Volvo Penta Industrial Engine Installation ISO 3046 Standard
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 know how 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
Volvo diesel generator 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)