Installation B

Aquamatic DPH, DPR 1(1)

Inboard

  D4, D6
 Table of Content
Safety Information ...................................................................................... 3
General Information .................................................................................... 6
Metric Conversion Chart ........................................................................... 8
Installation Tools and Documentation ...................................................... 9
Chemicals ................................................................................................. 9
Publications ............................................................................................. 10
Special Tools .......................................................................................... 11
Chemical products ............................................................................... 13
System Information .................................................................................. 14
EVC .......................................................................................................... 14
Engine Characteristics ............................................................................. 15
Engine Application Ratings .................................................................. 15
Engine Performance .............................................................................. 16
Arrangement and Planning ...................................................................... 22
Choice of Engine .................................................................................... 22
Propeller Rotation ................................................................................ 36
Engine Placement .................................................................................. 37
Engine Inclination ................................................................................. 37
Weight Distribution ............................................................................... 38
Engine Room .......................................................................................... 39
Accessibility for Maintenance ............................................................... 39
Engine Room Ventilation ..................................................................... 42
Dimensioning of air intake and ducts ................................................... 44
Location of Ventilators and Air Intakes ................................................ 48
Sound Absorption .................................................................................. 49
Electrochemical Corrosion ................................................................... 53
General ................................................................................................ 53
Corrosion theory .................................................................................. 53
Corrosion protection ............................................................................. 58
Anodes to use ...................................................................................... 60
Definitions ............................................................................................ 61
Protection against electrochemical corrosion ...................................... 62
Protection against electrostatic discharge and lightning ...................... 63
Bottom Painting .................................................................................... 63
Checking Protective Anodes ................................................................ 68
Checking for leakage from the electrical system ................................. 69
Checking electrochemical corrosion .................................................... 71
Installation ................................................................................................. 73
Aquamatic drive ..................................................................................... 73
Transom Shield Installation ................................................................ 73
Engine Foundation ............................................................................... 93
Engine Installation ............................................................................... 96
Cooling System .................................................................................. 111
Steering System ................................................................................. 112
Sterndrive Installation ....................................................................... 150
Inboard Applications ........................................................................... 168
Engine Foundation ............................................................................. 168
Engine Installation ............................................................................. 173
Cooling System .................................................................................. 181
Keel cooling ........................................................................................ 192

47704210 02-2018 © AB VOLVO PENTA 1

 Cooling System .................................................................................... 215
Water Quality ..................................................................................... 215
Coolant Level, Checking and Topping Up ......................................... 215
Exhaust System ................................................................................... 217
Wet Exhaust Line ............................................................................... 219
Dry Exhaust Line ................................................................................ 230
Fuel System .......................................................................................... 233
General ................................................................................................ 233
Fuel Tanks .......................................................................................... 235
Lubrication System .............................................................................. 245
Draining the Engine ........................................................................... 245
Viscosity ............................................................................................. 246
Electrical System ................................................................................. 247
General .............................................................................................. 247
Batteries .............................................................................................. 248
Alternator ............................................................................................ 256
Voltage Supply ................................................................................... 259
Connection ......................................................................................... 261
Fire Extinguishing System .................................................................. 281
Power Take-off ..................................................................................... 283
Launching and Sea Trial ........................................................................ 289
Launching and Starting ......................................................................... 289
Starting the Engine (Cold Start) ............................................................ 294
Sea Trial ................................................................................................ 300
Index ......................................................................................................... 301

2 47704210 02-2018 © AB VOLVO PENTA

Safety Information
This installation manual contains information required
for the correct installation of your Volvo Penta
product. Check that you have the correct manual.
Carefully read the chapters Safety precautions
and General information in the manual before
servicing or running the engine.
The following types of special warning messages can
be found in this manual and on the engine:
WARNING!
Indicates a hazardous situation, which, if not avoided,
could result in death or serious personal injury.
IMPORTANT!
Indicates a situation which, if not avoided, could result
in property damage.
NOTICE! Important information that facilitates the
work process or item.
Set out below is a list of risks that must always be
borne in mind and the safety precautions that must
always be taken.
Plan ahead so that there is always sufficient
space for safe installation and (future) disassembly.
Lay out the engine compartment (and other
compartments such as the battery compartment) so
that all service points are accessible. Make sure not
to come into contact with rotating components, hot
surfaces or sharp edges when checking and servicing
the engine. Make sure that all equipment (e.g. pump
drives, compressors) has protective covers.
Make sure the engine cannot be started while
work is in progress by not connecting the electrical
system or by switching off electrical power to the
engine at the main switches and locking them in the
OFF position. Erect a warning sign at the helm station.
47704210 02-2018 © AB VOLVO PENTA
Only start the engine in well-ventilated areas.
Remember that exhaust fumes are toxic and
dangerous to inhale. Use an exhaust extractor to lead
exhaust fumes away from the exhaust pipe and
crankcase ventilator when the engine is run in a
confined space.
Always wear protective goggles if there is a risk
of splinters, sparks and splashes from acid or other
chemicals. Eyes are extremely sensitive and injury
may result in loss of sight!
Avoid getting oil on the skin! Prolonged or
repeated contact with oil may lead to the
disappearance of the skin's natural oils. This will
cause irritation, dry skin, eczema and other skin
problems. Old oil is more hazardous to health than
new. Use protective gloves and avoid oil-soaked
clothes and rags. wash regularly, especially before
meals. Use special skin creams that facilitate cleaning
and prevent the skin from drying out.
Most chemical used in the product (engine and
reverse gear oil, glycol, gasoline and diesel) or
chemicals intended for use in the workshop
(degreasing agents, paints and solvents) are health
hazards. Read the instructions on the product
packaging carefully! Always follow safety instructions
(the use of protective masks, protective goggles,
gloves etc.). Make sure that other personnel are not
inadvertently exposed to hazardous substances, e.g.
in the air they breathe. Ensure good ventilation. Hand
in used and surplus chemicals to a recycling station.
Take extreme care when searching for fuel
system leaks and testing injectors. Wear protective
goggles. The spray from an injector is at very high
pressure and fuel can force its way into tissue and
cause a serious risk of blood poisoning (septicemia).
Stop the engine and disconnect the power at the
main switches before working on the electrical
system.
3
Safety Information
Coupling adjustments must be made with the
engine stopped.
Use the lifting eyes installed on the engine/
reverse gear when lifting off the drive. Always check
that the lifting equipment is in good condition and has
the capacity to lift the engine (engine weight including
reverse gear and any auxiliary equipment installed).
If the engine has auxiliary equipment that has
altered its center of gravity, special lifting devices may
be required to obtain the correct balance for safe
handling.
Never work on an engine that is suspended in an
engine hoist.
It is mandatory that no work be carried out on a
running engine. There are however adjustments that
require the engine to be run. Approaching a running
engine is a safety risk. Loose clothes and long hair
can catch in rotating parts and cause serious injury. A
careless movement or a dropped tool may result in
injury when working in the vicinity of a running engine.
Be careful to avoid hot surfaces (exhaust pipes,
turbochargers, charge air manifolds, start elements
etc.) and hot liquids in pipes and hoses on engines
that are running or recently stopped. Re-install all
protective covers that were removed during
maintenance work before starting the engine.
Make sure that all warning and information decals
on the product are always visible. Change decals that
are damaged or painted over
Turbocharged engines: never start the engine
without the air cleaner installed. The rotating
compressor turbine in the turbocharger can cause
severe injury. Foreign objects that enter the inlet ducts
can also cause mechanical damage.
Never use start spray in the air intake. The use
of such products may result in an explosion in the inlet
manifold. Risk of injury.
4 47704210 02-2018 © AB VOLVO PENTA
Do not open the engine coolant filler cap
(freshwater cooled engines) when the engine is hot.
Steam or hot coolant may be ejected when system
pressure is released. Open the filler cap slowly and
release the system pressure carefully (freshwater
cooled engines). Hot coolant may spray out if the filler
cap or drain tap is opened, or if a plug or coolant pipe
is removed from a hot engine.
Hot oil can cause burns. Avoid getting oil on the
skin. Be sure to release the pressure from the
lubrication system before starting work on it. Never
start or run an engine without the oil filler cap
attached. There is a risk of oil being ejected.
If the boat is in the water – stop the engine and
close the seawater tap before working on the system.
All fuels, and many chemicals, are flammable.
Make sure they are not exposed to open flames or
sparks. Gasoline, certain solvents and hydrogen from
batteries are extremely flammable and explosive in
the right concentration in air. No Smoking! Make sure
the workplace is well ventilated and take the
necessary safety precautions before welding or
grinding in the vicinity. Always have a fire extinguisher
accessible at the workplace.
Store oil, fuel-soaked rags and old fuel and oil
filters in the correct manner. Oil-soaked rags may
ignite spontaneously in certain conditions. Old fuel
and oil filters are harmful to the environment and must
be handed to a recycling station for destruction.
Make sure the battery compartment is built
according to current safety standards. Never allow
open flames or electrical sparks in the vicinity of the
batteries. Never smoke in the vicinity of the batteries.
Batteries give off hydrogen gas during charging,
which may combine with air to form an explosive
mixture. The gas mixture is extremely volatile and
easily ignited. Incorrect battery connection may cause
sparks which in turn may cause an explosion. Do not
change the battery connections when attempting to
start the engine (risk for sparks) and do not lean over
the batteries.

Make sure that the positive (+) and negative (–)
battery cables are correctly connected to the
corresponding battery terminals. Wrong connection
may cause severe damage to electrical equipment.
Refer to the wiring diagram.
Always wear protective goggles when charging
or handling batteries. Battery electrolyte contains
highly corrosive sulfuric acid. Wash immediately with
soap and copious amounts of water if battery
electrolyte comes into contact with the skin. Flush
immediately with water and seek medical attention if
battery acid gets in the eyes.
Never work alone when installing heavy
components, even when using safe lifting equipment
e.g. lockable blocks. Most lifting devices require the
two people, one to take care of the hoist and the other
to make sure no components catch or are damaged.
The components in the electrical system, ignition
system (gasoline engines) and fuel system on Volvo
Penta products are designed and manufactured to
minimize the risk of fire and explosion. Do not run
engines in areas where there are explosive materials.
47704210 02-2018 © AB VOLVO PENTA
Safety Information
Always use fuels recommended by Volvo Penta.
Refer to the Operator's Manual. Poor quality fuel may
damage the engine. Poor fuel quality in a diesel
engine may cause the fuel control mechanism to bind
which will lead to engine overspeeding with the risk of
engine damage and personal injury. Low fuel quality
may also lead to higher service costs.
Use an adjustable lifting beam to provide a safe
lift and to avoid damage to components on the top of
the engine. All chains and cables must run parallel
and be as square as possible to the top of the engine.
Before electric welding, make sure to disconnect
engine control unit connector and PCU connector.
Only reconnect the engine control unit connector and
PCU connector after welding equipment has been
disconnected.
5
General Information
General Information
About this installation manual
This publication is intended as an installation guide for
Volvo Penta marine diesel engines. The publication is
not exhaustive and does not cover all conceivable
installations, but should be considered as
recommendations and guidance according to Volvo
Penta standards. Detailed installation instructions
accompany most accessory kits.
The recommendations are the result of many years'
practical experience from all over the world. If it is
necessary or desirable to depart from recommended
routines, Volvo Penta is happy to offer assistance in
finding a solution for the installation in question.
It is the responsibility of the installer to ensure that
installation is 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 current instructions and
regulations.
This installation manual is intended for use by
professionally qualified, skilled personnel. It is
therefore assumed that those persons using the
manual have fundamental knowledge of marine
propulsion systems and are capable of carrying out
the associated mechanical and electrical work.
Volvo Penta continually improves its 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.
After this date all important product modifications that
change installation methods will be communicated by
service bulletin.
6 47704210 02-2018 © AB VOLVO PENTA
Removal of complete engine assembly
In the event of a requirement to remove the entire
engine assembly from the vessel, it is the
responsibility of the installer (boat builder) to arrange
reasonable means for removal and re-installation.
'Reasonable means' means that the engine assembly
can be lifted in and out within a moderate amount of
time using normal resources and methods available
to the industry. In this way costs and operational
down-time are kept to a minimum. With due regard to
the great demand placed on boatyards etc. during
high season, the boat builder's instructions must be
followed.
It is Volvo Penta policy to avoid unreasonable
installations that increase extra costs for boat owners
during the lifetime of the boat.
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 facilitates correct planning and installation right
from the start.
Plan the engine compartment so that it will be easy to
perform routine service that involves replacing
components. Compare the engine workshop manual
to the original drawings where dimensions are
specified.
When installing engines, it is extremely important that
no dirt or foreign objects enter the fuel, cooling, inlet
or turbo systems, as this may cause faults or the
engine to seize. Because of this, systems must be
sealed. Clean pipes and hoses before they are
connected to the engine. 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 both new engines and
those in operation fulfill legislation and regulations.
The engine must correspond to the unit used for
certification. In order for Volvo Penta to be able to
declare that engines fulfill environmental legislation,
the following must be observed during installation:
• Service on injection pumps, pump settings and
injectors 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!
Only use genuine Volvo Penta parts. If non-Volvo
Penta parts are used it will mean that Volvo Penta
is no longer able to take responsibility for the
engine fulfilling certification requirements. Volvo
Penta will not reimburse damages and costs arising
from the use of non-Volvo Penta spare parts.
Seaworthiness
It is the responsibility of the boat builder to meet all
safety requirements applicable in the market where
the boat is sold. For example, in the U.S.A. US
Federal Regulations for pleasure boats specify
requirements. Requirements applicable in the EU are
described below. Other markets: contact the
competent national authority for information and
detailed descriptions of safety requirements.
47704210 02-2018 © AB VOLVO PENTA
General Information
From June 16 1998, all recreational craft and certain
associated equipment that is marketed and used
within the EU must be provided with a CE label
confirming fulfillment of safety requirements
established by the European Parliament and
European commission in the Recreational Craft
Directive. These normative standards are reflected in
the standards established in support of the directive's
objective regarding uniform safety requirements for
recreational craft within the EU.
Lifeboats and boats used in commercial navigation
are approved by classification societies in the country
where the boat is registered.
Mutual responsibility
Every engine consists of a large number of
components working in unison. If one component
deviates from technical specifications it may lead to
the engine having a significantly greater impact on the
environment. It is therefore essential that adjustable
systems are set correctly and that genuine Volvo
Penta parts 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. No work may be performed on sealed
parts by unauthorized personnel.
Remember that most chemical products can harm the
environment if they are used in the wrong manner.
Volvo Penta recommends the use of bio-degradable
de-greasing agents for cleaning engine components,
unless the workshop manual states otherwise. When
working on board take especial care to ensure that oil
and spills are collected for handing to a re-cycling
station and not unintentionally pumped into the
environment with bilge water.
7
General Information

Metric Conversion Chart

Metric to American or UK units: American or UK to metric units:
To convert Multiply To convert Multiply
From To with From To with
Length mm in. 0.03937 in. mm 25.40
cm in. 0.3937 in. cm 2.540
m ft. 3.2808 ft. m 0.3048
Area mm² sq. in. 0.00155 sq. in. mm² 645.3
m² sq.ft. 10.76 sq. ft. m² 0.093
Volume cm³ cu. in. 0.06102 cu. in. cm³ 16.388
l, dm³ cu. ft. 0.03531 cu. ft. l, dm³ 28.317
l, dm³ cu. in. 61.023 cu. in. l, dm³ 0.01639
l, dm³ imp. gallon 0.220 imp. gallon l, dm³ 4.545
l, dm³ U.S. gallon 0.2642 U.S. gallon l, dm³ 3.785
m³ cu. ft. 35.315 cu. ft. cm³ 0.0283
Power N lbf 0.2248 lbf N 4.448
Weight kg kg lb. 2.205 lb. kg 0.454
Output kW hp (metric) 1.36 hp (metric) (1) kW 0.735
(1)

kW bhp 1.341 bhp kW 0.7457

kW BTU/min 56.87 BTU/min kW 0.0176
Tightening Nm lbf ft 0.738 lbf ft Nm 1.356
torques
Pressures Bar psi 14.5038 psi Bar 0.06895
MPa psi 145.038 psi MPa 0.006895
Pa mm Wg 0.102 mm Wg Pa 9.807
Pa in Wg 0.004 in Wg Pa 249.098
kPa in Wg 4.0 in Wg kPa 0.24908
mWg in Wg 39.37 in Wg mWg 0.0254
Energy kJ/kWh BTU/hph 0.697 BTU/hph kJ/kWh 1.435
Labor kJ/kg BTU/lb 0.430 BTU/lb kJ/kg 2.326
MJ/kg BTU/lb 430 BTU/lb MJ/kg 0.00233
kJ/kg kcal/kg 0.239 kcal/kg kJ/kg 4.184
Fuel cons. g/kWh g/hph 0.736 g/hph g/kWh 1.36
g/kWh lb/hph 0.00162 lb/hph g/kWh 616.78
Moment of kgm² lbft² 23.734 lbft² kgm² 0.042
inertia
Flow, gas m³/h cu.ft./min. 0.5886 cu.ft./min. m³/h 1.699
Flow, fluidsm³/h US gal/min 4.403 US gal/min m³/h 0.2271
Speed m/s ft./s 3.281 ft./s m/s 0.3048
mph knots 0.869 knots mph 1.1508
Temperature Celsius Fahrenheit °F=9/5 x °C+32 Fahrenheit Celsius °C=5/9 x (°F–32)
ΔT °C ΔT °F °F=9/5 x °C ΔT °F ΔT °C °C=5/9 x °F
1) All catalog output data specified in horsepower refers to metric horsepower.

8 47704210 02-2018 © AB VOLVO PENTA

 Installation Tools and Documentation

Installation Tools and Documentation

Chemicals
There is a large range of chemicals available from
Volvo Penta.

Some examples:
• Oil and coolant
• Sealing compound and grease
• Touch-up paint
Refer to Volvo Penta Spare Parts & accessories.
An
t if ouli n g

P0004585

47704210 02-2018 © AB VOLVO PENTA 9

Installation Tools and Documentation

Publications
Installation manuals
Instal For EVC system installations, refer to Installation
Electri
lation EVC.
c VesselEVC - C3
Contr
BE
ol

P00008984

Installation instructions
Installation instructions are included with most kits.

3 Posters
EVC-C
For EVC system installation and Calibration.

P00008985

92 mm (3.622")
Templates for panels and controls
46 mm (1.811")
7 mm
(0.276") Installation instructions and templates are included
with each kit. Refer to the chapter about templates.
44 mm (1.732")
88 mm (3.465")

85 mm
(3.346")

P00004541

10 47704210 02-2018 © AB VOLVO PENTA

 Installation Tools and Documentation, Special Tools

VODIA diagnostic tool

VODIA
VODIA is used for reading fault codes in plain
language during diagnostic work. It can also be used
for setting EVC parameters.

The tool is very practical for fault tracing as it is possible

to see the values the EVC nodes are reading and
transmitting.
p0006256 Refer to VODIA information at Volvo Penta Partner
Network or contact Volvo Penta to order.

Special Tools

Aquamatic

P0006106
P0001864
P0006106

884573 Screwdriver (flexible) 885595 Mounting tool 885597 Handle

Facilitates sterndrive Facilitates sterndrive
For tightening hose clamps. installation on transom shield (2 installation on transom shield (2
pcs.) pcs, handles and pins)

p0010472
P0006111

P0006110

21318669 Rotation tool 885800 Suspension tool 21679632 Drill jig

Tightening the forward Laying out engine bed and
propeller nut Locking and securing forward engine mounts
sterndrive in up position

P0006112 P0006113

3863258 Fixture 3588044 Purging tool

Drilling holes in transom for Filling and venting the power
shield installation steering system

47704210 02-2018 © AB VOLVO PENTA 11

Installation Tools and Documentation, Special Tools

P0004576 P0004576

21504294 Reference 885164 Flange 885683 Flange

electrode
Ag/AgCl electrode. Measuring Measuring temperature and Measuring temperature and
galvanic current and stray back pressure in the exhaust back pressure in the exhaust
current system, D6 system, D4

VODIA
-60
-40

-80
-20

-100

p0005125

P0002942
p0008375

88820052 VODIA, diagnostic 88890074 Multimeter 9990150 Manometer

tool Measuring fuel feed pressure
Complete P0004333

P0002945

9996065 Pressure gauge 9996066 Nipple 9996666 Nipple

Measuring exhaust back Checking fuel feed pressure Checking exhaust back
pressure pressure

P0004580 P0008329
P0016687

9998493 Hose 21244540 Measuring tool 884502 Cone

Used in combination with Measuring engine mount The wedge is used to measure
9990150 Manometer. compression the gap between the transom
shield projections at
installation.

12 47704210 02-2018 © AB VOLVO PENTA

 Installation Tools and Documentation, Special Tools

Chemical products

P0008962

828250 Grease 1161995 ATF oil

3817243 3809439 / 3809441-3

Rubber lubricant Transmission oil.

47704210 02-2018 © AB VOLVO PENTA 13

System Information, EVC

System Information
EVC
Refer to the Installation EVC installation manual for
EVC system installation instructions.

14 47704210 02-2018 © AB VOLVO PENTA

 Engine Characteristics, Engine Application Ratings

Engine Characteristics
Engine Application Ratings
The engines covered by this manual are used chiefly
in two different operating conditions: Rating 4 and
Rating 5, as described below.

Rating 4
Special light commercial traffic
For light, planing boats in commercial traffic. Operated
for fewer than 800 hours per year.

Typical boats: High-speed patrol boats for search and

rescue and the armed forces, and special high-speed
fishing boats. Recommended cruising speed: 25
knots.

Full power may be utilized for max 1 hour per 12 hour

period. Between full-throttle periods, engine
revolutions must be reduced by at least 10% from full
rpm.

Rating 5
Recreational use
Only for pleasure boats operated by owners for their
recreation. Operated for fewer than 300 hours per
year.

Full power may be utilized for max 1 hour per 12 hour

period.

Between full-throttle periods, engine revolutions must

be reduced by at least 10% from full rpm.

47704210 02-2018 © AB VOLVO PENTA 15

Engine Characteristics, Engine Performance

Engine Performance
Marine engines and their environment
Marine engine power is specified, just like that of
automobile and truck engines, according to one or
more power norms. Power is expressed in kW, usually
at maximum rpm.

Most engines provide the power specified on the

condition that they have been tested in the conditions
the power norms state, and have been broken in
properly. According to ISO standards, tolerances are
normally ±5 %, which is a reality that must be accepted
for series-produced engines.

Power measurement
Engine manufacturers normally measure engine
power at the flywheel, but before power reaches the
propeller, losses occur in the drive train and propeller
shaft bearings. These losses amount to 4 to 6 %.

All larger marine engine manufacturers state engine

power according to ISO 8665 (supplement to ISO 3046
for pleasure boats), based on ISO 3046, which means
that propeller shaft power is indicated. If an exhaust
system is not included, engine tests are performed with
a back pressure of 10 kPa (1.45 psi). If all engine
manufacturers used the same test procedure it would
be simpler for boat builders to compare products from
different manufacturers.

16 47704210 02-2018 © AB VOLVO PENTA

 Engine Characteristics, Engine Performance

Engine performance
1 Engine power is affected by a number of different
A factors. Among the most important are air pressure,
outdoor temperature, humidity, fuel calorific value and
3 exhaust back pressure. Deviations from normal values
B affect diesel and gasoline engines in different ways.
4 C
Diesel engines use large amounts of air for
combustion. If the mass of air is reduced, the first sign
is an increase in black exhaust smoke. The effects of
5 this are especially noticeable at the planing threshold
6
when the engine must produce maximum torque.

If the deviation differs significantly from normal air flow,

the diesel engine will also lose power. In the worst case
the loss may be so great that torque is insufficient for
the boat to overcome the planing threshold.

2 Point A is where the indicated engine power is equal

P0004571
to the power acting on the propeller. It is correct to
select a propeller where the values at point A are
The above graph shows the effect of variations in climate and
propeller size. reached in order to utilize indicated power to the
maximum in a given combination of weather and load.
1 Power
2 rpm If atmospheric conditions cause power to drop to point
B, the propeller plot will cross the engine power plot at
3 Power loss due to atmospheric conditions
point C. A secondary performance loss has occurred
4 Loss due to large propeller because the propeller is too big. The propeller reduces
5 Critical area engine rpm.
6 Indicated rpm By changing to a smaller propeller, the engine power
plot crosses at point B, which makes it possible to
regain the earlier rpm, but at reduced power.

The critical area is the planing threshold for planing or

semi-planing boats, which usually occurs at around
50-60% of cruising speed. In this case it is important
that there be a sufficiently large distance between the
engine max power plot and the propeller plot.

47704210 02-2018 © AB VOLVO PENTA 17

Engine Characteristics, Engine Performance

Other factors that influence performance

It is important to keep exhaust back pressure low.
Power losses caused by back pressure are directly
proportional to the increase in back pressure, which
also increases exhaust temperature.

Boat weight is another important factor that influences

speed. Increased boat weight has a great influence on
speed, especially on planing or semi-planing hulls. A
new boat that is tested with half full fuel and water tanks
and without a load, will easily lose 2-3 knots when it is
driven fully loaded with fuel, water and equipment for
the voyage. This situation arises because the propeller
is often chosen to provide max speed when the boat is
factory tested. It is therefore advisable to reduce
propeller pitch by an inch or two to compensate for load
and a warm climate. Top speed is reduced somewhat,
but overall performance will improve and provide better
acceleration, even with a heavily laden boat.

Considering this, it is important to remember that boats

made of GRP absorb water when they are in the water,
which makes the boat heavier over time. Marine fouling
is an often-overlooked problem that greatly affects
boat performance.

18 47704210 02-2018 © AB VOLVO PENTA

 Engine Characteristics, Engine Performance

1 Choice of propeller
8
Propeller selection must be made by a boat builder,
marine engineer or other qualified individual. The
engine performance data required to select the right
3 propeller is found in the technical literature.
4
5
When it comes to the choice of propeller, it is important
to achieve the correct engine rpm. For this purpose we
recommend the full throttle range (8).

The propeller must be selected for this operational

2 area in order to provide best all-round performance.
p0012219
6 7
When the prototype and first production boat are built,
1 Engine power, kW
the boat builder and a representative from Volvo Penta
2 rpm carry out a full load trial with the boat under conditions
3 Propeller too large similar to those the boat will meet with the customer.
4 Right size propeller
5 Propeller too small
6 Indicated engine power
7 Engine speed limitation
8 100% power. Full throttle range.

47704210 02-2018 © AB VOLVO PENTA 19

Engine Characteristics, Engine Performance

The most important conditions during the tests

are:
• Full fuel and water tanks onboard
• Ballast evenly distributed to represent the owner's
equipment including such things as outboards,
rubber boats etc.
• Alternator, air conditioning and all other equipment
installed.
• A suitable number of passengers onboard.
When the boat has been equipped according to the
above, a complete engine/propeller test is carried out.
All engine parameters such as rpm, fuel consumption,
relative loads, reference rpm, charge pressure,
exhaust temperature, engine compartment
temperature etc. are analyzed.
When the right propeller has been selected on the
basis of the tests, engine rpm must be within the “full
throttle range” at full load.

It is however advisable to reduce pitch further in order

to compensate for varying conditions and marine
fouling. Therefore boat builders must check the
relevant situations in their various markets.

A propeller that is selected for the highest speed

performance must not be used for towing as the engine
is loaded at the highest torque without reaching the
correct speed range. The engine becomes overloaded
resulting in the risk of permanent damage.

20 47704210 02-2018 © AB VOLVO PENTA

 Engine Characteristics, Engine Performance

Relationship between influencing factors

The graph below describes a typical example of a
planing hull and how displacement and deviations in
engine power influence performance.

1 Thrust/power Manufacturing tolerances

2 Speed (knots)
3 Engine power/thrust
4 Displacement / hull drag
5 Max deviation interval
The correct propeller is crucial for ensuring optimal
performance and long service life. The correct
propeller selection allows the engine to provide its
entire power and thus achieve the performance
anticipated.

There are a number of factors whose tolerances can

Nominal Nominal significantly affect boat performance. These must be
power displaceme identified before the correct engine and propeller
nt 13 tons combination can be selected.
Power ±3 % Displaceme
These factors are:
nt ±3 %
Propeller A Engine power may vary within international
precision power norm tolerances.
tolerance ±3 B Calculated hull resistance and displacement
% may vary within certain limits.
C Propeller manufacturing tolerances generally
influence engine rpm in that propeller power
varies.

47704210 02-2018 © AB VOLVO PENTA 21

Arrangement and Planning, Choice of Engine

Arrangement and Planning

Choice of Engine
Inboard engines

It is important to carefully consider the information in
the illustration below to achieve the best performance
and characteristics from an installation. The trial and
error method is often necessary to find the final
combination of performance requirements the
installation must fulfill.
The analysis may vary depending on what is
prioritized: top speed, economy, safety or other. Read
the Volvo Penta information material and consult our
computer program, or contact Volvo Penta for advice.

6 2

5 3

p0005807

Performance requirements 3. Limitations

What are the requirements for top speed and cruising Include limitations such as engine and propeller
speed? dimensions in the calculations.

1. Boat/vessel 4. Power requirement

Define the hull category: Use data to determine the power requirement. Do not
forget to include power losses from power take-offs,
• Displacement
climate, and fuel quality etc.
• Semi-planing
5. Engine
• Planing
Look through Volvo Penta sales literature for a
Consider the boat's size and judge the weight and suitable engine that at a minimum provides the power
longitudinal center of gravity, etc. Drawings and, required for proper classification. Check which
ideally, hydrodynamic data from tank tests or similar reverse gears are available.
will be required. 6. Reverse gears and propellers
2. Propulsion system Calculate the optimum gear ratio, as well as propeller
Look for the most suitable propulsion system and size and type.
engine geometry. Consider the characteristics of
different propulsion systems.

22 47704210 02-2018 © AB VOLVO PENTA

 Arrangement and Planning, Choice of Engine

The illustration shows a twin installation with two types of exhaust systems, both water cooled. The system on
the starboard side is a so-called Aqualift system. The starboard propeller shaft is installed with a water lubricated
packing box and rubber seal. The port propeller shaft has a grease lubricated packing box as a seal. On both
shafts outboard of the hull fitting there is a “wing” that augments water flow into the packing box. The engines are
equipped with Volvo Penta EVC systems (Electronic Vessel Control). The steering system is hydraulic.

47704210 02-2018 © AB VOLVO PENTA 23

Arrangement and Planning, Choice of Engine

General

Plan the engine compartment so that maintenance
work can be performed without difficulty. Using the
Operator's Manual, make sure that all filter changes,
oil changes and other service work can be done
normally. Also make sure that it is possible to install
and remove the engine.
Check that the latest current drawings for the engine
and equipment are used before installation work is
begun. The drawings contain all necessary
dimensions for installation, e.g. distances between
crankshaft center and engine mounts (reverse gear
mounts) and to the propeller shaft centerline.
Note that the small outline sketches on information
material and brochures may not be used for this
purpose.
Propeller pressure waves are transmitted through the
water to the hull. Propeller vibrations are transferred
to the hull via support brackets, bearings and seals.
If the propeller works at a great angle, the pressure
waves and vibrations can be considerable. If an
incorrect propeller is used, this may result in cavitation
which will cause noise and vibrations.
On the other hand, torsional vibrations from correctly
selected components in the drive assembly are often
insignificant.
NOTICE! Always take national and international
legislation into consideration.

The engine and drivetrain must be installed so that

noise and vibrations, e.g. airborne and structural
noise, are minimized.

Vibration from engines and propellers are transferred

to the hull via engine mounts and the engine bed.
Other vibration channels are exhaust pipes, coolant
pipes, fuel pipes, the electrical system and control
cables.

24 47704210 02-2018 © AB VOLVO PENTA


Planning items
1. Engine compartment layout
Only use approved, updated drawings. Study the
drawings carefully. Take sound insulation materials,
engine movement under way and service and repair
accessibility into consideration. In twin installations,
the distance between the engines must be sufficient
to allow comfortable inspection and service.
2. Weight distribution
The distribution of weight in the boat is of great
importance. Make sure that weight is evenly
distributed even in the case of different levels in the
fuel and water tanks. Distribute heavy components
such that the boat is balanced around the center of
gravity in accordance with the designer's
recommendations.
NOTICE! Take great care to ensure the best possible
center of gravity location in order to achieve a good
trim angle under way. The center of gravity has a great
effect on the performance of planing boats.
3. Fuel system
Decide on the type of fuel system. Choose between
using fuel hoses or fuel pipes. Pay attention to
classification requirements. Determine the location of
auxiliary water separators for the fuel, and plan the
running of fuel pipes and hoses, fuel filler and
ventilation hoses, shut-off devices, etc. Fuel feed and
return hoses or pipes must be located deep down in
the engine compartment so that excess heat is not
transferred to the fuel.
4. Cooling system
Select the locations for the seawater inlet and
seawater filter. Plan the hose runs. In boats where the
engines are located low in relation to the waterline, an
anti-siphon valve must be considered.
5. Exhaust system
Select between dry or wet exhaust systems. Plan the
installation of the exhaust system components such
as silencers and hoses.
6. Electrical system
Plan cable runs and check the length of instrument
cable kits. Decide on where circuit breaker boxes and
main switches will be located.
47704210 02-2018 © AB VOLVO PENTA
Arrangement and Planning, Choice of Engine
Avoid joints and connections in places where there is
a risk of moisture or water. Do not locate joints or
connections behind fixed bulkheads or similar places
that are difficult to reach when the boat is completed.
7. Electrochemical corrosion
The problems of potential galvanic corrosion and
stray current corrosion must be taken into
consideration when electrical installations are
planned and equipment is selected. Use protection
anodes.
8. Air supply, ventilation and noise insulation
Carefully check that duct dimensions have sufficient
cross sections and place great importance on
optimizing air outlets. Plan how engine ventilation and
inlet air ducts (hoses) are to be run so that they do not
make the installation of batteries and fuel tanks etc.
difficult.
Engine compartment noise insulation is of great
importance in keeping noise levels as low as possible.
Leave sufficient space for noise insulating materials.
The best way to achieve good noise insulation is to
build a completely sealed engine compartment whose
only openings are ventilation ducts and pipes.
9. Controls and steering
Plan control cable and steering system runs, twin
helm stations etc. Bear in mind accessibility for
service and replacements.
If mechanical control cables are used, it is of great
importance for smooth function that the runs have as
few bends as possible.
10. Power take-off
A power take-off can be driven by an auxiliary belt
pulley that drives various auxiliary equipment.
If larger power requirements are in question, a
mechanical power take-off can be installed on the
front of the crankshaft.
25
Arrangement and Planning, Choice of Engine

Inboard engines

In order to achieve the best performance for the boat

the propeller and gear ratio must be selected to suit the
individual boat, engine and speed range.

Below is a short description of how propeller systems

are constructed. It is not just engine performance that
determines boat speed. It depends equally on the
mechanical efficiency of the reverse gear and the
propeller system. A proper propeller system provides
not only good fuel economy and higher speed, but also
better comfort with lower noise and vibration levels.

The following description is very general and explains

only superficially how a propeller is designed. The
propeller manual Propellers publ. no. 7739174
provides more detailed information.

Computer programs for propellers and

performance
Volvo Penta has developed computer programs for
calculating speeds, gear ratios and propellers. The
programs are excellent regarding the simple and exact
calculation of speed and propellers.

The program's calculated speed information is based

on experience from a great number of installations.

Propeller calculations
Theoretical calculations of speed and propellers are
made using well-established methods and the
experience from a number of practical tests, but remain
the result of approximations and assessments. We
believe they can provide a reasonable assessment for
standard boats on the condition that input data is
correct and complete. However, Volvo Penta cannot
assume responsibility for the final result, which can
only be established by sea trials.

26 47704210 02-2018 © AB VOLVO PENTA

 Arrangement and Planning, Choice of Engine

Inboard engines

C The gear ratio, shaft diameter and propeller size

A
B Propellers must be selected with great care. Take the
p0005809
A Boat full load graph
B Propeller load graph (propeller OK)
C Recommended max. operating area
combination can be calculated using the Volvo Penta
calculation program. Calculation of correct propeller
size can be carried out by Volvo Penta if desired. In
this case all boat information (ideally drawings) must
be sent in in good time.
distance between the hull and the keel strake into
consideration. Refer to the recommendations for
propellers and propeller shaft angles and the
recommended clearance between propeller and hull.
Refer to the section below. On planing boats the hull
above the propeller is often fairly flat. The hull may be
reinforced on the inside in order to reduce noise and
vibrations caused by propeller blade pulses.
Best propeller efficiency is achieved with as small an
angle as possible between the propeller shaft and the
water line. The larger the angle, the lower the
efficiency. If possible, avoid angles in excess of 12°.
This means that when the boat is at rest, the propeller
shaft angle may not exceed 12°. This is especially
important on planing boats. Greater shaft angles may
affect speed, noise and vibrations negatively.

Check the shaft angle. If the shaft angle exceeds 12°,

the use of a smaller propeller should be considered.
This can be compensated by more blades or larger
blade surfaces.

The keel or the propeller shaft support forward of the

propeller must have a profile that provides a minimum
R2
of resistance and turbulence. Propeller tunnel shape is
R1 also extremely important. Poor propeller tunnel design
may create turbulence forward of, and around, the
propeller and reduce boat buoyancy at the stern. It is
crucial that the radius R1 at the beginning of the tunnel
is large enough so that turbulence in the propeller is
avoided.

Make sure there is sufficient clearance between the

propeller, hull, keel, keel strake and rudder. It must be
possible to slide the propeller shaft aft at least 200 mm
(8") to allow removal of the reverse gear or coupling.
Also make sure that no transverse bulkheads hinder
P0005810
removal. There must be sufficient play, approximately
1 x shaft diameter, between the propeller and the stern
bearing to prevent the propeller from pressing against
the stern bearing. There must also be space for line
cutters if such are to be fitted. See illustration, position
(E).

47704210 02-2018 © AB VOLVO PENTA 27

Arrangement and Planning, Choice of Engine

Minimum distance to hull, keel, keel strake

and rudder

d = Propeller diameter

A 0.10 x d
A
B 0.15 x d
E
C 0.10 x d
D 0.08 x d
E Approximately 1 x shaft diameter
F Shaft angle. If possible, avoid angles in excess of
12°.

Example:
C
Dimension (A) on a boat with a propeller diameter of
762 mm (30") is at least 0.10 x 762 = 76 mm (0.10 x
D B 30" = 3").
P0005812
Dimension (A) may never be less than 50 mm (2").
Classification authority requirements must be followed
when the boat is classified.

P0005813

Single and twin installations

A single installation is generally the most efficient
B method of propulsion. If more power is required, two
engines may be installed, each with a separate
F propeller shaft.
A
Twin installations and separate shafts provide better
E maneuverability as power can be controlled separately
P0005814 D and individually for each engine. For example, one
engine can be run astern and the other ahead when
maneuvering at low speed.

28 47704210 02-2018 © AB VOLVO PENTA

 Arrangement and Planning, Choice of Engine

Selection of gear ratios

The propeller shaft usually rotates more slowly than
the engine crankshaft. This reduction is normally
achieved in the reverse gear.

As a rule, the greatest possible reduction gear must be

selected for slow displacement boats. Thus propeller
diameter can also be relatively large with high thrust
within the applicable rpm range. Depending on hull
type and speed range, a lower gear ratio may be
selected for higher speed if required. Refer to the table.
This is in order to achieve the greatest thrust in the
chosen speed range. Thrust may be lower than
calculated optimal thrust if a non-recommended gear
ratio is selected. The boat's top speed may not
necessarily be affected.

Always check that the hull has sufficient clearance for

the propeller; refer to the information on the previous
page.

Engine speed range 3400 – 3500 rpm with a conventional shaft and propeller system
D4-180 engine Engine D4/D6 Main operational area Boat speed
Indicated rpm Indicated rpm
2700-2900 rpm 3400-3500 rpm
2.0:1–3.0:1 2.5:1–3.5:1 Commercial boats 7–15 knots
Displacement boats
Planing boats, low speed,
in general
1.5:1–2.0:1 2.0:1–2.5:1 Semi-planing to planing 16–30 knots
boats, patrol boats,
sportfishing and leisure
boats
1.5:1–2.0:1 Planing boats 25–40 knots
Patrol boats
sportfishing and leisure
boats

47704210 02-2018 © AB VOLVO PENTA 29

Arrangement and Planning, Choice of Engine
P0005923
A Single taper shaft
B Double taper shaft
30
Inboard engines
Propeller shafts
There are many things to take into consideration when
selecting a propeller shaft for a given application. Shaft
material and shaft dimensions must suit the individual
vessel design and application.
The shaft material must be strong and corrosion
resistant. Stronger materials have advantages in many
sport boat applications thanks to their smaller diameter
providing lower water resistance and turbulence for the
propeller.
Depending on its length, a shaft may require
supporting with bearings. The minimum distance from
the shaft coupling to the first fixed bearing must be 6
to 10 x shaft diameter. The distance must be sufficient
to allow the engine to move without subjecting the shaft
system to unreasonable stresses. The maximum
distance between bearings is determined by shaft
critical speed. This is calculated on the basis of the
installation type and shaft characteristics.
It is of the utmost importance during installation to
protect the shaft's precision straightness and polished
surface finish. When lifting shafts it is best to use lifting
straps with a load distribution device to avoid shaft
bending.
Always check propeller shaft straightness. Run-out
may not exceed 0.3 mm (0.012") from 100 percent
straightness per meter of shaft.
Propeller shaft dimensions and bearing distances
The propeller shaft must be dimensioned according to
the torsional and bending forces it will be exposed to.
There must also be a certain safety margin. The
maximum distance between bearings has great
influence on shaft dimension calculations.
Refer to the graph: check the Volvo Penta computer
program or ask the shaft supplier for advice when
deciding shaft dimensions and bearing distances.
The graph for calculating the distance between shaft
bearings (or propeller shaft support bearings) shown
here is based on the formula for shaft critical speed.
47704210 02-2018 © AB VOLVO PENTA

A The graph is applicable to stainless steel SIS 2324-02
0,6
P0005925
A Distance between bearings (m)
B Propeller shaft speed (rpm)
C Propeller shaft diameter (mm)
47704210 02-2018 © AB VOLVO PENTA
Arrangement and Planning, Choice of Engine
or equivalent.
Example:
Engine: D4, 210 hp
Engine speed: 3500 rpm
Gear ratio: 2.04:1
Shaft diameter: 45 mm
Material: Stainless steel SIS 2324‑02
Type of installation: Refer to the illustration,
alternative 1 in the Engine mounting section of the
Engine chapter. Installation, page 168
C Do the following:
1 Calculate shaft rpm: 3500/2.04 = 1 715 rpm
(approx).
2 Begin to the right of the graph, where the plot for
B the 45 mm shaft diameter begins.
3 Follow the plot to the left until it crosses the vertical
line for propeller shaft speed (1 715 rpm).
4 Draw a straight line to the left from this point (length
in meters). which gives a distance or 2.1 m between
bearings.
31
Arrangement and Planning, Choice of Engine

Reverse gear flange

N Hd T

Dd

Pcd
D

P0005928 A

Reverse gear D Pcd d T A N x Hd

HS45AE 127 108 ±0.2 63,5H8 10 -4.0* 4 x 11.5
HS63AE 127 108 ±0.2 63,5H8 10 -4.0* 4 x 11.5
HS63IVE 133 108 ±0.1 63,5H8 9.5 -4.0* 4 x 11.5
HS80AE 146 120.65 ±0.2 76,2g7 14 4.0 6 x 16.3
HS80IVE 146 120.65 ±0.2 76.2g7 16 3.2 6 x 13.0
HS85AE 146 120.65 ±0.2 76.2g7 16 3.2 6 x 16.3
HS85IVE 146 120.65 ±0.2 76.2g7 16 3.2 6 x 13.0

*) Female coupling, socket in flange plane. Dotted line

in illustration.

Coupling, flywheel housing: SAE 4

Flexible propeller shaft coupling

If the engine has flexible mounts and a fixed packing
box, the propeller shaft must be fitted with a flexible
shaft coupling.

NOTICE! Engine alignment is just as important with the

above equipment as it is with fixed couplings. The
flexible packing box and the flexible propeller shaft
coupling are not designed to absorb constant angular
deviations.

The flexible shaft coupling must be installed as

illustrated.

P0005931

32 47704210 02-2018 © AB VOLVO PENTA

 Arrangement and Planning, Choice of Engine

Packing boxes
There are several ways to lubricate the shaft seal. The
two most common are water-lubricated and grease-
lubricated packing boxes. Make sure it is easy to
maintain and inspect the packing box. Some packing
boxes require a certain play toward the reverse gear
flange to allow changing without disconnecting the
shaft.

Water-lubricated packing box

Water has two tasks in a water-lubricated packing box;
lubrication and cooling. Water can be fed to the water-
lubricated packing box in several ways. One method
suitable for displacement boats is to use water intakes
in the stern tube.
Feed tubes must be designed so that pressure is built
up by boat movement through water.
P0005932 When a new installation is test driven it is also
important to check that water lubrication functions
1 Shaft sealing
satisfactorily at full speed. Check that the feed tubes
2 Feed tube (2) provide sufficient water flow. Vent the installation
up at the shaft seal (1).

Coolant from engine

Another method common in planing boats is to provide
the packing box with water from the engine cooling
system. Replace the nipple in the charge air cooler with
the nipple illustrated to the left. The nipple is not
available as a Volvo Penta part; it must be
manufactured. Note that the zinc anode must remain
in place on the charge air cooler. This nipple prevents
excessive water drainage. If too much water is lost
through the shaft seal outlet, the exhaust hose may
overheat.
P0012309
Attach a hose with max diameter 12 mm (1/2") to the
T-connector and run it to the propeller shaft packing
box.

Ø12,5 ± 0,3 Propeller shaft water lubrication nipple

Ø10,5 ± 0,3 Use a M14x1,5 nipple with inner diameter of max 7,5
A-A mm (0.295"). Alternatively, machine a nipple according
± 0,5 Ø6,5 to the provided drawing.
A R3 These dimensions provide the correct flow for propeller
R2 shaft lubrication for both D4 and D6 engines. Hole
15±1 30 ± 1

±0
,5 length and diameter are important.
1 ± 0,2

Material: acid resistant steel. The nipple key diameter

must be 18 mm (0.71"). After machining, the nipple
must be free from burr.
Tighten the nipple to 8±1 Nm (5.9±0.7 lbf.ft).
15±1

55

A
°±

NOTICE! Boats that run at more than 15 knots must

5°

2x 1 ± 0,2x45° 2 ± 0,2
Ø12 ± 0,3 have external water cooling as described above for the
shafts and bearings. At lower speeds the natural
M14x1,5 6g
turbulence that forces its way via the feed tube in the
P0012308
shaft tube external intake (2). It is very important to
vent the shaft internally so that water reaches the very
end of the shaft.

47704210 02-2018 © AB VOLVO PENTA 33

Arrangement and Planning, Choice of Engine

Grease lubricated shaft seal

Grease is fed to the packing box either through a
grease nipple on the packing box, or from a separate
grease packer. The grease packer cover must not be
tightened too hard as this may cause propeller shaft
overheating and wear.

P0005934

Installation of propeller shaft tube and

shaft bearing
The fixed point (A) is determined among other things
by propeller size. The engine may be used as a fixture
when deciding the location of the stern tube and
bearing. The engine must be adjusted to its nominal
position.

In series production, custom-made fixtures can often

A
be used instead of the engine when positioning the
stern tube.

P0005935

Slide the propeller shaft into place and align the shaft
and stern bearing with the reverse gear output shaft
(reverse gear flange). To prevent the shaft from
bending in the stern tube, center the shaft as follows:
• Install the shaft bearing (1).
• Center the shaft (2) in the propeller shaft tube (3)
using wedge-shaped guides (4). The play between
the guides and the shaft must be 4 mm (0.16").
• Check that the shaft is not bent forward of the tube;
support the shaft as necessary.
• When putting the boat into operation, the rubber
shaft seal must be vented and greased according to
the instructions in the "Launching, Sea trials"
P0005936
chapter.

34 47704210 02-2018 © AB VOLVO PENTA

 Arrangement and Planning, Choice of Engine

Once accurate alignment has been achieved, the stern

tube may be bolted or glued in place.

If the stern tube must be bolted into the stern, the

bearing flange contact surface must first be ground flat.
Apply sealing compound e.g. silicone rubber, and
tighten the bearing retaining bolts.

NOTICE! Check the alignment after gluing.

Cut the propeller shaft to the correct length. Bear in

mind that the distance between the stern bearing aft
edge and the propeller must be 1 x propeller shaft
diameter (A = B).

P0005938

A Shaft diameter
B 1 x shaft diameter

There must be 2 mm (0.08") play between the shaft

forward end and the reverse gear flange (flexible
coupling).

P0005939

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Arrangement and Planning, Choice of Engine

Propeller Rotation
Inboard engines

A clockwise turning propeller is recommended for

single installations.

In twin installations the starboard propeller should

normally rotate clockwise and the port propeller
counterclockwise, seen from aft looking forward.
Otherwise there is a risk that air bubbles are drawn
down into the water between the two propellers
causing cavitation.

NOTICE! Refer to the Installation EVC-C3 installation

P0004880
manual for information about propeller rotation and
gear shift valves.

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 Arrangement and Planning, Engine Placement

Engine Placement
Engine Inclination
Inboard engines

To ensure that the engine receives lubrication and

cooling in a satisfactory manner, it is important that
maximum engine inclination is not exceeded. Engine
inclination must therefore be checked.

Be careful to avoid the front of the engine being lower

than the flywheel, i.e. an exaggerated negative
inclination that may impair engine lubrication and
cooling system venting.

Each engine type has a maximum permissible

engine inclination while the boat is under way. This
inclination includes both the installation angle and the
increase in trim angle the boat attains when moving at
speed through the water.
A Engine inclination with the boat at rest.
B Boat trim angle under way.
C Total engine inclination under way, maximum
permissible inclination (A+B).

P0005822

Max. engine inclination

Static Standard Flywheel Flywheel
Max 10° Max 0° lubrication downward upward
system Max inclination Max inclination
WL
Static 10° 0°
Under way 20° 10°

Under way
Max 10°
Max 20°

WL

Flywheel downward Flywheel upward

WL = Waterline

47704210 02-2018 © AB VOLVO PENTA 37

Arrangement and Planning, Engine Placement

Weight Distribution
Inboard engines

General
The location of the longitudinal center of gravity
(LCoG) is of great importance for trim angle at top
speed etc. Generally speaking, a fast boat has its
center of gravity further aft than a slower boat.

The center of gravity has great influence on a boat's

static and dynamic stability. It is therefore important to
consider CoG position both when the boat is loaded
and unloaded.

Planing and semi-planing hulls.

It is especially important in planing and semi-planing
hulls that heavy components such as engines, fuel and
water tanks and batteries be located so that the best
possible trim is achieved with the boat in the water.
A
Fuel and water tanks must be located longitudinally as
close to the center of gravity as possible in order that
the center of gravity is not moved when water and fuel
levels change.

It is an advantage not to locate the fuel tanks in the

vicinity of the hot engine compartment. If possible, the
B batteries must be located in a separate, well ventilated
P0005831
section.

Engine distance, twin installation

Figure A shows an installation with good weight distribution and trim
angle.
Figure B shows an incorrect installation with poor trim angle as the
result.
Consideration must always be given for the minimum
distance between engine centerlines in a twin
installation, in regard to service accessibility.
Moreover, a greater distance provides improved
maneuvering characteristics.

Use the installation drawings to calculate a suitable

distance.
A Generally speaking, the minimum recommended
distance (A) between engine centerlines is 950 mm
(37").

P0005862

38 47704210 02-2018 © AB VOLVO PENTA

 Arrangement and Planning, Engine Room

Engine Room
Accessibility for Maintenance
When designing the engine installation, place great
emphasis on engine service accessibility. Also ensure
that the complete engine can be lifted out without
damage to the boat structure.

NOTICE! There must also be sufficient space for

sound-dampening materials. The recommended
minimum distance from sound-dampening materials is
180 mm (7") (A) and 200 mm (8") (B); see illustration.

Aquamatic only
Carefully study the installation drawings for the engine
concerned. The minimum distance between engines in
a twin installation is 950 mm (38").

Removal of complete engine assembly

If it is necessary to remove the entire engine assembly
from the vessel, it is the responsibility of the installer
(boat builder) to arrange reasonable means for
removal and re-installation. This means removal within
a moderate amount of time using normal resources
and methods available to the industry to limit costs and
operational downtime. It is Volvo Penta policy to avoid
installations that involve extra costs for boat owners
during the lifetime of the boat.

Considering the great demand placed on boatyards

etc. during high season, the boat builder's instructions
must be followed.

47704210 02-2018 © AB VOLVO PENTA 39

Arrangement and Planning, Engine Room

Aquamatic

P0007461

General maintenance Repairs

Items that require maintenance accessibility: Items that require repair accessibility:
• Coolant (A) • Removal of injectors, cylinder head, radiator
etc.
• Oil change and filling (engine (B), power
steering and Powertrim) • Removal or exchange of electrical components
• Filter changes (oil, fuel, air and crankcase • Removal of flywheel and vibration damper
breather)
• Removal or exchange of steering equipment
• Drivebelt change and adjustment/tensioning
• Measurement at diagnostic points
• Removal of valve cover
• Changing impeller, seawater pump
• Water filter, cleaning

40 47704210 02-2018 © AB VOLVO PENTA

 Arrangement and Planning, Engine Room

Inboard

P0005832

General maintenance Repairs

Items that require maintenance accessibility: Items that require repair accessibility:
• Coolant (A) • Removal of injectors, cylinder head, radiator
etc.
• Oil change and filling (engine (B), and reverse
gear) • Removal or exchange of electrical components
• Filter changes (oil, fuel, air and crankcase • Removal of flywheel and vibration damper
breather)
• Removal or exchange of reverse gear
• Drivebelt change and adjustment/tensioning
• Removal of propeller shaft
• Removal of valve cover
• Changing impeller, seawater pump
• Water filter, cleaning

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Arrangement and Planning, Engine Room

Engine Room Ventilation

Engine performance
Engine power is affected by a number of different
factors. Among the most important are air pressure, air
temperature and exhaust system back pressure.
Deviations from normal values influence engine
performance and function.

Diesel engines require a surplus of air. Deviations from

normal values first present themselves as more black
smoke than usual. This may be especially noticeable
at the planing threshold when the engine must deliver
the highest possible torque.

If deviations from normal values are great, the diesel

engine will lose power. The power loss may be so great
that a planing boat is unable to overcome the planing
threshold.

In order for the engine to function properly and provide

full power, it is absolutely essential that both inlet and
outlet air ducts are dimensioned and installed
correctly.

Two main conditions must be met:

1 The engine must receive sufficient air (oxygen) for
fuel combustion.
2 The engine compartment must be ventilated such
that the temperature can be kept at an acceptably
low level.

Ventilation is also important to keep the temperature

of engine electrical and fuel systems low, and to
guarantee normal engine cooling.

Ventilation must also be suitably adapted if crew

members will be present in the engine compartment.

NOTICE! Current national safety regulations and

legislation must be followed. Each classification
society has its own rules that must be followed as
required.

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 Arrangement and Planning, Engine Room

Performance in high altitude operations

In most cases marine engines are used at, or close to,
sea level. However, there are lakes at high altitudes
above sea level.

Operations at high altitudes entail a power loss owing

to a drop in air density – and thus oxygen levels – as
altitude increases. This will result in the development
of smoke and the turbocharger running at abnormally
high rpm with increased wear.

At altitudes in excess of 500 m (1640 ft) above sea

level, power loss is around 2% per 100 m (328 ft). This
applies at “normal” atmospheric pressure; during
periods of low pressure engine performance is
impaired further.

NOTICE! Great attention must be paid to the engine

choice for boats that will be operated at high altitudes.
This is especially noticeable during major power
demands when the boat is passing its planing
threshold or performing at maximum power. It
influences the choice of propeller.

NOTICE! D4 and D6 engines are not suitable for

operations at altitudes above:

D4 180 3,000 m (9.900 ft)

D4 225 2,000 m (6.600 ft)
D4 260 2,000 m (6.600 ft)
D4 300 1,500 m (5.000 ft)
D6 300 2,000 m (6.600 ft)
D6 330 2,000 m (6.600 ft)
D6 370 1,500 m (5.000 ft)
D6 400 1,500 m (5.000 ft)
D6 435 1,500 m (5.000 ft)

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Arrangement and Planning, Engine Room

Dimensioning of air intake and

ducts
The following fundamentals must be included in
calculations when planning an installation:
• All combustion engines, regardless of manufacture
or type, require a certain level of oxygen (or air) for
the combustion process. However, diesel engines
work with a somewhat larger air surplus than
gasoline engines.
• Furthermore, all engines emit a certain amount of
heat to the surroundings, i.e. the engine
compartment.
• Heat radiation is smaller on modern, compact
engines than on older, less compact engines.
Modern engines enjoy a great advantage in this.

Ducts and pipes for inlet and outlet air

It is an advantage if ducts and pipes for inlet and outlet
air can be planned as early as the design stage, as they
can then be built into the hull or superstructure. This
eliminates the requirement for separate ducts.

It is relatively simple to design a system for providing

the engine with a sufficient quantity of combustion air,
but significantly more difficult to ventilate heat radiation
away.

The engine draws in air efficiently and naturally takes

it from whatever direction it can. If inlet and outlet ducts
are too small, the engine will draw in air from both ducts
and no ventilation air will be expelled through the outlet
duct. This will create dangerously high temperatures in
the engine compartment.

Most of the engine heat radiation must be carried away

from the engine compartment. It is a mandatory
requirement to keep engine compartment temperature
below the maximum permissible limit.

Engine temperature
It is important that inlet temperature be kept as low as
possible bearing in mind that engine performance
figures apply at a test temperature of +25 °C (+77 °F).

Inlet air temperature at the air filter may not be higher

than +25 °C (+77 °F) for full power. During sea trials
the temperature in the air filter must not be higher than
20 °C (36 °F) above the outside temperature.
Power losses at temperatures above 25 °C are approx
1% per 10 °C.

Actual engine temperature is relatively high in certain

places. Certain individual engine components such as
charge regulators and relays must therefore be
installed on bulkheads or other locations where the
temperature is relatively low.

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 Arrangement and Planning, Engine Room

Maximum temperature at electrical component

installation locations is 70 °C (158 °F). However, the
starter motor and alternator have their given locations.

Engine compartment pressure

Volvo Penta recommends that the negative pressure
in the engine compartment not fall below –0.5 kPa (–
0.07 psi) at full speed. A slight negative pressure in the
engine compartment is not harmful and it prevents
gases from being forced out of the engine
compartment into other boat spaces.

Coefficient of bends Engine air consumption

The engine consumes a certain amount of air during
Duct length, m (ft.) the combustion process. This requires the inlet duct to
Quantity 1 2 3 4 5 have a certain internal cross-sectional area.
bends (3.3) (6.6) (9.8) (13.1) (16.4)
This area can be calculated using the formula:
1 1 1,04 1,09 1,13 1,20 A (cm2/in2) = 1.9 × engine power
2 1,39 1,41 1,43 1,45 1,49 The value applies to inlets up to 1 m (3.3 ft) long with
3 – 1,70 1,72 1,74 1,78 only one 90-degree bend. The bend radius must be at
least twice duct diameter.

If longer ducts or more bends are used, the area must

be corrected by multiplying with the coefficient in the
table below.

Correction factor Engine compartment ventilation

In addition to its air consumption, the engine radiates
Outside temperature °C Correction factor
heat. Heat radiation must be carried away from the
(°F)
engine compartment in order to keep the temperature
+20 (68) 0,7 down to permissible levels.
+30 (86) 1,0 The same dimensions must be chosen for the outlet
+40 (104) 1,4 and inlet channels in order to achieve low flow speeds
and low noise levels.

Calculation of area
Ventilation inlet/outlet cross-sectional area (cm²/in2) is
calculated according to the following formula:
Inlet air = 1.65 × engine power (kW)
Outlet air = 1.65 × engine power (kW)

However, these values must be corrected in

accordance with the table in regard to bends and duct
length. Outdoor temperature is assumed to be +30 °C
(86 °F). Correction factors in the table must be used
where applicable.

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Arrangement and Planning, Engine Room
Air duct calculation examples
Example 1: Two D6 diesel engines, 228 kW (310
hp)
Calculation of areas for two 228 kW engines with an
unlimited airflow and an outside temperature of +30
°C (+86°F).
Air temperature correction = 1.0 (refer to the
Correction factor table).
The following is obtained for each engine:
Area for engine air consumption: 1.9 × 228 = 434
cm2 (67 sq.in).
The area 434 cm² (67 sq.in) gives a duct diameter of
235 mm (9.3") for a single installation.
Ventilation, engine compartment:
1 Inlet, engine compartment: Area = 1.65 × 228
= 376 cm2 (58 sq.in). This gives a diameter of
215 mm (8.4") for a single engine.
2 Outlet, engine compartment: Area = 1.65 ×
228 = 376 cm2 (58 sq.in). This gives a diameter
of 215 mm (8.4") for a single engine.
3 Capacity, extraction fan: 0.07 × 228 (kW) =
16.0 m3/min (570 ft3/min).
4 NOTICE! Multiply the numbers by 2 in the case
of a twin installation.
46
Example 2: One D4 diesel engine, 155 kW (210 hp)
Area calculation for one engine with a 2 m (6.6 ft) long
duct, 2 bends and an outside temperature of +20 °C
(+68 °F).
Area for engine air consumption: 1.9 × 155 = 294
cm2 (46 sq.in).
Air temperature correction = 0.7 (refer to the
Correction factor table).
Correction for duct length and bends = 1.41 (refer to
the Bend coefficient table.).
This gives 294 × 0.7 × 1.41 = 290 cm2 (45 sq.in). The
area 290 cm2 (45 sq.in) corresponds to a duct
diameter of 190 mm (7.5").
Ventilation, engine compartment:
1 Inlet, engine compartment: Area = 1.65 × 155
= 255 cm2 (40 sq.in). This corresponds to a duct
diameter of 178 mm (7.0").
2 Outlet, engine compartment: Area = 1.65 ×
155 = 255 cm2 (40 sq.in). This corresponds to a
duct diameter of 178 mm (7.0").
3 Correction, inlet and outlet:
Air temperature = 0.7
Correction for duct length and bends = 1.41l .
This gives 255 × 0.7 × 1.41 = 252 cm2 (39 sq.in).
This corresponds to a duct diameter of 175 mm
(6.9") for each inlet and outlet.
4 Capacity, extraction fan: 0.07 × 155 (kW) =
11.0 m3/min (388 ft3/min).
47704210 02-2018 © AB VOLVO PENTA
 Arrangement and Planning, Engine Room

Choice of fan
Normally an extraction fan must be installed in the
outlet duct to ventilate the engine compartment more
efficiently and thus keep engine compartment
temperature low.

Conversely, fans may never be installed in the inlet

duct as this may lead to engine compartment
overpressure, with the risk of gases or air leaking into
other parts of the boat.

For diesel engines the fan may often be thermostat

controlled; it must start at an engine compartment
temperature of around +60 °C (+140 °F), measured in
the engine compartment.

The fan must be dimensioned for airflow according to

the following:
Outlet air = 0.07 x engine power

Airflow volume in m3/min

Engine power in kW. The total pressure increase at the
fan must be 10 mm (0.39") water gauge (100 Pa).

These two values, flow and total pressure increase, are

sufficient for selecting a fan. If the fan is installed
directly on the bulkhead, i.e. without a connecting duct,
the total pressure increase value may be reduced by 7
mm (0.28") water gauge (70 Pa). This means that a
somewhat smaller fan may be used.

NOTICE! Fan hose connections for diesel engines

must be located as high up in the engine compartment
as possible to carry away hot air, but as low as possible
for gasoline engines to carry away fumes.

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Arrangement and Planning, Engine Room

Location of Ventilators and Air

Intakes
NOTICE! Air inlets and outlets may never be located
on the transom. Air in this area mixes with water and
exhaust fumes, and must never be allowed into the
boat.
5 Air inlet function
3
Air inlets and outlets must function well even in bad
weather and must therefore have efficient water traps.
For the most part noise insulation must be built in.
4 Air inlets and outlets must be located as far away from
1 each other as possible so that an effective through flow
is achieved.

If inlets and outlets are too close to each other air is

able to recirculate, which will provide inadequate
2 ventilation.

Location of air ducts

P0004733 Ducts or pipes for engine air supply must be run to a
place as close to the air filter as possible, but with a
1 Engine air filter minimum distance of 20–30 cm (8–12") in order to
2 Inlet duct, engine compartment definitely prevent water from entering the engine.
3 Ventilation Refer to the illustrations.
4 Water trap Example of how inlet and outlet air ducts may be
5 Extraction fan installed in leisure craft and similar hulls with diesel
engines.

The inlet ventilation duct for diesel engines must be led

deep into the engine compartment, but not so deep
that any bilge water is able to block air supply. The
outlet duct must be located diametrically opposite on
the other side of the engine.

All ducts and pipes must be run such that there is the
least possible flow resistance. Bends may not be
sharp, but must be moderately rounded. The minimum
radius is double the diameter. Obstacles or
constrictions must always be avoided.

The ducts must be cut obliquely at the ends to provide

best flow.

In certain countries there are special regulations that

must be followed.

If it is not possible to arrange drainage, ventilation

hoses must be bent upwards somewhat in order to
form a gooseneck that prevents seawater forcing its
way into the engine compartment. Remember to build
P0004734
the engine compartment as spaciously as possible to
facilitate engine service.

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 Arrangement and Planning, Sound Absorption

Sound Absorption
The drive assembly must be installed so that noise and
vibrations are minimized. The noise that occurs is party
airborne noise and partly structural noise (vibrations).

Structural noise
Engine vibrations are transferred to the hull via the
engine mounts and engine bed. Other transfer routes
are through the transmission and propeller system,
exhaust pipes, coolant pipes, fuel pipes and electrical
and control cables.

Propeller pressure waves are transmitted through the

water to the hull. Propeller drive pulses are transferred
to the hull via support brackets, bearings and seals.

Airborne noise
This section concerns airborne noise from the engine
compartment. The most important method of reducing
airborne noise from the engine compartment is to seal
it properly. Further noise reductions can be achieved
by laying sound insulation material and by designing
noise baffles in the air inlets.

The engine installation must be noise insulated to

provide as low a noise level as possible. Build noise
baffles into the engine compartment. There are
different types of noise baffles to choose from. The
illustration shows a type that also provides drainage.

It is important to ensure that the insulation material is

sufficiently thick.

The greatest possible care must be taken to screen the

noise source as much as possible. Screen off the entire
bulkhead down to the hull, but leave a little gap so that
bilge water does not force its way into the insulation
material.

Engine compartment noise baffles

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Arrangement and Planning, Sound Absorption

Cracks and openings etc. must be carefully sealed with

insulation material. In cases where the engine is
installed beneath the deck, all bulkheads and decks
must be insulated.

Make sure that there is sufficient space for inspections,

service and repairs and for engine movement during
operations before the insulation material is installed.
Also make sure that all covers are properly insulated.

A Min. 180 mm (7”)

B Min. 200 mm (8”)

P0004738
Check cover sealing

P0006333

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 Arrangement and Planning, Sound Absorption

Examples of insulation material design are shown

below. This type of insulation material is glued to the
frame.

P0004739
Insulation material installed on GRP:

Insulation material installed on wood (plywood): 1 GRP

1 Wood (plywood) 2 Iron/PVC, thickness 2.5 mm (0.1”)

2 Flameproof absorbent layer 3 Flameproof absorbent layer

3 Flameproof, reflective and noise insulating foil 4 Flameproof, reflective and noise insulating foil

NOTICE! The insulation materials look different

depending on the material the frame is made of - GRP
or wood.

When electrical cables are run through a bulkhead, it

is advantageous to run them through a conduit or
grommet that can be sealed properly. This also
protects the cable against wear.

Bulkhead bushings

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Arrangement and Planning, Sound Absorption

Fuel hoses that are run through bulkheads must be

protected by grommets. The grommet seals and
protects the hose against sharp edges that may cause
leaks.

Other lines such as electrical and battery cables can

be run through a rubber hose or a special PVC pipe
(installation pipe) built into the hull. Any gaps between
the pipes and the cables can be sealed with insulating
material or sealing compound.

Fuel hose protected by a grommet

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 Arrangement and Planning, Electrochemical Corrosion

Electrochemical Corrosion
General
NOTICE! Refer to the Service handbook Corrosion
measurement, DPH/DPR & IPS for further information.

Corrosion theory
Corrosion in water is always electrochemical in nature.
This means that a weak electric current occurs at the
same time as chemical reactions takes place. Two
chemical reactions are required to make a metal
corrode, an oxidation reaction (metal dissolving) and a
reduction reaction (generally oxygen consuming).
Oxidation is referred to as an anode reaction and
reduction is referred to as a cathodic reaction. In an
oxidation reaction, electrons are freed which are
transported in the metal to another point, where they
are consumed in a cathodic reaction.

Electrons are thus transported in the metal from the

anode to the cathode. This causes a weak DC current
Fe Fe2+ +2 e- ANODE in the opposite direction. An electric circuit must be
closed. This is achieved by the transport of ions in the
water.

O2 + H2O + 2 e 2 OH-
CATHODE

P0011416

Anodic and cathodic reactions must always balance

each other, which means that the electrons released
at the anode must be consumed at the cathode. If the
anodic and cathodic reactions occur evenly distributed
across the entire surface, general corrosion occurs.
I The depth of attack then becomes basically equal
across the entire surface. This commonly occurs on
steel and bronze.

P0011417

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Arrangement and Planning, Electrochemical Corrosion

If the anodic and cathodic reactions occur at different

points, local corrosion occurs, i.e. deeper attack at
certain points. The attacks on materials which can be
passivated, such as stainless steel and aluminum are
generally localized. There are different types of local
corrosion. The most common types of attack on
stainless steels and aluminum are pitting corrosion and
crevice corrosion.

In addition to these local attacks, attack can be caused

by galvanic corrosion or stray currents. In areas where
rapid water flow occurs, damage caused by cavitation
and erosion can also occur.

If we ignore attacks related to material defects, the

following types of corrosion can occur:
- General corrosion.
- Pitting.
- Crevice corrosion.
- Galvanic corrosion.
- Stray current corrosion.
- Cavitation.

A brief description of each type of corrosion is given

below.

General corrosion
General corrosion is the most common type of
corrosion. This results in even attack across all or large
parts of the surface.

In seawater, mild steel and bronze are subject to

general corrosion, but not stainless steel. In stationary
seawater, the corrosion rate of mild steel is about 0.1
mm/year (0.3 mm/year at the waterline) unless the
steel is protected by cathodic protection. Bronze is
initially attacked at a rate of 0.05 mm/year, but after
some time the corrosion rate falls to a low level, since
the corrosion products (black, brown) have a protective
effect. Green/blue corrosion products are a sign of
higher corrosion rates and that the protective layer has
p0011418
not been developed.

Aluminum can be subject to a certain amount of

general corrosion in rapidly flowing water, but not in
stationary water.

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 Arrangement and Planning, Electrochemical Corrosion

Pitting corrosion
Pitting corrosion can occur on stainless steel and
aluminum. The attack is caused by localized
breakdown of the passive oxide film on the metal
surface. In natural water, it is generally chloride ions
that initiate the attack. The risk increases with rising
water temperatures. There is a number of aluminum
alloys with very good resistance to corrosion by
seawater. If these are connected together with more
noble metals, they will be attacked due to galvanic
corrosion, however.

Very high levels of chromium and molybdenum are

p0011419
required, above all, to make stainless steel fully
resistant to the risk of pitting corrosion. If there is weak
cathodic protection (sacrificial anodes), excellent
protection against pitting corrosion can be obtained on
simpler steels. Alloys of lower grades than 316 should
be avoided, however.

Crevice corrosion
An attack in the gap between two metal surfaces, or
between one metal surface and another materials is
called crevice corrosion. A so-called oxygen depletion
cell is formed when oxygen transport into the crevice
is lower than oxygen transport out to the cell opening.
Separate anodic and cathodic surfaces are formed.

The cathodic process, which requires access to

oxygen, is formed in the gap opening and the anodic
process, metal dissolving, takes place inside the gap.
Crevice corrosion can occur on most metals, but the
risk is greatest on metals that can be passivated, such
as aluminum and stainless steel.

p0011420 Deposit corrosion is closely related to crevice

corrosion. It takes place under deposits and marine
fouling such as barnacles.

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Arrangement and Planning, Electrochemical Corrosion

Galvanic corrosion
Metals From To Galvanic corrosion is probably the most common
Graphite +0,19 +0.25V type of corrosion. It occurs when two metals of
different nobility are in electric contact and are
Stainless steel 18‑8, Mo, ±0,00 -0.10 V
submerged in the same body of water at the same
in passive state *
time. The least noble metal is corroded.
Stainless steel 18‑8 in ‑0,05 -0.10 V
passive state *
Information about the nobility of different metals is
Nickel ‑0,10 -0.20 V obtained from galvanic potential tables which have
Nickel-aluminum-bronze -0,13 -0.22 V been prepared in various fluids, such as seawater.
Lead ‑0,19 -0.25 V See table to the left:
Silicon bronze (Cu, Zn, Si, ‑0,26 -0.29 V There are four factors which influence the
Mn, Sn) seriousness of galvanic corrosion in each individual
Manganese bronze (Cu, ‑0,27 -0.34 V case. These are:
Zn, Si, Mn, Sn)
- Area relationship between the anode (less
Aluminum brass (Cu, Zn, ‑0,28 -0.36 V noble metal) and the cathode (more noble
Al) metal). If the anode is small in relation to the
Solder (Pb, Sn) ‑0,28 -0.37 V cathode, the depth of attack will be greater than
Copper ‑0,30 -0.57 V if the situation was reversed.
Tin ‑0,31 -0.33 V - Conductivity of the water. Seawater conducts
Red brass (Cu, Zn) ‑0,30 -0.40 V electricity better than fresh water, and corrosion
takes place at a greater rate.
Yellow brass (Cu, Zn) ‑0,30 -0.40 V
Aluminum bronze ‑0,31 -0.42 V - Potential difference between the two metals. A
large potential difference increases the power
Stainless steel 18‑8, Mo, ‑0,43 -0.54 V
behind the process.
in active state **
Stainless steel 18‑8 in ‑0,46 -0.58 V - Lower corrosion rate can be obtained if the
active state ** more noble metal can be passivated. This
means that stainless steel is more noble than
Cast iron ‑0,60 -0.71 V copper, but the galvanic corrosion will be more
Steel ‑0,60 -0.71 V severe on aluminum when connected to copper
Aluminum alloy ‑0,76 -1.00 V than when connected to stainless steel.
Galvanized iron and steel ‑0,98 -1.03 V
Zinc ‑0,98 -1.03 V In seawater, total galvanic corrosion counted in
grammes of metal, will be greater than in water which
Magnesium and ‑1,60 -1.63 V
is not so salt. The greatest depth of corrosion on a
magnesium alloy
metal can be equally large in brackish or fresh water.
consumed
The better conductivity of seawater means that the
attack will be distributed evenly across the entire
* Metals are in a passive state when they have a thin, surface. In fresh water, there will be more local attack
corrosion inhibiting coating. This coating is not close to the point of contact.
present in the active state.
** Still water.

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 Arrangement and Planning, Electrochemical Corrosion

1 The following should be considered, to counteract

galvanic corrosion:
- Do not connect metals which are far away from
each other in the galvanic potential table.
- Insulate different metals from each other by
cathode anode using plastic or rubber (must not contain
graphite).
2 - Paint the structure. The surface of both metals
should be painted. If painting is restricted to only
the less noble metal, heavy galvanic corrosion
could occur on surfaces where there is paint
damage. The reason for this is that the cathode/
anode relationship will be unfavorable.
cathode anode - Install cathodic protection.
P0011421

1 Seawater
2 Fresh water

Stray current corrosion

1200 As we learned in the corrosion theory chapter,
1000 corrosion occurs when a DC current flows into the
water from a metal surface. Similar stray currents from
cm3/Ampere

800
the drive can occur if there is a fault in the boat’s
600 electrical system, such as if couplings are exposed to
400 dirt and moisture, components are incorrectly installed
or damaged. Stray currents can come from shore
200
current installations or adjacent boats. All metals,
0 except a few noble metals, are corroded by stray
CU AC

FE DC

FE AC
AL DC

CU DC
AL AC

currents. Corrosion rates can be very high.

The sacrificial anodes on the drive are not

P0011422
dimensioned to counteract any stray currents. If stray
currents occur, the anodes will be consumed very
quickly and the drive will be attacked.

Aluminum is particularly vulnerable to stray currents. If

the current density on the surface is high, corrosion can
also occur when there is a stray inwards current. AC
currents can also cause damage. The AC corrosion
rate for aluminum is 30% of the rate for DC. The
corresponding rates for steel, copper and zinc are
much lower, at 1 %. Please refer to the figure to the
left.

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Arrangement and Planning, Electrochemical Corrosion

Corrosion protection
Drives are protected from corrosion by a number of
measures.
- Alloys which are resistant to salt water.
- Avoidance of unsuitable combinations of metals.
Where appropriate, a favorable relationship
between anode and cathode is established.
- High quality surface treatment.
- Cathodic protection.
- Carefully designed electrical system.
- Recommendations to minimize external
interference.

Recommendations from Volvo Penta and anti fouling

manufacturers must be followed. In addition, the
material must be resistant to the alkali that is formed
on cathodically protected surfaces.

Cathodic protection is arranged by supplying a weak

DC current from an anode to the protected object. The
current which leaks in counteracts the corrosion
current. The higher the protection current, the lower is
the rate of corrosion.

Zn

P0011424

The current required for protection can be generated

in two ways. These are either with sacrificial anodes or
by applying a current. If sacrificial anodes are used, the
current is generated by connecting the protected
object with a less noble metal (anode). The difference
in electric potential creates a protective galvanic
current. It can be said that corrosion is transferred to
Zn the anode, which is why they are referred to as
sacrificial anodes.

P0011425

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 Arrangement and Planning, Electrochemical Corrosion

If a current is applied, this is supplied from an external

source (rectifier, battery).

The materials used in sacrificial anodes are zinc,

aluminum, magnesium and iron. Please note that
special alloys are used, to meet the following
requirements:
- No passivation, i.e. they do not stop supplying
current.
- Even consumption.
P0011426 - Low polarization tendency, i.e. they retain a
sufficient potential difference to the object.
- Low self-corrosion.

Only use original anodes. Never paint over the anodes.

Iron anodes can be used to protect stainless steel and

bronze objects. Magnesium anodes can be used in
fresh water where the current supplied by zinc anodes
may not be enough in some cases. Please note that
magnesium anodes give overprotection to aluminum
in seawater. There is no risk of overprotection of
aluminium if zinc or aluminum anodes are used for
protection.

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Anodes to use
Anodes are installed from the factory on all Volvo
Penta drives and transom shield. Anodes are
manufactured for different environments and will react
to those. There are some general recommendations
when choosing anodes. See chart below.

Zink and Aluminium anodes will if used in fresh water

become covered with white crust of oxide which will
stop the anode from working when returned to salt
water. Zinc anodes react the same way in brackish
water while the Aluminium anodes will work effectively
in rivers estuaries and other brackish conditions.

Magnesium anodes are not designed for use in salt

water so if you are taking your boat into salt water for
more then 7 days you should consider changing the
anodes. The same can also be applied for zinc and
aluminium anodes if moving your boat between
different waters.

It is important to inspect the anodes after shifting

waters and if necessary also clean the anodes. The
anodes can also be pacified just by being away from
water. If the drive has been tilted or for example placed
on a trailer for some time make sure to take a look on
the anodes.

If an anode for example looks yellow or is covered in

white crust it has been pacified and needs to be
cleaned or changed to provide protection. This can be
done using sandpaper.

NOTICE! Never use a wire brush with steel bristles.

Use sand paper without iron or iron oxide otherwise the
anode might be pacified.

Make sure to inspect the anodes on a regular basis and

change them if more then 1/3 has been used up by
corrosion. All anodes do not share the same quality!
Always use anodes produced by Volvo Penta since
they have been tested to ensure maximum protection
on stern drives and props.

Anode Material Water condition

Transom shield Zinc Salt water
Sterndrive Zinc Salt water
Transom shield Aluminum Brackish water
Sterndrive Aluminum Brackish water
Transom shield Magnesium Fresh water
Sterndrive Magnesium Fresh water

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Definitions
Single-pole system
In a single-pole system the actual engine block is used
as the negative ground return for all components on
the engine block.

Two-pole system
In a two-pole system each electrical component on the
engine has an insulated direct current ground return.
The alternator, starter motor and all sensors/senders
are electrically insulated from the engine block.

NOTICE! D4 and D6 engines are supplied with a

braided ground strap between the starter motor and
engine block. The battery negative terminal (-) is not
connected to the engine block.
Both types of engine are two-pole and must be
installed accordingly.

Kits are available that enhance the isolation between

the engine block and electrical ground.

Isolation transformer
A transformer with galvanically separated input and
output windings.

The isolation transformer separates galvanic shore

power from the boat and reduces the risk for galvanic
corrosion and stray current corrosion as described in
ABYC circuit diagram 8 and text E-11.7.2.2.1.4 thru 5.
Corrosion damage caused by stray currents will not be
compensated for under warranty.

Ground fault circuit interrupter (GFCI)

A health and safety protection device, the GFCI cuts
the current to a circuit when current to ground exceeds
a predetermined value.

Spark generation between live conductors and ground

may occur at relatively low currents and will not trip
circuit breakers. Moreover, very low currents may also
constitute a danger for personnel. A GFCI must be
installed on the other side of the isolation transformer
as ground fault protection in the boat. GFCI tripping
sensitivity and tripping times must meet local
standards.

A GFCI located on the other side of the isolation

transformer safeguards ground fault protection in the
boat. This is supplement to ABYC E-11 that ensures a
higher level of protection against electric shock.

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Protection against electrochemical

corrosion
In order to avoid galvanic corrosion to underwater
components such as hull fittings, swim ladders etc., it
is important that they be protected. Volvo Penta
recommends connecting all components to a
protection anode (normally made of zinc) installed on
the transom. Trim tabs may have their own protection.

NOTICE! Normally, the system connecting individual

components must not have any contact with the
negative circuit in the boat electrical system.

Local recommendations, e.g. ABYC, may state that the

battery negative terminal be connected to the galvanic
circuit. If the galvanic circuit is connected to the battery
negative terminal (-), the engine block must also be
connected by a cable of a capacity sufficient to conduct
current at engine start; refer to the description in ABYC
chapter E-11.

P0008280

Inboard engines

IMPORTANT!
If there is a risk for galvanic corrosion and stray current
corrosion, an isolation transformer must be installed.

If the negative battery terminal is connected to the

galvanic circuit as recommended by ABYC, the risk for
galvanic corrosion and stray currents increases.

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DPH/DPR sterndrives
The DPH/DPR sterndrive is manufactured in aluminum
and is protected against galvanic corrosion by its own
protection anodes. The DPH/DPR sterndrive
protection anode only protects the actual drive and
may not be connected to other components below the
water line.

If the engine has a braided ground strap installed

between the starter motor and engine block, any other
metal objects connected to the DC negative terminal
must be fitted with their own cathodic protection
system.

Protection against electrostatic

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.

In particular, the publications IEC 60092-507:2000

Electrical installation in ships Part 507: Pleasure craft,
and ABYC Standards and guidelines H-33 and E-4
may prove helpful.

Bottom Painting
Aquamatic

10mm When bottom paint is applied to the hull, a 10–15

mm (0.4–0.6") border must be left around the transom
shield.

P0008330

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Shore supply and alternator installation

Example of an installation with isolation
transformer
For installation, refer to local regulations.

Single phase, 240 VAC system

16 15

21 19 17
24 23 22 20 18

14

5 6 7
4 8

1 2 3 9
11 12 13
10
P0004769

1 Phase
2 Zero
3 Protective ground
4 2-pole, 3-wire grounded contact and female socket
5 Shore side
6 Boatside
7 Transformer shield
8 Alternator circuit breaker
9 Alternator (accessory)
10 To DC negative buss and ground plate, boat
11 Phase
12 Zero
13 Protective ground
14 240 VAC ground, female socket
15 240 V AC apparatus
16 Separate circuit breaker (typical)
17 GFCI
18 Changeover switch, land / alternator
19 Encapsulated single-phase 1:1 isolated transformer with metal shield
20 Main switch, shore power, with overvoltage protection
21 Power supply (isolated electrically from boat)
22 Connector, shore power cable
23 Shore supply cable
24 Shore connection

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Two-phase, 120/240 VAC primary, 120/240 VAC secondary

18
19
27 26 25 24 23
22 21 20

17

6
5 7 8
9

1
2 34 10 12 13 14 15
P0004770 11 16

1 Phase
2 Zero
3 Phase
4 Protective ground
5 3-pole, grounded pin-type connector and 4-conductor socket
6 Shore side
7 Boatside
8 Transformer shield
9 Circuit breaker, alternator
10 Alternator (accessory)
11 To DC negative buss and ground plate, boat
12 Phase
13 Zero
14 Phase
15 Protective ground
16 240 VAC apparatus
17 120 VAC ground, female socket
18 120 VAC apparatus
19 Separate circuit breaker (typical)
20 GFCI
21 Changeover switch, land / alternator
22 Encapsulated single-phase 1:1 isolated transformer with metal shield
23 Main switch, shore power, with overvoltage protection
24 Power supply (isolated electrically from boat)
25 Connector, shore power cable
26 Shore power cable
27 Shore connection

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Recommendations Shore power

In regard to personal safety and equipment care,
Volvo Penta provides the following recommendations
for the installation of AC shore power:
Installations should be carried out according to figures
above.
Single phase, shows a single-phase installation for
240 VAC or 120 VAC.
Two-phase, shows an installation with a 240 VAC
input, 120/240 VAC output.
The figures are based on ABYC E-11 diagrams 8 and
11 but require a GFCI and an isolation transformer.
The figures are considered to be best practice and
follow recommendations from ABYC and ISO, and
offer protection against electrochemical corrosion and
electric shock.
When shore power (120/230 V) is connected, shore
power ground protection must not be connected to the
engine or any other grounding point in the boat. Shore
power ground protection must always be connected
to the shore power connection box ground. Shore
power ground protection in the boat must be
galvanically separated.
WARNING!
Work on the low voltage circuits in the boats should
be done by a person with electrical training or
knowledge. Installation or work on land current
equipment must only be done by a competent
electrician, in accordance with local regulations for
mains electricity.

The safety-related components are important for the Battery charging

following reasons:
Battery chargers directly connected to a shore
Isolation transformer connection must be of the type “Full Transformer”
Refer to Definitions, page 61 for further information. (galvanically separated windings) in order to reduce
the risk for galvanic corrosion and stray current
GFCI corrosion.
Refer to Definitions, page 61 for further information.

Ground plate
A common ground plate below the waterline must be
connected to the AC/DC electrical system in order to
guarantee crew safety.

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Prevention of stray current during

installation
Correct installation reduces the risk of stray current
throughout boat service life.
• All DC circuits must have an insulated ground
return.
• All joints in the system such as connectors,
connector rails etc., must be installed such that they
are not exposed to moisture or bilge water. The
same applies to switches and fuse holders etc.
• Cables must be run as high as possible above bilge
water level. If a cable must be run such that it is
exposed to water, it must be run in a watertight
sheath, and the connectors must also be watertight.
• Cables that may be exposed to wear must be
installed in self-draining conduits, sheaths, cable
channels or similar.
• For information regarding the installation of batteries
and main switches, refer to the
Installation, page 248 and Installation, page 256
chapters.
• Engines and drivetrains may not be used as ground
connections for radio, navigation or other equipment
where separate ground cables are used.
• All separate ground cables (ground cables for radio,
navigation equipment, echo sounders etc.) must be
connected to a common grounding point, e.g. a
cable that in normal circumstances does not
function as a ground return for the equipment.
• When shore power (120/230 V) is connected,
ground protection must not be connected to the
engine or any other grounding point in the boat. The
ground protection must always be connected to the
shore power connection box ground.
• Converters such as battery chargers connected to
shore power, must have ground protection
connected on the input side (120/230 V), but the
negative connection on the output side (12/24 V)
must not be connected to ground protection without
being galvanically separated.
WARNING!
Work on the low voltage circuits in the boats should be
done by a person with electrical training or knowledge.
Installation or work on land current equipment must
only be done by a competent electrician, in accordance
with local regulations for mains electricity.

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Checking Protective Anodes

Aquamatic

Note how the protection anodes are located; one on

the cavitation plate, the second on the lower part of the
transom shield and the third in the exhaust pipe.
Change the anodes if less than 50% of its weight
remains.

IMPORTANT!
Make sure the anode has good metallic contact with the
sterndrive and transom shield. Never paint the
protection anodes. Never use a steel wire brush to clean
the anodes. A steel brush will reduce galvanic
protection.

Before the boat is launched, the anodes must be

cleaned (be activated) with sandpaper to remove the
oxide layer.

Zinc anodes
The stern drive, transom shield and exhaust pipe are
equipped with zinc anodes as intended for use in salt
water as standard.

Magnesium anodes
If the boat is operated in freshwater, magnesium
anodes must be used.

Aluminum anodes
When the boat is operated in brackish water, the use
of aluminum anodes is recommended.

DPH/DPR propellers
Volvo Penta propellers installed on DPH/DPR
sterndrives are electrically insulated from the drive and
will therefore not cause any anode consumption.

NOTICE! There is also a protection anode (2) in the

1 exhaust pipe on late generation engines.
Gr8e28250
ase

P0015839

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Checking for leakage from the

electrical system
A simple way of testing the boat’s electrical integrity is
to employ the following procedure:

First check that fuses and circuit breakers are fitted and
intact, that the battery main switches are on, and that
all other switches and appliances are off. Theoretically,
there should be no current flowing from the battery.
Any flow will indicate a leak.

To check if any current is leaking

1. Disconnect equipment that may consume current
even when switched off (clock or radio).

2. Lift off the positive battery terminal connector.

3. Connect a 12 Volt, 3 W test lamp between the

positive terminal and the loosened connector. You can
also use a Voltmeter for this test.

If there is no leak, the lamp will fail to light. A faint glow

indicates a small leak, and a bright light means that you
P0008281 have a more serious leak.

To check how much current is flowing

1. Use a multimeter, and set it to read “DC Amps”.

2. Connect the red test lead to the battery positive

terminal, and the black lead to the loosened connector.
The meter will now show how much current is leaking.
If you do not get a reading, change to the ’’DC mAmps’’
scale.

P0008282

Double-check to see the resistance in the circuit

1. Set the multimeter to Ohms.
2. Connect the black test lead to the loosened negative
connector, and the red test lead to the loosened
positive connector. You should now see a reading of
the resistance of the circuit.

NOTICE! Certain equipment may also cause a current

drain when shut off, such as a radio, clock or automatic
P0004774
bilge pump. This equipment must be disconnected.

The rough guide below indicates what these

readings means in practical terms:
• 10.000 Ohm up to open circuit A next to perfect
circuit, no problems.
• 5.000 Ohm – There is a small leak.

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Arrangement and Planning, Electrochemical Corrosion

• 1.000 Ohm – There is a leak that must be found and

corrected.
• 500 Ohms or less – A heavy leak. Disconnect the
battery terminals. Repair as soon as possible.
A B To find the leak.
With the test lamp connected as step 1 above, loosen
one fuse at a time and put it back again. When you
remove a fuse and the test lamp goes out, then you
have found the circuit that is causing the problem.
Trace the circuit until the fault is found, and repair it.

P0004775

A Charging
B Oil pressure

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Checking electrochemical
corrosion
Tools:
88890074 Multimeter
21504294 Reference electrode

Measuring galvanic current and stray

current in water
Volvo Penta has developed a method for measuring
21504294 Reference electrode
galvanic current and stray current in water using a
reference electrode.

21504294 Reference electrode (Ag/AgCl)(1) is

connected to 88890074 Multimeter. The multimeter is
used to measure the difference in potential.

p0005125 NOTICE! If another multimeter is used, it must have an

accuracy of 1 mV.
88890074 Multimeter
Depending on the method used, the results provide an
average voltage for the whole measured object, e.g. a
shaft, or the voltage an individual component
produces.

Examples of such measuring points are rudders and

water inlets etc.

NOTICE! The reference electrode may be used in

water with varying salt levels, or in freshwater.

The process measures the difference in potential

between the measured object and the reference
electrode. The reference electrode has a known
constant electrode potential. Thus the measured
difference in potential is always related to a special
reference electrode and the same electrolyte, i.e. the
same water and water temperature. Water flow must
always be the same if the results from different
measurements are to be compared.

Measurement theory
The protection anode works by emitting an electrical
current – protective current – in order to counteract
corrosion current. When the protective current
increases and corrosion current is reduced, the
potential of the protected object is also reduced. When
a given potential is reached, the corrosion current
disappears and the object has complete cathodic
protection.

Thus a given electrode potential for the metal serves

as a guide to when cathodic protection is active and
whether it is sufficient. The reference electrode is able

1. Ideally, do not combine the blue 885156 calomel electrode with

the amber 21504294 Ag/AgCl electrode. In such cases the 40 mV
must be added to the measured value from the Ag/AgCl electrode
when comparing with the calomel electrode.

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Arrangement and Planning, Electrochemical Corrosion

to measure whether the protective potential is provided

for.

Checking galvanic electricity, reference

electrode
Connect 21504294 Reference electrode to
88890074 Multimeter.

Connect the multimeter to a suitable screw in contact

with the drive unit. Set the multimeter for DC current
measurement.

Carefully remove the protective sleeve from the

reference electrode. The protective sleeve is filled with
a saturated salt solution (NaCl or KCl). Clean the tip
with a clean paper napkin or similar before replacing
after measuring.

Dip the electrode into the water about 30 cm (12") from

the propeller and the propeller shaft. The result is
an average value for the entire propeller shaft. The
result should be between (minus) -900 mV and -1100
mV.

To check individual components, the electrode must

be pointed so that the tip is aimed at the object, about
5 mm (0.2") from the surface where the component is
installed. Here too the measured result must be
between -900 and -1100 mV.

If the result is higher (e.g. a more positive result than

-800) the proportion of “precious” metal in the stainless
steel, bronze etc is too great for the cathodic protection
to overcome the corrosive current. The number of
anodes must therefore be increased.

The result may also depend on stray current caused

by faulty or incorrectly connected positive (+) cables,
or positive (+) cables exposed to bilge water. Flowing
water increases the consumption of anodes.

Over protection is present if the multimeter shows a

value lower than -1100 mV. This may also be caused
by stray current from separate ground cables from a
VHF radio or other equipment fitted with an incorrectly
connected ground cable.

The cause may also be that the anodes are emitting

excessive protection current, e.g. magnesium anodes
in saltwater.

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 Installation, Aquamatic drive

Installation
Aquamatic drive
Transom Shield Installation

Water level at maximum load

Aquamatic

IMPORTANT!
The highest waterline level (A) above the crankshaft
centerline (CL) must conform to the data below.
A CL All D6 single installations must have exhaust risers
installed. It is extremely important that the maximum
water level is checked in all other AQ installations.
X
If the margin above the surface of the water is not
attained it may cause water to enter the engine
resulting in major engine damage.

NOTICE! Note that waterline conditions change

markedly if auxiliary equipment such as stern-mounted
P0021610 capstans or davits is retrofitted, and too small a margin
to the surface may result. If auxiliary equipment is
installed, Volvo Penta strongly recommends the
installation of an exhaust riser.

NOTICE! In order to determine dimension X use the

tables for recommended X dimensions in the Transom,
Cutout, page 78 chapter.

NOTICE! When the waterline is set out the boat must

be in its static float plane.

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Installation, Aquamatic drive

IMPORTANT!
There are different methods, depending on how the
boat is loaded: make sure that the maximum water
level is not exceeded regardless of the weight
distribution in each load case.

P0007465

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 Installation, Aquamatic drive

No riser installed
Pos. A: The boat is fully laden with fuel and water. No
extra load and no crew. Water level above crankshaft:
Max. 220 mm (8.7").

Pos B: Boat laden to approved CE level. Crew must

be in stern area with other weight located at boat center
of gravity. Water level above crankshaft: Max. 330
mm (13.0").

If the waterline is higher an exhaust riser must be

installed after the turbocharger instead of an exhaust
elbow. This increases the permissible water level
above crankshaft centerline by max 170 mm (6.7") (A).

With riser installed

Pos C: The boat is fully laden with fuel and water. No
extra load and no crew. Water level above crankshaft:
Max. 390 mm (15.4").

Pos D: Boat laden to approved CE level. Crew must

be in stern area with other weight located at boat center
of gravity. Water level above crankshaft: Max. 500
mm (19.7").

P0007466

Exhaust riser installed

Extension
If waterline level still presents a problem, an extension
must be installed on the sterndrive. This makes it
possible to raise the engine and transom shield at the
CL same time as the cavitation plate position, dimension
(D), is maintained.

Extension height (H) = 25.4 mm (1").

Follow the installation instructions in the extension kit.

Calculate the position of the hole for the transom shield
with installed extension.

Use the recommended X dimension and add the

extension length (H), 25.4 mm (1").
P0021613 NOTICE! Refer to the tables for recommended X
dimensions in the Transom, Cutout, page 78
chapter.

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Installation, Aquamatic drive

Transom
Minimum distances
A 650 mm (26")
B 1500 mm (59")
C 800 mm (32")

NOTICE! Make sure there is nothing forward of the

sterndrive that can cause turbulence ahead of the
propellers.
Log and echo-sounder sensors, etc. may not be
C located inside the shaded area.
Keels, strakes, ladders, etc. may not be within distance
B from the transom.

A
B

P0007450

Single installation

Twin installation
Critical areas may overlap one another depending on
the distance between the engines.

A
B
P0007451

Twin installation

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 Installation, Aquamatic drive

The transom must be flat inside the area where the

shield will be installed.

The inboard and outboard transom surfaces must be

parallel to within ±3 mm (0.12").

The inboard transom surface must be flat to within ±3

mm (0.12"). The outboard transom surface must be flat
to within ±1.6 mm (0.063").

P0007462

The transom must be between 51 - 57 mm (2.00–

2.25") thick. When installing low power engines such
51-57 mm (2.00-2.55”) as the D4 series it is acceptable to use a somewhat
thinner transom of 45 - 51 mm (1.75–2.00").
The recommended transom angle is 13°.

13
P0007463

1 When installing aquamatic drives in thin hulls e.g.

aluminum some form of spacer must be used in order
to achieve the correct thickness between the hull and
drive (1).
2
NOTICE! Always reinforce the engine bed with
transom brackets (2).

P0016610

P0016610

Spacer milled from an aluminium billet for welding to

the transom.

Alternatively, aluminum brackets may be welded to

the sides of the transom and a plastic slab fastened
to it. The plastic slab (fiber glass) must be high density
so that it is stiff and immovable.

P0016611

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Installation, Aquamatic drive

Transom, Cutout
Aquamatic

Ascertaining the transom angle

Boat transom angle can be measured with several
different protractors or workshop instruments. Two
protractors that are commonly used are the adjustable
protractor (A) and the protractor with integral level (B).
Both types of protractor can be bought in regular tool
stores.

P0007475

Locate the transom centerline

1 Draw lines parallel with the boat's port and
starboard sides.
2 Draw intersecting lines parallel to, and at the
same distance from, the boat bottom on the port
and starboard sides. Mark the points where the
lines intersect. The points make up the center for
the two arcs that must be drawn when the
1 transom centerline is marked out.

NOTICE! The transom centerline is most

accurately determined with the aid of a beam
compass. A practical beam compass can be
made by securing a pivot point and a pen to a slat.
A stiff wire with eyes at each end for the pivot
point and pen may also work if used accurately.

P0007477

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 Installation, Aquamatic drive

3 Draw an arc in the upper part of the transom using

one side point as the center, and an intersecting
arc from the other side point, without altering the
radius of the beam circle. Exactly the same radius
must be used for both arcs for the transom upper
center point to be positioned precisely. Repeat
the procedure to mark out the lower transom
center point; if necessary use a different radius.
P0007478

4 If the boat bottom is flat, or has a very broad V

shape, the lower center point can be located by
measuring across the transom from side point to
side point, and marking the center point on the
transom.

P0007479

5 Draw a vertical line through the upper and lower

center points. The transom centerline is used as
a centerline for the transom shield on single
installations, and as a reference line on twin
installations.

P0007480

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Installation, Aquamatic drive

6 The dimension X is the position of the crankshaft

α° centerline (CL) measured from the lowest point of
the boat bottom at the transom, and determines
the height at which the sterndrive must be
located.
CL The recommended transom angle is 13° (α°).
Other transom inclinations specified in the table
may also be used.
X
NOTICE! Refer to the table for recommended X
dimensions in the penetration instructions section
for single and twin installations.

Every combination of boat model and sterndrive

is unique; water does not flow under the hull in
exactly the same way on different boat models.
P0007481
The X dimension mentioned herinafter is a good
choice for most boats, but the best installation
height (X dimension) can only be determined by
testing. The Volvo Penta recommended X
dimension must be used as a starting point.

Recommendations
Volvo Penta recommends that the following routine be
used to find the best installation height for a specific
boat model:
1 Increase the recommended Volvo Penta X
dimension by 15 mm (0.6") (“raise” the sterndrive
15 mm) on the first hull.
2 Run the boat and carry out accurate performance
tests at various trim angles and load conditions in
order to assess the installation height.
3 Install a 25 mm (1") extension to the sterndrive and
repeat the tests.
4 By comparing the results and the boat's overall
qualities it will be possible to select the best X
dimension for series manufacture.

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Single installation
7 Select an X dimension from the table below and
mark out the height from the bottom of the boat
to the crankshaft centerline (X dimension).

8 Use a set square to mark out a horizontal line at

right angles to the vertical centerline at the
crankshaft centerline mark.
P0007482

CL = Crankshaft centerline
A = Keel line
Y = Check measurement (not to be used for
installation)
NOTICE! The Y dimension is not a defining
measurement. Should be checked after
installation.

P0007483

Recommended X-dimensions (the recommended transom angle is 13°).

Transom angle (α°) 15° 14° 13° 12° 11° 10°
X dimension, DPH/DPR, mm (inches) 366 363 360 357 354 351
(14.41) (14.29) (14.17) (14.06) (13.94) (13.82)

Reference dimension: Transom shield lower edge, boat

Transom angle (α°) 15° 14° 13° 12° 11° 10°
Y, DPH/DPR, mm (inches) 67 (2.64) 64 (2.52) 61 (2.40) 58 (2.28) 55 (2.17) 52 (2.05)

D/d dimension: Cavitation plate bottom, boat

When the recommended X dimension is used the D/d
dimension may be used as a reference dimension.

Single installation
DPH(D): 12.0 mm (0.47") below boat bottom
DPR(d): 36.5 mm (1.44") below boat bottom

DPR only:
Single installations on stepped hulls or "ski" (flat
bottom) across a 150 mm (6") wide area:
Standard X dimension minus 20 mm (0.79").
d=16.5 mm (0.65") above boat bottom

P0007484

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Twin installation
NOTICE! The minimum distance between the engine
center lines in a twin installation determines the
distance between the transom shield center lines and
the space between the engines. The minimum
distance between the center lines of D4 and D6
engines is 950 mm (38").

7 Use a set square to mark out the transom. Place

a mark (A) on the port side at the selected engine
distance from the transom center line. Place a
mark (B) on the starboard side at the selected
engine distance from the transom center line.

P0007485

8 Take the same measurements from the transom

center line close to the bottom to mark out the
lower points.

P0007485

9 Use a set square or steel rule to join the two points

on the port and starboard sides of the center line.
Check the top and bottom distances to ensure
that the shield centerlines are at the same
distance from the transom centerline.

P0007487

X dimension
10 Select an X dimension from the table and mark
out the height from the bottom of the boat to the
crankshaft centerline.
Minimum distance between engine centers (B) is
950 mm (37.4").
CL = Crankshaft centerline
A = Keel line
Y = Check measurement (not to be used for
installation)
P0007488

NOTICE! The Y dimension is not a defining

measurement. Should be checked after
installation.

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Recommended X-dimensions (the recommended transom angle is 13°).

Transom angle (α°) 15° 14° 13° 12° 11° 10°
X dimension, DPH/DPR, mm (inches) 354 351 348 345 342 339
(13.94) (13.82) (13.70) (13.58) (13.46) (13.35)

Reference dimension: Transom shield lower edge, boat

Transom angle (α°) 15° 14° 13° 12° 11° 10°
Y, twin installation DPH/DPR, mm 55 (2.17) 52 (2.05) 49 (1.93) 46 (1.81) 43 (1.70) 40 (1.57)
(inches)

D/d dimension: Cavitation plate bottom, boat

When the recommended X dimension is used the D/d
dimension may be used as a reference dimension.

Twin installation
DPH(D): 24.0 mm (0.94") below boat bottom
DPR(d): 24.5 mm (0.96") below boat bottom

DPR only:
Twin installations with stepped hulls:
Begin by reducing the X dimension by 10 mm
(3/8"). Check and test the sterndrive position.
d=14.5 mm (0.57") above boat bottom

P0007489

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Using the drill jig

Tools:
3863258 Fixture
1 Align 3863258 Fixture against the transom. The
V-notches must coincide with the centerline and
horizontal line at four points.

NOTICE! The UP mark on the jig must be at the

top.

P0007490

2 Temporarily fasten 3863258 Fixture using two

self-tapping screws (1), diameter 6 mm (1/4").
Drill all six shield bolt holes to a diameter of 14
mm (9/16").

NOTICE! Drill perpendicular to the transom.

P0007491

3 Mark out the shield hole on the transom using a

pen.

NOTICE! Do not mark around the self-tapping

screws.

Remove 3863258 Fixture.

P0007492

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4 Cut out the hole using a power jigsaw. Be careful

to hold the saw at a 90° angle to the transom.

P0007493

5 Chamfer the inboard side of the transom as

illustrated to allow water to drain away. Width (A):
40 mm (1.5"), depth (B): 20 mm (0.75")

P0007494

6 Seal all sawn surfaces with sealant.

P0007495

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Using the paper template

1 Place the template against the transom so that
the vertical and horizontal lines through the
crankshaft centerline (CL) on both the transom
and the template coincide.

P0007496

2 Use a 6 mm (1/4") drill and mark out the six holes

by drilling holes approx. 5 mm (0.2") deep.

P0007497

3 Drill the six shield bolt holes to a diameter of 14

mm (9/16").

NOTICE! Use a drill guide to ensure that the holes

are drilled exactly perpendicular to the transom.
Also take care that the holes are drilled in
precisely the right locations. If this is unsuccessful
it will be extremely difficult to install the transom
shield.

P0007498

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4 Cut out the transom hole in the paper template.

Mark out the shield hole on the transom using a
pen. Drill a hole at one corner sufficiently large to
admit a power jigsaw.
Remove the template.

P0007499

5 Cut out the hole using the power jigsaw. Be

careful to hold the saw perpendicular to the
transom.

P0007493

6 Chamfer the inboard side of the transom as

illustrated to allow water to drain away. Width (A):
40 mm (1.5"), depth (B): 20 mm (0.75")

P0007494

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7 Seal all sawn surfaces with sealant.

P0007495

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Transom Shield Installation

Aquamatic

IMPORTANT!
When bottom paint is applied to the hull, a 10–15
mm (0.4–0.6") border must be left around the transom
shield.

NOTICE! In twin DPH unit installations, the starboard

shield has the steering cylinder on the starboard side,
and the port shield has the steering cylinder on the port
side, as illustrated.
In twin DPR unit installations, the port and starboard
shields have steering cylinders on both sides, with the
parallel rod still installed.
(This also applies to DPH with electronic steering).

P0007501

1 Steering cylinders
2 Transom shields
3 Valve block

1 Pass the trim pump, hydraulic steering hoses,

gearshift cable sheath and the water inlet hose
through the transom hole.

NOTICE! The hoses must always be positioned

on the starboard side.
2 Align the transom shield studs with the holes in
the transom and place the shield against the
transom.

p0007502

The illustration shows a DPH transom shield with hydraulic steering.

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3 When the shield is in position, install the six

rectangular washers on the studs and screw on
the nuts. Tighten the nuts evenly.
Tightening torque: 80 Nm (57.8 lbf.ft)

p0007503

4 Install the trim pump on the transom or a

bulkhead. Make sure it is easily accessible for
fluid filling and service and that it is clear of any
bilge water.

IMPORTANT!
The trim pump must be installed vertically; see
illustration.

5 Pass the gearshift cable through the sheath and

out through the transom. Apply a little oil on the
cable for ease of installation.

NOTICE! Control cable quality is important for

shift control function. Use only Volvo Penta X-
ACT cable.

p0007505

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6 Clamp the gearshift cable sheath and the

accessory hose (autopilot/rudder indicator).
Clamp the trim pump hydraulic hoses.

IMPORTANT!
The hose ends must always be positioned and
clamped such that they are a good distance above
maximum waterline level (WL) to avoid water entry
into the boat.

7 Bend the gearshift cable and fasten it to the

inboard side of the transom.

NOTICE! Make as few bends as possible.

r Recommended maximum combined angle of the
total number of bends is 270°. Minimum radius (r)
when bending the cable: 200 mm (8"). If the
p0007507
radius is smaller, gearshift movement will be stiff
and may seize. Recommended max gearshift
cable length is 4.5 meters (15 ft).

Installing the gearshift actuator and

gearshift cable

IMPORTANT!
The actuator must be installed above the waterline at
α an angle of at least 5° (α) as illustrated.

α
p0007508

1 Install the actuator in a location where the

gearshift cable (push/pull cable) can be installed
and fastened correctly.

r NOTICE! Cable bend minimum radius (r):

200 mm (8"). Recommended maximum
combined angle of the total number of bends is
p0007507
270°.

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2 Install the actuator using four suitable screws.

NOTICE! The actuator pin (1) must always face

downward. Adjust the position and fix the self-
adhesive tape (2) over the upper slit.

p0007509

3 Install the washer (1) and gearshift cable with

clamp (2) and bolts to the underside of the
actuator.

NOTICE! The control cable may be installed on

either side of the actuator to facilitate actuator
installation in the boat. However, the pin must
always be installed facing down.

p0007510

4 Screw the threaded part of the cable into the

adapter. Fasten the adapter to the gearshift cable
pin by means of a split pin.

IMPORTANT!
Do not forget to start the EVC system before the
gearshift cable is attached to the sterndrive. This
is done to ensure that the actuator is in the correct
position for the neutral position (N).

p0007511

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Engine Foundation
Aquamatic

Tools:
21679632 Drill jig

For information on installations with jackshafts, refer to

the Jackshaft, Installation, page 108 chapter.
1 The engine bed must be built up in the following
dimensions:
A 125 mm (5.0")
B 449 mm (17.7")
C 572 mm (22.5")
D 83 mm (3.3")

Dimension (D) crankshaft centerline (CL) – engine

bed must be 83 ±8 mm (3.25 ±0.3").
P0007701

The free space around the flywheel housing, and

A the oil pan bottom and sides (A) should be at
least 20 mm (3/4").

Build in drainage channels so that bilge water is

able to run to the bilge pump.

P0004618
A

The engine bed must be filled to reduce noise

and vibrations.

Build up the engine bed with spacing material (A)

so that the undersides of the engine mounts/
rubber mounts almost rest on the bed. Leave
space for the steel strip and fiber glass.

P0007702

A. Spacing material, ideally high density material

B. Fiber glass, approx. 10-15 mm (0.4–0.6")
C. Galvanized steel strip, approx. 10 mm (0.4") thick
W. Steel strip width: min 80 mm (3")

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2 Cut out a space for the exhaust pipe furthest aft

on the starboard side engine bed; see illustration.
A 130 mm (5")
B 200 mm (8")
C 300 mm (12")
D Max 137 mm (5.4").
a 45°

P0007703

3 Install 21679632 Drill jig special tool for the

engine bed.

NOTICE! Carefully check that the tool plate is

correctly installed on the transom shield.

Special tool 21679632 Drill jig fits Volvo Penta

D4 and D6 engines with DPH and DPR
sterndrives. Four positions are marked on the
bar:
D4 659, 789
D6 895, 1025

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4 Build up the engine bed so that the undersides of

the tool plates rest on the upper part of the bed.
Build in a galvanized steel plate that is around 10
mm (3/8") thick, at least 80 mm (3") wide and 250
mm (10") long.

p0007706

5 Install the adjustable 21679632 Drill jig in the

correct position for the engine type concerned
(D4 or D6).
6 Mark out 6 mm (1/4") holes on the bed for the
flexible engine mounts. Then remove the special
tool.

7 Drill and then tap the holes using a thread tap.

Size: M12 mm (1/2" UNC) or equivalent.

p0007708

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Engine Installation
Aquamatic

Preparing the engine

NOTICE! Before the engine is installed, installation of
fuel, steering and electrical systems must be as
complete as possible.

IMPORTANT!
Always use both lifting eyes when lifting the engine.

Fit extra equipment and accessories such as auxiliary

alternator, hot water take-off, power take-off etc. to the
engine before it is installed.

NOTICE! All engines and reverse gears are supplied

by Volvo Penta without engine oil and coolant. Check
that the bottom plugs are in position and that coolant
and hot water drain taps etc. are closed.

Fill oil and coolant. Carry out a leakage check.

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Installing the exhaust pipe

Tools:
21244540 Measuring tool
1 Check that the large O-ring and small O-ring are
in place in the transom shield. The O-rings are
factory installed (glued). Grease the exhaust pipe
flange interface with grease 828250.

2 Install the exhaust pipe and tighten the bolts.

Tightening torque: 40 Nm (30 lbf.ft)

Check the bypass hose connection to the exhaust

pipe.

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3 Place the stainless steel hose clamp on the

exhaust hose.

NOTICE! The lower part of the bellows is factory

installed. It may be necessary to loosen the lower
hose clamp to facilitate fitting the bellows to the
riser. If the lower hose clamp has been loosened,
ensure a minimum overlap of 40 mm (1.57”)
between the bellows and the plastic sleeve on
reassembly. Re-tighten the clamp with a torque
of 14 Nm (10.3 lbf ft). No grease allowed between
the bellows and the pipe.
For safety reasons, the torque on the lower hose
clamp joint fasteners is checked and a 100%
leakage control test is carried out at the Volvo
Penta plant before delivery. Take extra caution if
the hose clamp has been loosened.

4 Install the large rubber ring (1) on the flywheel

1 housing collar. Grease the rubber ring before
installation using rubber lubricant: 3817243.
5 Install the flexible engine mounts on the engine
brackets as follows: Apply Volvo Penta grease
part # 828250 onto the threads.
Lift the engine by attaching a lifting device to both
engine lifting eyes.

IMPORTANT!
Forces acting on the lifting eyes must be vertical.
p0007756

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The engine bed must be in a single plane. Check

that the engine bed surfaces where the engine
mounts will be installed are parallel to the engine
mount bottom plates, and that bed incline is
correct (use an inclinometer).

Once the engine is installed, the load on the

starboard mounts must be equal to the load on
the port mounts. Max permissible variation
p0005943
between the port and starboard mounts is ±1.5
mm (±0.06").

Check engine mount loads by measuring mount

compression with the aid of
21244540 Measuring tool. Nominal
compression is around 5 mm (0.2").

We strongly recommend rocking the engine

between engine mount height adjustments the
better to distribute engine weight through the
rubber.
p0005944
The adjustable engine mount starting point is the
center of the attachment plate holes. The
attachment plates have oblong adjustment
holes. These may face forward or aft, whichever
provides best accessibility.
Nominal height: 116 mm (4.6")
H
H = Nominal height ± adjustment: ±8 mm
(±0.3")
V = Lateral adjustment: ±7 mm (±0.3")

p0005969 V

IMPORTANT!
The distance between the engine mount and the
lower edge of the center adjuster nut (A) must
never exceed 20 mm (0.8"). If this occurs, the
threads may strip.

NOTICE! The engine must rest on its engine

pads 24 hours before installation for alignment
A
to work (the pads compress a little under load).
This applies only if the engine did not rest on its
pads during transportation.

p0005972

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6 Lower the engine and center the flywheel housing

collar. Push the engine aft. Grease the rubber ring
(1). Place the rubber ring (1) on the tensioning
ring (2) and fasten it to the flywheel housing with
the three lock plates (3). Pull the engine and
clamping ring together using six bolts.
Tightening torque: 35 Nm (25 lbf.ft)

IMPORTANT!
Do not forget to grease the threads and bolt head
undersides. Lock the bolts by bending the lock
washer tabs against the bolt heads.
Lower the engine onto the engine bed. Screw in
p0007757 the engine mount retaining bolts without
tightening them.

7 Grease the double rubber rings (1) using rubber

1 lubricant: 3817243.

P0016684

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8 Align the engine and make sure it has the correct

angle to the transom. Check the installation using
the method described below. Use a digital
inclinometer.

Longitudinal alignment
a Measure the angle (α) on the top of the
engine. A negative angle corresponds to the
front of the engine pointing down, and vice
versa.
b Measure the angle (β) on the inboard side
of the transom.
c Calculate the total aligning angle (γ) using
the formula γ = 180° - β - α. The value must
be in the 103° ±1 range.
d If the total angle γ is less than 102°, the front
of the engine must be adjusted down. If the
angle is greater than 104°, the front of the
P0008589
engine must be adjusted up. Calculate the
difference between the total angle γ and
103°. Place the inclinometer on the top of
the engine cover and adjust the engine
mounts up or down until the angle difference
is added.

NOTICE! The transom shield is designed for a

standard transom slope of 13°.

NOTICE! Maximum inclination for the engine with

flywheel upward is 0° while boat is static.

Transverse alignment
a Check the transverse alignment by
measuring the distances at each bracket
located on the sides and compare with the
top side of the flywheel housing in relation to
the transom shield (parallel). A difference of
2 mm (0.08") is acceptable.
b Adjust the height with the flexible engine
mounts until the requirements are met.

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The special wedge tool # 884502 facilitates

adjustment of the distance between the transom
shield projections.

P0016685

9 Tighten the bolts to fasten the engine mounts to

the engine bed (recommended bolt size M12 or
1/2" UNC).
Tighten the adjuster nuts on the mounts using a
counterhold.
Adjuster nut tightening torque: 300 Nm (220
lbf.ft)
Tightening torque, engine bed bolts: 120 ±5
Nm (88.51 ±4 lbf.ft). This requires a level
bed with embedded steel strips of the
correct length, width and thickness.
Check engine bed construction with the
boat builder before commencing
installation.

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Engines with power steering:

10 Connect the seawater hose to the steering
system oil cooler.

IMPORTANT!
Use two hose clamps.

P0007760

Illustration shows DPH with hydraulic steering.

Port engine, twin installation:

11 Connect the seawater hose to the union for the
hose to the seawater pump.

IMPORTANT!
Use two hose clamps.

P0007761

Engine without power steering.

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12 Connect the two hydraulic hoses to the steering

system and oil cooler (DPR has two oil coolers).
Tightening torque, oil cooler (A): 22 Nm (16
lbf.ft)
Tightening torque, power steering pump (B):
15 Nm (11 lbf.ft)

P0007762
B

Illustration shows DPH – twin installation (hydraulic steering).

B
P0007763

DPR – twin installation

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13 Connect the exhaust hose to the exhaust elbow

or exhaust riser, if such are installed.
Connect the bypass hose to the exhaust elbow.

P0016445

14 Connect the 6-pin connector (1) from the

Powertrim pump cable kit to the connector
marked POWERTRIM CONN on the engine/
transmission cable.

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15 Connect the 3-pole trim sender cable to the trim

sender on the transom shield. Fasten the cable
securely using clamps.

p0007765

16 Connect the gear shift actuator to the connector

marked GEARBOX CONN on the engine/
transmission cable.

IMPORTANT!
Do not forget to start the EVC system before the
gearshift cable is attached to the sterndrive. This
is done to ensure that the actuator is correctly
aligned for the neutral position (N).
17 Connect the transom shield ground cable (1) to
the power steering oil cooler/seawater
connection retaining bolt (2).

p0007767
p0007766

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NOTICE! There is a protection anode (1) installed in

the exhaust pipe on late model engines.
1

P0016593

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Jackshaft, Installation
Aquamatic

Tools:
3863099 Adjustment tool

P0007798

General WARNING!
Working with or approaching a running engine is a
In some installations it is desirable to move the engine
safety risk. Watch out for rotating components and hot
forward while retaining the advantages of a
surfaces.
sterndrive. One reason can be to make the aft deck
useable for sports fishing or similar, or to move boat Stop the engine before work on the jackshaft is begun.
center of gravity forward. Do not run the engine with safety covers removed.
To achieve this, a jackshaft may be used between the
sterndrive and the engine.
When installing a jackshaft, the longitudinal center of
gravity must be checked in regard to the more forward
engine location. Fuel and water tanks must be located
as close to the center of gravity as possible.

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Selecting a jackshaft
A driveshaft of type SAE 1500 must be used. Volvo
Penta offers drive shafts that are suitable for its
engines.

The recommended maximum length from flange to

flange is 1600 mm (63.0").

This provides a maximum distance of 1888 mm (74.3")

from the flywheel housing plane on the engine to the
intersection point for the crankshaft centerline and the
P0007799 outside of the transom.

If the engine must be installed even further forward

than the recommendation above, a split driveshaft with
a central support bearing will be required. Such split
driveshafts are not supplied by Volvo Penta.

Alignment
The engine flywheel flange must be aligned with the
jackshaft bearing housing on the transom shield. This
can be done using 3863099 Adjustment tool.

Universal joint working angles

The following basic rules must be followed when
installing a jackshaft:
• Universal joint working angles at each shaft end
may deviate at the most by one degree in relation to
one another.
• Universal joint working angles should not be greater
than 3 degrees. For greater working angles, refer to
the Installation instructions included in the jackshaft
kit.
P0007800

A good basic rule is to try to install the shaft as straight

as possible.

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Cooling system
Water block off kit (option)
The water block off kit is used when the installation has
a seawater intake in the hull instead of taking in water
through the sterndrive.

The water block off flange replaces the water intake

pipe and hose that are included with the transom shield
as standard.

Seawater intake via hull fitting

Hose diameter:
D4: 38 mm (1½")
D6: 50 mm (2")

Seawater intake via the sterndrive

It is possible to take cooling water from the sterndrive
if this is preferred. Hoses and pipes are included in the
kit, but in some cases extra hoses must be purchased
by the boat builder.
p0007801

NOTICE! When ordering engine mounted seawater

filters the hose diameter is 50 mm for D4 and D6
engines alike.

IMPORTANT!
The hose must be reinforced and designed for marine
wet exhaust systems, and able to withstand
temperatures up to 100 °C (212 °F) and vacuums down
to -60 kPa (-8.7 psi). It must also meet ISO 13363.2 or
SAE J200R2 DN standards.

For further information, refer to the Installation

instructions included in the jackshaft kit.

Exhaust system
Installing the exhaust block off kit
It is not possible to lead exhaust gases through the
sterndrive in jackshaft installations. Refer to the
Installation, page 217 chapter.

Before the exhaust system block off kit is installed,

check that the water and exhaust O-rings on the
transom shield are in place and undamaged.

P0007802

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Cooling System

Raw Water System

Aquamatic

The complete seawater system including seawater

filter is supplied by Volvo Penta.

The water inlet is located in the sterndrive. Volvo Penta

cooling systems are designed for seawater
temperatures of maximum 32 °C (90 °F).

Water circulation from the seawater system cools:

• engine coolant
• engine oil.
• charge air
• power steering fluid
• exhaust
P0008185

Inboard engines
3

Water circulation from the seawater system cools:

4
• engine coolant
• engine oil.
• charge air
• reverse gear oil
Seawater system water is also used to cool exhaust
gases in installations with wet exhaust systems. In
2
most cases engines must be fitted with seawater filters.
Volvo Penta cooling systems are designed for
seawater temperatures of maximum 32 °C (90 °F).
1

P0008186

1 Strainer
2 Seacock
3 Seawater filter
4 Seawater pump

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Steering System

Electronic Steering System

Aquamatic

Main components

1 Wheel hub (steering unit)

2 Joystick
3 HCU (helm control unit), inside control lever
4 Connection panel on engine
5 Steering cylinder with position indicator
6 SCU (Steering Control Unit)
7 Expansion tank for hydraulic oil

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 Installation, Aquamatic drive

NOTICE! Refer to the EVC literature for instructions

regarding how the helm steering unit, joystick and SCU
are connected.

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Installation, Aquamatic drive

Installation
Aquamatic

IMPORTANT!
Be extremely thorough with cleanliness when working
on steering system hydraulics. Thoroughly clean the
components externally before disassembly. The
workplace must be clean and well lit.

A B 1 Install the SCU using four screws, suitably on the

inboard side of the transom. Secure all hoses to
the transom shield with clamps.

IMPORTANT!
Move the hoses aside to avoid contact with the
C
engine. Minimum radius (r) 60 mm (2.4").

Do not undo the hose unions.

Technical data, SCU unit

D
Hole size (A): 10 mm (0.4")
Hole pattern: 70 x 324 mm (2.8 x 12.8")

Width (B): 218 mm (8.6")

Height (C): 344 mm (13.5")
Depth (D): 142 mm (5.6")
r Weight: 8 kg (17.6 lbs)

P0011708

IMPORTANT!
The unit may be installed vertically, horizontally, or
on the underside of a surface. However, the unit
may not be installed with the hoses uppermost.

P0009197

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 Installation, Aquamatic drive

2 Install the recovery tank in a suitable place, for

example on a bulkhead. First install the tank
backplate using two screws. The slide the tank
securely onto the backplate.

IMPORTANT!
The recovery tank may not be installed on the
engine.
The tank must be the highest installation point.

P0009998

3 Connect the hoses from the power steering pump

(1) and oil cooler (2) to the recovery tank.
4 Connect the two hoses (3) from the SCU to the
hose (4) from the power steering pump and the
hose (5) from the oil cooler.
2
Tightening torque: 22 Nm (16.2 lbf.ft)
1

3
5

P0010395

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Installation, Aquamatic drive

5 Connect power to the SCU from the engine start

battery. Install the harness fuse to the battery
positive terminal. Also install a switch to the
battery positive terminal.

NOTICE! The SCU units must be connected to

separate battery arrays.
6 Fill the recovery tank with ATF oil of type Dexron
II or III while the engine is running. Volvo Penta
part # 1161995 is recommended.

P0013413

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 Installation, Aquamatic drive

Summary

Summary, electronic steering

• No retrofitting, only new installation.

• Only twin installations.
• The minimum distance between engine centers is
950 mm.
• Hydraulic system to be thoroughly vented at initial
start-up.
• The joystick must be calibrated at the fist start.
• Separate battery arrays for start and the ES system.
• The system is supplied pre-installed and tested by
the manufacturer.
• Do not install the SCU with hoses pointing up.

NOTICE! Important; chassis numbers must match to

ensure plug and play function.

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Installation, Aquamatic drive

Hydraulic Steering System

Aquamatic

NOTICE! No hydraulic parallel rod connections are

described in the illustrations. For information regarding
the parallel rod system, refer to the
Installation, page 150 chapter.

Single installation – DPH/DPR

Single helm station

1 Steering pump
2 Plugged connection
a. Relief valve
3 Hydraulic hoses, low
pressure
4 Connections
5 Hydraulic hoses, high
pressure
6 Drain hose
7 4-way connections
8 P-clamp
9 Valve block
10 Recovery tank
(reservoir)
11 Power steering pump
12 Oil cooler

P0007719

IMPORTANT!
The connection at plug no. 2 may never be used; this
is to ensure the correct oil level in the steering pump.

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Single installation – DPH/DPR

Main helm station and secondary helm station

p0007720

1 Steering pump The connections to the oil cooler and power steering
a. Steering pump, secondary helm station pump are not shown; refer to the illustration for single
installations, single helm station
2 Plugged connection
a. Relief valve
b. Plug
IMPORTANT!
3 Hydraulic hoses, low pressure The connection at plug no. 2 may never be used; this
is to ensure the correct oil level in the steering pump.
4 Connections
5 Hydraulic hoses, high pressure
6 Drain hose
7 4-way connections
8 P-clamp
9 Valve block
10 Recovery tank (reservoir)
11 —
12 —
13 T-connections

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Single installation – DPH/DPR

Single helm station
Autopilot installed

2a

14
10 8
6
4 2
8

12

11
P0007721

1 Steering pump IMPORTANT!

2 Plugged connection The connection at plug no. 2 may never be used; this
a. Relief valve is to ensure the correct oil level in the steering pump.
3 Hydraulic hoses, low pressure
4 Connections
5 Hydraulic hoses, high pressure
6 Drain hose
7 4-way connections
8 P-clamp
9 Valve block
10 Recovery tank (reservoir)
11 Power steering pump
12 Oil cooler
13 —
14 Autopilot

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 Installation, Aquamatic drive

Single installation – DPH/DPR

Main helm station and secondary helm station
Autopilot installed

14

p0007722

1 Steering pump The connections to the oil cooler and power steering
a. Steering pump, secondary helm station pump are not shown; refer to the illustration for single
installations, autopilot installed.
2 Plugged connection
a. Relief valve
b. Plug
IMPORTANT!
3 Hydraulic hoses, low pressure The connection at plug no. 2 may never be used; this
is to ensure the correct oil level in the steering pump.
4 Connections
5 Hydraulic hoses, high pressure
6 Drain hose
7 4-way connections
8 P-clamp
9 Valve block
10 Recovery tank (reservoir)
11 —
12 —
13 T-connections
14 Autopilot

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Installation, Aquamatic drive

Twin installation – DPH

Single helm station

2a

10 8

6 1

4 2
8 9a
8

12
5

15

16
11

P0007723

1 Steering pump IMPORTANT!

2 Plugged connection The connection at plug no. 2 may never be used; this
a. Relief valve is to ensure the correct oil level in the steering pump.
3 Hydraulic hoses, low pressure
4 Connections
5 Hydraulic hoses, high pressure
6 Drain hose
7 4-way connections
8 P-clamp
9 Valve block
a. Hoses from the port sterndrive
10 Recovery tank (reservoir)
11 Power steering pump
12 Oil cooler
13 —
14 —
15 Starboard transom shield
16 Port transom shield

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Twin installation – DPH

Main helm station and secondary helm station

p0007724

1 Steering pump The connections to the oil cooler and power steering
a. Steering pump, secondary helm station pump are not shown; refer to Twin installation, single
helm station.
2 Plugged connection
a. Relief valve
b. Plug
IMPORTANT!
3 Hydraulic hoses, low pressure The connection at plug no. 2 may never be used; this
is to ensure the correct oil level in the steering pump.
4 Connections
5 Hydraulic hoses, high pressure
6 Drain hose
7 4-way connections
8 P-clamp
9 Valve block
a. Hoses from the port sterndrive
10 Recovery tank (reservoir)
11 —
12 —
13 T-connections
14 —
15 Starboard transom shield
16 Port transom shield

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Installation, Aquamatic drive

Twin installation – DPH

Single helm station
Autopilot installed

2a

14
10 8
1
6 2
4 9a
8 8

9
12

15

11
P0007725 16

1 Steering pump IMPORTANT!

2 Plugged connection The connection at plug no. 2 may never be used; this
a. Relief valve is to ensure the correct oil level in the steering pump.
3 Hydraulic hoses, low pressure
4 Connections
5 Hydraulic hoses, high pressure
6 Drain hose
7 4-way connections
8 P-clamp
9 Valve block
a. Hoses from the port sterndrive
10 Recovery tank (reservoir)
11 Power steering pump
12 Oil cooler
13 —
14 Autopilot
15 Starboard transom shield
16 Port transom shield

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 Installation, Aquamatic drive

Twin installation – DPH

Main helm station and secondary helm station
Autopilot installed

2b

1a

p0007726

1 Steering pump The connections to the oil cooler and power steering
a. Steering pump, secondary helm station pump are not shown; refer to Twin installation, single
helm station, autopilot installed.
2 Plugged connection
a. Relief valve
b. Plug
IMPORTANT!
3 Hydraulic hoses, low pressure The connection at plug no. 2 may never be used; this
is to ensure the correct oil level in the steering pump.
4 Connections
5 Hydraulic hoses, high pressure
6 Drain hose
7 4-way connections
8 P-clamp
9 Valve block
a. Hoses from the port sterndrive
10 Recovery tank (reservoir)
11 —
12 —
13 T-connections
14 Autopilot
15 Starboard transom shield
16 Port transom shield

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Installation, Aquamatic drive

Twin installation – DPR

Single helm station

11
P0007727

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 Installation, Aquamatic drive

1 Steering pump IMPORTANT!

2 Plugged connection The connection at plug no. 2 may never be used; this
a. Relief valve is to ensure the correct oil level in the steering pump.
3 Hydraulic hoses, low pressure
4 Connections
5 Hydraulic hoses, high pressure
6 Drain hose
7 4-way connections
8 P-clamp
9 Valve block
10 Recovery tank (reservoir)
11 Power steering pump
12 Oil cooler
13 —
14 —
15 Starboard transom shield
16 Port transom shield
17 Manifold
18 Union, 4-way

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Installation, Aquamatic drive

Twin installation – DPR

Main helm station and secondary helm station

P0007728

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 Installation, Aquamatic drive

1 Steering pump The connections to the oil cooler and power steering
a. Steering pump, secondary helm station pump are not shown; refer to Twin installation, single
helm station.
2 Plugged connection
a. Relief valve
b. Plug
IMPORTANT!
3 Hydraulic hoses, low pressure The connection at plug no. 2 may never be used; this
is to ensure the correct oil level in the steering pump.
4 Connections
5 Hydraulic hoses, high pressure
6 Drain hose
7 4-way connections
8 P-clamp
9 Valve block
10 Recovery tank (reservoir)
11 —
12 —
13 T-connections
14 —
15 Starboard transom shield
16 Port transom shield
17 Manifold
18 Union, 4-way

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Installation, Aquamatic drive

Twin installation – DPR

Single helm station
Autopilot installed

11
P0007729

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 Installation, Aquamatic drive

1 Steering pump IMPORTANT!

2 Plugged connection The connection at plug no. 2 may never be used; this
a. Relief valve is to ensure the correct oil level in the steering pump.
3 Hydraulic hoses, low pressure
4 Connections
5 Hydraulic hoses, high pressure
6 Drain hose
7 4-way connections
8 P-clamp
9 Valve block
10 Recovery tank (reservoir)
11 Power steering pump
12 Oil cooler
13 T-connection
14 Autopilot
15 Starboard transom shield
16 Port transom shield
17 Manifold
18 Union, 4-way

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Installation, Aquamatic drive

Twin installation – DPR

Main helm station and secondary helm station
Autopilot installed

P0007730

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 Installation, Aquamatic drive

1 Steering pump The connections to the oil cooler and power steering
a. Steering pump, secondary helm station pump are not shown; refer to Twin installation, single
helm station, autopilot installed.
2 Plugged connection
a. Relief valve
b. Plug
IMPORTANT!
3 Hydraulic hoses, low pressure The connection at plug no. 2 may never be used; this
is to ensure the correct oil level in the steering pump.
4 Connections
5 Hydraulic hoses, high pressure
6 Drain hose
7 4-way connections
8 P-clamp
9 Valve block
10 Recovery tank (reservoir)
11 —
12 —
13 T-connections
14 Autopilot
15 Starboard transom shield
16 Port transom shield
17 Manifold
18 Union, 4-way

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Installation, Aquamatic drive

Installation
Aquamatic

IMPORTANT!
Be extremely thorough with cleanliness when working
on steering system hydraulics. Thoroughly clean the
components externally before disassembly. The
workplace must be clean and well lit.

IMPORTANT!
Always use Volvo Penta hydraulic hoses in order to
attain good steering characteristics. Make sure the
hoses do not come into contact with hot surfaces.
Secure the hoses with suitable brackets. Distance
between brackets: approx. 250 mm (10").

p0007731

Before the engine is installed, steps 1–2

7 1 Install the hoses (4) and the 4-way connections
(7).
Tightening torque: 22 Nm (16.2 lbf.ft)
4
Twin installation – DPH:
9
9a 8 2 Connect the hoses (9a) from the port transom
shield (16) to the valve block (9) on the starboard
transom shield (15).
Tightening torque: 21 Nm (15.5 lbf.ft)

IMPORTANT!
Clamp all hoses securely (8).

15
P0007732
16

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 Installation, Aquamatic drive

Twin installation – DPR:

2a Remove the valve block from the starboard
transom shield and the hydraulic manifold from
the port transom shield.

2b Install the new hydraulic manifold on the the port

transom shield and fasten the larger manifold to
the transom.

2c Connect the hoses from the transom shields to

the larger manifold (17).

2d Change the disc and the old ground wire on the

port transom shield. Install the inner steering
cylinder on the port transom shield.
Tightening torque: 21 Nm (15.5 lbf.ft)

IMPORTANT!
Clamp all hoses securely.

p0007733

The following steps, 3-6, can be

completed when the engine is installed
3 Run the hoses to the main helm station. Install the
steering pump (1) and connect the hoses to the
pump as illustrated.
Tightening torques for hose unions on the
steering pump back: Tighten by hand, and
then a further 1½-2½ turns depending on
the required union direction. Max. torque
17.5 Nm (13 lbf.ft).

IMPORTANT!
p0007734 Clamp all hoses securely.

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Installation, Aquamatic drive

Secondary helm station, where fitted:

4 Install the T-connections and the steering pump
(1a) at the second helm station; see illustrations.
Connect and secure the hoses.
Connect the drainage hose (6) to the recovery
tank (10). Position (2) is a plug.
Tightening torques, T-connections: 22 Nm
(16 lbf.ft)
Tightening torques for hose unions on the
steering pump back: Tighten by hand, and
then a further 1½-2½ turns depending on
the required union direction. Max. torque
17.5 Nm (13 lbf.ft).

IMPORTANT!
Clamp all hoses securely.
5 Replace the relief valve (2a) on the lower steering
pump with a seal plug (2b). In this case, the lower
steering pump is the one at the main helm station.

p0007736

Autopilot, if such is to be included:

7 6 Install the autopilot (14). Fit a T-connector to the
drainage hose (6) that runs to the recovery tank
(10).
14 Connect the hoses from the autopilot to the
6 existing 4-way connectors (7) on the hoses, and
to the T-connector on the drainage hose (6).

IMPORTANT!
10
Clamp all hoses securely.
p0007722 The 4-way connectors are also used for venting.

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 Installation, Aquamatic drive

After engine installation, steps 7-10

7 When the engine installation is completed, the
recovery tank (10) must be installed in a suitable
place, e.g. on a bulkhead and higher than the
steering valve on the transom shield (or on the
transom for DPR twin steering).

NOTICE! The tank must not be installed on the

engine. Connect the return hoses from the
steering pump and autopilot to the recovery tank.

IMPORTANT!
Because of their weight, all three hoses to the
recovery tank must be securely clamped to a
bulkhead or similar, as illustrated. A = max. 0.5 m
(20").

p0007738

8 Connect the two high pressure hoses (A and B)

from the valve block:
10 Hose union (A) to the power steering pump (11)
on the engine. Tightening torque: 22 Nm (16
lbf.ft).
Hose union (B) to the steering system oil cooler
(12). Tightening torque: 22 Nm (16 lbf.ft).

12 NOTICE! There are two steering system oil

coolers on a DPR twin installation.
9 Fill the system with ATF oil of type Dexron II or III.
Volvo Penta part no. 1161995 is recommended.
10 Vent the steering system. Refer to the Steering
System, Bleeding and Fillingsection.

11

P0007762

DPH/DPR single, DPH twin

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Installation, Aquamatic drive

Overview of hose unions – DPH twin installations

Tightening torques
B
A A B
A A

A
A A
A

A A

P0007740

A 22 Nm (16.2 lbf.ft)
B Tighten by hand, then 1.5–2.5 turns. Max. 17.5 Nm (13 lbf.ft).

Hydraulic flow diagram

1 Steering pump

1 2 Power steering
pump (high
pressure)
2 3
3 Oil cooler
4
4 Reservoir

p0007741

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 Installation, Aquamatic drive

Overview of hose unions – DPR twin installations

Tightening torques
C
2 1

1 2
3 4
3 4

C
1 2 1 2

3 4 3 4

A A
A
A A

A 22 Nm (16.2 lbf.ft)
B 21 Nm (15.5 lbf.ft)
C Tighten by hand, then 1.5–2.5 turns. Max. 17.5 Nm (13 lbf.ft).

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Installation, Aquamatic drive

Hydraulic flow diagram

1 Steering pump
2 Power steering
1 pump (high
pressure)
2 3 4
3 Oil cooler
5 4 Oil cooler
5 Reservoir

p0007743

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With engine installed
C
B
3588044 A
P0008959
NOTICE! This section applies to both DPH and DPR
applications. The power steering reservoir 3588044
illustrated must be placed above the highest installed
steering pump in the system when venting.
IMPORTANT!
Be extremely thorough with cleanliness when working
on steering system hydraulics. Thoroughly clean the
components externally before disassembly. The
workplace must be clean and well lit.
Power steering fluid
The recommended power steering fluid is ATF oil type
Dexron II or III, Volvo Penta part no. 1161995.
47704210 02-2018 © AB VOLVO PENTA
Installation, Aquamatic drive
Steering System, Bleeding and
Filling
IMPORTANT!
Never use brake fluid or hydraulic fluid. Non-approved
fluids may cause irreparable damage, loss of steering
ability and warranty revocation.
IMPORTANT!
In cases of extreme emergency, any kind of non-toxic
fluid will provide temporary steering ability.
Filling and venting the autopilot
The autopilot must be connected to the 4-way
connectors, filled and vented together with the Volvo
Penta steering system.
141
Installation, Aquamatic drive

Tools:
885597 Handle
3588044 Purging tool

1 Check that the steering system hoses and

connections are correctly installed.

IMPORTANT!
Make sure the hoses have a continual drop from
the recovery tank to the 4-way connectors, that
they do not run in loops or bends, and that the
connections point up or to the side. This speeds
up the venting process.

2 Locate the filler tank/venting tool

(3588044 Purging tool) as high as possible and
above the highest located helm station so that
the hoses have a continual drop to the 4-way
connectors. Remove the plugs (A) from the 4-
way connectors and install the two adapters (B)
on the venting tool lines. Install the two
connectors (C) from the venting tool to the
adapters.

3 Remove the cover to the recovery tank for the

power steering and undo the snap connector (D)
from the recovery tank cover. Connect the return
hose with the aid of the associated snap
connector (E).

4 Rudder and hose venting

Single helm station

Turn the wheel approximately 150 turns in one
direction or (if the tank is visible from the helm station)
until no more large air bubbles can be seen in the
recovery tank pipes. The hoses between the 4-way
connectors and the helm station are now filled.

Twin helm stations

IMPORTANT!
When an installation with an auxiliary helm station
(flybridge) is filled, the wheel at the lower helm station
must be turned first, and then the upper.

Beginning with the wheel at the lower helm station;

turn it about 60 turns to starboard.
Then turn the wheel at the upper helm station about
150 turns to starboard.

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 Installation, Aquamatic drive

5 Autopilot, venting

Run the autopilot to starboard for at least one minute.

Then run the autopilot to port for at least one minute.

NOTICE! Refer to the autopilot manufacturer's

documentation regarding operational limits.

6 Venting steering cylinders

NOTICE! Rapid movement of the sterndrive or

cylinder may cause the fluid in the recovery tank to
overflow.

With installed sterndrive

If the boat is on land turn the sterndrives by hand hard
to port. Wait around 5 seconds and then turn it hard
to starboard. Wait 15 seconds. Repeat this procedure
four times. If the boat is in water follow the procedure
to purge the system with the filler tank/venting tool
then disconnect the venting tool snap connectors (C).
Turn the sterndrives hard to port using the steering
wheel. Wait around 5 seconds and then turn it hard to
starboard. Wait 15 seconds. Connect the filler tank/
venting tool snap connectors (C) and repeat the same
procedure four more times.

P0008871

No installed sterndrive
If the sterndrive is not installed, each steering cylinder
piston rod must be pulled out and pushed in manually.
Repeat five times and check that each cylinder piston
rod moves in when the other is pulled out to simulate
sterndrive movement.

P0008872

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Installation, Aquamatic drive

NOTICE! Check that the cylinders are left in the dead

ahead position with 337 mm (13.27") distance from
pin to pin. It is possible to lock the cylinders by
installing 885597 Handle. If both cylinders are left
completely pushed in or drawn out it will be impossible
to install the sterndrive.

7 First disconnect the snap connectors (C) to

minimize spillage. Then disconnect the adapters
(B) from the 4-way connectors. B and C can be
found in the illustrations at the beginning of this
chapter. Hold a rag under the adapters to collect
the fluid that remains in the connectors. Plug the
two 4-way connectors.

Tightening torque: 22 Nm (16.2 lbf.ft.).

8 Remove the hose from the filler tank to the power

steering recovery line. Replace the recovery
P0008873 885 597 tank cover and reconnect the line to the recovery
tank cover.

NOTICE! In order to ensure correct steering

system venting, fill fluid to the rim and start the
engine. Fill the system again as necessary after
the engine has been shut down. Further topping
off may be necessary if the boat has been
unused for some time after the first system
venting.

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 Installation, Aquamatic drive

Engine not installed

3588044

D
E
D

P0008960

1 Fill and vent the system according to the

procedure described earlier in the With engine
installed section.

NOTICE! Use the snap connector (D) from the

recovery tank cover to connect to the snap
connector female part (E) from 3588044 Purging
tool. The recovery tank and cover are included in
the engine kit.

NOTICE! Allow the two plugs (F) to remain in the

hose connectors.
2 When the engine is installed and the steering
system vented, the recovery tank may be filled so
that the level reaches the tank collar. Refer to the
Filling with engine installed section on the next
page.

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Installation, Aquamatic drive

Filling with engine installed

1 Fill the power steering system so that the level is
just beneath the tank collar.
2 Fill the steering pump (only the uppermost
steering pump).

P0008876

For pumps with a horizontal wheel shaft, and up to

20°:
The fluid level must be:
Min
12 mm (½ ) 20 - at least 12 mm (1/2") below the filler hole lower rim.
- maximum at the filler hole lower edge.

P0008877

Pumps that are at an angle >20° and up to vertical:

The fluid level must be approximately 12 mm (1/2")
below the filler hole lower rim.

NOTICE! Always check the fluid levels in the steering

>20° pumps and recovery tank after sea trials.
12 mm (½ )

P0008878

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 Installation, Aquamatic drive

Steering system checks

Check that the steering system pipes, hoses and
connections are correctly connected, that there are no
leaks and that venting has been properly completed.
1 Disconnect the hoses and connectors to the
venting tool and plug the T-connectors.
Tightening torque: 22 Nm (16 lbf.ft.).
2 Turn the wheel (turn all wheels on systems with
several helm stations) very hard to port. Turn the
wheel hard over enough to exceed relief valve
pressure. The steering pump will slip and stutter
when the relief valve lifts. The steering pump and
steering system will not be damaged during this
procedure.
3 Maintain the pressure on the wheel and check
port side connections and connectors.
4 Repeat the procedure by turning the wheel to
starboard.
5 Check the fluid level in the steering pump when
the wheel has been turned hard over in both
directions.

If the fluid has not dropped noticeably:

All air is absent.

If the fluid has dropped noticeably:

Air in the system was compressed; further topping
off and venting is required.

If there are no leaks, the system is ready for use.

IMPORTANT!
Remedy leaks before the system is used. Failure
to remedy a leak may cause the fluid level in the
system to drop, with the loss of steering ability as
a result.

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Installation, Aquamatic drive
Fault
1 The steering is very light and
there are more turns between
full locks than usual.
VP standard pump, 3½ turns
between helms hard over.
2 During replenishment the
steering pump will be
completely locked.
3 The system is very difficult to fill.
Air will issue from the top of the
steering pump even after the
system appears full.
4 Steering is stiff and difficult
even when the boat is
stationary.
5 One steering unit in the system
is very jerky and requires too
many turns between end stops.
148
Engine Troubleshooting Guides
The majority of faults occur when installation
instructions are not followed, and usually appear as
soon as the system is replenished. The most common
faults and their probable causes and remedies are
listed below.
Occasionally a slight resistance is felt and a clicking
sound heard when the wheel is released after being
hard over. This is not because of a fault in the system,
but is a perfectly normal sound from the steering pump.
IMPORTANT!
Where the text below indicates a solution that requires
the system to be dismantled or removed from the boat,
the work may only be performed by a mechanic trained
in marine hydraulics. Volvo Penta provides the
following information purely as a guide and takes no
responsibility for consequences that may arise from
incorrectly performed disassembly or repairs.
Cause Solution
• Air in the system. • Replenish fluid in steering pump and
recovery tank.
Follow the instructions for filling and venting
again.
• Blockage in the line • Check that no pipe or hose was pinched
between the helm during installation. If this is the case, the
station(s) and damaged section must be replaced with a
cylinder(s). new section spliced in with pipe unions.
Check the connections with regard to
imperfectly drilled holes. However,
imperfectly drilled holes in unions are
unusual.
• Air in the system. • Follow the instructions for filling and venting
again.
• Flow restriction in • Find restriction and remedy.
hoses or unions.
NOTICE! A pinched or bent hose is sufficient
to cause a flow restriction.
• Air in the system. • Follow the instructions for filling and venting
again.
• Wrong type of fluid • Empty the system and fill with recommended
used when fluid.
replenishing the
system.
• Air in the system. • Follow the instructions for filling and venting
again.
• Dirt in the steering • Disassemble the steering pump and remove
pump control the contaminants from the control valves.
valves.
47704210 02-2018 © AB VOLVO PENTA

Fault
6 Steering is easy in harbor, but
becomes difficult when the
vessel is boat way.
7 The boat turns to port or
starboard when under way,
even if the wheel is not turned.
8 When the wheel is turned, the
other wheel turns
simultaneously.
9 Seals may sometimes leak if
the steering system is not
vented at the upper helm
station.
47704210 02-2018 © AB VOLVO PENTA
Installation, Aquamatic drive
Cause Solution
• Wheel is too small. • Install a larger wheel if possible; refer to the
installation instructions. Continue to the next
cause and remedy or contact Volvo Penta if
the problem cannot be solved by the above
remedies.
• Faulty sterndrive • Adjust the trim.
trim adjustment.
• Air in the system. • Follow the instructions for filling and venting
again.
• Dirt in the control • Remove the plugs for the steering valves.
valves. These are the large plugs on each side of the
rear of the steering pump. Clean the valve
seats and balls. Reinstall.
NOTICE! Be prepared for a certain amount
of fluid leakage during this procedure. Have
a small container available. Replenish the
system again when the steering valves have
been reinstalled.
• Refer to fault no. 6. • Refer to fault no. 6.
• The steering pump has an easily-replaced
shaft seal that is replaced simply by removing
the wheel and seal cover attached by three
small screws.
149
Installation, Aquamatic drive

Sterndrive Installation
Aquamatic

Tools:
884573 Screwdriver (flexible)
885595 Mounting tool
885597 Handle
885800 Suspension tool

Preparations
1 Open the package by lifting off the upper part.

VO
PELV
NTO
A

P0007768

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 Installation, Aquamatic drive

2 Install the u-joint bellows on the upper gear case

collar. Slide the hose clamp onto the u-joint
bellows and install it. Align the hose clamp screw
in the 6 o'clock position, and then tighten the
clamp. Use 884573 Screwdriver (flexible).
Tightening torque 4–7 Nm (3.0–5.2 lbf.ft.).

IMPORTANT!
Note the clamp positions and the mark UP on the
bellows.

THIS SIDE UP

DRIVE

P0021611

3 Remove the lock bolts and washers. Pull the pivot

pins out.

P0007770

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Installation, Aquamatic drive

4 Grease the pivot pins. Use Volvo Penta

waterproof grease, part # 828250. Press the pivot
pins in again until they are level with the inboard
828 250 side of the transom.

p0007771

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 Installation, Aquamatic drive

Installing the sterndrive on the transom

shield

There are four different ways of lifting and

installing the sterndrive.
A Lift the sterndrive with a hoist and lifting strap (1).
Strap length must be around 2.5 m (101"). Note how
the strap is attached.
B Use a pallet lifter to lift the sterndrive into position.
The sterndrive must remain in the box.
C Two people can lift the sterndrive by hand using the
handles, special tool 885597 Handle. The tool kit
comprises two handles and four pins.
D Lift the sterndrive using a hoist and straps secured
with shackles to 885597 Handle.

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Installation, Aquamatic drive

1 Install the slide brackets, special tool

885595 Mounting tool on the pivot pins on both
sides of the transom shield.

P0007773

2 Install the pivot pin bushings.

3 Hang a hose clamp on the bellows.

P0007774

4 Lift the sterndrive up onto the slide brackets

installed on the transom shield.

P0007775

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 Installation, Aquamatic drive

5 Push the sterndrive forward toward the driveshaft

0
8 25 and turn the u-joint at the same time so that the
82 drive shaft splines fit into the corresponding
grooves in the u-joint. Grease the splines before
installation.

P0007776

6 Align the suspension fork so that the pivot pins

line up with the holes in the suspension fork.
Make sure the pivot pins are well greased. Using
a plastic mallet, tap the pins into position so that
their ends are level with the transom shield.

NOTICE! Never use a regular hammer; this may

damage the pivot pins and make them difficult to
remove.

Remove the slide brackets.

P0007777

7 Grease the lock bolts and install them. Use Volvo

Penta waterproof grease, part # 828250.

NOTICE! Do not forget the washers under the

bolt heads.

Tightening torque: 24 Nm (17 lbf.ft.)

0
25
28 8

P0007778

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Installation, Aquamatic drive

8 Install the u-joint bellows on the flywheel housing

collar. Carefully check that the rubber bellows is
seated correctly.
Tighten the hose clamp with the screw in the 3
o'clock position. The screw head must point
downwards. Tightening torque 4–7 Nm (3.0–5.2
lbf.ft.).

P0007779

9 Always use the locking tool, special tool

885 800 885800 Suspension tool, when working under the
sterndrive. The locking tool locks the sterndrive in
the raised position.

Installing the locking tool:

Lift the sterndrive by hand. Hold the sterndrive in
position and install the locking tool on the
starboard side, as illustrated.
WARNING!
Secure the drive unit in a raised position in such
a way that it cannot fall when working on the drive
bellows. A falling drive may cause serious injury.
P0007780

10 Turn the drive to starboard. Install a hose clamp

on the seawater hose.
Connect the hose to the hose union. Check that
the hose clamp screw is in the 8 o'clock position
with the screw head facing upwards. Tighten the
hose clamp using 884573 screwdriver (flexible).
Tightening torque 4–7 Nm (3.0–5.2 lbf.ft.).

IMPORTANT!
Bend the hose clamp band as illustrated to protect
the bellows.

P0007781

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 Installation, Aquamatic drive

11 Install the exhaust bellows onto the sterndrive

with a hose clamp. Carefully check that the rubber
bellows is seated correctly.
The exhaust bellows is factory installed on the
transom shield.
Tighten the hose clamp with 884573 Screwdriver
(flexible) so that the screw is in the 10 o'clock
position with the screw head facing downwards.
Tightening torque 4–7 Nm (3.0–5.2 lbf.ft.).
Remove 885800 Suspension tool from the
sterndrive.

P0007782

12 Slide the trim cylinders into the suspension fork.

Grease the clevis pins with water resistant
grease, VP part # 828250. Center the holes and
install the pins. Lock the bolts with cotter pins;
bend the pin legs carefully, as illustrated.

250
828

P0008813

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Installation, Aquamatic drive

13 Slide the steering cylinders into the suspension

fork. Grease the clevis pins with water resistant
grease, VP part # 828250. Center the holes and
install the pins. Connect the ground cables to the
steering cylinders and then slide them into the
sterndrive steering cylinder attachment points.
Lock the bolts with cotter pins; bend the pin legs
carefully, as illustrated.

828
2 50

P0007687

Connecting gearshift cables and ground

cables

IMPORTANT!
Do not forget to start the EVC system before the
gearshift cable is attached to the sterndrive. This is to
ensure that the actuator is correctly aligned in the
neutral position (N).

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 Installation, Aquamatic drive

N
14 Install the gearshift cable using the cable clamp
R
(1)
F
NOTICE! Control cable quality is important for
shift control function. Use only Volvo Penta X-
ACT cable.

NOTICE! The clamp can only be installed one

R way.

Adjust the gear shift cable.

N Put the gear lever in the neutral position and the
sterndrive shift arm (3) in the horizontal position.

F Check for any play in the cable and adjust as

follows:
3 B
A=B a Push the wire as far into the sheath as
A possible and then pull it out as far as
possible.
1
b Push the wire into the sheath again to a
distance equivalent to half the play.
With the gearshift cable in the correct position
according to the above, install the locking nut and
linkage onto the gearshift cable sufficiently far in
2 for the linkage to be fitted into the lever without
having to be moved in either direction.
Fasten the linkage to the shift arm with a washer
and cotter pin. Bend out the cotter pin in the
correct manner.

P0007784

15 Also attach the ground wire (2) to one of the clamp

screws. In twin installations the port side ground
cable must be run above the exhaust bellows.

P0007785

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Installation, Aquamatic drive

In twin installations the port side sterndrive

ground cable (2) must be run above the exhaust
bellows.

P0008901

16 Install the cover with six bolts.

P0007787

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 Installation, Aquamatic drive

Parallel rod
Aquamatic
In twin installations an external parallel rod must be
installed between the drives. Volvo Penta has two
types of parallel rods: mechanical and hydraulic.

Mechanical parallel rod

Mechanical parallel rods are available in two versions,
and the distance between crankshaft centers can be
adjusted as follows:

Standard: 950–1,030 mm (37.4–40.6”)

Extra long: 1,050–1,240 mm (41.3–48.8”)

1 Set both sterndrives in the straight ahead position.

828 Undo the sleeves (1) on the parallel rod and screw
250
both P ends (2) as far as possible into the parallel
rod.

DPH only
2 Apply Volvo Penta grease part no. 828250 onto the
2 1 bolts. Attach one end of the parallel rod to one of
the stern rive steering cylinder attachments. Install
the clevis pin and lock with a cotter pin. Bend out
the cotter pin legs carefully.

NOTICE! The clevis pins and cotter pins are

3
1 supplied with the sterndrive. Adjust parallel rod
P0007788
length by turning the center section (3) at the same
time as the fee end is held fast.

DPR only
2 Attach one end of the parallel rod under one of the
sterndrive steering cylinder attachments. Install
1 the bolt and washers and fasten with a nut.
2
NOTICE! Adjust parallel rod length by turning the
center section (3) at the same time as the fee end
is held fast.

3 3 Adjust parallel rod length until the P end fits

1 properly in position on the other sterndrive steering
P0007789
cylinder attachment.

Install the clevis pin and cotter pin. Bend out the
cotter pin legs carefully.

Check the toe-in angle.

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Installation, Aquamatic drive

A B Toe-in angle
To achieve good performance and rudder feel on twin
installations, toe-in must be adjusted.

Because water flow aft of the transom differs

depending on hull form and boat speed, toe-in can be
adjusted to optimize top speed or cruising speed.

Less toe-in (sterndrives set straighter) is suitable for

• deeper V hulls.
• optimizing for high top speed.
P0007790

A Low speed
B High speed

Standard recommendation:
A Use B = A as the starting point for planing boats, which
generally provides good results. For optimal results set
the dimension B somewhat smaller than dimension A
so that a suitable toe-in configuration is achieved. An
optimal result can only be achieved by trial and error,
and the precise toe-in angle varies from boat to boat.

B 4 Lock the parallel rod by tightening the two sleeves.

P0007791

IMPORTANT!
Check that no thread is showing outside the sleeves
(1) before they are tightened.

Tighten the sleeves.

Tightening torque: 125 ±5 Nm (92.1±4 lb ft)

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 Installation, Aquamatic drive

Hydraulic parallel rod (DPH only)

In the hydraulic parallel rod concept the hydraulic rams
(the inner steering cylinders) (1) are installed on each
sterndrive and connected hydraulically via the valve
block (2).

Purging and replenishing the steering system

After filling the parallel rods, the steering system must
be replenished according to the standard procedure
described in the Steering System, Bleeding and
Filling chapter.

NOTICE! When the hydraulic parallel rod is installed,

1
the hoses between the cylinders and purging points
are longer than on a normal installation. It takes more
P0007792 time for air bubbles to proceed the entire way to the
purging lines. Therefore wait 10-15 seconds instead of
5 seconds on each standard procedure that requires a
wait period.
3 Adjusting the hydraulic parallel rod
The parallel rod can be adjusted when the boat is in
the water or on land.

2 1 Boat in the water:

1.1 Loosen the adjuster bolt (3) 1-2 turns.
1.2 With the engines running, turn the helm hard to one
side, until the helm pump reaches the stop
position. Both sterndrives are then fully turned to
one side.
1.3 Tighten the adjuster bolt (3 securely, tightening
torque 30 Nm (22.1 lbf.ft.).

This procedure ensures the sterndrives are parallel to

one another (straight ahead).

2 Boat ashore:
2.1 Loosen the adjuster bolt (3) 1-2 turns.
P0008930
2.2 Align the sterndrives in the desired direction
(straight ahead recommended).
2.3 Tighten the adjuster bolt (3 securely, tightening
torque 30 Nm (22.1 lbf.ft.).

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Installation, Aquamatic drive

Rudder Indicator and Autopilot

Interface
Aquamatic

NOTICE! The rudder indicator cable must always be

installed on the starboard side of the single or
starboard sterndrive.

The illustration shows the rudder indicator push-pull

cable installed on the sterndrive steering cylinder.

P0007794

0 0 Connecting the cable to a rudder indicator/autopilot

interface.

X
X X

P0007795

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 Installation, Aquamatic drive

Propeller, Installation
Tools:
21318669 Rotation tool

Only G series propellers may be used on DPH

sterndrives.
Only GR series propellers may be used on DPR
sterndrives.
WARNING!
Make sure the engine can not start during work on
propeller(s); remove ignition key(s) and shift drive into
forward or reverse.

1 Lock the propeller shaft. This may be done in one

of two ways:
a Remove the shift cable from the sterndrive.
Connect the sterndrive manually.
IMPORTANT!
Never use the EVC control to connect the
drive.
b Select NEUTRAL. Place a block of wood
between the cavitation plate and one of the
propeller blades.
2 DPH
25 0
828
Grease the propeller shaft and propeller hub with
water resistant grease.
Install the ahead propeller (1) and the nut (2).
Using 21318669 Rotation tool torque the nut to
250 200 Nm
828 200 Nm (150 lbf.ft).
(150 lbf.ft)

1
2
21318669
P0010473

DPR
2 50
828 Grease the propeller shaft and propeller hub with
1 water resistant grease.
Install the ahead propeller (1) and the nut (2).
250 Using 21318669 Rotation tool torque the nut to
828 200 Nm
(150 lbf.ft) 200 Nm (150 lbf.ft).

2
21318669
P0010474

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Installation, Aquamatic drive

3 DPH
Lock the propeller shaft according to 1a or 1b.
Grease the propeller shaft and propeller hub with
water resistant grease.
Install the aft propeller (1) and propeller cone (2).
Torque the cone with a 27 mm wrench to 100 Nm
(75 lbf.ft). Tighten the bolt (3) to 80 Nm (59 lbf.ft.).

0 DPR
25 Lock the propeller shaft according to 1a or 1b.
828
Grease the propeller shaft and propeller hub with
water resistant grease.
50
828 2 Install the aft propeller (1) and the nut (2).
30 mm Tighten the nut with a 30 mm (1.18 tum) socket
till 100 Nm (75 lbf.ft).
1 2

P0007693

4 The gear must be in the NEUTRAL position

before the engine is started.

Choosing propellers
NOTICE! Engines with outputs from 370 hp to 400 hp
may NOT be run using G9 - G10 propellers.

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 Installation, Aquamatic drive

Shift Actuator, Check-up

Check the actuator in the engine compartment
1 Remove the cotter pin (1) from the actuator pin (2).
2 Pull the sleeve (3) and cable from the actuator pin
(2).
3 Make sure the cable is properly in the neutral
position by feeling the forward and aft play.
NOTICE! Forward/aft play should only be felt on the
cable and sterndrive actuator. Do not pull hard
enough for a gear to engage.
4 With the cable detached, make sure the actuator is
in the neutral position by switching the ignition on
and off once.
2
5 When the cable is fully in the neutral position it
P0012628 3 1 should be possible to slide the sleeve (3) onto the
pin (2) without having to tension the cable in either
direction.
a If the cable requires tension forward or aft it must
be adjusted by undoing the locking nut and
screwing the sleeve (3) a suitable number of turns.
b Lock the sleeve with the locking nut.
6 Install the cotter pin (1).

IMPORTANT!
Use a new cotter pin if the old one is defective.

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Installation, Inboard Applications

Inboard Applications
Engine Foundation
Inboard engines

Leveling the boat

Installation will be easier if the hull is leveled before
work is begun. Chock the boat so that the calculated
WL
waterlines, longitudinal and transverse, are parallel
with the horizontal plane. A spirit level is very helpful.

When the bed is built up, check that the upper bed
plane, the level plane, is correctly positioned and
P0005915 parallel in relation to the propeller shaft center line. A
guide sleeve with the same diameter as the propeller
shaft may be used in the stern tube to assist with
aligning the engine bed.

General
The engine bed must be dimensioned such that it is
rigid in all directions in order to distribute as much of
the load to the hull as possible. The largest possible
engine bed and cross beam surface area must be fixed
to the hull in order to provide the best noise and
vibration insulation.

P0005916

An example of a well-designed engine bed

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 Installation, Inboard Applications

Design
The bed must be of a design that is able, with sufficient
margin, to absorb engine torque, propeller thrust and
the dynamic torsional forces that occur during
movement in rough seas.

It is important that there is sufficient space beneath the

engine for it to be able to move and for inspection
covers to be accessible (certain engine versions).

If possible, the engine bed must be designed so that

the reverse gear and the flexible coupling can be
disassembled and lifted out separately.

Where possible, boat and engine drawings must be

p0005917 used to check the space around the engine, plus
engine bed height and position relative to the propeller
shaft. The height will depend on whether flexible or
rigid engine mounts are used. The bed incline must
correspond to the propeller shaft incline. The height
should include a 10 mm (0.4") spacer to prevent the
bed from being too high.

It is important that bilge water around the engine is able

to drain to the bilge pump location.

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Installation, Inboard Applications

Fiber glass hulls

Fiber glass engine beds must be designed such that
they are rigid vertically, longitudinally and transversely
in order to distribute loads over the greatest possible
hull area. Beds are often built as box structures. As
much as possible of the engine bed, including cross
beams, must be fixed to the hull to ensure the lowest
possible levels of noise and vibration.

The engine bed may be built separately and fitted and

p0005918 fastened accurately to the hull later, or it may be built
directly into the hull. It is important that bed contact with
the hull be over large arcs comprising several layers of
fiber glass.

Steel, aluminum or wooden hulls

In steel or wooden boats, the engine bed must be built
as a welded steel structure. Sheet thickness must be
dimensioned to provide a stable structure.

In steel or aluminum boats, the engine bed plane must

be welded to every frame rib along the whole of its
length.
In wooden boats, the bed must be fastened to the ribs
with nuts and bolts.
The bed must be as long as possible to distribute the
load.
If the engine has an auxiliary power take-off at the front
that requires extra support, this must be built into the
p0005919
bed. There must be space in front of the power take-
off for it to be removed.
Calculate brackets and beds etc. for other systems,
fuel and exhaust systems and auxiliary equipment.

Engine bed construction

The engine can be used as a jig to determine engine
bed location.

Lay out the engine, propeller shaft and stern bearing

in their places. The engine must be attached to the
propeller shaft.

Begin building up the bed in relation to the engine

mount locations.

A
P0005920

A = Fixed point. The stern tube is neither fixed, molded nor bolted
fast.

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 Installation, Inboard Applications

The engine bed must have the following dimensions:

A 125 mm (5.0")
B 449 mm (17.7")
C 572 mm (22.5")
D 83 mm (3.3")

P0007701

When the engine bed is complete, check that the

A space for the flywheel housing, oil sump bottom and
sides etc. has a clearance (A) of at least 20 mm (3/4").

P0004618
A

Fiber glass engine bed

The engine bed must be filled to reduce noise and
vibrations. Make sure the filling material is not water
absorbent. High density material is generally better at
dampening noise.

P0007702

A. Spacing material, ideally high density material

B. Fiber glass, approx. 10-15 mm (0.4–0.6")
C. Galvanized steel strip, approx. 10 mm (0.4") thick
W. Steel strip, width: min. 80 mm (3")
Minimum engine bed width: 112 mm (4.4")

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Installation, Inboard Applications

Build up the engine bed with spacing material (A) so

that the undersides of the engine mounts/rubber
mounts almost rest on the bed. There must be room
for the steel strip and fiber glass.

Build in a galvanized steel plate that is around 10 mm

(3/8") thick, at least 80 mm (3") wide and 250 mm (10")
long.

Build in drainage channels so that bilge water is able

to run to the bilge pump.

P0004619

Drilling holes for the engine mounts

It is of course a good idea to drill and tap the bolt holes
at an early construction stage using jigs, after accurate
measurement. In series production and other frequent
installations, more sophisticated methods may be
desirable, and may therefore be used.

NOTICE! If the engine and engine mount is used as a

drill jig, the engine mount/flexible mount holes must be
drilled in conjunction with engine installation in the
boat.

Drilling holes for engine mounts

1 Align the engine with the propeller shaft and mark
out the engine mount holes.
2 Drill and tap the holes in the engine bed steel strips.
P0005922 3 Recommended bolt size for Volvo Penta D4 and D6
flexible engine mounts is M12 (½" UNC).

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 Installation, Inboard Applications

Engine Installation

Engine Mountings
Inboard engines

Selecting engine mounts

There are two types of engine mounts: flexible rubber
mounts and rigid mounts. Flexible engine mounts are
recommended for this type of engine.

Flexible mounting
A sufficiently rigid engine bed is a precondition for
rubber mounts to work as efficient vibration dampers.
The bed must also be parallel with the engine so that
tension does not build up in the engine mounts.
Tension can increase vibration levels and also shorten
engine mount service life.

NOTICE! Rubber mount flexibility must never be used

to compensate for deviations in the engine bed.

Rubber mounts provide good vibration damping

between the engine and the bed, thus also reducing
noise levels.

Always follow Volvo Penta recommendations when

selecting engine mountings. The wrong rubber mounts
may result in abnormal vibrations, which in turn can
cause damage to engine components and also impair
comfort.

NOTICE! If flexible engine mounts are used, all

P0005894 connections to the engine must also be flexible. The
Flexible engine mounts propeller shaft must also have a flexible packing box
or a flexible shaft coupling.

Fuel, exhaust and coolant connections must also be

flexible.

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Installation, Inboard Applications

1 3

D4 D6

P0005895

1 Propeller thrust
2 Axial force
3 Vertical force

IV reverse gear
A lifting force (3) is exerted at the reverse gear on all
installations with propeller shafts inclined downward.
When the engine is connected to an IV reverse gear,
this force may be greater than the downward force
exerted by engine and reverse gear weight.

Therefore special mounts are required at the IV

reverse gear end of D6 engines intended for this type
of application. Modified flexible mounts that can cope
with upward forces are used for D4 engines They are
marked red.

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 Installation, Inboard Applications

Engine Suspension
Inboard engines

Engine mounts and propeller shafts

Stainless steel propeller shafts are available in
different diameters. The choice of shaft dimensions
must be based on engine power, gear ratio, distance
between supports points and propeller shaft material.

NOTICE! A flexible shaft coupling may never be

installed together with a flexible packing box; this may
cause vibration problems.

The following alternative installations and

combinations are recommended:
1 Flexible engine mounts and flexible shaft seal

L NOTICE! In this example, a flexible shaft coupling

may not be installed.
1 1 2 3 1 Flexible engine mounts
4
2 Rigid shaft coupling
P0005896
3 Flexibly-installed shaft seal
4 Water-lubricated stern bearing

L: Maximum distance between support points;

refer to Arrangement and Planning, page 30.
2 Flexible engine mounts and rigid shaft seal
B 1 Flexible engine mounts
L
2 Flexible shaft coupling
1 1 2 3 Rigid forward stern bearing and shaft seal
3 4
4 Water-lubricated stern bearing
P0005898
5 Maximum distance between support points

L: Maximum distance between support points;

refer to Arrangement and Planning, page 30.

B: Distance between reverse gear flange – support

point.
Minimum recommended B is 6-10 x shaft
diameter.
Max. B is calculated in the same way as max. L.

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Installation, Inboard Applications

Engine Installation
Inboard engines

Preparing the engine

NOTICE! Before the engine is installed, installation of
fuel, steering and electrical systems must be as
complete as possible.

WARNING!
Always use both lifting eyes when lifting the engine.

Fit auxiliary equipment and accessories such as

auxiliary alternator, hot water take-off, power take-off
etc. to the engine before it is installed.

NOTICE! All engines and reverse gears are supplied

by Volvo Penta without engine oil and coolant. Check
that the bottom plugs are in position and that coolant
and hot water drain cocks, etc. are closed.

NOTICE! Be careful with the harnesses when intsalling

the engine (lowering the engine into the engine
compartment).

Fill oil and coolant. Carry out a leakage check.

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 Installation, Inboard Applications

Engine pads

Tools:
21244540 Measuring tool

Install the engine pads on the engine brackets as

follows: Apply Volvo Penta grease part # 828250 onto
the threads.

Lift the engine by attaching a lifting device to both

engine lifting eyes.

IMPORTANT!
Forces acting on the lifting eyes must be vertical.

NOTICE! The engine must rest on its engine pads 24

hours before installation for alignment to work (the
pads compress under load). This applies only if the
engine did not rest on its pads during transportation.

The engine bed must be in a single plane. Check that

the engine bed surfaces where the engine mounts will
be installed are parallel to the engine pad bottom
plates, and that bed incline is correct (use an
inclinometer).

Once the engine is installed the load on the starboard

mounts must be equal to the load on the port mounts.
Max permissible variation between the port and
p0005943
starboard mounts is ±1.5 mm (±0.06").

Check engine pad load by measuring their

compression with the aid of 21244540 Measuring
tool. Nominal compression is around 5 mm (0.2").

We strongly recommend rocking the engine between

engine mount height adjustments the better to
distribute engine weight through the rubber.

The adjustable engine mount starting point is the

center of the attachment plate holes. The attachment
plates have oblong adjustment holes. These may face
p0005944
forward or aft, whichever provides best accessibility.
Nominal height: 116 mm (4.6")
H = Adjustment, height: ±8 mm (±0.3")
V = Lateral adjustment: ±7 mm (±0.3")

p0005969 V

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Installation, Inboard Applications

IMPORTANT!
The measurement between the engine pad and the
lower edge of the center adjuster nut (A) may never
exceed 20 mm (0.8"). If this occurs, the threads may
strip.

Tighten bolts that fasten the engine pads to the engine

A bed and the adjuster nuts on the mounts. Use a
counterhold on the nuts.

p0005972

Recommended bolt size for Volvo Penta flexible

engine mounts is M12 (1/2" UNC).
Tightening torque, adjuster nuts: 300 Nm (220 lbf.ft)
Tightening torque, engine bed bolts: 120 ±5 Nm
(88.51 ±4 lbf.ft) . This requires a level bed with
embedded steel strips of the correct length,
thickness and quality. Check engine bed
construction with the boat builder before
commencing installation.

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Engine pads for IV reverse gears

Install the engine pads for IV reverse gear installations
as illustrated.

Nominal attachment height for IV-drive:

D4: 116 ±8 mm (4.6" ±0.3), D6: 115 ±5 mm (4.5" ±0.2).

Lateral adjustment:
D4: ±7 mm (±0.3"), D6: ±9 mm (±0.35").

Tighten the nut when alignment is done.

Tightening torque, adjuster nuts: 300 Nm (220 lbf.ft)
Tightening torque, engine bed bolts: 120 ±5 Nm
(88.51 ±4 lbf.ft) . This requires a level bed with
embedded steel strips of the correct length,
thickness and quality. Check engine bed
D4 D6 construction with the boat builder before
P0008385 commencing installation.

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Installation, Inboard Applications

Engine Alignment
Inboard engines

Check that the flange contact surfaces are parallel

before the propeller shaft is attached to the reverse
gear flange.

Push the flanges together such that the guide pin slots
in. With the flanges pressed together, check that it is
not possible to introduce a 0.10 mm (0.004") feeler
gauge anywhere between them. Then rotate the
flanges 90°, 180° and 270° and repeat the feeler gauge
checks. Make sure the flanges are pressed together
throughout the checks. If the deviation is greater than
0.10 mm (0.004"), the alignment must be readjusted.

Remove any aids and bolt the shaft to the reverse gear
flange or the flexible coupling.

IMPORTANT!
The alignment must be checked again a few days after
launch when the boat is ready and rigged (sailboats).

P0005976

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General
P0008184
The engines are water cooled and have seawater
cooled heat exchangers. Coolant is circulated through
the freshwater system by a gearwheel driven
circulation pump. Seawater from the heat exchanger
passes out through the exhaust system (wet exhaust
system).
The cooling system installer is responsible for
ensuring the cooling system functions in accordance
with these installation instructions.
The cooling system must be dimensioned generously
enough to guarantee that cooling performance is not
affected by fouling and repainting even after a long
period of operations.
Pipe and hose diameters specified in the installation
instructions must be regarded as recommendations.
The only way to determine if the installation is correct
is by checking pressures, temperatures and flow with
the engine running. Contact Volvo Penta in the case
of uncertainty.
Carefully plan the location of connections so that they
are accessible. Lines must be arranged so that they
are as short as possible.
47704210 02-2018 © AB VOLVO PENTA
Installation, Inboard Applications
Cooling System
In order to reduce corrosion to a minimum the correct
combinations of materials must be used in pipes and
valves, etc. and a correctly dimensioned, pressurized
expansion tank.
Electrolytic corrosion may occur when two dissimilar
materials are in contact with each other and are
placed in an electrolyte such as moisture or seawater.
Use genuine Volvo Penta accessories and spare
parts whenever necessary. Make sure that parts not
supplied by Volvo Penta do not reduce or impede
pressures and flows in the engine. Lines that have
insufficient diameters, unsuitable runs, incorrect
connections, etc. will cause a reduction in flow and
lead to abnormal engine temperatures.
Use Volvo Penta coolant. The type of coolant used
affects engine cooling performance and its corrosion
protection.
NOTICE! Do not mix coolants of different types or
manufacture.
181
Installation, Inboard Applications

Raw Water System

Seawater inlet
The seawater inlet should ideally be made in bronze
alloy (brass is unsuitable as it corrodes owing to its
high zinc content). However, in the case of steel hulls,
the same material the boat is made of may be used. If
the materials in the hull and seawater inlet are
dissimilar, it may be necessary to galvanically insulate
the inlet from the hull using a plastic or rubber plate to
avoid galvanic corrosion. Note that the hull is also
A insulated.

The seawater inlet, sea cock and strainer must have

sufficiently high flow to avoid capacity losses and a
consequent reduction in water supply to the pump. The
pressure differential at the seawater pump inlet may
not exceed 30 kPa (4.35 psi).

The seawater inlet must have a diameter that fits a

hose with an internal diameter of:
B D4: 50 mm (2").
D6: 50 mm (2").
P0008187
The seawater inlet strainer must have a minimum flow
cross section of:
1.5 x hose internal cross section area

The seawater inlet must be located deep enough so

that it is underwater even when the boat rolls or is
moving through heavy seas. Do not locate the
seawater inlet too far forward in the boat.

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Sea cock
Install the inlet (1) with the opening facing forward (A)
except on sailboats where the opening (strainer) must
point aft (B) to prevent water being forced up into the
coolant line when the boat is under sail. The sea cock
must be closed when the boat is being towed.
3
4 Apply a suitable sealant, e.g. silicone rubber, on the
sealing surfaces. Tighten the inlet using the nut (2).

2 Install the sea cock and hose union (3). Use a non-
hardening sealant.
1
NOTICE! Always use two hose clamps on all hose
unions in the seawater system. Align the hose clamp
screws (4) as illustrated.
P0008188
The seawater line must have gradual bends to avoid
1 Strainer unnecessary stresses and flow restrictions. Use
2 Nut reinforced rubber hose that can withstand negative
pressure.
3 Hose union and sea cock
4 Hose clamps NOTICE! The hose between the seawater inlet
(seawater filter) and the engine must not be under
tension; a certain flexibility must be allowed. If the hose
passes through a bulkhead or similar it must be
protected against chafing.

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Seawater filter
During operations in shallow areas and harbors, etc. it
is impossible to prevent particles, sludge and sand
from entering the seawater inlet. These foreign objects
can be caught by a filter in the suction line. A seawater
filter contributes to longer pump service life and also
prevents engine damage that may occur due to
200 mm insufficient cooling in the charge air cooler or heat
(8´´) exchanger.

The seawater filter must be installed in an accessible

location, at least 200 mm (8") above the waterline in
a laden boat, e.g. on an easily accessible bulkhead. If
the filter is installed in a sailboat, this installation
dimension must also be applicable at full heel.
The illustration shows a bulkhead-mounted installation
in a reverse gear version.

P0008189

Seawater filter, (inboard engine)

When a Volvo Penta seawater filter is used the sea
cock inlet diameter is:
D4: 50 mm (2")
D6: 50 mm (2")

Seawater filter diameter for D4/D6:

Inlet: 50 mm (2")
Outlet: 50 mm (2")

Inlet diameter to seawater pump:

D4: 38 mm (1.5")
D6: 50 mm (2")

Clearance for removal of filter cartridge:

A 200 mm (8")

P0008190

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 Installation, Inboard Applications

The seawater pump for D4 inboard engines has a

diameter of 38 mm. The transition joint (1) is to enable
connection to a bulkhead-mounted seawater filter.
Dimensions 38 to 50 mm.

Anti-siphon valve
An anti-siphon must be installed in cases where the
engine is mounted so low in the boat that the distance
between the exhaust pipe flange (lower edge) and the
waterline is less than 200 mm (8"). If the valve is
correctly installed, water will be prevented from
siphoning into the engine.
200 mm
(8´´)

P0008191

C A B NOTICE! The anti-siphon valve must be installed at

least 500 mm (20") (A) above the waterline of a laden
Min. 1
boat.
200 mm
(8´´) The valve is not supplied by Volvo Penta. It must be
specially made.

Make sure that there is at least 200 mm (8") space

above the filter to allow removal of the filter insert.
Item number one (1) in the illustration shows the hull
fitting.

P0008192

A Hose, internal Ø 45 mm (1¾")

B Hose, internal Ø 50 mm (2")
C Hose, internal Ø 6 – 10 mm (¼" – 3/8")

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Freshwater System

General Coolant mixture

Freshwater circulates through the engine cooling
WARNING!
ducts and heat exchanger with the aid of a centrifugal
All coolant is hazardous and harmful to the
pump.
environment. Do not consume. Coolant is flammable.
As long as the coolant is cold the thermostat is closed,
IMPORTANT!
which prevents the coolant from passing through the
heat exchanger. The coolant passes instead through Ethylene glycol may not be mixed with other types of
a bypass/shunt line back to the suction side of the glycol.
pump. This means the engine quickly reaches its
Mix 40% ”Volvo Penta coolant” (con. coolant) with
working temperature. The thermostat also controls
60% water.
correct temperature under low power and loads.
This mixture protects the engine against corrosion,
Coolant cavitation and freezing temperatures down to -28 °C;
(a 60% glycol mixture reduces the freezing point to
We recommend “Volvo Penta Coolant, Ready Mixed”,
-54 °C). Never mix more than 60% concentrate (Volvo
or “Volvo Penta Coolant” (concentrated) mixed with
Penta Coolant) in the coolant mixture as this reduces
pure water according to specifications; refer to Water
cooling effect, increases the risk for overheating and
quality. Only coolant of this grade is suitable and
provides reduced protection against freezing.
approved by Volvo Penta.
IMPORTANT!
Coolant must contain good quality ethylene glycol of
a suitable chemical composition in order to achieve The coolant must be mixed with clean water. Use
the right engine protection. The use of corrosion distilled/deionized water. The water must fulfill
protection alone is not permitted in Volvo Penta requirements specified by Volvo Penta; refer to Water
engines. Never use water alone as the coolant. Quality, page 215.

IMPORTANT!
Coolant must be used all year round. This is in order
to ensure that the engine has the proper corrosion
protection even though there may never be any risk
of freezing. Future warranty claims related to the
engine and accessories may be declined if the wrong
coolant has been used, or if the instructions for
coolant mixture have not been followed.
”Volvo Penta coolant” is a concentrated coolant that
must be mixed with water. It has been developed to
function optimally in Volvo Penta engines and it
provides excellent protection against corrosion,
cavitation and freeze damage.
IMPORTANT!
It is extremely important that the system be filled with
the correct coolant concentration. Mix the liquids in a
separate, clean container before filling the cooling
system. Check that the liquids mix properly.
NOTICE! From and including 2011 all Volvo Penta
engines use yellow glycol (VCS). Volvo Penta coolant
(green glycol) may under no circumstances be mixed
with VCS (yellow glycol). The expansion tank is
marked with the type of glycol to be used.

”Volvo Penta coolant, ready mixed” is a ready

mixed coolant comprised of 40% ”Volvo Penta
coolant” and 60% water. This concentration protects
the engine from corrosion, cavitation damage and the
risk of freezing down to -28 °C (18 °F).

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Hot water connections

Hot water connections may be made to the thermostat
housing (outlet) and the circulation pump (inlet). The
unions supplied by Volvo Penta are intended for hoses
with and inner diameter of 16 mm (5/8”).

P0004776

1 1/2” NPTF

Install the auxiliary hot water circuit so that its highest

point is at least 50 mm (2”) (A) lower than the fluid
level in the expansion tank. If this is not possible, a
separate expansion tank must be installed.

P0004777

Shut-off taps
Volvo Penta recommends that shut-off taps be
installed on both the inlet and outlet sides of the
auxiliary circuit. Locate the taps as close to the engine
as possible.

P0008197

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Extra expansion tank

3 1
B

2
A

P0008198

1 Venting hose Capacity, freshwater system (standard)

2 Hot water heater and auxiliary circuits
3 Min. water level The volume of the engine freshwater system can be
increased without the need for an extra expansion
A Min. 50 mm (2”) tank in the system.
Max. 1200 mm (3.9”)
maximum additional volume for D4 and D6 engines
B Min. 50 mm (2”) with standard engine-mounted expansion tank: 5.0 l
Max. 1200 mm (3.9”) (1.3 US gal).

If the volume is expanded further, or if an additional

circuit is located above the engine, the cooling system
must be equipped with a larger expansion tank.

Hot water circuits and cabin heating are examples of

auxiliary circuits.

An auxiliary expansion tank must be installed with the

low level mark at least 50 mm (2”) and at most 1 200
mm (3.9 ft.) above the engine's highest point (B), or
the highest point in the external circuit (A); see above
illustration.

The auxiliary expansion tank must be located so that

it is easily accessible for level checks and filling.

The venting hoses (1) may not be run beneath their

respective engine connection points. Item (2) in the
illustration is a hot water heater.

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 Installation, Inboard Applications

Volume in engine Maximum additional

including heat volume in auxiliary
exchanger, liters (US circuit with standard,
gal) engine-mounted
expansion tank, liters,
(US gal)
D4 12,5 (3.3) 5,0 (1.3)
D6 15,7 (4.2) 5,0 (1.3)
3 Expansion tank volume must be 15 % of cooling
system total capacity.

1 Of this volume:

MAX 5% is intended for coolant expansion when it is hot

(expansion volume)

MIN 5% is intended for the difference between the MAX

and MIN levels
2 5 % is reserve volume.

The engine expansion tank must have a separate

venting line to the auxiliary tank connected below the
1 Expansion volume, approx. 5 %
MIN level.
2 Reserve volume, approx. 5 %
The hose must withstand temperatures of up to 115
3 Pressure cap
°C (240 °F).

The engine pressure cap must be replaced with a

sealed cap. The regular engine venting hose from the
thermostat housing may be connected to the auxiliary
expansion tank below the MIN level to facilitate venting
when coolant is filled.

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Venting the system

In most cases, as in the system illustrated, the system
is self-venting to the expansion tank.

P0006218

1 Cabin heater with defroster unit

2 Outlet tap
3 Inlet tap
4 Venting nipple
5 Hot water heater
6 Heater
7 Expansion tank
H: Lowest level

If an auxiliary system does not vent normally to the

expansion tank, a separate venting nipple (4) must be
installed.

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 Installation, Inboard Applications

Water Quality

ASTM D4985:

Total solid particles <340 ppm

Total hardness <9,5° dH
Chloride <40 ppm
Sulfate <100 ppm
pH value 5.5–9
Silica (acc. ASTM D859) <20 mg SiO2/l
Iron (acc. ASTM D1068) <0.10 ppm
Manganese (acc. ASTM D858) <0.05 ppm
Conductivity (acc. ASTM D1125) <500 µS/cm
Organic content, CODMn (acc. <15 mg KMnO4/l
ISO8467)

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Keel cooling
Box cooling The principle for connecting engines to a keel cooling
system is the same as for a heat exchanger system.

NOTICE! Always use Volvo Penta antifreeze, which is

available ready-mixed or in concentrated form. Do not
mix with other makes of coolants.

P0010804

Keel cooling (tube cooling system)

P0010805

Tube cooling system (detail)

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 Installation, Inboard Applications

Keel cooling (hull cooling system)

P0010806

Hull cooling (detail)

Condensation Water Collector

1 Exhaust gases from internal combustion engines
always contain water vapor. This water vapor may
condense into water and in the worst cases run into the
engine when it is switched off.

Rainwater or condensate that gets into the engine can

cause great damage. Long exhaust systems must
therefore be equipped with water drainage located as
close to the engine as possible.
2

p0011503

1 Exhaust elbow
2 Example: Condensate collector.

A condensate collector (2 and 3) must always be

installed where the exhaust line is inclined downwards
towards the engine. It must be located at the lowest
point in the completed system.

The condensate collector must be equipped with a

valve or drain plug at the bottom.

3
P0011504

Example: Installation of a condensate collector (3).

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Installation, Inboard Applications

Insulated Exhaust Systems

Because of the high temperatures that occur in dry
exhaust pipes – 400–500 °C = 752–932 °F – it is
sometimes necessary to insulate them. In this way the
temperature in the engine compartment can be kept
low and injuries avoided. The insulation also
contributes toward keeping noise levels low.

Insulation of long exhaust systems affects exhaust

backpressure and exhaust pipe diameter must
therefore be increased.

Flexible Exhaust Compensator

Exhaust pipes are usually insulated from engine
movements via a flexible compensator.

The compensator must be fitted to the exhaust elbow.

In special cases the compensator may be installed at
max. 0,5 m (1.65 ft.) from the engine exhaust outlet.
One or more compensators are recommended for long
pipe runs, depending on the design and length of the
pipe.

IMPORTANT!
The compensator must be installed in an unstressed
state with the flanges parallel.

Flexible exhaust compensators have three

functions:
• Insulating vibrations and relieving exhaust pipe
weight from the engine.
• Compensating for exhaust pipe thermal expansion.
Max
0,5 m • Compensating for sideways motion when the
1.65 ft) engine starts or stops when the engine is on flexible
mounts.

The flexible pipe is able to take up large axial

movements, small radial movements but no twisting
movements.

It may not be bent. The flexible compensator may be

P0021625 fitted in different positions, but should ideally be
installed vertically.

Exhaust line attachments must be designed to prevent

radial movements generated by pressure pulses in the
line from being transferred to the compensator.

Thermal expansion in the exhaust piping must be

planned to avoid excessive loads on supports and
attachment fittings. For every temperature increase of
100 °C (212 °F) one meter of steel pipe will expand
around 1.2 mm (0.047"). It is therefore important to
locate the holders such that the pipe is able to expand
away from the engine to avoid straining and twisting
connected equipment. Furthermore, it must be

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 Installation, Inboard Applications

possible to remove equipment without the need for

additional support.

Long pipes are divided into sections using expansion

joints. Each section is fixed at one end and is able to
expand at the other.

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Installation, Inboard Applications

Measurements in mm (in)

Pos. in fig Description

3" (curved) 4" (curved)
A Hose length 122 (4.1) 134 (5.3)
B Total nominal length 200 (7.9) 251 (9.8)
C Bend diameter 110 (4.3) 160 (6.3)
D Outer dia., flange 138 (5.4) 196 (7.7)
- Number of holes in flange 4 8
E Dia., holes in flange 14 (0.55) 14 (0.55)
F Flange thickness 15 (0.59) 15 (0.59)
G Internal diameter 68 (2.7) 107 (4.2)
H Length exhaust elbow–compensator elbow 103 (4.6) 167 (6.3)

Compensator 3" (D4, curved) Compensator 4" (D6, curved)

A B
A B

F F

G
G
H
H
E
E

C
C P0011868 D
P0011866 D

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 Installation, Inboard Applications

Installation data

Compensator type Total nominal length Flexibility in mm (in)

B Radial Axial
3" (curved) 200 (7.9) missing missing
4" (curved) 250 (9.8) missing missing

Silencer
6 Generally speaking there are two types of silencer:
absorbing and reactive.
6
Absorbing silencers
These silencers work according to the principal of
5 2 absorbing sound with the aid of an absorbent lining
4 inside the silencer. They usually provide silencing over
1 a broad frequency range.
2 3
Absorbing silencers are generally of straight-through
design and only offer a marginally higher backpressure
than a straight pipe of the same length.
P0011509

Exhaust line
1 Compensator
2 Insulation
3 Fiber glass on outside of insulation
4 Three-point attachment fitting
5 Silencer
6 Flexible attachment fitting

Expansion silencers (reactive)

These silencers work according to the principal of
reflecting sound and thereby retaining it inside the
silencer. The silencer has internal baffle plates that
divide it up into sections that can be adjusted
individually to a given frequency. A reactive silencer
creates a relatively high backpressure owing to the
serpentine route of the gas flow, i.e. past the baffles
that redirect the flow.

Volvo Penta HD silencers combine reactive and

absorbing silencing.

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Calculation of Back Pressure

Calculating exhaust pipe backpressure Example:
Determine flow resistance in a straight exhaust Engine D6 435 I
pipe by using the exhaust flow value to calculate Power 320 kW / 3500 rpm
the backpressure in a given silencer (HD). Silencer 5" HD
The following formula is recommended:
Calculating pressure loss through the silencer
Lx Q2 1 Q (m3/min)
P = 6.32 –––––– x ––––––– Flow speed (m/s) = –––––––––––––
D5 (T + 273) Pipe surface (m2) x 60
P = backpressure through exhaust pipe in Pa 46.4 m3/h
L = total equivalent length for a straight pipe in
Q = 46.4 m3/h = ––––––––– = 0.77 m3/s
meters
60 s
Q= exhaust flow (m3/s)
D= pipe diameter in meters - this value was extracted from Technical data in the
T = exhaust temperature °C Sales guide, marine diesel engines, propulsion.

NOTICE! Where there are bends in an exhaust π x D2

system, the pressure loss is expressed as the Pipe surface = ––––– (m2)
equivalent length of straight pipe. 4
Refer to the table below for the equivalent straight D = 5" = 0.127 m
length:
Pipe surface will be A = 0.0127 m2 (0.137 ft.2)
Pipe diameter Bend 45° Bend 90° Flow speed ≈ 59.2m/s (171 ft./s)
(inches) (m/bend) (m/bend) The resistance in mm water column can be found in the
3.5 0.57 1.33 “Velocity/Resistance graph...” on the previous page.
4 0.65 1.52 The resistance is approx 275 mm (7.7") water column.
5 0.81 1.90
6 0.98 2.28 The pressure loss is calculated according to the following
7 1.22 2.70 formula:

Pressure loss (mm water column) =

The total exhaust system backpressure is
obtained by adding the pressure losses through Resistance from graph (mm water column) * 673
the silencer to the losses through the pipes. This –––––––––––––––––––––––––––––––––––
figure may not exceed the figure specified in the (T °C + 273)
Sales guide, marine diesel engines,
propulsion for the engine and category 275 * 673
concerned. –––––––––––––––––––––––––––––––––––
(391 + 273)

= 279 mmWc

T = Exhaust gas temperature (refer to Technical data in

the Sales guide, marine diesel engines, propulsion)
T = 391 °C (735.8 °F)

The pressure loss will be:

P = 279 mm (7.5") water column = 2.773 kPa (0.396 psi)

The pressure loss through the silencer is 2.773 kPa

(0.396 psi).

NOTICE! Check that the total backpressure (silencer

backpressure and pipe backpressures) are within the
limits in the Back Pressure section.

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Velocity/Resistance curve at 400 °C

400
100,0
300

75,0 250

200

50,0 150
40,0

30,0 100
90
25,0 80
70
20,0
60
15,0 50
A B 1.0 2.0 3.0 4.0 5.0 7.0 9.0 20.0 30.0
C 6.0 8.0 10.0

20 50 100 150 200 250 500 750

P0004244 D

A = Bore velocity in m/s

B = Bore velocity in ft/s
C = Resistance in inches Wc
D = Resistance in mm Wc

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Exhaust Elbow
Refer to the Sales guide, marine diesel engines,
propulsion for exhaust elbow dimensions.

Compensator 3" (D4, curved) Compensator 4" (D6, curved)

A B
A B

F F

G
G
H
H
E
E

C
C P0011868 D
P0011866 D

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 Installation, Inboard Applications

Multiple Exhaust Outlets

If more than one engine is installed, engine exhaust
gases may not be led through the same exhaust duct.

The reason for this is that if one engine is at rest while

the other is running, exhaust gases, condensate and
soot will be forced into the resting engine's exhaust
system and on into the cylinders, which may cause
corrosion.

If a good quality butterfly valve is installed in each

exhaust system close to the duct, multiple exhausts
with a common exhaust line may sometimes be
approved.

Use the following formula for calculating the total

diameter of the shared exhaust pipe:

Dtotal = D x K

where:
D is exhaust pipe diameter for one engine
K is a factor

Number of engines Factor K

2 1.32
3 1.55
4 1.74
5 1.90
6 2.05

Factor K = 5√ (number of engines)2

Standard System Size

Engine Dry exhaust line

D4 3"/68 mm
D6 4"/107 mm

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Installation, Inboard Applications

Measuring Exhaust Temperature

Dry and wet exhaust systems
Exhaust temperature checks are sometimes
necessary 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
correct probe position in the gas flow. See illustration.

Accurate measurements (± 2%) allow comparisons to

be made with technical data for verification, provided
that compensation is made for atmospheric conditions.
Exhaust analysis gauges are usually less accurate.
A Dry exhaust systems
B Wet exhaust systems

NOTICE! If the above method of measuring exhaust

temperature is not suitable for the engine concerned,
use one of the nipples in the dry exhaust elbow
downstream of the turbocharger. Refer to the previous
page: Dry exhaust system.

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 Installation, Inboard Applications

External Cooling
Cooling System
It is advisable to fit a closed cooling system (keel system) when the boat operates in waters where there is a lot
of sand, silt or ice.
There are several possible cooling system arrangements:
• Hull cooling (profiles against the hull)
• Pipe assemblies (cooling coil and box cooling)
• Double bottom (hull cooling)
• External cooling tanks (tank cooling)

The underlying principle in an external cooling installation is for the standard engine circulation pump also to
circulate coolant in the external cooler.
It is important to use the correct substances in the coolers. Use Volvo Penta coolant, an antifreeze mixture.
A number of factors must be taken into account when designing an external cooling system.
• Volvo Penta does supply engines suitable for connection to external cooling systems. This chapter describes
coolant systems and lists pressures and flows in tables that must be taken into account when calculating a
system.
• It is essential to choose the correct pipe diameters and lengths (with few bends) for tube coolers, and the
correct tank height and width for double-bottom coolers with regard to backpressure, flows and heat
dissipation.
• The system may not include any sharp bends or tanks that end abruptly.
• Volvo Penta strongly recommends the use of shut-off valves for inlets and outlets.
• External cooling systems should always be dimensioned by qualified personnel in order to achieve a good,
functional installation.

P0010805

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Installation, Inboard Applications

P0010806

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 Installation, Inboard Applications

LT circuit
Engine type Power Power Rating Heat Water Water Max Max Max
[kW] [hp] rejection flow flow temp temp pressure
keel through through before after drop over
cooler[kW] keel keel keel keel keel cooler
cooler cooler [l/ cooler cooler [kPa] @
[m3/h] min] [°C] [°C] Max Flow
Two-circuit system with two keel coolers.
D4–180 BT 132 180 4 37 7.5 125 30 20
D4–225 BT 165 225 4 62 8.4 140 30 22
D4–260 BT 191 260 5 63 8.4 140 30 22
D4–300 BT 221 300 5 79 8.4 140 30 22
D6–300 BT 221 300 4 86 12.9 215 30 30
D6–330 BT 243 330 4 95 12.9 215 30 30
D6–370 BT 272 370 5 103 12.9 215 30 30
D6–435 BT 320 435 5 106 12.9 215 30 30

D4–180 I 132 180 4 42 7.5 125 30 20

D4–225 I 165 225 4 69 8.4 140 30 22
D4–260 I 191 260 5 71 8.4 140 30 22
D4–300 I 221 300 5 88 8.4 140 30 22
D6–300 I 221 300 4 95 12.9 215 30 30
D6–330 I 243 330 4 105 12.9 215 30 30
D6–370 I 272 370 5 114 12.9 215 30 30
D6–435 I 320 435 5 119 12.9 215 30 30

D4–225 A 165 215 4 64 8.4 140 30 22

D4–260 A 191 250 5 65 8.4 140 30 22
D4–300 A 221 291 5 81 8.4 140 30 22
D6–300 A 221 289 4 88 12.9 215 30 30
D6–330 A 243 317 4 98 12.9 215 30 30
D6–370 A 272 355 5 106 12.9 215 30 30
D6–400 A 281 382 5 109 12.9 215 30 30

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Installation, Inboard Applications

HT circuit
Engine type Heat rejection keel Water flow Water flow Coolant Max temp Max pressure
cooler[kW] through through keel temp after keel drop over keel
keel cooler cooler [l/min] before keel cooler [°C] cooler [kPa] @
[m3/h] cooler [°C] Max Flow
Two-circuit system with two keel coolers.
D4–180 BT 73 315 80 37
D4–225 BT 78 360 80 40
D4–260 BT 113 360 77 40
D4–300 BT 141 360 75 40
D6–300 BT 161 360 73 40
D6–330 BT 177 360 72 40
D6–370 BT 201 360 70 40
D6–435 BT 208 360 69 40

D4–180 I 73 315 80 37
D4–225 I 78 360 80 40
D4–260 I 113 360 77 40
D4–300 I 141 360 75 40
D6–300 I 161 360 73 40
D6–330 I 177 360 72 40
D6–370 I 201 360 70 40
D6–435 I 208 360 69 40

D4–225 A 78 360 80 40
D4–260 A 113 360 77 40
D4–300 A 141 360 75 40
D6–300 A 161 360 73 40
D6–330 A 177 360 72 40
D6–370 A 201 360 70 40
D6–400 A 208 360 69 40

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 Installation, Inboard Applications

Coolant, Mixing
WARNING!
All coolant is hazardous and harmful to the
environment. Do not consume. Coolant is flammable.

IMPORTANT!
Volvo Coolant VCS (yellow) must be used for all
engines today.

IMPORTANT!
Volvo Coolant (green) may no longer be used in new
engines. Never mix different kinds of coolant.

Volvo Penta recommends ready mix coolant ahead of

the concentrated alternative.

Mix: 40% conc. Volvo Penta coolant and 60% water

This mixture protects against internal corrosion,

cavitation and freeze bursting down to –28°C (–18°F).
A 60% glycol admix lowers the freezing point to -54 °C
(-65 °F).
Never mix more than 60% Volvo Penta concentrate in
the coolant. A greater concentration provides reduced
cooling effect with the risk for overheating and reduced
anti-freeze protection.

The coolant must be mixed with distilled, deionized

water. The water must fulfill the requirements specified
by Volvo Penta; refer to Water Quality. It is extremely
important that the system be filled with the correct
coolant concentration. Mix in a separate clean vessel
before filling the cooling system. Make sure that the
liquids mix.

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Coolant flow and connections for

engines adapted for external
cooling

Engines modified for external cooling differ from

seawater cooled engines.
The heat exchanger is removed from keel-cooled
engines. The seawater pump is used as an LT pump
(low temperature circuit pump).
The engines are equipped with connections for the
external cooling system.

The following illustrations show engine connections

and internal hose diameters.

NOTICE! Volvo Penta twin-circuit, keel-cooled

engines are supplied without an LT expansion tank and
T-connector to the LT pump.
The recommended T-connector dimension from the
tank is Ø 20 mm (0.78") pressurized. Proposal for T-
connector: refer to illustration on left. A = to LT
expansion tank.

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 Installation, Inboard Applications

D4/D6
Twin-circuit system with twin keel coolers

HT
LT
LT
HT

P0020205

P0020205

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Installation, Inboard Applications

Engine Engine volume Total system volume Maximum capacity, freshwater system,
D4 12.5 l (3.3 US gal.) 5.0 l (1.3 US gal.) keel-cooled engines
This table shows engine volume excluding heat
D6 15.7 l (4.2 US gal.) 5.0 l (1.3 US gal.) exchanger and the max permitted cooling system
volume with standard expansion tank, including keel
cooler and other circuits such as engine heater or
cabin heater circuits.

NOTICE! A larger expansion tank must be installed if

these values are exceeded.

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 Installation, Inboard Applications

Max temperature increase, ΔTmax

- across engine circuit, T1–T2
- across charge air cooler circuit, T3–T4

Also refer to the Function diagrams, external cooling chapter for each engine type.

Engine Classification ΔTmax engine circuit ΔTmax charge air cooler

T1–T2 (T5–T6 D12) circuit
T3–T4
°C (°F) °C (°F)
D4 3500 rpm 1 ≤ 8 (14.4) - -
D4, 3500 rpm 1 ≤ 8 (14.4) - -
D4, 3500 rpm 2 ≤ 10 (18) - -
D4T, 3500 rpm 2 ≤ 9 (16.2) - -
D6, 3500 rpm 1 ≤ 8 (14.4) ≤ 2 (3.6)
D6, 3500 rpm 1 ≤ 7 (12.6) ≤ 3 (5.4)
D6, 3500 rpm 2 ≤ 9 (16.2) ≤ 2 (3.6)
D6, 3500 rpm 2 ≤ 8 (14.4) ≤ 3 (5.4)

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Measuring temperature and

pressure in keel cooling systems
1 Gauge connections
T-nipple for measuring pressure and temperature
The T-nipple is used for measuring both temperature
and pressure in the coolant circuit. The tool is not
1/4”R carried by Volvo Penta.

3
P0010816

NOTICE! It is important to place the probe correctly in

the coolant flow. See illustration to left.
3
Pressure upstream and downstream of engine
Connections for measuring pressure in cooling circuits
must be integrated into the boat circuit close to the
0.75 x D engine connections.
D

P0010817

1 Temperature measurement
2 Pressure measurement
3 Temperature probe
4 Threaded as required

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D4/D6
External cooling. Twin-circuit system with twin keel coolers
P0020100
1 Engine
2 Expansion tank
3 Keel cooler, engine
coolant circuit
4 Keel cooler, charge air
cooler circuit
5 Expansion tank, LT circuit
Refer to Technical data, Sales guide, marine diesel engines, propulsion for temperature, maximum pressure
drop and coolant flow.
47704210 02-2018 © AB VOLVO PENTA
Installation, Inboard Applications
Function diagrams, external cooling
Components such as reverse gear oil coolers,
expansion tanks, etc. are not always supplied by Volvo
Penta. These components are not the responsibility of
Volvo Penta.
The limit of Volvo Penta supplier responsibility is
demarcated in the diagram by:
—-—-—
Refer to the table in the Coolant flows and connections
for engines adapted to external cooling chapter for
internal temperature increases across engine circuits
(keel cooler 1, T1-T2) and charge air cooler circuits
(keel cooler 2, T3-T4).
A External systems
B Volvo Penta internal system
Volvo Penta supplier responsibility
• FC = Fuel Cooler
• CAC = Charge Air Cooler
• EOC = Engine Oil Cooler
• PSC/GOC = Power Steering Cooler or Reverse Gear Cooler
213
Installation, Inboard Applications

Engine Heater
Cold starts are one of the most important determining
factors regarding the service life of an engine.
Frequent cold starts followed by extended periods of
idling significantly increase wear on the engine. An
engine heater extends the service life of the engine
and batteries. A heater lowers emissions during start
and prevents hunting.

The engine heater heats and circulates coolant

through the engine block. It is important that the engine
heater is of the right type, is correctly connected and
maintains the engine coolant at the right temperature.

The heater must have its own circulation pump and be

located in a protected place.

NOTICE! It is very important that the engine heater is

correctly protected in order to avoid galvanic corrosion.
Refer to the Protection against galvanic corrosion
chapter.

1 Direction of flow
2 Pump
3 Heater element
4 Check valve
5 D4: The connection is performed on the existing
drainage hose.
6 D6: Replace the standard drain screw with hose
nipple according to picture.

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 Installation, Cooling System

Cooling System
Water Quality

ASTM D4985:

Total solid particles <340 ppm

Total hardness <9,5° dH
Chloride <40 ppm
Sulfate <100 ppm
pH value 5.5–9
Silica (acc. ASTM D859) <20 mg SiO2/l
Iron (acc. ASTM D1068) <0.10 ppm
Manganese (acc. ASTM D858) <0.05 ppm
Conductivity (acc. ASTM D1125) <500 µS/cm
Organic content, CODMn (acc. <15 mg KMnO4/l
ISO8467)

Coolant Level, Checking and

Topping Up
Filling coolant
NOTICE! Coolant must be filled when the engine is
stopped and cold.

Fill the system carefully through the opening in the

expansion tank, around 10–15 l/min (2.5–4.0 US gal/
min) so that the system vents during filling.

Cooling system volume without auxiliary circuits:

• D4: 12.5 liter (3.3 US gal).
• D6: 15.7 liter (4.2 US gal).

NOTICE! Volvo Penta VCS Readymix coolant should

be used.

p0004704

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Fill and check coolant level

1 Fill the system until it is completely full, including
the expansion tank. The coolant level must be
between MIN and MAX.
MAX
MIN
2 Start the engine and let it run without load at
1000–1500 rpm for around 5 minutes.
3 Check coolant level.

NOTICE! If it is difficult to check the expansion tank

coolant level, Volvo Penta has a coolant level sensor
that can be installed in the tank.

External systems:
If external systems are connected to the engine cooling
system, the system valves must be open and system
units vented during filling. Special venting nipples may
be installed in the external circuits; this applies
especially to systems located above the engine.
p0004706
IMPORTANT!
Do not start the engine until the system is completely
filled with coolant.
WARNING!
Do not open the coolant filler cap when the engine is
hot. Steam or hot fluid could spray out, causing severe
burns.

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Exhaust System
Dry exhaust systems
Wet exhaust systems
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Installation, Exhaust System
Inboard engines
General
• Wet exhaust line
• Dry exhaust line, insulated
Most boats with inboard engines in the Volvo Penta
power range are equipped with wet exhaust systems.
Water is led into the system to cool the exhaust gases,
and the water passes out together with the exhaust
gases.
A wet system has several advantages compared to a
dry system. The water lowers exhaust gas temperature
significantly once the water has been led into the
system, which means that flexible rubber hoses can be
used in the system. Flexible hoses are often easier to
install than pipes, hoses are not affected by corrosion
or loads and they take up movement from flexibly
installed engine. Wet exhaust systems need no
insulation and radiate less heat.
It is important to design a wet exhaust system properly
to ensure that water cannot force its way backwards
into the engine.
IMPORTANT!
The exhaust system must be designed and installed to
allow the passage of exhaust without back pressure
harmful to the engine, and without any adjacent
components being exposed to the risk of overheating.
The requirement for noise muffling must also be met and
the system must be arranged such that exhaust gases
do not enter the boat. All exhaust systems must be
installed in such a way that water cannot force its way
back into the engine when it is switched off. When
designing the exhaust system, note that back pressure
may not exceed the values shown in the table in the
Installation, page 230 chapter.
NOTICE! There may be local regulations regarding
noise levels, which must be taken into consideration
when the exhaust system is constructed.
Dry exhaust systems for inboard diesels are used
chiefly on slower vessels in commercial traffic. A dry
exhaust system may be necessary to avoid freezing
when engines are used in cold climates with
temperatures below 0 °C (32 °F). Dry systems
generally require less maintenance and have longer
service lives. System insulation is often required as
temperatures can be dangerously high and heat
radiation in the engine compartment affects the engine
negatively.
Volvo Penta does not sell complete exhaust systems,
but does supply some key components.
217
Installation, Exhaust System

Backdraughting
As long as we continue to use internal combustion
engines as power sources we will be presented with
the problem of exhaust emissions. Even though
exhaust emission levels have been minimized in
modern combustion engines, smoke and fumes are
still emitted when fuel is burned.

When we also have angular objects in motion other

problems arise. One of them is a phenomenon called
“backdraughting”.

On boats with broad, high transoms and high

superstructures, backdraughting causes exhaust
gases to be drawn up to the aft deck, smutting up the
cockpit and creating unpleasant conditions for people
on board. The problem arises from recirculating air.
When the boat moves forward in an aft moving
P0005977
airstream, a vortex is created behind the boat. into
which exhaust gasses are drawn.

It is of the utmost importance that the exhaust system

is designed and located in the correct manner in order
to avoid this problem.

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 Installation, Exhaust System

Wet Exhaust Line

Inboard engines

General
The term "wet exhaust system" means that cooling
water that has passed through the engine is fed into
the exhaust system to cool the gases and silence
engine noise.

Volvo Penta supplies complete exhaust systems for

such engines.

A wet exhaust system may for the most part be

constructed from oil and heat-resistant rubber hoses.
It is therefor often the best system in terms of simple
installation and silencing.

Boat and engine compartment design can vary from

generous spaces to extremely compact, tailored
systems.

Marine engine manufacturers do not usually make

complete wet exhaust systems. Instead it is equipment
manufacturers, boatyards and boat builders, etc. that
design systems, select components and carry out trials
to develop finalized exhaust systems that fulfill all
requirements.

The recommendations in this section must be seen as

a framework based on experience; they apply to
complete systems with a maximum length of 10 meter
(33 ft.) and a maximum of 4 x 90° bends

All systems with silencers, especially Aqualift,

contribute to total system back pressure. Each
silencer's contribution must be assessed and carefully
calculated, and measurements must be taken during
sea trials.

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Installation, Exhaust System

Dimensioning exhaust systems

Exhaust systems must be dimensioned to avoid
harmful back pressure. This is especially important for
turbocharged engines. Excess back pressure will
mean power loss and may cause functional faults such
as increased smoke levels and shorter service life.
Refer to the Installation, page 230 chapter for
recommendations.

Exhaust hose diameter

The table below specifies standard connection
diameters for wet exhaust systems. Note that a
complete exhaust system may require a larger
diameter depending on length, silencers and outlet
configuration.

Hose diameter, internal:

D4: 100 mm (4")
D6: 125 mm (5")

P0005981

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 Installation, Exhaust System

Exhaust elbow angle (α°) in relation to the

waterline, fig. A must be at least 10° (18 %).
The silencer must be installed as close to the engine
H as possible. The hose must be run with a continual
drop toward the silencer along its entire length; see
figure A.

NOTICE! The minimum height (H) between the

exhaust elbow centerline and the silencer inlet must be
150 mm (6").
A
Length (A) Minimum height (H)
650 mm (25") 150 mm (6")
1,000 mm (40") 190 mm (7.5")
A 1,500 mm (59") 220 mm (8.5")

P0005982

If the hose between the exhaust bend and the silencer

is of such a length or run that it risks hanging, it must
be supported; see figure A.

All longitudinal exhaust lines, before and after the

silencer must have an average drop angle of at least
4° (7%) (β), as shown in figures B and C.

All transverse exhaust lines, before and after the

silencer, must have average drop angles of at east
10° (17%), angle (γ).

C (Also refer to the next section for sailboats).

β γ

P0005984

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Installation, Exhaust System

ABYC coolant loss alarm sensor

ABYC alarm sensor for coolant loss and overheating

risk in the exhaust hose.

P0016569

Sensor installation position in the exhaust manifold

and connection of the ABYC harness to the engine
terminal.
Install the harness on the engine so that it does not
get in the way, risk being pinched or exposed to hot
areas when connected. Secure the cables in a
suitable manner.

NOTICE! If the boat is fitted with a IV reverse gear and

chosen exhaust riser, no ABYC sensor need be
installed. An electronic device must be fitted to the
engine harness to prevent activation of the alarm. This
device is included in the exhaust riser kit when a new
engine with IV reverse gear is ordered.

NOTICE! If a custom exhaust system is built the

above-mentioned electronic device must be
connected. In this case the devices are sold as
individual kits.
P0016570

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 Installation, Exhaust System

Alternative installation of exhaust hose

for a D4–300 with a HS80AE reverse gear
If the exhaust hose needs to be installed at an angle
greater than 42 degrees the reverse gear oil cooler
must be moved back for the change to be feasible.
When the oil cooler is relocated a longer coolant hose
must also be installed.

Installation material for relocated oil cooler: 1

• Spacers, (11x22x52), part number: 836184
• Bolts, M10x80, part number: 955328
• Longer coolant hose (D6), part number:
3583845

Installation material for the hose: 2

• P clamp, part number: 980476
• Spacer, (8.4x15x54), part number: 833244
• Bolt, M8x70, part number: 965181

New oil cooler location

Spacers (1) for the relocated oil cooler

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Installation, Exhaust System

The current position allows an exhaust hose angle

between the waterline (horizontal plane) and the hose
centerline of between 10 to 42 degrees.

If the oil cooler is relocated the exhaust hose may be

run beneath the oil cooler coolant outlet. This allows
an exhaust hose installation angle greater than 63
degrees.

NOTICE! There is a zone between 42 - 63 degrees

where it is not possible to install the exhaust hose; (the
oil cooler outlet is in the way of the exhaust hose in this
zone).

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 Installation, Exhaust System

Sailboat system principles

The last part of the exhaust line must be run in a bend
(gooseneck) to prevent water entering from the stern.
The bend must be at least 350 mm (14") (A) above
the waterline when the boat is laden.

Always use stainless steel hose brackets. If the hose

passes through a bulkhead or similar it must be
protected against chafing.

Volvo Penta silencers must be angled 5–7.5° (a) with

the inlet pointing upward.
B
Volvo Penta recommends that the exhaust outlet be
located at the side of the hull and close to the transom
to reduce the risk of backdraughting.

NOTICE! If a Volvo Penta silencer is installed athwart

the boat, it must be angled 25–45° (b) with the inlet
b
pointing upwards. The angle is important for
p0005987
preventing water from forcing its way into the engine
when the boat heels (especially on sailboats).

Anti-siphon valve (vacuum valve)

Exhaust elbow height above the waterline (B) must be
at least 200 mm (8") as illustrated. If the height is lower
an anti-siphon valve (1) is required in the cooling
system to avoid water entry through the exhaust
system.

For installation instructions, refer to the Hot water

connections, page 187 chapter.

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Silencers
There are different types of silencer depending on the
installation. Two very common types are:
• Aqualift silencers
• Straight silencers
Aqualift silencers, wet exhaust lines in motorboats
The illustration shows an example of an engine with an
D Aqualift silencer system.

A
WL

p0005988

A. Min. 350 mm (14")

D. Internal diameter, exhaust hoses

Check that the Aqualift silencer has sufficient space for

the volume of water when the engine is switched off.
The waterline (1) must be well below the silencer inlet
(2).

Exhaust hose internal diameters (D) must be selected

2 according to engine power to ensure low back
pressure.
1
The distance between the lower edge of the silencer
A and the waterline (A) must be at least 350 mm (14") if
there is no gooseneck in the system.

P0021612 Recommended hose diameter, exhaust elbow –

silencer and silencer outlet (D)
Aqualift system
Engine Exhaust hose internal diameter (D)
D4 100 mm (4")
D6 125 mm (5")

Exhaust system, horizontal, straight silencer (wet

exhaust line)
A straight silencer is most suitable when the exhaust
outlet is located high in relation to the waterline, such
that an acceptable down angle cannot be achieved. It
is important that the system drains when the engine is
switched off.

Refer to the table on , page 226 for recommended hose

diameters.
D A NOTICE! A system using a horizontal, straight silencer
D
is not recommended where the dimension (A) is less
than 350 mm (14").

P0006074

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 Installation, Exhaust System

Exhaust riser
If the distance between the exhaust outlet and the
waterline is less than 350 mm (14"), or the
B recommended exhaust line drop cannot be achieved,
an exhaust riser must be installed.

The minimum angle at the exhaust riser outlet must be

10°.

NOTICE! All D6 single installations must have exhaust

risers installed. It is extremely important that the
maximum water level is checked in all other AQ
installations.

A
Maximum height (B) increase at minimum 10°
down angle compared to the standard exhaust
elbow is around:
D4: 175 mm (6.9")
P0007960
D6: 180 mm (7.1")

Risers suitable for 100 mm (4") and 125 mm (5")

exhaust elbows are available from Volvo Penta.

Refer to the table on , page 226 for recommended

(internal) hose diameters.

NOTICE! Systems with cylindrical silencers are not

recommended when the distance between the exhaust
elbow and the waterline (A) is less than 350 mm (14").

Exhaust outlet – hull fittings

Hull fittings must be located in suitable places above
the waterline of a laden boat. If hull fittings end up
below the waterline, a shut-off valve must be installed
at the outlet, or a pipe connected.

This type of outlet is a standard component, and must

not be located on flat transoms; refer to the Exhaust
systems, Backdraughting section.

P0008067

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Exhaust outlet through the hull bottom –

general arrangements
In certain installations, an exhaust outlet through the
1 hull bottom is preferable. In such installations a
substantial pipe (metal, plastic or similar) runs from the
hull up to a level above the static waterline to avoid the
2 necessity of a shut-off valve.

Angle the pipe backwards somewhat and design the

outlet through the bottom of the hull so that water is not
forced up the pipe when the boat is towed or is only
driven on one engine.
A Locate the outlet in the bottom such that exhaust gases
do not create negative turbulence in the water flow to
the propeller or trim tab, not even during turns, as this
3 will impair boat performance.

A bypass outlet from the exhaust pipe to a point above

the waterline must be installed in the hull above the
5 waterline to avoid high back pressure when the engine
4 is started, and to reduce noisy pressure pulses against
the hull at low idle.
P0008068
A riser is often necessary to achieve the correct
1 Exhaust riser distance (350 mm (14")) to the waterline. Refer to the
2 Exhaust hose exhaust riser illustration onInstallation, page 227 and
Installation, page 228.
3 Exhaust pipe (substantial pipe)
4 Exhaust outlet
5 Bypass outlet
A 350 mm (14")

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 Installation, Exhaust System

Air turbulence behind the boat – exhaust

boot
Diagram showing system with exhaust boot
When the boat moves forward an aft-moving airstream
is created that generates a vortex behind the boat. This
is especially strong on boats with abrupt, high
transoms and high superstructures which cause
exhaust gases to be drawn into the boat. Refer to the
Backdraught section in the Installation, page 217
chapter.

W
L

P0006076

In order to minimize this problem, the flow of water aft

of the propeller may be used to release exhaust gases
further away from the transom. Preferably, the exhaust
boot should be placed in line with the propeller shaft
immediately behind the propeller and rudder. In this
way exhaust gases are introduced into the flow of
water behind the propeller. Refer to the Backdraught
section in the Installation, page 217 chapter.

The system can be designed to meet individual

boatbuilder requirements. Volvo Penta has
considerable experience in the application of custom
built exhaust boots and is able to provide outline
solutions for hydromechanically developed exhaust
boots for local manufacture.

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Installation, Exhaust System
1 Flexible compensator
2 Flexible bracket
3 Flexible brackets
4 Silencers
230
Dry Exhaust Line
Tools:
885164 Flange
885683 Flange
9996065 Pressure gauge
9996666 Nipple
Inboard engines
The illustration shows an example of how a dry exhaust
line may be installed. Ideally, the line should be made
of acid proof stainless steel, but satisfactory service life
may also be achieved using piping of other types of
stainless steel. Copper piping may not be used for
diesel engines. Because of the high temperatures
400–500 °C (840–930 °F) that occur in dry exhaust
systems, piping must be insulated to avoid the risks of
fire and personal injury.
The system must also be equipped with a flexible
compensator (1) to absorb heat expansion and engine
vibrations. The compensator must be installed close to
the engine exhaust manifold in order to transfer as little
load as possible.
The exhaust system must be insulated throughout its
length, but compensator movement must not be
hindered. After the compensator the exhaust system,
including the silencer (4) must be suspended by
flexible brackets (2, 3) so that movement due to heat
expansion is not hindered.
The exhaust outlet must be located in a suitable
position, with a good margin to the waterline when the
boat is loaded; furthermore, the outlet must be
insulated against the hull to avoid heat damage.
A device for draining condensate must be installed at
the lowest point in the system.
When dimensioning the exhaust system, back
pressure may not exceed the values shown in the
table ; refer to the following page. Permissible exhaust
back pressure at indicated rpm, page 231.
NOTICE! The engine continues to release cooling
water from the seawater pump (connected to a suitable
side of the boat).
47704210 02-2018 © AB VOLVO PENTA
 Installation, Exhaust System

Excessive back pressure may cause damage and

lead to:
• Loss of power
• Lower fuel economy
• High exhaust temperature
Such conditions will cause overheating and excessive
engine smoke, and will reduce valve and turbocharger
service life.

Permissible exhaust back pressure at indicated rpm

D4 180 x x x x x
D4 210 x x x x x
D4 225 x x x x x
D4 260 x x x x x
D4 300 x x Permissib x x
le
D6 300 x x x x
D6 330 x x x x
D6 370 x x x x
D6 400 x x x x
D6 435 x x x x
0 5 10 15 20 25 30 35 kPa
0 0.7 1.5 2.2 2.9 3.6 4.4 5.1 psi
0 510 1020 1530 2040 2550 3060 3570 mm
wc

Measuring exhaust back pressure

Back pressure must always be checked after the
exhaust line has been installed.
When the test is done, the engine must be run under
full load long enough to give a stable value.
1 Measuring procedure
Remove the exhaust pipe from the turbocharger
exhaust outlet. Clean the contact surface.

Install 885164 Flange (D6) (1) or 885683 Flange (D4)

with a V-clamp to the turbine housing flange. Install the
2 exhaust elbow on the measurement flange.

Connect9996065 Pressure gauge (2) with pressure

hose and 9996666 Nipple at the measuring flange.

Run the engine at full load and max rpm for several
minutes, and check that back pressure is not higher
than the permissible value.

P0006081

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Installation, Exhaust System

NOTICE! Alternatively, a transparent plastic tube may

be connected to the measurement flange as illustrated.
The difference between the water columns (A) shows
exhaust system back pressure in mm water column
(the dimension A can be up to 4000 mm (157")).
A
Run the engine at full load and max rpm for several
minutes, and check that back pressure is not higher
than the permissible value.

Permissible exhaust back pressure in exhaust pipe:

Refer to the table Permissible exhaust back pressure
at indicated rpm, page 231.
P0006082

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 Installation, Fuel System

Fuel System
General

2 1 Fuel tank
3
2 Filler cap

A A 3 Vent line
4 Suction line
5 Inspection cover
8
6 Remotely operated fuel shut-off valve
5
6 7 Fuel level sensor
7
8 Return line
9 Bottom plug

A Nipple in installations with a rubber

hose

4
P0004674 9

The installation of fuel system components such as fuel tank,
taps, fuel pipes and auxiliary fuel filters etc., must be carried out
very carefully in order to ensure sufficient fuel to the engine and
that the requirements for perfect sealing and fire safety are met.
Plan the locations of the tanks carefully before starting work.
Use quality taps to avoid leakage. A leaking fuel system always
entails great risk of functional faults and fire.
Use first-class quality components.
Ideally, the taps must be installed on the outside of the engine
compartment, or be remotely operable.
NOTICE! There may be local legislation that
always sets aside engine manufacturer
literature and recommendations.
In Europe, materials and installation of fixed
fuel systems must fulfill the requirements of
ISO 10088. In the USA the installation must
fulfill the requirements of the ABYC and
USCG.
When working on the fuel system, it is
important to keep it clean and free from dirt.

Fuel may be divided up between several tanks in order to keep

the center of gravity low and also to allow adjustment of the fore-
and-aft CoG.

If the tanks are to be built in, the surrounding space must have
good ventilation.

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Installation, Fuel System

2 1 Fuel tank
3
2 Filler cap

A A 3 Vent line
4 Suction line
5 Inspection cover
8
6 Remotely operated fuel shut-off valve
5
6 7 Fuel level sensor
7
8 Return line
9 Bottom plug

A Nipple in installations with a rubber

hose

4
P0004674 9

The installation of fuel system components such as fuel
tank, taps, fuel pipes and auxiliary fuel filters, etc. must
be carried out very carefully in order to ensure sufficient
fuel to the engine and that the requirements for perfect
sealing and fire safety are met.
Plan the locations of the tanks carefully before starting
work. Use quality taps to avoid leakage. A leaking fuel
system always entails great risk of functional faults and
fire.
Use first-class quality components.
NOTICE! There may be local legislation that
always sets aside engine manufacturer literature
and recommendations.
In Europe, materials and installation of fixed fuel
systems must fulfill the requirements of ISO 10088.
In the USA the installation must fulfill the
requirements of the ABYC and USCG.
Do not fix any of the fuel hoses/pipes and keep the
original clamps on the engine, otherwise there is a
risk that the pipes will break resulting in a fire.

Ideally, taps must be installed on the outside of the When working on the fuel system, it is important to
engine compartment, or be remotely operable. keep it clean and free from dirt.

Fuel may be divided up between several tanks in order

to keep the center of gravity low and also to allow
adjustment of the fore-and-aft CoG.

If the tanks are to be built in, the surrounding space must

have good ventilation.

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 Installation, Fuel System

Fuel Tanks
If possible, the tanks must be located so that they are
on the same level as, or a little higher than, the engine.
If they are located lower, bear in mind that fuel feed
pump maximum suction height varies between 1.5–2.0
m (60–78") for the engines. Note that the suction height
must be measured from the suction line lower opening,
i.e. 25 mm (1") above the tank bottom.

The return line must be installed at a distance from the

suction line, and about 15 mm (0.6") above tank bottom
in order to prevent air entering when the engine is
stopped.

If the tanks are located lower than the level permitted

by the common rail suction height, fuel must first be
pumped up to a day tank using a hand pump or electric
pump. In this case, return fuel must be led back to the
day tank.

The fuel tanks may not be located higher than 1.0 m (3

ft) above the engine valve cover.

Twin tanks must be cross-connected at the base by a

pipe equipped with shut-off taps. The lower cross-
connection pipe must have an inner diameter of at
least 25 mm (1") so that the tanks can be filled from
one side of the boat. It is acceptable to use alternative
fuel tank shapes if these are adapted to the installation
geometry. Regardless of the shape chosen it is
important to design the tank such that there is a lower
section from which water and sludge can be drained.

NOTICE! An auxiliary fuel filter with water separator

must be installed for use with all Volvo Penta engines.

If a day tank is installed, it is advisable to connect the

return line to this tank.

A shut-off tap must be installed in the feed line,

between the tank and the filter. It must be possible to
operate this tap from the outside of the engine
compartment.

Suitable materials for fuel tanks are stainless steel and

aluminum sheet.

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Installation, Fuel System

WARNING!
Hot fuel can cause burns.

If a thermoplastic tank is used, its heat resistant

qualities must be checked and if necessary a fuel
cooler must be installed on the return line.

Heat emitted to the return flow

Return fuel temperature at rated full power on D6-435
engines is 55°C (131°F) under the following conditions:
ambient air temperature 20°C (68°F), seawater
temperature 25°C (77°F) and fuel feed temperature
40°C (104°F). Return flow is approx 60 liters per hour.
Fuel heat output under these conditions is approx 460
W.

The boat builder must take the above-mentioned

temperatures and flows into consideration when
choosing a plastic fuel tank

236 47704210 02-2018 © AB VOLVO PENTA

 Installation, Fuel System

NOTICE! All tanks must be equipped with at least one

slosh baffle per 150 l (37 US gal) volume. Check to see
if there are special restrictions regarding volumes and
slosh baffles.

Filling and ventilation connections may not be located

on the sides of the tank.

The fuel tanks have filling, ventilation, suction line,

return line, and fuel level sensor connections, and an
inspection opening with cover. The suction and return
lines must always be kept apart as illustrated.

P0004675

Diesel engine return lines must be run back to the

bottom of the tank in order to prevent air entering when
the engine is stopped.

P0004676

Mount the tank on a soft base. Do not mount the tank

on wooden blocks or other type of uneven base as this
may cause uneven loading with the attendant risk of
fatigue cracks in the tank.

Install the tank in the boat. Secure the tank with clamps
to prevent it from moving in heavy seas. The fuel tank
must be located by itself in a cool space in order to
avoid fuel being heated or spread to other parts of the
boat in the event of a leak.

In boats where space is limited, the tank may be

shaped in order to fit under the aft deck or similar
space.
P0004677

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Installation, Fuel System

The tank must be well ventilated. The tank ventilation

line (1) must have an inner diameter of 12 mm (1/2").
Run the hose with an upward bend inboard to prevent
water entry.

The deck filler (2) must be designed such that it

accepts hose connections of at least 50 mm (2.0")
diameter. The hose between the deck filler and the
tank must overlap the hose connections at both ends
by at least 75 mm (3.0") and be secured using two
hose clamps at each end. The hose clamps must be
made of corrosion free material.

No common ground conductor for the fuel tank, fuel

filler etc. is normally required for diesel installations.
However, regional authorities may require this for all
boats.
P0004678

NOTICE! Install the filler and ventilation hoses so that

1 Ventilation line
no U-bends (3) are formed where fuel is able to collect.
2 Deck filler (gland)
NOTICE! The fuel filler and ventilation must be
3 Prohibited U-bend
installed such that overfilling is prevented and that fuel
cannot enter the air inlets.

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 Installation, Fuel System

Fuel System, Piping

All fuel lines must be installed and fastened correctly
close to the bottom of the boat in order to avoid heat
absorption. Air temperature is lower in the bottom of
the engine compartment.

Rubber hoses (D)

Secure the fuel lines using clamps. Distance between
clamps approx 300 mm (12").

NOTICE! Hose kit 21967719 (B) provides an internal

thread for 10 mm (1/4"-18 NPSF) connections.

NOTICE! Some classification societies and other

authorities do not allow rubber hoses as fuel lines, or
require the hoses to meet certain specifications. Check
to see if the boat will be used in such areas.

Make sure the hose cannot be damaged by sharp

edges.

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Installation, Fuel System

D4 engines D6 engines
Internal diameter Internal diameter

Minimum internal diameter required for Minimum internal diameter required for
- fuel feed line: 10 mm (3/8") - fuel feed line: 10 mm (3/8")
- return hose: 10 mm (3/8") - return hose: 10 mm (3/8")

NOTICE! Use only approved flexible hoses. NOTICE! Use only approved flexible hoses.

Suction distance and suction height. Suction distance and suction height.
Maximum suction distance: 8.0 m (26.3 ft.) Maximum suction distance: 6.0 m (19.5 ft.)
Maximum suction height: 2.0 m (6.5 ft.) Maximum suction height: 1.5 m (5.0 ft.)

Nipples (A)
Minimum internal diameter: 7.0 mm (0.28")
Male thread: 1/4" NPTF
Volvo Penta part #: 3825000

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 Installation, Fuel System

Steel and copper pipes

Secure the fuel lines using clamps. Distance between
clamps approx 300 mm (12").

When steel and copper pipes are used there must be

a flexible connection (hose) between the pipe and the
engine.

The illustration shows the transition from flexible hose (1) to steel or copper pipe (2, 3).
1 Flexible hose
2 Min. diameter 12 mm (1/2")
3 Min. diameter 10 mm (3/8")
4 3/4"–16UNF
5 1/4"–18NPTF
6 Nipples
7 Return, contains check valve

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Installation, Fuel System

D4 engines D6 engines
External diameter External diameter

Minimum external diameter required for: Minimum external diameter required for
- fuel feed line: 10 mm (3/8"), see diagram or 12 - fuel feed line: 12 mm (1/2")
mm (1/2")
- fuel feed return line: 10 mm (3/8")
- fuel feed return line: 10 mm (3/8")
Suction distance and suction height, feed line
Suction distance and suction height 10 mm (3/8") Maximum suction distance: 6.0 m (19.5 ft.)
feed line Maximum suction height: 1.5 m (5.0 ft.)
A
1 Nipples (A)
2 Minimum internal diameter: 7.0 mm (0.28")
3 Male thread: 1/4" NPTF
Volvo Penta part #: 3825000
4
5
6
7
8
9
10

0,5 0,8 1,0 1,5 2,0 B

P0006215

A Suction pipe length (m)

B Suction height (m)

Suction distance and suction height 12 mm (1/2")

feed line
Maximum suction distance: 8.0 m (26.3 ft.)
Maximum suction height: 2.0 m (6.5 ft.)

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 Installation, Fuel System

Fuel Flow
Fuel flow comprises the amount of fuel that passes
through the fuel line from the tank to the engine, which
includes both the fuel that is consumed and that which
returns to the tank. This must be borne in mind when
selecting the fuel pre-filter.

The table below shows fuel flow for a given rpm.

Engine l/h US gal/h

D4 180 95 25.1
D4 210 100 26.4
D4 225 105 27.7
D4 260 115 30.4
D4 300 120 31.7
D6 300 125 33.0
D6 330 130 34.3
D6 370 140 37.0
D6 400 145 38.0
D6 435 150 39.6

Fuel filter
Use a fuel pre-filter of the correct size to avoid high
resistance across the filter. Recommended filtration is
10 microns (10µ).

NOTICE! Fuel pre-filters with glass bowls may not be

installed in boats that are to be CE marked.

NOTICE! Filters that provide a capacity equal to

double the flow are recommended in order to reduce
service requirements.

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Installation, Fuel System

Fuel line, checking negative pressure

Tools:
9990150 Manometer
9996066 Nipple
9998493 Hose

NOTICE! It is not normally necessary to check fuel

feed pressure. This need only be done if there is a
suspicion of too great a resistance in the system.
Follow the instructions below as necessary.

Fuel feed pressure cannot be measured normally as

the feed pump is integrated in the high pressure pump.

On the other hand, it is very important that the

negative pressure in fuel lines, fuel filters and water
separators does not exceed maximum values.
Because the vacuum gauge is connected after the fuel
filter it is possible to measure the total value from the
fuel tank to the high pressure pump.

Two consequences of a faulty value are that the high

pressure pump has difficulty in governing rail pressure
and that cavitation damage may occur in the pump.

NOTICE! Measurements must be made with new filter

elements fitted. Both the fuel filter (engine) and pre-
filter must be new.

1 Remove the plug and gasket (1).

Connect9996066 Nipple to 9998493 Hose
and9990150 Manometer.
2 Start the engine.
3 Run the engine under load and increase the rpm
through the entire rpm range. Feed pressure
(negative pressure) must be: 0 – -37 kPa (0 – -5.4
psi) measured with a new filter element. 0 – -50
kPa (0 – -7.3 psi) is mentioned in the workshop
literature as max negative pressure. This value is
in respect of dirty filter elements.
4 if the pressure is too low (negative pressure):
Check the filter element and fuel lines. Investigate
P0006216 pipe or hose dimensions. Check the pre-filter.
5 Remove the measuring equipment and install the
plug (1). Use a new gasket.

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 Installation, Lubrication System

Lubrication System
Draining the Engine
General
Engine installations in boats and ships have a
potentially negative impact on the environment. The
fluids handled are harmful to the environment and must
be handled in a safe manner.

Oil drain pump

An electrical oil drain pump is available as an accessory.
The pump is installed in a suitable location using a
bracket. Pump direction may be changed by switching
polarity.

P0010246

Oil hoses
Oil hoses should have a shut-off tap or only be
connected at oil changes in order to avoid the risk of
inadvertent drainage.

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Installation, Lubrication System

Viscosity

Select the viscosity according to the table.

The temperature values refer to stable ambient

temperatures.

* SAE 5W/30 refers to synthetic or semi-synthetic oils.

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 Installation, Electrical System

Electrical System
General

The electrical installation must be planned very Two-pole electrical system

carefully and installed with the greatest of care. Strive
for simplicity when designing the electrical system.
Cables and connectors used in the installation must
be approved for marine use. The cables must be run
in conduits and securely fastened.
D4 and D6 engines have two-pole electrical systems
with insulated ground return. In a two-pole system
each electrical component on the engine has an
insulated direct current ground return.

Be careful not to run cables too close to engine hot IMPORTANT!

spots or close to other heat sources.
The cables must not be subjected to mechanical
wear. Where necessary, run cables through conduits.
Strive to minimize the number of joints in the system.
Make sure that the cables and particularly the joints
are accessible for inspection and repair.
Do not ground any cables to the engine block.
Kits are available that enhance the isolation between
the engine block and electrical ground.
Power supply

IMPORTANT!
There must be a circuit diagram in the boat covering
the entire system. This will considerably simplify fault Large power consumers such as bow thrusters,
tracing and the installation of further equipment. capstans etc. must be connected to a separate
auxiliary battery and not to the start batteries.
NOTICE! Make sure that all components used are
suitable for marine environments. Take care to ensure
that no joints in the engine compartment are located
far down. All joints must be located higher than the
alternator.

IMPORTANT!
Supply cables – batteries, alternators, distributors,
starter motors and heavy loads must be installed
separately from the EVC buss cable and the control
unit cables in Volvo Penta IPS installations.

Positive (+) and negative cables (-) must be secured

adjacent to one another, not separately.

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Installation, Electrical System

Batteries
Battery terminology
Capacity
Capacity is measured in ampere hours (Ah). Start
battery capacity (Ah) is normally specified as the
battery 20-hour capacity, i.e. the battery will be
discharged by a constant current over 20 hours until it
reaches a final voltage of 1.75 V per cell. For example:
If a battery is able to produce 3 A over 20 hours, its
capacity is 60 Ah.

The ampere value at cold start (CCA) measures

battery start capacity. The SAE (Society of Automotive
Engineers) specifies the following test: A battery at a
temperature of -18 °C (0 °F) must be able to provide
current equivalent to the ampere value during a 30-
second cold start with a constant voltage level above
1.2 V per cell or 7.2 V for a 12 V battery. There are
other CCA tests defined by DIN, JIS, and ETN, etc.
These tests give other CCA values than the SAE test.

Battery capacity is influenced by temperature. Battery

capacity is specified at +20 °C (68 °F). Cold
significantly reduces a battery's ability to release
energy. The following table shows capacity differences
at +20 °C (68 °F) and -18 °C (0 °F).

Temperature +20 °C (68 °F) -18 °C (0 °F)

Capacity 100 % 50 %
70 % 35 %
40 % 25 %

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 Installation, Electrical System

Connecting batteries
If the boat has several batteries, the following
connection method must be used:

Parallel connection:
Two (or more) 12 V batteries are connected in parallel
to increase capacity. Boat system voltage is the same
as battery voltage.
• The batteries must have the same nominal voltage.
• The batteries may have different capacities.
• The batteries do not need to be of equal age.
When two batteries are connected in parallel the
voltage remains same, but capacity is the sum of the
respective battery capacities. During charging each
battery receives a charging current lower than that
specified on the charger. Measure the charging current
at each battery using an ammeter in order to assess
charge current to each battery.

P0004709
Example: When two 12 V batteries, each with a capacity of 88 Ah,
are connected in parallel, the voltage will be 12 V and the total
capacity 176 Ah.
If one of the batteries in a parallel connection has a
shorted cell, the nominal system voltage will be around
10 V.
Series connection:
When two 12 V batteries are connected in series, boat
system voltage will be 24 V.

IMPORTANT!
Always check boat system voltage before connection.
Engines may be in 12 V or 24 V configurations.
• The batteries must be the same (have the same
capacity and voltage).
• The batteries must be of equal age as the charge
current required for a given voltage changes with
battery age.
• Different loads may not occur (the equipment must
burden both batteries, not just one). A small power
consumer, such as a radio connected to only one
battery can quickly destroy both batteries.

Two batteries connected in series provide the same

capacity, but double the voltage. During charging,
each battery takes current from the charger. The total
battery voltage may not exceed the battery voltage
stated on the charger.

When two 12 V batteries are connected in series and

one of the batteries has a shorted cell, the voltage of
P0004708
the two batteries will be around 23 V.
Example: When two 12 V batteries, each with a capacity of 88 Ah,
are connected in series, voltage will be 24 V and the total capacity
88 Ah.

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Installation, Electrical System
1
P0004705
Engine:
D4 (one battery per engine)
D4 (normal start array)
D6 (one battery per engine)
D6 (normal start array)
250
Batteries, Installation
Install the batteries in a box with a tight-fitting lid.
Ventilate the box with 25 mm (1”) hoses (1). The
ventilation hoses must lead to the outside of the boat
in order to release the flammable gas the batteries
produce.
The batteries must be secured and may only move
max. 10 mm (3/8").
WARNING!
Risk of fire and explosion. Never allow an open flame
or electric sparks near the battery or batteries.
Batteries that are not sealed may only be installed in
the engine compartment if they are in a separate,
sealed and well-ventilated battery box. Battery gas is
highly inflammable and extremely volatile.
Starting Group Battery Capacity
The batteries below are recommended for start of
engines at the stated temperatures. The list applies to
both 12 V and 24 V applications.
NOTICE! Battery capacity drops by around 1% per
degree Celsius from +20 °C (68 °F), which must be
taken into consideration in extreme temperatures.
Min. battery capacity (SAE) Min. battery capacity (SAE)
Lowest temperature: +5 °C (41 °F) Lowest temp: -5 °C (23 °F)
750 CCA and 75 Ah 800 CCA and 75 Ah
750 CCA and 88 Ah 800 CCA and 88 Ah
750 CCA and 75 Ah 1 150 CCA and 120 Ah
750 CCA and 88 Ah 1 150 CCA and 120 Ah
Two 680 CCA and 75 Ah batteries may be used
instead of one 1 150 CCA and 120 Ah battery.
Normal start array: One battery is used to start both
engines (twin installation).
47704210 02-2018 © AB VOLVO PENTA
 Installation, Electrical System

Accessory Battery
The use of a separate battery array for service power
consumption is mandatory.

Volvo Penta recommends the use of a charge

distributor to charge the service batteries.

Cross-over switch
The use of a battery cross-over switch between the
service battery and the start battery is recommended.
3
1 Start battery
2 Service battery

- - 3 Battery cross-over switch

+ +
1 2
4 Start motor

-
4
P0015381

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Installation, Electrical System

Mixed Voltage Systems

Note that auxiliary alternators can only be installed on
engines without power steering pumps. Refer to the
Power take-off, Universal bracket section.

Power steering
pump
Single inst. D4/D6 AQ Yes
Twin inst. D4/D6 AQ starboard Yes
Twin inst. D4/D6 AQ port No
All inboard inst. D4/D6 No

One engine
Engine 12 V Auxiliary alternator 24 V*
Engine 24 V Auxiliary alternator 12 V*

*) These arrangements are non-standard and require

a solution using a power take-off. Refer to the
Installation, page 283 chapter.

Two engines
Engine 12 V Auxiliary alternator 24 V (80
A)
Engine 24 V Auxiliary alternator 12 V (115
A)

IMPORTANT!
In systems with different voltages, the two drivetrains
must have the same voltage.

This means that a boat may have two 12 V engines

with a 24 V electrical system for accessories, or that a
boat may have two 24 V engines with a 12 V electrical
system for accessories. It is not possible to have a
boat with one 12 V engine and one 24 V engine, no
matter how the electrical system is otherwise
configured.

Alternator voltage from both engines must be the same

to safeguard the function of the EVC system.

Refer to the Power Transmission chapter for

information regarding auxiliary alternators.

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 Installation, Electrical System

Starting Battery Cable Area

Volvo Penta recommends cable cross-sections
according to the table below in order to provide
sufficient power from the battery to the starter motor.

NOTICE! The list applies to both 12 V and 24 V

systems.

Measure the total cable length from the battery

positive terminal (+) via the main switch to the starter
motor positive connection (+), and from the starter
3 motor negative connection (-) back to the battery
+ + - negative terminal (-).
1
- 2 Then select the recommended cable area according to
table below for both the negative cable (-) and the
positive cable (+).

Because the cable must absorb generated heat, the

P0015387
cross-sectional area must be no less than 50 mm²
1 Battery (0.076 in.2).
2 Start motor
3 Main switch

Recommended start battery cable length and cable cross sectional area

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Installation, Electrical System

Comparison cable cross section (mm²) – diameter (mm) according to Volvo standard (SS
IEC 228)
Cross section, mm² (AWG) 50 (0) 70 (00) 95 (000) 120 (0000)
Core diameter approx., mm (in.) 12 (0.47) 14 (0.55) 16 (0.63) 18 (0.71)

Battery Charging
IMPORTANT!
Always connect the battery charger directly to the
battery positive (+) and negative (-) terminals.

For charge voltages and charging times, refer to the

battery manufacturer instructions.

When a battery charger is used in a 12 V system

battery voltage increases to around 13.8–14.4 V.
Charging at high speed with high gas generation may
result in the following:
• Battery service life is reduced
• Capacity is reduced
• There is a risk of shorting in the battery
P0002111
• There is an explosion risk
The following parameters govern charging time
duration:
• How discharged the battery was at commencement
of charging
• Charger capacity (how much current a charger is
able to supply)
• Battery size (capacity in Ah)
• Battery temperature. A longer charging time is
required when a battery is cold. A battery is not able
to receive a high charge current at low
temperatures.

It is better to charge at 10 A for 5 hours than at 50 A

for 1 hour, even though the total charge is 50 Ah in both
cases. The battery may have difficulty in accepting a
high charge current.
WARNING!
Explosion hazard. Batteries contain and give off an
explosive gas which is highly flammable and explosive.
A short circuit, open flame or spark could cause a
violent explosion. Ventilate well.

IMPORTANT!
Switch off power to the battery charger before
connections are removed.

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State of charge (SOC)

State of charge (SOC) is the level to which the battery
is charged. This state can be measured either by
measuring the specific gravity of the battery acid in
each cell, or by measuring the voltage in each cell or
across the battery terminals plus and minus without
load or charge, open circuit voltage (OCV), since at
least 2 hours.

Measuring the voltage across the terminals provides

entirely incorrect information if one of the cells is
defective. Instead, battery acid specific gravity must be
measured using a battery acid hydrometer.

State of health (SOH)

State of health (SOH) is defined as the ratio of
SOCmax and SOCnom. Where the nominal value is
the initial capacity of the battery. This maximum
capacity will not change depending on ageing. The
SOCmax value is the present maximum capacity and
will change depending on ageing of the battery.

Typically, a lead-acid battery SOH will fall rapidly after

it has reached 70%. A lead-acid battery is
recommended to be replaced when the SOH is equal
to 73%.

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Installation, Electrical System

Alternator
Classification
Alternators for D4 and D6 engines have the following
ratings:

12 V for D4, D6: 115 A 24 V for D6: 80 A

Sensor and power cables from alternator

IMPORTANT!
In systems without separate service batteries, the
factory-installed sensor cable from the alternator to the
positive connection on the starter motor must remain
in place, as must the power cable from the alternator
to the starter motor.

In systems with separate service batteries, do as

follows:
1 Locate the yellow sensor cable, 0.75 mm2 (18
AWG), between the alternator and the starter
motor. Undo the cable and cut it at both ends.
2 Locate the red sensor cable, 16 mm2 (6 AWG),
between the alternator and the starter motor. Undo
the cable and cut it at each end.
3 Install a new (preferably yellow) 0.75 mm2 cable (18
AWG), between the service battery main switch
and the connection to the alternator sensor.
4 Install a new (preferably red) power cable between
the alternator and the charge distributor. Also make
a new (preferably red) power cable between the
charge distributor and the main switches (starter
motor and accessories).
5 Add the length of the two cables, 1 and 2. Negative
cable (-) cross-sectional areas must be at least the
same as that of the positive cables (+).
6 Find the correct cable area in the table below.
1 +
2 +
3 -
4 Sensor cable

Total cable length and cable area from alternator to battery

12 V alternator 1.0 1.5 2.5 3.5 5.0 7.0 10.0 12.0
Total length for cables 1 (3.3) (4.9) (8.2) (11.5) (16.4) (23) (32.8) (39.4)
and 2, max length, m (ft.) 24 V alternator 2.0 3.2 5.0 7.0 10.0 14.0 19.0 24.0
(6.6) (10.5) (16.4) (23) (32.8) (45.9) (62.3) (78.7)

Cable area, mm² (AWG) 10 (8) 16 (6) 25 (4) 35 (2) 50 (0) 70 95 120
(00) (000) (0000)

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 Installation, Electrical System

Main switch
A main switch must be installed on the positive side.
When the cables are run through bulkheads both the
positive and negative cables must be fitted with rubber
bushings. Locate the main switch on the outside of the
engine compartment, but as close to the engine as
possible in order to reduce cable length.

P0004714

Technical requirements, main switch

Nominal capacity
Normal Continuous Under 5 sec. Under 5.5 Operating Standard Protection
voltage min. temperature, rating
max.
≤48 V 150 A 1 000 A 450 A +85 °C SAE marine IP 66
+185 °F J1171

Alternator connections
S W B+ Battery positive (+)
B- Battery negative (-)
S Sensor cable
D
D Magnetization
W Rpm (not used)
B-

B+

P0004716

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Charge distributor
12 V and 24 V, engine and boat
Example
The charge distributor automatically charges two
battery circuits, independently of each other. One
circuit is used to start the engine and the other circuit
for other electrical equipment.

This means that if the service battery is discharged the

engine will still be able to be started with the start
battery.

1 Start battery
2 Service battery
3 Sensor cable
4 Power consumers (accessories)
5 Charge distributor
6 Battery changeover switch
7 Starter motor
8 Alternator
9 Negative cable

Extra Alternators
Refer to the Power Transmission chapter for
information regarding auxiliary alternators.

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Voltage Supply

Power Supply, Powertrim Pump

Aquamatic

The 6-pin harness terminal from the Powertrim pump

harness and the cable from the trim sensor to the trim
pump 3-pin harness terminal are connected.

1 Power supply from engine

2 To the connection marked POWERTRIM CONN on the EVC
cable, 6-pole (3-pole harness to the trim sensor).
3 Connections to drive

20 and 50 A circuit breaker (+)

20 A
50 A Connect the supply cable to the power trim pump on
the port side of the engine (1).

Secure all cables correctly using clamps.

1
P0016626

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Engine electrical connection interface

AUX BUS AUX BUS DATALINK SENDERS

P0016607

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 Installation, Electrical System

Connection

Connections to Starter Motor

Connecting battery cables, 2-pole system
Starter motors are available in 12/24 V versions.

The negative cable (-) from the battery is connected to

the starter motor negative terminal (-).
2
The positive cable (+) from the battery is connected to
the starter motor positive terminal (+).
1
Refer to the Installation, page 248 chapter for
dimensioning of start batteries and cables.

P0006270

Terminal 1 (-)
• Battery
• Alternator (factory installed)
• Power supply, engine (factory installed)
• Powertrim (factory installed)
Terminal 2 (+)
• Battery
• Alternator (factory installed)
• Power supply, engine (factory installed)
• Sensor cable (factory installed)
• Powertrim (factory installed)

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Installation, Electrical System

Single installation, D4/D6 12 V or 24 V

1 2 Recommended installation
• NOTICE! No equipment is connected to the start
3 battery array.
5 • Two separate service battery arrays.
5 Navigation equipment is connected to service
4
battery I.
6 7 8 • Bow and stern thrusters, capstans and other large
10 power consumers are connected to service battery
II. This prevents voltage drop in equipment
9 connected to the service battery, such as navigation
P0008310
instruments.
• NOTICE! Large power consumers must have a
1 Alternator separate switch that is connected directly to the
2 Sensor cable service battery positive terminal (+).
3 3-way charge distributor (not Volvo Penta accessory)
• All other equipment such as lamps, fans, fridges
4 Battery changeover switch etc., (navigation equipment excepted) may be
5 Accessories
connected to service battery I or II.

6 Start battery
7 Service battery I
8 Bow thrusters, capstans etc. (major power consumers)
9 Starter motor
10 Service battery II

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 Installation, Electrical System

1 2 Alternative installation
• Navigation equipment of max. 15 A/180 W (12 V),
3 7.5 A/180 W (24 V) may be connected to the start
battery array. This counteracts voltage drop when
5 using power consumers such as bow thrusters and
capstans etc. If no bow thrusters are used,
4 10 navigation equipment must not be connected to the
6 7 start battery array.
8
NOTICE! Refer to the adjacent illustration. The use
of navigation equipment when the engines are shut
down may discharge the battery and cause start
9 problems.
P0008311
• All other equipment, including large power
1 Alternator consumers, must be connected to the service
battery.
2 Sensor cable
3 3-way charge distributor (not Volvo Penta accessory) NOTICE! Large power consumers must have a
separate switch that is connected directly to the
4 Battery changeover switch
service battery positive terminal (+).
5 Accessories
6 Start battery
7 Service battery I
8 Navigation equipment
Max. 15 A (180 W) 12 V
Max. 7.5 A (180 W) 24 V
9 Starter motor
10 Bow thrusters, capstans etc. (major power consumers)

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Installation, Electrical System

Twin installation, 12 V or 24 V, two

separate service battery arrays
(Tolerant system in case of fault in one installation)

10 10 Recommended installation
1 2 1 2
5
• Separate start battery arrays for each engine
5 (drivetrain).
3 3
• NOTICE! No equipment connected to start battery
array.
4 4
6 • Two separate service battery arrays.
6 Navigation equipment is connected to the port side
8 service battery.
7 7 NOTICE! Navigation equipment must not be
connected to the start battery array.

9 9
• Connect the sensor cables from the alternators to
the service battery arrays.
P0008312

• Bow and stern thrusters, capstans and other major

1 Alternator power consumers are connected to the starboard
2 Sensor cable side service battery (II). This prevents voltage drop
in equipment connected to the port service battery,
3 3-way charge distributor (not Volvo Penta accessory)
such as navigation instruments.
4 Battery changeover switch
NOTICE! Large power consumers must have a
5 Accessories (normal consumers), not navigation equipment
separate switch that is connected directly to the
6 Start battery service battery positive terminal (+).
7 Service batteries I and II
• All other equipment such as lamps, fans, fridges
8 Bow thrusters, capstans etc. (major power consumers) etc., (navigation equipment excepted) may be
9 Starter motor connected to the port or starboard service battery.
10 Only used for Volvo Penta IPS Tolerant system in case of fault in one installation
If a short circuit occurs in one of the drivetrains, this will
not affect the other drivetrain.

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 Installation, Electrical System

Twin installation, 12 V or 24 V, one

separate service battery array
(Tolerant system in case of fault in one installation)

Alternative installation
• Separate start battery arrays for each engine
(drivetrain).
• Connect the sensor cable from the starboard
alternator to the service battery array.
• Navigation equipment of max. 15 A/180 W (12 V),
7.5 A/180 W (24 V) is connected to one of the start
battery arrays. This counteracts voltage drop when
using major power consumers such as bow
thrusters and capstans etc. If no bow thrusters are
used, navigation equipment must not be connected
to the start battery array.
NOTICE! Refer to the adjacent illustration. If
1 Alternator navigation equipment is used while the engines are
2 Sensor cable, Aquamatic and inboard engines not running, the batteries may be discharged and
cause start problems.
3 3-way charge distributor (not Volvo Penta accessory)
4 Battery changeover switch • One separate service battery array.
5 Accessories (normal consumers) • All equipment, large power consumers, bow
6 Start battery, port thrusters and capstans, lamps, fans, fridge etc. are
connected to the service battery array.
7 Service battery
8 Bow thrusters, capstans etc. (major power consumers)
NOTICE! Large power consumers must have a
separate switch that is connected directly to the
9 Starter motor
service battery positive terminal (+).
10 Start battery, starboard
Certain sensitive navigation equipment may cease
11 Navigation equipment to function temporarily when they are connected to
Max 15 A (180 W) 12 V
Max 7.5 A (180 W) 24 V
the same battery array as a bow thruster.
12 Only used for Volvo Penta IPS Tolerant system in case of fault in one installation
If a short circuit occurs in one of the drivetrains, this will
not affect the other drivetrain.

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Installation, Electrical System

Twin installation 12 V or 24 V
(Non-tolerant system in case of fault in one
installation)

1 1 Alternative installation

3
2 • No equipment connected to start battery array.
NOTICE! A common start battery array for both
5 engines is permitted. Refer to the
4 11 Installation, page 248chapter.

6 7 8 • Navigation equipment is connected to service

battery I.
10
• Bow and stern thrusters, capstans and other large
power consumers are connected to service battery
9 9 II. This prevents voltage drop in equipment
P0008314 connected to the service battery, such as navigation
instruments.
1 Alternator
NOTICE! Large power consumers must have a
2 Sensor cable separate switch that is connected directly to the
3 3-way charge distributor (not Volvo Penta accessory) service battery positive terminal (+).
4 Battery changeover switch • All other equipment such as lamps, fans, fridges
5 Service battery I etc., (navigation equipment excepted) may be
Navigation equipment, other types of consumers connected to service battery I or II.
6 Start battery
Non-tolerant system in case of fault in one
7 Service battery I installation
8 Bow thrusters, capstans etc. (major power consumers) If a short circuit occurs in one of the drivetrains, this
9 Starter motors may affect the other drivetrain.
10 Service battery II
11 Service battery II

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 Installation, Electrical System

Twin installation 12 V or 24 V
(Non-tolerant system in case of fault in one
installation)

1 1 Alternative installation

2 2
• Navigation equipment of max. 15 A/180 W (12 V),
3 3 7.5 A/180 W (24 V) may be connected to the start
battery array. This counteracts disruptions (voltage
5
drops) when using power consumers such as bow
thrusters and capstans etc. If no bow thrusters are
4 8 used, navigation equipment must not be connected
6 7 to the start battery array.
NOTICE! Refer to the adjacent illustration. The use
of navigation equipment when the engines are shut
9 10 down may discharge the battery and cause start
problems.
P0008315
NOTICE! Large power consumers must have a
1 Alternators separate switch that is connected directly to the
service battery positive terminal (+).
2 Sensor cable
3 3-way charge distributor (not Volvo Penta accessory) NOTICE! A common start battery array for both
engines is permitted. Refer to the
4 Battery changeover switch
Installation, page 248chapter.
5 Accessories (normal consumers) All other equipment, including large power
6 Start battery consumers, must be connected to the service
7 Service battery
battery.

8 Bow thrusters, capstans etc. (major power consumers) Non-tolerant system in case of fault in one
9 Starter motors installation
10 Navigation equipment
If a short circuit occurs in one of the drivetrains, this
Max 15 A (180 W) 12 V may affect the other drivetrain.
Max 7.5 A (180 W) 24 V

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Installation, Electrical System

Auxiliary alternator, single or twin

installations, 12 V or 24 V.

Example
• Keep 12 V and 24 V systems separate.
• Connect the sensor cables to the correct voltage
group, 12 V or 24 V.

NOTICE! Large power consumers such as bow

thrusters must have a separate switch that is
connected directly to the service battery positive
terminal (+).

1 Alternator
2 Sensor cable
3 Accessories 12 V/24 V
4 Bow thrusters, capstans etc. (major power consumers)
5 NOTICE!
Connect to start array, negative (-).

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 Installation, Electrical System

Twin installation, 12 V or 24 V, two

separate service battery arrays
(Tolerant system in case of fault in one installation)

10 10 Recommended installation
1 2 1 2
5
• Separate start battery arrays for each engine
5 (drivetrain).
3 3
• NOTICE! No equipment connected to start battery
array.
4 4
6 • Two separate service battery arrays.
6 Navigation equipment is connected to the port side
8 service battery.
7 7 NOTICE! Navigation equipment must not be
connected to the start battery array.

9 9
• Connect the sensor cables from the alternators to
the service battery arrays.
P0008312

• Bow and stern thrusters, capstans and other major

1 Alternator power consumers are connected to the starboard
2 Sensor cable side service battery (II). This prevents voltage drop
in equipment connected to the port service battery,
3 3-way charge distributor (not Volvo Penta accessory)
such as navigation instruments.
4 Battery changeover switch
NOTICE! Large power consumers must have a
5 Accessories (normal consumers), not navigation equipment
separate switch that is connected directly to the
6 Start battery service battery positive terminal (+).
7 Service batteries I and II
• All other equipment such as lamps, fans, fridges
8 Capstans etc. (major power consumers) etc., (navigation equipment excepted) may be
9 Starter motor connected to the port or starboard service battery.
10 Sensor cable Volvo Penta IPS Tolerant system in case of fault in one installation
If a short circuit occurs in one of the drivetrains, this will
not affect the other drivetrain.

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Installation, Electrical System

Twin installation, 12 V or 24 V, one

separate service battery array
(Tolerant system in case of fault in one installation)

Alternative installation
• Separate start battery arrays for each engine
(drivetrain).
• Connect the sensor cable from the starboard
alternator to the service battery array.
• Navigation equipment of max. 15 A/180 W (12 V),
7.5 A/180 W (24 V) is connected to one of the start
battery arrays. This counteracts voltage drop when
using major power consumers such as bow
thrusters and capstans etc. If no bow thrusters are
used, navigation equipment must not be connected
to the start battery array.
NOTICE! Refer to the adjacent illustration. If
1 Alternator navigation equipment is used while the engines are
2 Sensor cable, Aquamatic and inboard engines not running, the batteries may be discharged and
cause start problems.
3 3-way charge distributor (not Volvo Penta accessory)
4 Battery changeover switch • One separate service battery array.
5 Accessories (normal consumers) • All equipment, large power consumers, bow
6 Start battery, port thrusters and capstans, lamps, fans, fridge etc. are
connected to the service battery array.
7 Service battery
8 Capstans etc. (major power consumers)
NOTICE! Large power consumers must have a
separate switch that is connected directly to the
9 Starter motor
service battery positive terminal (+).
10 Start battery, starboard
Certain sensitive navigation equipment may cease
11 Navigation equipment to function temporarily when they are connected to
Max 15 A (180 W) 12 V
Max 7.5 A (180 W) 24 V
the same battery array as a bow thruster.
12 Sensor cable Volvo Penta IPS Tolerant system in case of fault in one installation
If a short circuit occurs in one of the drivetrains, this will
not affect the other drivetrain.

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 Installation, Electrical System

Auxiliary alternator, single or twin

installations, 12 V or 24 V.

Example
• Keep 12 V and 24 V systems separate.
• Connect the sensor cables to the correct voltage
group, 12 V or 24 V.

NOTICE! Large power consumers such as bow

thrusters must have a separate switch that is
connected directly to the service battery positive
terminal (+).

1 Alternator
2 Sensor cable
3 Accessories 12 V/24 V
4 Capstans etc. (major power consumers)
5 NOTICE!
Connect to start array, negative (-).

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Installation, Electrical System

External accessories

P0004723

1 Ground cable junction box (-)

2 Fuse box (+)
3 Junction box, lanterns

Before auxiliary equipment such as navigation
equipment, auxiliary lighting, radio, echo sounders etc.
are installed, their total power consumption must be
accurately calculated in order to ensure that boat
charging capacity is sufficient.
The above schematic shows how equipment may be
installed in the boat. Fasten the cables to brackets at
short intervals and mark the cables at fuse boxes and
junction boxes (1-3) with each cable consumer such as
communication radio, fridge, lanterns etc.
Install the electrical system control panel close to the
instrument panel, in an easily accessible place that
is not exposed to moisture.
If a 230 V system is installed, this part of the
electrical panel must be clearly marked.
NOTICE! Make sure that all components used are
suitable for marine environments. Spray all electrical
equipment with water repellent spray.

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 Installation, Electrical System

Calculate the supply cable area

Note that power supply cable length and area (A+, A-)
depends on the number of accessories connected.
• Add all the accessories (power consumers).
• Measure the total length of the supply cable (A+,
A-) on the positive (+) and negative (-) sides.
• Refer to the chart Calculating cable
area, page 274. The chart shows supply cable area.

P0004724

Calculate cable area for power consumers

• Measure the distance from the terminal block to the
accessory.
• Multiply the distance by two.
• Then calculate the cable area according to the chart
Calculating cable area, page 274.

- +
P0004723

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Installation, Electrical System

Calculating cable area

1 Load
12V 24V
1 1 A Length (m)
A B C D A B C D B Surface (mm²)
30 30
700 4000 C Current (A)
25 70 25
50 600 120 150
20
50
500 20
95
3000 D Output (W)
40
35 70
400 100
15 25 15 50
30
2000
35 80
16 300
10 10 25 1500
20 60
10
8 200 8 16 50
6 15
40 1000
6 6 10
4 150
800
5 5 6 30
2,5 10
4 100 4 4 600
1,5 8
20 500
3 1 80 3 2,5
6
0,75 1,5 400
5 60 15
1
2 50 2 300
4
0,75
1,5 40 1,5 10
0,5 3
200
8
30 0,5
1 1 150
2 6
0,8 20 0,8 5

P0004726

AWG – American Wire Gauge Example: If a 12 V fridge consumes 70 W and the

AWG mm² (std) mm² sq. in distance between the terminal block and the fridge is
four meters, draw a straight line between 8 (4 x 2) on
18 0,75 0,82 0.0013
the meter scale and 70 on the consumer scale.
16 1,5 1,31 0.0020
14 2,5 2,08 0.0032 The line dissects the area scale in the 2.5 space; 2.5
12 4 3,31 0.0051 corresponds to the area required (2.5 mm2).
10 6 5,26 0.0082
8 10 8,37 0.013 The calculation is based on the maximum permissible
6 16 13,29 0.021 voltage drop in all cables between the positive
5 16 16,76 0.026 connection to the consumer and back to the negative
4 25 21,14 0.033 connection.
3 25 26,65 0.041
Total voltage drop when applying the above
2 35 33,61 0.052
table:
0 (1/0) 50 53,46 0.083
00 (2/0) 70 67,40 0.104 12 V system 0.4 V
000 (3/0) 95 84,97 0.132
24 V system 0.6 V
0000 (4/0) 120 107,16 0.166

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 Installation, Electrical System

Controls
Aquamatic

General
For the boat to be steered and operated in a
comfortable and safe manner, the helm station must
be designed so that levers, steering, instruments,
navigation equipment and alarm systems are laid out
in a practical way. This applies to every helm station.

Levers for EVC engines (Electronic Vessel

Control)
Refer to the installation manual Installation EVC
regarding the installation of controls and other EVC
system components.

Top-mounted control for single Top-mounted control for twin Side-mounted control for single
engine engines engine, with Powertrim control
buttons and harness.

Joystick

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Installation, Electrical System

Controls
Inboard engines

General
For the boat to be steered and operated in a
comfortable and safe manner, the helm station must
be designed so that levers, steering, instruments,
navigation equipment and alarm systems are laid out
in a practical way. This applies to every helm station.

Levers for EVC engines (Electronic Vessel

Control)
Refer to the installation manual Installation EVC
regarding the installation of controls and other EVC
system components.

Top-mounted control for single Top-mounted control for twin Side-mounted control for single
engine engines engine

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 Installation, Electrical System

Controls and Steering System

General
In order for the boat to be able to be steered in a
comfortable and safe manner, the helm station must
be arranged so that levers, steering, instruments,
navigation equipment and alarm systems are located
in a practical way. This applies to every helm station.

Levers for EVC engines (Electronic Vessel

Control)
Refer to the installation manual Installation Electronic
Vessel Control EVC Volvo Penta IPS for installation of
levers and other EVC system components.

Steering node including tilt unit

P0005306

P0005305

Steering node including cables to HCUs in the EVC Tilt unit

system

IMPORTANT!
Tilt units are mandatory for Volvo Penta IPS.

Installation instructions
Refer to the installation manual Installation Electronic
Vessel Control EVC Volvo Penta IPS when installing
the steering node and tilt unit.

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Installation, Electrical System

Steering System
Inboard engines

General
The following instructions provide general information
applicable to all types of installations.

IMPORTANT!
It is important that all components are installed correctly
when the steering system is installed. Incorrect
installation may endanger the boat's maneuvering
capabilities and in the worst case render it impossible to
steer. Also refer to the Installation instructions supplied
with the parallel stay kit.

IMPORTANT!
Hydraulic steering systems: Observe exceptional
cleanliness. Make sure the working area is free from
dust and dirt. Keep protective plugs on unions until pipes
and hoses are connected. Make sure that pipes and
hoses are clean and free from dirt etc. Use a knife to cut
hoses and suchlike.

Single helm station

The mechanical steering system control cable must
not be longer than 9 m (30 ft). This includes
P0006083
installations with 3 x 90° bends and unbracketed
cables. Installations that require cable lengths of 9–12
Mechanical system m (30–40 ft) must be tested in each individual case.
When it comes to such a very long cable it is extremely
important that it be installed as straight as possible and
bracketed. However, it would be better to install
hydraulic steering in such cases.

Twin helm stations

It is generally speaking better to use a hydraulic
steering system in installations with two helm stations.
When a mechanical steering system is used with a DS
unit, a maximum DS unit cable length of 7 m (23 ft.) is
recommended. This includes 3 x 90° bends for each
cable. The DS unit has a 2.25 m (7.38 ft.) cable as
standard, which means that a maximum cable length
828
of 9.25 m (30.33 ft.) is permissible between the
250 steering position and the rudder when a DS unit is
installed.

The following instructions provide general information

applicable to all types of installations.

P0006084

Hydraulic systems

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 Installation, Electrical System

Location of mechanical steering box

Choose a suitable installation location for the steering
box to avoid bending the steering cable too much. If
possible, avoid more than one bend.

Make sure there is enough space for the wheel and for
a comfortable operating posture.

The space (A) behind the steering box must be at least

200 mm (8").

Steering may be installed on either the port or

starboard side of the boat.

NOTICE! Remember to locate gear shift and engine

rpm controls such that the steering cable can be
A installed without extra bends.

P0008201

Running cables
Select the correct length steering cable.
A + B + C = steering cable length.

If a rudder angle indicator is installed, the unit must be

r located in a dry, accessible place. It must preferably be
A r
C located as close to the tiller as possible.

B Finally, attach cable brackets along the entire length of

the steering cable. Distance between brackets:
approx. 250 mm (10").
P0008202
NOTICE! Run the steering cable with bends as gentle
as possible. Minimum radius (r): 250 mm (10").

Hydraulic steering, location of steering

pump
Choose a suitable location for the steering pump.
Check that there is enough space for the wheel and
the steering pump.

Running hydraulic hoses

Install the hydraulic hoses. Minimum bend radius: 60
P0008203
mm (2.5").

Make sure the hoses do not come into contact with hot
surfaces. Bind the hoses together using plastic cable
ties. The distance between cable ties must be around
250 mm (10"). Metal clamps must not be used.

82 Cut the hoses to the correct length. Use a knife to cut

82
50 to avoid swarf and burrs. Ensure that the ends are cut
square and that they are completely clean.

P0006085

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Installation, Electrical System

Hydraulic system with parallel stays

Gauges

Refer to the installation manuals Installation EVC

Electronic Vessel Control D4, D6 and Installation EVC
Electronic Vessel Control Volvo Penta IPS for
instrumentation installation instructions.

P0005054

7” display

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 Installation, Fire Extinguishing System

Fire Extinguishing System

Fire shut-off system, separate relay and
connection
Fault codes will appear if the fire shut-off system input
is activated:

VODIA/EVC display fault

• Serious communication fault, PCU
PPID 6, FMI: 11

1 depicts the fire shut-off system harness connector on

the engine. A depicts the relay under the engine cover.

Recommended installation
Active (+) at stop (energized to stop)
1 Pin 1 R (+)
87a 2 Pin 2 SB (-)
30
87 3 Accessory cable kit, 10 m (32.8 ft.)
4 Fire extinguishing system
(+)86 (-) 85
5 From main switch (+) or accessory relay (ignition
switch)

1
2
3

4 5
P0006324

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Installation, Fire Extinguishing System

Alternative installation
Inactive (+) when closed (energized to run)
85 NOTICE! If there is a requirement for a pause function
on the relay with an active positive (+) from the fire
shut-off system when the engine is running, and no
87 active positive (+) to switch off the system, the cables
must be connected in the relay base as illustrated.

Terminal 85 is connected to the battery (-) and terminal

30 +86 to the fire alarm unit.

87a + 86
P0006325
87a is not used.

The illustration shows a circuit diagram of an energized

circuit.
87a
1 Pin 1 R (+)
30 2 Pin 2 SB (-)
87
3 Accessory cable kit, 10 m (32.8 ft.)
(+)86 (-) 85 4 Fire shut-off unit
5 Main switch (+)
Do not use accessory relay for EVC

1
2
3

5
P0006326 4

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 Installation, Power Take-off

Power Take-off
Auxiliary alternator
Specially-built kits for the installation of auxiliary
alternators are available from Volvo Penta. The
alternator is installed in the same place as the power
steering pump.

Auxiliary alternators can be fitted to the following

engine types:
• All inboard engines
• Aquamatic – only the port engine. The starboard
engine is equipped with the power steering pump
and has no space for an auxiliary alternator.

Refer to Installation instructions supplied with the

alternator kit for more detailed instructions.

P0004743

Power take-off at front

Belt pulleys:
2 x HC50
Multi-V

P0004744

Installation of belt pulley

Install the wedge belt pulley bolts and tighten them in
the sequence illustrated.

P0004745

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Installation, Power Take-off

Tighten the bolts in two steps:

1 Torque all the bolts to 100 ±10 Nm (74 ±7.4 lbf.ft).
2 Then tighten all the bolts a further 45°.

Max. power take-off, Nm (lbf.ft)

Torque limits

Engine Belt pulley, Nm (lbf.ft)

D4 180 55 (40.7)
D4 210 55 (40.7)
D4 225 55 (40.7)
D4 260 55 (40.7)
D4 300 55 (40.7)
D6 300 55 (40.7)
D6 330 55 (40.7)
D6 370 55 (40.7)
D6 400 see below 1)
P0004746
D6 435 see below 1)
see below 1)
see below 1)

1) Max. permissible torque varies depending on:

• whether the engine is equipped with a compressor
or not.
• whether the direction of force applies to one or more
auxiliary units; refer to the illustrations.

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 Installation, Power Take-off

Example 1: D6-350/370 DPH/DPR, Volvo Penta IPS

500/600
The engine is a D6-350, D6-370 or Volvo Penta IPS
500/600 and the directions of force for the two
auxiliary units are A=20° and B=135°.

Max. permissible torque for auxiliary unit A and B

depends on the sum of the vectors for their directions
of force and torque. The combination must reach the
permissible torque area.

In this example torque for the auxiliaries A=36 Nm

(26.6 lbf ft) and B=27 Nm (20 lbf.ft).
18 Nm(13.3 lbf.ft) The resulting force gives a torque of C=34.5 Nm (25.5
27 Nm(20.0 lbf.ft) lbf.ft) with a direction of force of 65.5°. The result is
36 Nm(26.6 lbf.ft)
within the permissible torque area.
45 Nm(33.3 lbf.ft)
P0004747 55 Nm(40.7 lbf.ft) In all circumstances:
Read off the result of two torques with different
D6-350/370 DPH/DPR – the shaded areas in the installation
directions of force by drawing a parallelogram in the
indicates the area of impermissible torque.
table according to the same principals as shown in the
example.

18 Nm(13.3 lbf.ft)
27 Nm(20.0 lbf.ft) P0004748
36 Nm(26.6 lbf.ft)
45 Nm(33.3 lbf.ft) Power take-off in two directions
P0004749 55 Nm(40.7 lbf.ft)

Power distribution – the shaded area in the illustration indicates

areas with impermissible torque.

Example: D6-370 inboard engine

The engine is a D6-370 inboard engine and the
50 direction of force for one auxiliary is A=135°.
135
Max. permissible torque: 27 Nm (20 lbf.ft)
A
170
180
55 Nm(40.7 lbf.ft)
36 Nm(26.6 lbf.ft)
27 Nm(20.0 lbf.ft)
P0008584

Power distribution – the shaded area in the illustration indicates

areas with impermissible torque.

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Installation, Power Take-off

Universal bracket
The front-mounted universal bracket allows the
installation of auxiliary equipment such as an
alternator, refrigerator compressor, hydraulic pump
etc.

NOTICE! D4/D6 115 A standard alternators cannot be

rotated counter clockwise.

Total width of bracket (W): 564 mm (22.2")

Distance from engine bracket center (L): 540 mm
A (21.3")

Maximum load is 10 kg (22 lbs).

NOTICE! The center of gravity must be within the

marked area (A) on the universal bracket.

L
P0004750

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 Installation, Power Take-off

Inline power take-offs

Torque limit, all D4 and D6 engines: 200 Nm (20 lbf ft).

A Bolt circle diameter Ø 60

When using inline installed power take-offs, a torsion

vibration calculation (TCV calculation) must be made.

IMPORTANT!
Special bolts, part no. 465815 (6 pcs.) are used to
fasten the coupling to the standard crankshaft-
mounted wedge belt pulley.

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Installation, Power Take-off

Install the coupling bolts and tighten them in the order

according to the schedule.

Tighten the bolts in two steps

1 Torque all the bolts to 100 ±10 Nm (74 ±7.4 lbf.ft).
2 Then tighten all the bolts a further 45°.

P0004745

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 Launching and Sea Trial

Launching and Sea Trial

Launching and Starting
Checks before launching
• Check that all valves and taps at hull fittings are
closed.
• Check that the correct propeller size is installed.
Also check that the propeller has the correct
direction of rotation (left or right).
• Water-lubricated stern bearings. Check the water
pipes are open.

P0004753
• Check that the anodes on the transom shield,
sterndrive and exhaust pipe are the correct types:
Zinc anodes are the most suitable in most cases,
and are installed as standard. Magnesium and
aluminum anodes are accessories.
Refer to the Operator's Manual.

DPH/DPR sterndrives:
• Check the oil level in the drive. Trim the sterndrive
up until the filler hole is horizontal. Top off with gear
lubricant as necessary. For DPH with a 1.59:1 gear
ratio, use Volvo Penta grade: API GL-5 SAE
OIL
75W-140. For all drives except DPH with 1.59:1
gear ratios, use Volvo Penta grade: API GL-5 SAE
75W-90. We strongly recommend the continued use
of tried and tested Volvo Penta oils to safeguard
sterndrive function. (Check in the EPC catalog or
spare parts catalog to ensure selection of the correct
oil grade).

OIL

P0007677

• Power trim. Vent the system by trimming the

sterndrive up and down. Top up with ATF oil, Volvo
Penta part no. 1161995.

P0008271

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Launching and Sea Trial

Checks after launching

Check the following BEFORE starting the engine.

IMPORTANT!
Recommendations for oil, fluids and grease: refer to the
Operator's Manual.

Taps:
• Check taps.

P0006343

• Check hull fittings.

P0004754

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 Launching and Sea Trial

Engine:
• Top up lubrication oil.
• Check the status of drain taps and plugs.

P0003706

• Coolant. Topping off: refer to the Coolant Level,

Checking and Topping Up, page 215 chapter.
• Gear lubricant. Check the oil level. Screw in the oil
dipstick as far as it goes. The correct level is within
the marked area. Top up as necessary.

p0004704

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Launching and Sea Trial

Inboard engines, reverse gear:

• We recommend the use of Volvo Penta ATF oil to
safeguard reverse gear function. (Check in the EPC
catalog or spare parts catalog to ensure selection of
the correct oil grade).

MAX Check the oil level without screwing the dipstick into
MIN the threaded hole.

P0002487

Inboard engines, propeller shafts:

• Propeller shaft alignment. Preferably after 12 hours
in the water, with the boat rigged and ready.

P0005976

• Water-lubricated stern bearing: vent and grease the

rubber seal. Pump approx 1 cm3 waterproof grease
into the rubber seal, Volvo Penta part no. 828250.

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 Launching and Sea Trial

Hydraulic steering system:

• Check the oil level. Top off as necessary
• Vent the system

P0004757

Fuel system:
• Fuel level
• Filters and taps
• Venting, venting valve (1)
• Manual pump (2)

EVC system:
• Check the battery terminals
• Auto configuration (refer to the EVC system
installation manual)
• Verify that complete calibration has been made
(refer to the EVC system installation manual)
• Start the EVC display(s) and check functionality
• Check any fault codes

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Launching and Sea Trial

Starting the Engine (Cold Start)

WARNING!
Never use start spray or similar agents to start an
engine. This may cause an explosion in the inlet
manifold. Risk of personal injury.

IMPORTANT!
Also refer to the Operator's Manual for information on
how to start the engine.

General information about starting

The throttle must always be in the neutral position
before start. The engine control system ensures that
the engine receives the correct amount of fuel, even
when the engine is cold.

The engine is pre-heated by the control unit, which also

allows the start motor to crank a few revolutions before
fuel is injected. The colder the engine is, the more
revolutions the engine is cranked. This increases the
temperature in the combustion chambers, which
guarantees a safe start and reduces starting smoke.

Idle speed is also controlled by engine temperature

and is somewhat higher after a cold start.

EVC system checklist

The following actions must be taken before the

system is started:
1 Complete calibration
2 Start of EVC display(s)
3 Fault code checks

Pre-start checklist

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 Launching and Sea Trial

Carry out the following before start:

1 Open the fuel tap.

P0004754

2 Inboard engines: Open the sea cock.

3 Turn the main switches on.

IMPORTANT!
Never switch off the current at the main switch when
the engine is running. It may damage the alternator.
1
4 Start the engine compartment fan, where fitted, and
0 allow it to run for at least four minutes.
P0002431 5 Check that there is sufficient fuel for the planned
trip.

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Launching and Sea Trial

Start method
Put the gear in neutral
Put the gear in neutral by moving the lever(s) to the
neutral position at all helm stations.

Twin-lever control: Also check that the throttle lever

is in the idle position.

Starting with the start button

Depress the start button. Release the start button as
soon as the engine starts. Note that if you start the
engine from another helm station, the ignition key at
the main helm station must be in the I position. Abort
the start attempt if the engine does not start within 20
seconds.

Aquamatic
Turn the wheel hard to port and starboard at least five
times to vent the power steering circuit.

Overheating protection
If the starter motor is allowed to run for its maximum
activation time, the circuit will be disconnected to
protect the starter motor from overheating. Allow the
starter motor to cool for at least five minutes (if
possible) before making a new start attempt.

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 Launching and Sea Trial

After starting

Read off the instruments and warm up the engine

1 First allow the engine to idle for ten seconds and
then check that the instruments and displays are
showing normal values.
2 Check that no alarms are displayed and that none
of the warning lamps (accessories) are flashing.
3 Then warm up the engine at low rpm with low load
so that it reaches normal operating temperature
MAX before full power is demanded.
MIN IMPORTANT!
Never rev up the engine when it is cold.
4 Check the oil level in the reverse gear when it has
reached operating temperature.

P0002487

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Launching and Sea Trial

Disconnect the gearshift function

The gearshift function can be disconnected so that the
control lever only affects engine revolutions. Max
engine revolutions 1 500 rpm.

Do as follows to temporarily disconnect the

gearshift function:
1 Move the lever to the NEUTRAL position.

2 Depress the neutral button (N) and hold it down

while moving the control lever forwards to the
ahead gearshift position.
3 Release the neutral button (N). The green indicator
will flash to confirm that the gearshift function is
disconnected.
Now the lever only controls engine revolutions.
The lever automatically connects gearshift function
when it is returned to the neutral position. This is
confirmed by the green indicator lamp showing
P0017161 continuously.
CAUTION!
Take care not to engage the gear by mistake.

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 Launching and Sea Trial

Check the following when the engine is idling:

• Check for leaks in the fuel and cooling systems.
Hoses and pipes.

• Check that instruments and gauges are functional

and show the correct values
- +

• Check the reverse gear oil level once the engine has
! ! reached operating temperature.
• Check that all equipment such as lanterns,
instruments etc. is functioning normally.
P0008272
Check idle revolutions
Idle revolutions depend on engine type. refer to the
installation manual Installation Installation EVC-C3 if
idle revolutions need to be adjusted.

Checks when engine is stopped

Switch the engine off and check the following:

1 Turn the key to position 0.
2 Check engine oil level(s).
3 Check coolant level.
4 Check the water level in the wet exhaust system.
The level must be well below the lower edge of the
silencer inlet so that there is no risk of water
entering the engine. Note the limit specified by the
manufacturer.

P0004766

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Launching and Sea Trial

Sea Trial
Check during boat test run:
1 Instruments – Engine rpm, oil pressure, coolant
temperature and battery charging.
- +

2 Any occurrence of water, coolant, oil or fuel leaks

! ! in the engine installation.
3 Ability to reach maximum rpm; refer to the
Operator's Manual. If it is not possible to run the
P0008272 engine at maximum rpm, the wrong propeller size
may have been installed. It may also be because
the boat is loaded such that it has the wrong trim
angle in the water.
4 Inboard engines: Check exhaust back pressure.
Refer to the Installation, page 217 chapter.

Check across the entire speed range:

1 That engine temperature maintains an acceptable
level.
2 That no abnormal noise or vibrations occur.
3 Aquamatic: Check that the drive does not cavitate
abnormally, e.g. during hard turns. If the system
cavitates it can be because drive toe-in requires
adjustment. Refer to the Parallel rod chapter. It may
also be because the drive needs to be extended;
refer to the Water level at maximum load, page 73
chapter.
4 Inboard engines: Check that the water lubrication
of the propeller shaft seal is satisfactory during
operational trials. Also check that the water
lubrication works well at planing speed and above.
5 Check that steering and controls are correctly
connected and correspond to boat movements.

Checks after sea trials:

Fluid levels in power steering and Power trim.

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Index
A Engine Troubleshooting Guides............................. 148
Accessibility for Maintenance................................... 39
Accessory Battery.................................................. 251
Alternator................................................................ 256
Alternator connections............................................ 257
Anodes to use.......................................................... 60
Aquamatic drive........................................................ 73
Arrangement and Planning....................................... 22
B F
Batteries................................................................. 248
Batteries, Installation.............................................. 250
Battery Charging.................................................... 254
Bottom Painting........................................................ 63
C Fuel System, Piping...............................................
Calculation of Back Pressure................................. 198
Charge distributor................................................... 258
Checking electrochemical corrosion......................... 71
Checking for leakage from the electrical system...... 69
Checking Protective Anodes.................................... 68
Chemical products.................................................... 13
Chemicals................................................................... 9
Choice of Engine...................................................... 22
Condensation Water Collector............................... 193
Connection............................................................. 261
Connections to Starter Motor................................. 261
Controls.......................................................... 275, 276
Controls and Steering System................................ 277
Coolant flow and connections for engines
adapted for external cooling................................... 208
Coolant Level, Checking and Topping Up.............. 215
Coolant, Mixing....................................................... 207
Cooling System...................................... 111, 181, 215
Corrosion protection................................................. 58
Corrosion theory....................................................... 53
Cross-over switch................................................... 251
D Launching and Starting.......................................... 289
Definitions................................................................. 61
Dimensioning of air intake and ducts....................... 44
Draining the Engine................................................ 245
Dry Exhaust Line.................................................... 230
E Measuring Exhaust Temperature........................... 202
Electrical System.................................................... 247
Electrochemical Corrosion....................................... 53
Electronic Steering System.................................... 112
Engine Alignment................................................... 180
Engine Application Ratings...................................... 15
Engine Characteristics............................................. 15
Engine Foundation........................................... 93, 168
Engine Heater........................................................ 214
Engine Inclination..................................................... 37
Engine Installation.................................... 96, 173, 176
Engine Mountings................................................... 173
Engine Performance................................................. 16
Engine Placement.................................................... 37
Engine Room............................................................ 39
Engine Room Ventilation.......................................... 42
Engine Suspension................................................ 175
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EVC.......................................................................... 14
Exhaust Elbow........................................................ 200
Exhaust System..................................................... 217
External accessories.............................................. 272
External Cooling..................................................... 203
Extra Alternators..................................................... 258
Extra expansion tank.............................................. 188
Fire Extinguishing System...................................... 281
Flexible Exhaust Compensator.............................. 194
Freshwater System................................................ 186
Fuel Flow................................................................ 243
Fuel System........................................................... 233
239
Fuel Tanks.............................................................. 235
Function diagrams, external cooling....................... 213
G
Gauges................................................................... 280
General Information.................................................... 6
H
Hot water connections............................................ 187
Hydraulic Steering System..................................... 118
I
Inboard Applications............................................... 168
Installation................................................ 73, 114, 134
Installation Tools and Documentation........................ 9
Insulated Exhaust Systems.................................... 194
J
Jackshaft, Installation............................................. 108
K
Keel cooling............................................................ 192
L
Launching and Sea Trial........................................ 289
Location of Ventilators and Air Intakes..................... 48
Lubrication System................................................. 245
M
Main switch............................................................. 257
Measuring temperature and pressure in keel
cooling systems...................................................... 212
Metric Conversion Chart............................................. 8
Mixed Voltage Systems.......................................... 252
Multiple Exhaust Outlets......................................... 201
P
Parallel rod............................................................. 161
Power Supply, Powertrim Pump............................. 259
Power Take-off....................................................... 283
Propeller Rotation..................................................... 36
Propeller, Installation.............................................. 165
Protection against electrochemical corrosion........... 62
Protection against electrostatic discharge and
lightning.................................................................... 63
Publications.............................................................. 10
301
R
Raw Water System......................................... 111, 182
Rudder Indicator and Autopilot Interface................ 164
S
Safety Information...................................................... 3
Sea Trial................................................................. 300
Shift Actuator, Check-up........................................ 167
Silencer.................................................................. 197
Sound Absorption..................................................... 49
Special Tools............................................................ 11
Standard System Size............................................ 201
Starting Battery Cable Area.................................... 253
Starting Group Battery Capacity............................. 250
Starting the Engine (Cold Start)............................. 294
Steering System............................................. 112, 278
Steering System, Bleeding and Filling.................... 141
Sterndrive Installation............................................. 150
Summary................................................................ 117
System Information.................................................. 14
T
Transom................................................................... 76
Transom Shield Installation................................ 73, 89
Transom, Cutout....................................................... 78
V
Viscosity................................................................. 246
Voltage Supply....................................................... 259
W
Water level at maximum load................................... 73
Water Quality.................................................. 191, 215
Weight Distribution................................................... 38
Wet Exhaust Line................................................... 219

302
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AB Volvo Penta
Technical Information
SE-405 08 Göteborg
Sweden
47704210 English 02-2018