Volvo Penta Installation Checklist D4/D6/D8/D11/D13 Inboard (Version 3.7)

Volvo Penta Installation Checklist
D4/D6/D8/D11/D13 Inboard (Version 3.7)
Boat/Vessel Manufacturer: PT. Ben Santosa
Boat/Vessel Model/Type: Aluminium Patrol Boat
Engine Installation/Type: Volvo Penta 2 x D8-550I
Hull Identification Number: P.4002
Page 1 of 28
Volvo Penta Installation Checklist SALES ENGINEERING MARINE

D4/D6/D11/D13 Inboard Version 3.7 DEPT CB75200, GOTHENBURG SWEDEN
CamScanner
1 Check List Information
Some information stated in this checklist cannot be found in the manual so the checklist shall be considered as
a complement to the manual.
1.1 Issuer
Inspector Date
Boris De Palma Sitorus 4 august 2022
Company Phone
PT. Jagad Mandiri Marine +6281361017543
Address City
BSD -Tangerang Tangerang City
Country Email/Fax
Indonesia boris@jagadmarine.com
1.2 Installation Approval – Conditions
The Volvo Penta Certified Installation Certificate is based upon the inspection and testing of one boat
within a particular model designation. Volvo Penta will issue a certificate when it confirms that the
engine installation meets its requirements and standards established for a particular boat model to
which the Boat builder agrees to follow the Volvo Penta Certified Installation Procedures for all
installations within that model. The use of the Certificate (or certified installation decal) with subsequent
boats within that model designation is permitted provided that the engine installation is identical to the
engine installation in the inspected boat.
Failure to follow the agreed Certified Installation Procedures renders the certificate “void,” and the Boat
builder agrees to defend and indemnify Volvo Penta from any and all causes of actions arising from
failure to install and/ or test the boat in accordance with those procedures.
The Boat builder is obligated to contact Volvo Penta and request re- certification if changes in the design
or manufacture of the boat affect engine installation.
The Boat builder is obligated to provide an instruction for engine removal and refitting for the particular
boat model as well as an electrical schematic diagram.
Other than Boatbuilder’s agreement to reimbursement and hold harmless Volvo Penta for damages
pertaining to deviations described in the checklist, issuance of a Certified Installation Certificate does
not create any warranty, that differs from either the Volvo Penta International Warranty or additional
coverages provided by Volvo Penta to the Boat builder or end user.
The boat builder guarantees that the Certified Installation plate is not mounted in any boats that are not
Certified, nor is the boat model marketed as Certified Installation.
Volvo Penta is allowed to publish the certificate number and boat model designation for all certified boat
models.
Volvo Penta may withdraw a certificate at any time if it believes that an installation does not meet the
standards and requirements established by Volvo Penta for certified installation. At that time, the Boat
builder agrees to discontinue use and delivery of Volvo Penta Certified Installation Certificates from the
factory and through its retail dealers and distributors.
Volvo Penta does not by virtue of the Certified Installation Certificate or the inspection on which it was
based assume any product or other liability whatsoever for the certified boat model.
This document shall be regarded as a tool to systematically check and assess the installation. The
points in the checklist must be fulfilled without exceptions according to the requirements stated in
text/figures or in the Installation manual in order to obtain a fully approved Certified Installation. If any
deviation occurs, they should be committed by the Boat builder and mentioned as remarks in the
installation checklist and certificate. If a third party, including but not limited to end users, launches a
claim against Volvo Penta for any kind of damages or loss, including but not limited to warranty
replacements or repairs, AND such claim in any way pertains to any deviation described in this checklist,
THEN Boat builder will reimburse and hold harmless Volvo Penta from and against any damage or loss
suffered by Volvo Penta without limitation and, for the avoidance of doubt, including reasonable
attorney’s fees.
Page 3 of 28

CamScanner
2.3 Gear/Transmission
Gear/Transmission manufacturer Type and Model Reduction ratio
ZF ZF286 1,966 : 1
Electrical shift Trolling valve
Yes: No: Yes: No:
2.4 Propulsion
Propeller manufacturer Type Propeller diameter & pitch
Nakashima FPP 652 & 648

Number of blades Blade area ratio Impeller model/type/size (WJ)
Page 5 of 28

3 Installation
3.1 Engine bed and foundation
3.1.1 Engine bed design
Checked:
Remarks: Aluminium engine bed material
3.1.2 Engine bed dimensions, sufficient

clearance to bottom and bed
Checked:
Remarks: A: 200mm C: 750mm
B: 555mm
170 mm
Measurement A, B and C must

be within  5 mm (0.2")
230mm
3.1.3 Fitting and alignment of flexible engine NOTE! The engine must rest on the flex
mounts, nominal height mounts for 12 hours before adjustments can be
made. The compression must be equal side to
Checked: side, acceptable tolerance ± 1.5 mm.
NOTE! See installation manual for other engine
Boat builder informed about the importance of correct mounts.
engine mounting:
Remarks: D8-550 using flexible mounting from Volvo

Penta
Page 6 of 28

3.2 Fuel system
Page 7 of 28

3.2.1 Fuel tank setup, clamping, connection
locations, baffle plates
Checked:
Boat CE marked Boat ABYC marked
Remarks: Manufactured by shipyard
3.2.2 Proper fuel lines (feed and return), size, fire

resistance
Checked:
Copper feed line pipe outer diameter [mm/in]: ½ inch

Copper return line pipe outer diameter [mm/in]: ½ inch
Hose inner diameter [mm/in]: ½ inch
Remarks: length Stbd:1500mm , Port: 800mm
3.2.3 Fuel lines, installation, clamping,

positioning, suction height
Checked:
Remarks: suction height 650 mm
For engine specific suction height see manual
3.2.4 Extra water separator/fuel filters,

(recommended filtration is 10 micron)
Checked:
Type: 877770 by Volvo Penta
Remarks: Duplex separator filter The filters should be dimensioned as

size  2 x flow to secure longer service life
3.2.5 Shut off valves
Shut off valve on the supply side is required in

accordance with ISO/ABYC.
Shut off valve on return side must be avoided unless
local laws and regulations require it.
Checked:
Remarks: 5k25 shut off valve
Page 8 of 28

3.2.6 Tank ventilation, min 12 mm (0.5in)
installed, water ingress prevention
Checked:
Remarks: 1,5 inch
3.3 Electrical system
Page 9 of 28

3.3.1 Electrical schematic diagram available
(Required for Certified Installation) Yes No
Remarks:
3.3.2 Voltage Remarks:

Checked:
12V:
24V:
3.3.3 Battery capacity
NOTE!
Starting groups
Separate starting groups: Recommended minimum start battery
capacity can be found in the installation
Port Starboard manual.
Checked: Checked:
Ah: 2 x 200 Ah Ah: 2 x 200Ah If boat is delivered without batteries boat
builder must provide information regarding
CCA: CCA:
required battery capacity and installation to
CCA – Cold Cranking Amperage
the dealer.
AUX groups
Number of groups:
Charge distributor:
Remarks: Brand Yuasa Pafecta
Group 1 Group 2 190H52 – N200
Checked: Checked:
Ah: Ah:
Group 3 Group 4
Checked: Checked:
Ah: Ah:
Total battery capacity: 600 Ah
3.3.4 Battery cables

Port NOTE! See installation manual section
”Starting Battery Cable Area”. The cable area
Cable length battery-engine (plus and minus) [m/ft]:
vs. cable length matrix must be followed.
2m
Cable area [mm2/ in2/AWG]: 70 mm2
Remarks: According to manual
installation, 70mm cable area, length can up
Starboard
to 13m (24 volt system)
Cable length battery-engine (plus and minus) [m/ft]:
1,2 m
Cable area [mm2/ in2/AWG]: 70 mm2
AWG – American Wire Gauge (see manual)
Page 10 of 28

3.3.5 When charge distributor and separate
accessory battery/batteries are used Remarks: Not applied
Red power cable between alternator and the starter

motor disconnected at both ends to avoid short circuit.
Checked:
3.3.6 Heavy loads, connections

Aux 1 A2 A3 A4 Start IMPORTANT! No heavy loads should be
connected to start battery
Bow thruster
Remarks: No heavy load
Stern thruster
Anchor windlass
____________
____________
____________
3.3.7 Cable connections readily accessible, Remarks: Easy to access.

harness routing, clamping, distance from hot
areas
Checked:
3.3.8 Cable connections above estimated bilge Checked:

water level, minimum 200 mm [8 in] above Remarks: 1800mm above keel
keel
Page 11 of 28

3.3.9 Alternator sensor cable, connection point
Port
Checked:
Starter aux
Main switch:
Battery:
Charge distributor:
Alternator B+:
Starter B+:
Starboard
Checked:
Starter aux
Main switch:
Battery:
Charge distributor:
Alternator B+:
Starter B+:
Remarks: Charge distributor not applied
Page 12 of 28

3.4 Cooling system
3.4.1 Hot water connections fitted
Checked:
Yes: No:
Remarks: Not applied
3.4.2 Extra expansion tank fitted, system volume,

height
Checked:
Yes: No:
Remarks: Using only main expansion tank
Page 13 of 28

3.5 Exhaust system - wet
3.5.1 Exhaust elbow
Checked:
VP standard: Yes: No:

Angle :
Remarks: Using Riser
3.5.2 Exhaust hose connection to elbow, angle,

stress, double clamps
Checked:
Remarks: 26 degree
3.5.3 System dimensions

Checked:
Hose diameter [mm/in]: 5 inch

Total length [mm/in]: STBD: 1200mm,
PORT: 1700 mm
Remarks: Direct system.
3.5.4 Riser, Silencer fitted
Checked:
Riser fitted Yes: No:

Brand: Volvo Penta
Silencer fitted: Yes: No:
Remarks: Silencer not applied
Page 14 of 28

3.6 Exhaust system - dry
Page 15 of 28

3.6.1 Exhaust line insulated
Checked:
3.6.2 Flexible compensator, silencer fitted
Checked:
Compensator fitted: Yes: No:

Silencer fitted: Yes: No:
3.6.3 Exhaust line suspended by flexible brackets
Checked:
3.6.4 System dimensions
Checked:
Total length [mm/in]:

Pipe dimension [mm/in]:
Compensator dimension [mm/in]:
3.6.5 Condensation water collector fitted at the

lowest point of the line
Checked:
Page 16 of 28

3.6.6 Elbow, hood or self-closing cover fitted to
pipe outlet
Checked:
3.7 Ventilation
3.7.1 Total air intake and ventilation area
Engine room temp must be verified during sea trial.
Regardless air intake design. Fan may be required
to meet requirements.
Checked:
Areas according to manual:

Yes: No:
Remarks: ventilation dimension 450mm x 500mm
3.7.2 Location of ventilators and air intakes, Ventilators must not be placed on transom
water ingress prevention
Checked:
Remarks:
3.7.3 Electrical suction fan installed Hose connections from suction fans should be
(not at air inlet) located high in the engine room for diesel
engines
Checked:
Yes: No:
Capacity:
Remarks: Fan diameter 31,5 cm
From engine room
Page 17 of 28

3.8 EVC, electronic vessel control system
Page 18 of 28

3.8.1 EVC generation
Checked:
Generation: EVC 2
EVC-D
EVC-E
3.8.2 No external cables connected to the IMPORTANT! Never cut or modify the Volvo
EVC system Penta EVC cable harnesses. For extra power
Checked: supply use the Volvo Penta relay for
Remarks: No modification on EVC cables accessories.
3.8.3 System network requirements, no

extension to control units on EVC bus
cable allowed
Checked:
Remarks: No extension, only HCU
No extension Extension
3.8.4 Cables and cable harnesses

Instructions in production recommended
Cable coding
Clamping & routing
Strain relief
Remarks:
Page 19 of 28

3.8.5 Maximum cable lengths
Keep cable lengths as short as possible
Datalink / EVC bus, see figure
Checked:
Remarks: 13m
3.8.6 Multilink IMPORTANT! Maximum allowed cable length

on each helm station is 20 m (66 ft)
Checked:
Remarks: Single helm station
3.8.7 Multilink hub IMPORTANT! Not allowed to use a Y-split cable

connected in Multilink hub. Connect extra
Multilink hubs to the first Multilink hub. Do not
Checked:
connect them in series. If a unit (display, tacho
Remarks: 1 multilink hub, 1 HCU
etc.) is to be connected more than 3 m (10 ft)
from the Multilink hub it shall be connected to Y-
split cable before the first hub
3.8.8 AUX bus (EVC-E only) IMPORTANT! Termination plugs shall be

installed in the beginning and in the end of the
Checked: AUX bus. Maximum allowed cable length is 40
Remarks: Not applied m (131 ft)
3.8.9 Location and mounting of control units,

dry and accessible and with
connections pointing downwards
Checked:
Remarks: Location is dry and easy to access
Page 20 of 28

3.8.10 Fuel level sender installed, calibration(s)
done
Empty tank calibration (mandatory)
Full tank calibration
Multi-point calibration
Sender type: 3-180 ohm 230-30 ohm
Checked:
Remarks: Fuel sender by shipyard
3.8.11 Available options

Trip computer
Single lever mode
Lowspeed
Cruise control
NMEA 0183/2000
Multisensor
Remarks: Easy connect is installed
Page 21 of 28

3.9 Accessibility for maintenance and repairs (service access requirements are
found in installations drawings)
3.9.1 Engine room accessibility Sufficient access must exist in order to
perform service and maintenance according
to below points within a reasonable time.
Checked:
Remarks: engine to engine space = 800 mm
610 mm 800 mm
300 mm
3.9.2 Service access for maintenance and repairs
Checked:
Remarks: Easy access for maintenance and repair
Items that require maintenance accessibility: Items that require repair accessibility:
 Coolant  Removal of injectors, cylinder head,

radiator
 Oil change and filling (engine and reverse etc.
gear)
 Removal or exchange of electrical
 Filter changes (oil, fuel, air and crankcase components
breather)
 Removal of flywheel and vibration damper
 Driving belt change and
adjustment/tensioning  Removal or exchange of reverse gear
 Removal of valve cover  Removal of propeller shaft
 Changing impeller, seawater pump  Arrangement and Planning, Engine Room
 Water filter, cleaning
Page 22 of 28

3.9.3 Engine package removal (instruction
supplied by boat builder)
Checked:
Instruction available: Yes: No:
Remarks:
Time for removal/ refit of engine [h]: 3 hours

Actual: Estimated:
Flat rate for removal/ refit of engine according to

Volvo Penta flat rate database.
3.10 Installation steps when boat is in water

3.10.1 Back pressure
Checked:
Pressure [kPa]: No backpressure
Remarks: Direct, not using silencer
3.10.2 Seawater filter
Checked:
Accessible: Yes: No:

Type/Make: Local brand
Height above WL [mm/in]: 0 inch
Remarks:
3.10.3 Waterline level (loaded)

If any of the waterline requirements are not fulfilled,
riser must be installed
Checked:
Remarks: Waterline level in accordance with
requirements
Page 23 of 28

3.11 Sea trial (Full load condition*)
3.11.1 Max RPM, speed and displacement Remarks:
Checked:
Propeller type: FPP
Max RPM: Pt/Single 2880 Sb 2880
Max speed [knots/mph]: 24.0 knots
Displacement [kg/lb.]: 22049 kg

Scaled Estimated
LCG [m/ft]: 6,422 m
3.11.2 Temperature at air filter inlet** Remarks:
Checked:
Temperature at WOT [C/F]: 36C

Ambient [C/F]: 32C
3.11.3 VP Performance report Remarks:
Sea trial according to VP Performance report:

Yes: No:
Report number:
* It is important that the sea trial is carried out at full load

condition so that the right propellers are used. If not full load is possible, sea trial figures should be
checked with MPS to determine if the right propellers are used.
** The temperature should be measured as close to the air flow as possible. Inlet air temperature at air
filter may not be higher than 25C (77F). The temperature in air filter must also not be higher than 20C
(68F) above outside temperature at WOT speed.
Page 24 of 28

3.12 Photos / documents (add below)
Sea and Cost Guard – KN P.4002
Main Engine Engine mounting
Gearbox mounting Shutdown Valve
Page 25 of 28

Pre Fuel Filter (duplex) Fuel connection on engine
Fuel tank ventilation Battery
Battery connection on engine Cable routing
Page 26 of 28

Alternator Coolant Tank
Starboard Exhaust connection Portside Exhaust Connection
Exhaust Riser Ventilation
Page 27 of 28

EVC 2
HCU Bridge Emergency Stop and overide
Page 28 of 28


Volvo Penta Installation Checklist D4/D6/D8/D11/D13 Inboard (Version 3.7)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Volvo Penta Installation Checklist D4/D6/D8/D11/D13 Inboard (Version 3.7)

Uploaded by

Copyright:

Available Formats

Volvo Penta Installation Checklist

D4/D6/D8/D11/D13 Inboard (Version 3.7)

Boat/Vessel Manufacturer: PT. Ben Santosa

Boat/Vessel Model/Type: Aluminium Patrol Boat

Engine Installation/Type: Volvo Penta 2 x D8-550I

Hull Identification Number: P.4002

Volvo Penta Installation Checklist SALES ENGINEERING MARINE

1.2 Installation Approval – Conditions

Volvo Penta Installation Checklist SALES ENGINEERING MARINE

Yes: No: Yes: No:

Nakashima FPP 652 & 648

Volvo Penta Installation Checklist SALES ENGINEERING MARINE

3.1.2 Engine bed dimensions, sufficient

Measurement A, B and C must

Remarks: D8-550 using flexible mounting from Volvo

Volvo Penta Installation Checklist SALES ENGINEERING MARINE

Volvo Penta Installation Checklist SALES ENGINEERING MARINE

Boat CE marked Boat ABYC marked

Remarks: Manufactured by shipyard

3.2.2 Proper fuel lines (feed and return), size, fire

Copper feed line pipe outer diameter [mm/in]: ½ inch

Remarks: length Stbd:1500mm , Port: 800mm

3.2.3 Fuel lines, installation, clamping,

For engine specific suction height see manual

3.2.4 Extra water separator/fuel filters,

Type: 877770 by Volvo Penta

Remarks: Duplex separator filter The filters should be dimensioned as

3.2.5 Shut off valves

Shut off valve on the supply side is required in

Volvo Penta Installation Checklist SALES ENGINEERING MARINE

3.3 Electrical system

Volvo Penta Installation Checklist SALES ENGINEERING MARINE

3.3.2 Voltage Remarks:

Total battery capacity: 600 Ah

3.3.4 Battery cables

AWG – American Wire Gauge (see manual)

Volvo Penta Installation Checklist SALES ENGINEERING MARINE

Red power cable between alternator and the starter

3.3.6 Heavy loads, connections

3.3.7 Cable connections readily accessible, Remarks: Easy to access.

3.3.8 Cable connections above estimated bilge Checked:

Volvo Penta Installation Checklist SALES ENGINEERING MARINE

Remarks: Charge distributor not applied

Volvo Penta Installation Checklist SALES ENGINEERING MARINE

3.4.2 Extra expansion tank fitted, system volume,

Remarks: Using only main expansion tank

Volvo Penta Installation Checklist SALES ENGINEERING MARINE

VP standard: Yes: No:

Remarks: Using Riser

3.5.2 Exhaust hose connection to elbow, angle,

3.5.3 System dimensions

Hose diameter [mm/in]: 5 inch

Remarks: Direct system.

3.5.4 Riser, Silencer fitted

Riser fitted Yes: No:

Remarks: Silencer not applied

Volvo Penta Installation Checklist SALES ENGINEERING MARINE

Volvo Penta Installation Checklist SALES ENGINEERING MARINE

3.6.2 Flexible compensator, silencer fitted

Compensator fitted: Yes: No:

Remarks: Not applied

3.6.3 Exhaust line suspended by flexible brackets

3.6.4 System dimensions