller and the stern bearing to pre vent the propeller from pressing against the stern bearing Allowance should also be made for rope cut ters if they are to...

Page 30: ...he applicable speed range Depend ing on the hull type and speed range a smaller ratio can be chosen for higher speed if required See the table This is to obtain highest thrust within the re spective speed range If the ratio is chosen outside of the recommendations the thrust can be lower than the optimum calculated power The boat s top speed is not necessarily affected A check must always be done ...

Page 31: ...ting of the cooling system Each engine type has a maximum permitted engine inclination while the boat is under way This inclina tion includes both the installation inclination and the trim angle that the boat makes in motion at various speed through water A The engine s static inclination B The boat s trim angle under way C Total inclination of engine under way maximum permissible inclination A B ...

Page 32: ... 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 Planing and semi planing hulls For planing and semi planing hulls especially it is im portant that heavy equipment such as engines fuel tanks water tanks and batteries are positioned in a way as to obtain the best possible trim of the boat in the water Fuel ...

Page 33: ...ccessibility for maintenance Some areas that normally require access for maintenance Oil change and refill Engine and reverse gear Change of oil filters Change of fuel filters Change of air filter Check of belt tension Change of belts Removal of valve cover Change of impeller seawater pump Cleaning of water filter Accessibility for repairs Some areas that may require access for re pairs Removal of...

Page 34: ...d frame thus contributing to a low noise level Dimensions for flexible mountings see page 40 The rubber mounts are compressed during installation therefore the engine should rest on the rubber mounts for 12 hours before the height is adjusted Always follow the recommendations of Volvo Penta when selecting the engine suspension The use of in correct rubber mounts can result in abnormal vibra tions ...

Page 35: ...rive this force could be higher than that from the weight of the engine and gear box This will create a lifting force to the engine mounts fit ted at the same end as the gear box Therefore all en gines with a close coupled V drive must be equipped with mounts at the reverse gear end which are de signed for this type of application Reverse gear rubber mount Axial component Propeller thrust Vertical...

Page 36: ... 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 distance between support points and propeller shaft material The following installation alternatives and combinations are recommended 1 Engine wit...

Page 37: ...upling Flexible cou pling as an alternative 3 Fixed front stern bearing and shaft seal 4 Waterlubricatedsternbearing L Distance between support points For calculation L max see page 42 C Distance reverse gear flange sup port point C max is calculated in the same way as L max C L 1 1 2 4 3 Flexible coupling as an alternative ...

Page 38: ...uate margin the engine torque the compressive force of the propeller and the dynamic forces mass forces that occur during movement in rough sea When designing the bed it is important that there is sufficient space under the engine for the movement of the engine and that there is also access to the in spection covers certain engine versions If possible the bed should be designed so that the re vers...

Page 39: ...the load as far as possible to the hull The bed is often built as a box construction As much of possible of the engine bed including cross members should be attached to the hull to ensure the lowest possible noise and vibration level The engine bed can be built up separately and then carefully measured and bonded to the hull or be built up directly in the hull It is important that the bed con nect...

Page 40: ...ib along their entire length In a wooden boat the bed should be bolted to the frame ribs with bolts and nuts The length of the engine bed should be extended as far as possible to distribute the load If the engine has an extra PTO in the front end that re quires extra support the bed should be designed to accommodate this support There must be space in front of the PTO so that it can be dismantled ...

Page 41: ...ng loosely in place The engine must be connect ed to the propeller shaft Start building the bed in relation to the position of the engine mounts 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 20 mm 3 4 20 mm 3 4 Fixed point Sterntube is not fixed moulded or bolted ...

Page 42: ...iameter for Volvo Penta elastic mounts Engine and reverse gear excl HS63V V drive M12 alternatively 1 2 HS63V V drive M16 alternatively 5 8 Fibreglass engine bed A Spacer material B Filler rounding of corners C Fibreglass approx 10 15 mm 0 4 0 6 D Flat bar galvanized approx 10 mm 0 4 A B C D To reduce noise and vibrations the engine bed should be filled Make sure the material does not absorb wa te...

Page 43: ...d be sufficient to allow engine movements without excessive stresses to the shaft system The maximum distance between bearings is determined by shaft critical speed This can be calculated based on the type of installation and shaft properties During installation of the shaft it is of great impor tance to protect the precision straightness and fine surface finish When lifting shafts it is best to u...

Page 44: ...shaft mm 4 8 15 7 4 2 13 8 3 6 11 8 3 0 9 8 2 4 7 9 1 8 5 9 1 2 3 9 0 6 2 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 Propeller shaft dimensions and bearing distances The propeller shaft will be subject to both bending and torsional forces and must be dimensioned with regard to this Also a certain safety margin must also be ap plied The maximum bearing distance has a major in fluence for th...

Page 45: ...nt of the engine is just as impor tant with the above propeller equipment as for a rigid shaft connection The flexible stuffing box and propel ler shaft coupling are not designed to absorb a con stant angle deviation Reverse gear D Pcd d T A N x Hd MS25A L 102 80 60H8 12 3 5 4 x 11 5 HS25A 127 108 0 2 63 5H8 10 4 4 x 11 5 HS45A 127 108 0 2 63 5H8 10 4 4 x 11 5 HS63A 127 108 0 2 63 5H8 10 4 4 x 11 ...

Page 46: ...r and grease lu bricated seals Ensure easy access for maintenance and inspection of the seal Some seals require a cer tain clearance to the gearbox coupling in order to per mit replacement of packing without disconnecting the shaft Water lubricated shaft seal With water lubricated seal the water has two purpos es lubricating and cooling the seal Water could be supplied to the water lubricated shaf...

Page 47: ...l position In serial production tailor made fixtures are often used instead of the engine to locate the stern bearing Installation of stern tube and shaft bearing Grease lubricated shaft seal The grease is injected either with a grease cup fitted to the seal assembly or from a remote greaser The bolt holding the seal should not be overtightened as this may cause overheating and excessive wear on t...

Page 48: ...n bearing can be bolted or bonded in place 1 2 3 4 4 mm 0 16 The clearance between the propeller shaft and tube for a flexible mounted engine should be min 4 mm 0 16 If the stern bearing is to be bolted to the stern the contact surface for the bearing flange must be sanded flat first Apply sealing compound e g silicon rubber and tighten the bolts holding the bearing NOTE The alignment must be chec...

Page 49: ...accessories on the en gine such as extra alternator hot water outlet power take off etc before engine is installed The figure above shows a flexible mounted engine NOTE All engines and reverse gears are delivered from Volvo Penta without oil and coolant Check that the oil plug and draining cocks for coolant hot water cocks etc are closed Fill oil and coolant See chapters Coolant and Filling with c...

Page 50: ...he surface of the engine bed where the en gine mounts are supported and the base plates of the engine mounts are parallel and that the bed inclina tion is correct use a graded angle spirit level 8 mm 0 32 34 mm 1 38 40 mm 1 58 34 mm 1 38 40 mm 1 58 7 5 mm 0 30 Installing the engine on the engine bed ...

Page 51: ... Never use rubber mounts other than those intended for each particular engine type When the engine is installed the loading on the front mounts shall be equal as well as the loading on the rear mounts Check loading on the rubber mounts by measuring the distance A between the attachment plates and the housing A NOTE Make sure that the rubber mounts are installed so that no pre load or side forces o...

Page 52: ...appropriate thickness must be installed be tween the mount and the bed Move the flanges together so that the guide engages Then with the flanges pressed together check that they are parallel and that a 0 10 mm 0 004 feeler gauge cannot be inserted anywhere inbetween them A Then turn the flanges 90 180 and 270 and re peat this check at the new positions Make sure that the flanges are well pressed t...

Page 53: ...n several tanks to keep the centre of gravity low and also pro vide certain trimming possibilities for the hull If the tanks are built in the surrounding space should be provided with ventilation NOTE Local legislation may apply which in all over ride the engine manufacturers literature and recom mendations Be sure not to bend the high pressure pipes between injection pump and injectors and do not...

Page 54: ...ter separator must be installed for all Volvo Penta engines If a day tank is installed then it is advisable to con nect the return line to this tank A shut off valve must be installed in the supply pipe between the tank and the filter This tap should be able to be shut from a location outside the engine room Stainless steel or aluminum sheet metal is a suitable material for fuel tanks Fuel tanks I...

Page 55: ...ar space The tank must be properly vented The tank venting line 1 should have an inner diameter of min 12 mm 1 2 Raise the hose internally to create a water lock The filler fitting 2 should be adapted for a minimum 50 mm 2 0 hose connection The hose between the deck fitting and the tank must overlap the tubing at ei ther end with at least 75 mm 3 0 and be locked with two hose clamps The hose clamp...

Page 56: ...All fuel lines should be led and properly clamped near bottom of the boat to avoid heat absorbing The air temperature is lower at the bottom of the engine room Rubber hoses Required minimum inner diameter for the hose from tank to engine and return hose is 10 mm 3 8 Only use approved flexible hose NOTE Classification Societies and some registration bodies i e river authorities do not permit rubber...

Page 57: ...6 to the threaded hollow screw Pressure is measured after the fuel has passed through the fuel filter 9996666 25167 969299 25167 969299 Use a fuel pre filter of correct size to avoid too high resistance over the filter The recommended filtration is 10 m The fuel filter must not contain parts made of glass which can crack NOTE There must be sufficient space around the fil ter for inspection and ser...

Page 58: ...fuel injection pump Remove the nipples 2 in the fuel filter and fuel injec tion pump Drill and thread hollow screw to M10x1 as illustrated Use hollow screw M12 part no 969299 Connect the fuel hose to the fuel injection pump using pipescrew 969299 and 2 x copper washers 18817 Connect the fuel hose to the filter cover using the drilled and threaded hollow screw 969299 and 2 x cop per washers 18817 C...

Page 59: ...educe the engine speed rpm to low idling speed Read off the pressure within one minute The feed pressure should be Feed pump 3581310 45 55 kPa 6 5 8 0 psi The feed pressure after the fuel filter should never drop below 0 kPa for any of the pumps Low feed pressure can be caused by a blocked filter restricted fuel line etc Check for reduced flow a trapped line for example 9996065 9996666 ...

Page 60: ... contact the Volvo Penta organisation Carefully plan where the fittings are to be placed so that they are accessible The lines should be arranged so that they are as short as possible To reduce corrosion to a miniumum use the correct combinations of materials in pipes valves etc plus a correctly sized and pressurized expansion tank Elec trolytic corrosion may occur when two different materi als su...

Page 61: ...let of the sea water pump must not exceed 30 kPa 4 35 psi The hose connection on the engine has a diameter of 32 mm 1 The sea water intake should have a hose with an internal diameter of 32 mm 1 Minimum flow area of the strainer 1 5 x hose inner cross section area The sea water intake must be located so far below the waterline that the strainer is under water even when the boat heels over or moves...

Page 62: ...ch impurites can be trapped by installing a filter in the suction line A seawater filter contributes to a longer lifetime of the pump and also prevents engine damage which can result from unsatisfactory cooling in the charge air cooler or in the heat exchanger 200 mm 8 The seawater filter should be fitted in an accessible position min 200 mm 8 above the sea water line with the boat loaded e g on a...

Page 63: ...k the cooling system Water quality Always use clean water that complies with the require ments in ASTM D4985 X1 1 If these requirements are not met corrosion may occur which could lead to impaired cooling performance Specification Solid particles 340 ppm Total hardness 9 5 dH Chloride 40 ppm Sulphate 100 ppm pH value 5 5 9 0 Silica 20 mg SiO2 lit Iron 0 10 ppm Magnese 0 05 ppm Conductivity 500 µS ...

Page 64: ...er can spray out and the system pressure thus lost Low system pressure will cause insufficient cooling MAX MIN All systems Fill the system carefully through the ex pansion tank opening approximately 10 15 l min 2 5 4 0 US gal min so the system will be de aired during filling Cooling system volume see Operator s Manual Mixture ratio antifreeze glycol The mixing of concentrated coolant and water sho...

Page 65: ... is at least 50 mm 2 lower than the coolant level in the expansion tank If this cannot be obtained a separate expansion tank must be installed Shut off valves Volvo Penta recommends that shut off valves should be installed in the extra circuit on both the supply and return sides Locate the valves as close to the engine as possible Thermostat In order to reach correct engine temperature more quickl...

Page 66: ...rd system and extra circuits The volume of the engine s freshwater system can be increased by an extra circuit without adding an extra expansion tank to the system Hot water circuits and cabin heaters are examples of extra circuits When the volume is further increased or when the ex tra circuit is placed higher up than the engine the cool ing system has to be equipped with a larger expansion tank ...

Page 67: ...meant for the difference between MAX and MIN levels 5 is reserve volume The expansion tank of the engine must have a sepa rate vent to the extra tank connected below MIN level The hoses must be able to withstand temperatures up to 115 C 240 F The engine s pressure cap is replaced with a sealed cap The standard engine venting hose from the ther mostat housing can be connected to the extra expan sio...

Page 68: ...nected and maintains the engine coolant at the right tempera ture The heating capacity is depending on the ambient temperature but a guide line is to use a heater of 500 750 W The heater should have its own circulation pump and be located in a protected area NOTE The rating of the engine heater shall be cho sen so that the incoming coolant temperature in the engine does not exceed 50 C 122 F If th...

Page 69: ...ther and radiates less heat The importance of using a wet exhaust is to make a proper design and make sure the coolant cannot enter backwards into the engine IMPORTANT The exhaust system should be designed and installed in such a way that the exhaust emissions are taken out of the boat without any harmful backpressure for the engine and so that there is no risk of overheating any adjacent parts of...

Page 70: ...d The problem originates with what is known as recirculating air When a boat moves forward and creates a backward current of air an underpressure forms in the boat and the exhaust fumes are drawn into it To avoid such a problem it is of outmost importance to design and locate the exhaust outlet properly The dry exhaust system for inboard diesel engines is mainly used for slower vessels commercial ...

Page 71: ... be regard ed as empirical framework and reflects a total system with maximum length of 10 meters 33 and maxi mum 4 x 90 bends All systems with silencers especially the Aqua lifts contribute to the system s total backpressure The contribution of each silencer must be carefully esti mated and calculated as well as sea trialed and veri fied by measurements Wet exhaust line Dimensioning the exhaust l...

Page 72: ...owing page Fig B β β β β β 4 7 Exhaust elbow angle a relative to water line fig A should be min 15 26 The silencer should be fitted as close to the engine as possible The hose must be arranged with a continuos inclination into the silencer throughout the whole dis tance see fig A NOTE The minimun distance H between the engine exhaust centerline and the silencer inlet center should be 150 mm 6 Leng...

Page 73: ... or as high as possible It is recommended to position the exhaust outlet at the side of the hull and close to the transom to reduce the wagon back effect NOTE If the Volvo Penta silencer is installed athwart ships the boat it should be inclined between 25 45 C with the silencer inlet facing upwards This inclina tion is important to prevent water ingress in the engine when the boat heels over parti...

Page 74: ...ccomodate the water quantity after the engine is shut down The water level shall be well below the si lencer inlet The inner diameters of the exhaust hoses A and B should be chosen to suit the engine power to give low exhaust backpressure See table on page 72 for dimensioning hoses for and after the silencer The minimum height between the lower edge of the si lencer exhaust outlet and the water li...

Page 75: ...n relation to the water line so an acceptable downward inclination can be acheived The importance is that the system is drained when the en gine is shut off Recommended hose diameter innerdiameter A and B see table on page 72 NOTE An in line system is not recommended when height Cmin exhaust elbow waterline is less than 350 mm 13 7 WL B A Cmin ...

Page 76: ...ould not be located at flat transoms See Wagon back effect on page 68 Exhaust riser WL When distance between water level and lowest part of exhaust elbow is less than 350 mm 14 or recom mended exhaust line inclination can not be acieved an exhaust riser should be fitted Minimum inclination of the exhaust riser outlet should be 15 Maximum increase of height A at min inclination 15 compare with the ...

Page 77: ...if the boat is towed or running with one engine only Position the outlet in the bottom in a way so the ex haust gases will not create negative turbulance flow ing into the propeller or trim tabs not even when the boat is turning as this will affect the performance of the boat A by pass outlet should be installed from the exhaust pipe above the water line to an outlet above the wa ter line to avoid...

Page 78: ...elease the exhaust fumes far from the boat transom The outlets of the boots are preferably positioned in line with the propeller shaft just behind the propeller and rudder This way the exhaust emis sions are carried into the currents of water aft of the propeller See Wagon back effect page 68 This slipstream system can be profiled to meet the re quirements of individual boat builders Volvo Penta h...

Page 79: ...is fitted on the engine exhaust pipe flange as straight and stress relieved as possible The exhaust line must be insulated throughout its whole length noting that the movements of the com pensator must not be obstructed After the compensa tor the exhaust line including silencer 4 must be suspended by flexible brackets 2 3 so that the movements caused by heat expansion are not ob structed The exhau...

Page 80: ...damage and will lead to Loss of power output Poor fuel economy High exhaust temperature These conditions produce overheating and excessive smoke from the installation and reduce the service life of the valves and turbocharger Allowed backpressure in exhaust line at rated rpm kPa psi TAMD31 TAMD41 TAMD42WJ KAMD43 KAMD44 KAMD300 Acceptable Not acceptable 0 5 10 15 20 23 25 30 35 0 0 7 1 5 2 2 2 9 3 ...

Page 81: ...an the mating surface Install the measuring flange 885309 a with V clamp to the turbine housing flange Install the exhaust elbow pipe on the measuring flange Connect manometer 9996065 with pressure hose and a nipple 9996666 for connection to the measuring flange Alternatively a transparent plastic hose 2 can be connected to the measuring flange as illustrated The difference between the water colum...

Page 82: ...o produce a certain volt age changes with the age of the battery There must not be unequal loading equipment should load both batteries not just one A small load such as a radio connected across only one battery can quickly destroy the batteries Electrical installation General The electrical installation has to be planned very care fully and carried out with the utmost care Seek sim plicity when d...

Page 83: ...eries may have different capacities The batteries need not be the same age When two batteries are connected in parallel the volt age remains the same but the capacity is the sum of all the capacities When charging each battery re ceives a charge lower than that stated on the charger To find out the charge current supplied to each bat tery measure the charging current to each battery with an ampere...

Page 84: ...2V system 31 44 series 450A KAMD300 450A 24V system TAMD41 250A As a guideline the breakaway current can be calculat ed as 2 2 5 times cranking current Battery size When selecting battery size it is vital to look at both momentary and long term capacity The rating norm for long term capacity batteries marked with Ah the C20 norm is used C20 means the amount of current able to take out from the bat...

Page 85: ... switch outside the engine room but as close to the en gine as possible to reduce cable length Comparison cable area mm diameter mm according to Volvo standard Area mm 25 35 50 70 95 120 Core diameter mm 8 6 10 4 11 7 13 8 15 8 17 8 Cable diameter mm 10 8 12 8 14 5 16 6 19 0 21 0 Requirements main switch Normal Nominal capacity Working T C F Dimension Standard Protection voltage Contin During and ...

Page 86: ...ing The positive pole on the battery is connected to the positive pole on the starter motor Connections to starter motor Connecting the battery leads KAMD44 KAMD300 2 pole system e g EDC engines 11 The negative pole on the battery is connected to the negative pole on the starter motor The positive pole on the battery is connected to the positive pole on the starter motor Dimensions of start batter...

Page 87: ... oth er circuit for other electrical equipment This means that if you empty the accessory battery you will still be able to start the engine from the other battery Charging distributor How to calculate the cable area is described in the in stallation instruction included in the charging distribu tor kit cable cable D W B 1 Start battery 2 Accessory battery 3 Sensor cable 1 2 3 B ...

Page 88: ...it Add up all accessories power consumers Measure the length of the feeder cable A See table on the next page The table will give you the feeder cable area Before installing extra accessories such as naviga tion instruments extra lighting radio depth sounder etc carefully calculate the total electrical power con sumption of these extras in order to be sure that the charging capacity in the boat is...

Page 89: ...block to the accessory Then multiply the distance by two Then calculate the area in accordance with the table below Example If a 12 V refrigerator consumes 45 Watts and the distance between the terminal block and the refrigerator is three metres a straight line should be drawn between number 6 on the metre scale and number 45 on the load scale The line passes the area scale at 1 5 which is equal t...

Page 90: ... risk of short circuit in the battery There is a risk of explosion The following parameters determine the duration of the charge period The state of discharge when charging is com menced The capacity of the charger how much current can be supplied from the charger The size of the battery capacity in Ah The temperature of the battery Longer charging is required if the battery is cold The battery ca...

Page 91: ...the vicinity of the bat tery can cause a powerful explosion Ensure proper ventilation especially if the battery is charged in a closed room WARNING Always disconnect the charge current before removing the cable clamps Charge state The charge state is the level to which the battery is charged This state can be measured either by mea suring the battery acid specific gravity in each cell or by measur...

Page 92: ...ditonal instruments radio etc NOTE Maximum current outlet for both instrument panels together 5 Amps Oil pressure sensor Coolant temp sensor Main Y connector Flybridge Flybridge Full instrumentation Full instrumentation Tachometer NOTE When two panels full instrumen tation are used make sure oil pressure sender and coolant temperature sender for two instruments are used From engine Current outlet ...

Page 93: ...er or full instrumentation NOTE When two panels full instru mentation are used make sure oil pressure sender and coolant tempera ture sender for two instruments are used From engine Y connector Current outlet Power supply Extra outlets The extra outlets are located at the back of the alarm panel The outlets can be used to connect additonal instruments radio etc NOTE Maximum current outlet for both...

Page 94: ...it 4 Instrument kit boost pressure oil pressure reverse gear Harness lengths A B 180 mm A C 760 mm A D 3280 mm Instrument kit flybridge start stop buttons 1 Panel kit Available as option 2 Instrument kit temperature oil volt 3 Tachometer kit Harness lengths A B 500 mm A C 580 mm A D 1600 mm A B C C C C D 1 1 3 1 4 2 C C C 1 1 1 3 2 ...

Page 95: ... voltage Press in pin B and release pin B Pin B is not included in the tachometer kit Press in pin B Remove pin B when the correct code is displayed IMPORTANT Wait for 10 seconds with the unit connected to system voltage to confirm the code setting Shown on display A Notes Cd1 Codes are scrolled at 1 second intervals This is your code Compare with code table Switches to hours counting COdE Cd3 Cd4...

Page 96: ...of installing an indica tion for water in the fuel pre filter The sender can be installed individually or connected to a second alarm panel Code table Code Code shown Signal sender Engine on display 8 Cd8 Alternator W TAMD31 41 42 Alternator W KAMD43 14 Cd14 Inductive KAMD44 300 ...

Page 97: ...the cathode General NOTE For more detailed information about electro chemical corrosion see manual Marine Electrical Systems Part 1 Electrochemical corrosion Electrochemical corrosion of metals can cause very serious and expensive damage to propellers propeller shafts rudders keels and other equipment fitted to the boat The types of corrosion that are particularly significant to boats are Galvanic...

Page 98: ...V Tin 0 31 to 0 33V Red brass 85 Cu 15 Zn 0 30 to 0 40V Yellow brass 65 Cu 35 Zn 0 30 to 0 40V Aluminium bronze 0 31 to 0 42V Stainless steel 18 8 3 Mo in an active state 0 43 to 0 54V Stainless steel 18 8 in an active state 0 46 to 0 58V Cast iron 0 60 to 0 71V Steel 0 60 to 0 71V Aluminium alloys 0 76 to 1 00V Galvanised iron and steel 0 98 to 1 03V Zinc 0 98 to 1 03V Magnesium and magnesium all...

Page 99: ...ndation is to bond all of them to a protective anode normally made of zinc Protection against electrochemical corrosion NOTE This bonding system with its individual compo nents should normally have no contact to the negative circuit of the boats electrical system Local requirements i e ABYC may demand a battery minus connected to the galvanic bond ...

Page 100: ...plies stray current corrosion is caused by stray currents Stray currents can arise as a result of faults in the boat s electrical system such as connections and splices that are exposed to mois ture or bilge water equipment that is faulty as a result of damage or wear or an electrical system that is in correctly connected Stray current corrosion can also be caused by stray currents from neighbouri...

Page 101: ...heft protection bilge pumps and the operating switch for electrical main switches Engines and drive lines must not be connected galvanically to other equipment such as trim plane or bathing steps unless bonded to a protected an ode They must not be used as a ground for radio navigationorotherequipmentwhereseparate ground cables are used All separate ground cables ground connections for radio navig...

Page 102: ...must always be related to a particular refer ence electrode and the same electrolyte i e the same water and water temperature The water flow rate must also be the same if results from different measurements are to be compared Checking electrochemical corrosion Measuring galvanic currents and stray currents in water Volvo Penta has produced a method for measuring galvanic currents and stray current...

Page 103: ...l tester gives a re sult less than 1340 mV This could also be caused by stray currents from separate ground cables for VHF radio or other equipment fitted with separate ground cables which are incorrectly connected The reason may also be that the anodes provide too much protection current e g magnesium anodes in salt water Checking for leakages from the electrical system A simple way of testing th...

Page 104: ...onnected Below is a rough guide to what those readings means in practical terms 10 000 Ohm up to interruption A next to perfect circuit no problems 5 000 Ohm There is a small leak 1 000 Ohm There is a leak that must be found andcorrected 500 Ohms or less A heavy leak Let the battery connectors be disconnected Repair as soon as possible Charging Oil pressure 4 To find the leak With the test lamp co...

Page 105: ...ot pass through the planing threshold For the engine to function properly and give full power it is absolutely necessary that both the inlet and outlet air ducts are sufficiently dimensioned and installed correctly Two main conditions must be fulfilled A The engine must get enough air oxygen to allow for the combustion of the fuel B The engine room must be ventilated so that the temperature can be...

Page 106: ... is not ad justed de rated despite high air temperature the result will be very smoky exhaust increased thermal load and greatly increased engine wear and consequently greatly increased operating costs However the driver can reduce the throttle when op erating temporarily in such hot areas and thus avoid these types of unfavourable operating conditions Engine power output at high altitudes above s...

Page 107: ...ngine room This is an abso lute requirement to keep the engine room tempera ture below the permitted maximum limit Fans To ventilate the engine room more effectively and thus keep the engine room temperature at a low level a suction fan must normally be installed in the outlet air duct Fans must never be installed in the inlet air ducts as this could lead to overpressure in the engine room with th...

Page 108: ...ed us ing the formula Inlet air 1 65 engine power output Outlet air 1 65 engine power output Areas in cm and engine power output in kW These values must be corrected according to Table 1 with regard to bends and duct length The ambient air temperature outdoor air temperature is assumed to be 30 C 86 F Correction factors as per Table 2 shall be used where applicable Ambient air temperature Correcti...

Page 109: ...min 519 ft min 4 NOTE As this is a twin installtion figures have to bedoubled Example 2 A diesel engine 96 kW 129 hp Calculation of areas for one engine with 2 m 6 6 ft duct length 2 bends and an ambient air temperature of 20 C 68 F Area engine s air consumption 1 1 9 96 182 cm 28 sq in Also see fig 1 Correction for air temperature 0 7 from Table 2 and correction for duct length and bends 1 41 fro...

Page 110: ...4 200 268 300 402 400 536 500 670 kW Hp 210 kW Ex 1 400cm Ex 1 Cross section area cm square inch 0 100 3 9 50 2 0 150 5 9 200 7 9 250 9 8 300 11 8 350 13 8 ø mm ø in Ex 1 1 2 Ex 1 Air consumption duct diameter 225 mm 9 8 Ventilation duct diameter 210 mm 8 3 1000 155 800 124 600 93 400 62 200 31 800 124 600 93 400 62 200 31 347cm Ex 1 Fig 2 Conversion of area to diameter ...

Page 111: ...distance of 20 30 cm 8 12 to defi nitely prevent water from entering the engine See fig ures Example of how the inlet and outlet air ducts can be installed in pleasure boats and similar hulls using die sel engines For diesel engines the incoming ventilation air duct should open out low down in the engine room but not so low that any bilge water can block the air supply The outlet ducts should be l...

Page 112: ... the room proper ly Further improvements in noise level reduction can be achieved by sound insulation material and by de signing sound traps for the air inlets The engine installation should be soundproofed in or der to obtain a noise level that is as low as possible Build the engine compartment with sound traps Differ ent types of sound traps can be selected The figure reflects a type that is als...

Page 113: ...me proof absorption sheeting 3 Flame proof reflecting soundproofing foil Shift cables throttle cables and electrical wires com ing through bulkheads can perferably be drawn through a tube or a grommet sealing off properly At the same time the cables are protected against wear Fuel hoses going through a bulkhead should rest in a grommet where they pass through the bulkhead The grommet seals off and...

Page 114: ...s own enclosure exposed moving or hot parts of the engine that could cause personal injury must be effectively shielded Belt guards for 31 41 engines which can be fitted on the engine are available as optional equipment from Volvo Penta Protections can also be built in the en gine room by the boat builder ...

Page 115: ...anical steering systems the length of the steering cable should not exceed 9 m 29 50 ft This includes an installation with 3 90 bends and the ca ble not clamped Installations which reguire cable lengths of 9 12 m 29 50 39 30 ft must be tried out in each individual case When using such cable lengths it is extremily important for the cable to be installed as straight as possible and the cable to be ...

Page 116: ...comfortable driving position The steering can be installed either on the starboard or on the port side of the boat NOTE Remember to locate the shift and speed con trol in a way that the steering cable can be installed without being bent Location of steering head mechanical steering Location of steering pump hydraulic steering system Choose a suitable location for the steering pump Check that there...

Page 117: ...ft a bend as possible Minimum bending radius 250 mm 10 Assemble the steering cable to the transom and the steering tiller arm Hydraulic hose routing Install the hydraulic oil pipes Minimum bending radius 60 mm 2 Make sure that the pipes do not come into contact with hot surfaces Fix the pipes with plastic stripes Distance between stripes approx 250 mm 10 Metal clamps must not be used Cut the pipes...

Page 118: ...erating station The control could be either a single lever control or two lever control On a single lever control both shift ing and speed is operated with the same lever In a two lever control there is one lever for shifting and one for speed Example showing different control systems 1 Single lever control mechanical 2 Single lever control two stations mechanical DS unit 3 Two lever control two s...

Page 119: ...ation manual mainly covers this type of in stallation 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 EDC engines It offer very simple installation as well as smooth han dling with long cables and several control stations For further details about installa...

Page 120: ... the switch on the yellow red wire going to the no 50 terminal on the key switch The circuit should be closed in the neutral position Local legislation might apply making neutral switches compulsory Cable routing The speed control cable must be clamped in such a way that the movement of the cable close to the mechanism is not jeopardised The cable must not be clamped closer to the control than 0 9...

Page 121: ...t possible stroke on the control cable to provide the smoothest control procedure The pump lever however must al ways be in contact with the full speed stop at full throttle When double cables are connected as shown in fig ure the cables run freely through their attachments to the pump lever NOTE The nuts on the ends of the cables must be locked against each other when the pump lever and control l...

Page 122: ...stall the swivel and lock nut onto the cable Pull out the cable out of the conduit and push it in as far as possible in order to check the axial clearance of the cable A Then pull it out again to the half of this length adjust the swivel to its correct position and attach it to the outer pivot hole Fix the swivel in its final position on the gear shift lever with the lock nuts the washer and the c...

Page 123: ... al ways rotate clockwise and the port propeller anti clockwise seen from the aft forward Otherwise there is a risk that air bubbles will be drawn down into the water between the two propellers which can cause ventilation Install the shifting cable and make sure the cable is connected for the required rotation of the propeller shaft To alter the direction of the cable movement change the position ...

Page 124: ...ling valves can be fitted on reverse gears HS25 HS45 and HS63 as an accessory The trolling valve will reduce the oil pressure on the disc pack which will make it slip in a controlled way The speed of the propeller shaft can be reduced up to 80 compared to in a non slipping condition There is normally an engine rpm limit up to which the trolling valve can be used A thermostat valve is fitted to kee...

Page 125: ...on A Maximum slipping Position B Trolling fuction off Lever travel for the outer pivot point from position A to B 51 mm 2 Lever travel for the inner pivot point from position A to B 44 mm 1 7 A B 51 mm 2 44 mm 1 7 Engine ...

Page 126: ...er tical line Maximal torque extra V belt pulley 45 Nm 33lbf ft The Volvo Penta universal bracket must be modified locally to be used for these engines Dimensions in mm in Belt pulley 3 x type B Belt pulley 3 x type HC50 19 19 16 16 Diam 165 6 5 16 16 60 2 4 66 2 6 Diam 165 6 5 15 15 The most common way to add additional equipment such as hydraulic pumps water pumps refrigerators compressors etc i...

Page 127: ... KAMD44 KAMD300 Alternator 12V 60 Amp 24V 40 Amp This type of power take off may be used when more power than allowed with a crankshaft mounted pulley is required or the equipment is considered too heavy to be fitted to the engine The figure shows one concept of how to utilise the crankshaft power in line when all side thrusts are tak en up by the bearings 1 The torque figures are maxi mum levels ...

Page 128: ...Power take off 126 TAMD31 TAMD41 TAMD42WJ Alternator 12V 50 Amp 24V 25 Amp Alternator 12V 130 Amp 24V 100 Amp 376 mm 14 8 in max 411 mm 16 2 in 256 mm 10 in 411 mm 16 2 in ...

Page 129: ...extra equipment such as fridge compressor or hydraulic pump 234 9 2 76 3 0 169 6 6 124 4 9 16 Diam 165 6 5 16 16 19 19 16 Diam 165 6 5 60 2 4 66 2 6 Belt pulley 3 x type HC50 Belt pulley 3 x type B 38 1 5 Maximum Power Take off 45 Nm 33 lbf ft total load 15 Nm 11 lbf ft belt groove Dimensions in mm in Dimensions in mm in ...

Page 130: ...ng Oil and coolant drain systems General Engine installations in boats and vessels carry the potential for negative impact on the environment The liquids necessary are harmful and should be handled in a safe way The figure above shows a concept of how this could be solved via a central waste pump connected to the important positions in the engine room The systems must comply with local ruling and ...

Page 131: ...en valves at through hull fittings one by one Check for leakages in hull and through hull fittings Open valves for external systems hot water circuit etc That all drain cocks are closed and all drain plugs are installed Water lubricated stern bearings Vent the rubber seal Press thereafter approx 1 cm3 water resist ant grease into the rubber seal Volvo Penta part no 828250 1 Check that the water pi...

Page 132: ...nstall the lid and tighten it by hand Wipe off any diesel fuel which may have collected on the heat shield Check that the tap handle is in the open position all on if a twin filter has been installed Open the fuel cocks and vent the fuel system Reverse gear oil The oil capacity oil quality and viscosity See Operator sManual NOTE Since the marks on the dipstick apply at operating temperature with t...

Page 133: ... showing correct values Oil level in reverse gear when engine has reached operatingtemperature Equipment such as navigation lights instruments etc is working correctly Stop the engine Check Engine oil level Coolantlevel Water level in wet exhaust system The level shall be well below the lower edge of si lencer inlet so that there will be no risk of water en tering into the engine exhaust system Fo...

Page 134: ...ng size propeller might be installed Also the boat might be loaded in a way that results in a bad running at titude position in the water Exhaust backpressure See chapter Exhaust sys tem Backpressure page78 Propeller shaft bearings and seals These should be at a low temperature and without leakes Check over the whole speed range That the engine room temperature is kept at an ac ceptable level Abno...

Page 135: ...133 Notes ...

Page 136: ...134 Notes ...

Page 137: ...135 Notes ...

Page 138: ...136 References to Service Bulletins Group No Date Concerns ...

Page 139: ...opy of this page write your comments down and post it to us The address is at the bottom of the page 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 SE 405 08 Göteborg Sweden ...

Page 140: ...7741513 1 English 08 2001 ...

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Volvo Penta KAMD300, Installation Manual

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