Volvo Penta IPS 3 Installation Reference Manual

Installation Reference, Volvo Penta IPS 3, Propulsion Unit and Engine -
Installation reference , Volvo Penta IPS3 Propul-
sion Unit and Engine foundation
Revision:
Document N°: 47701029
Release date: 04-2010
NOTE! Read the "Installation Manual Volvo
1 Installation kit
Penta IPS" before the installation work of
IPS propulsion unit and engine is started.
Other electrical installations, please refer to
A B*
actual "Installation Manual EVC, Volvo Penta IPS."
WARNING! Make sure all safety precautions
are made prior to lifting to avoid personal
injuries and damage on equipment.
NOTE! Before installing propulsion unit and engine,
make sure that the rest of the installation work in
the engine compartment has been completed. In
E F
addition, all cables and hoses must be correctly
located and clamped.
* not included in the kit
4b Using the Fork lift
special tool
Put the propulsion unit on the special
tool. Remove the Clamp ring and rub-
ber sealing ring from the propulsion
unit.
Apply rubber lubricant on sealing ring,
Volvo Penta part no. 3817243.
8
Connecting the drive shaft
A Check:
Drive shaft flange-to-flange dis-
tance. Adjust engine if needed.
If drive shaft have been disassem-
bled us marking for proper assebly.
Male end against engine
Aligning of arrows.
370±15 mm
(15"±0.6)
Engine
IPS side
side
Tightening torque:
70–80 Nm (52–60 lbf.ft)
Jackshaft length
L-install
700–800 mm
1100–1200 mm
1500–1600 mm
1900–2000 mm
2400–2500 mm
12a Mount the protective anode
Protective
anode
2 Chassis no. identification
C*
D
IMPORTANT!
Check that engine chassis no. and propulsion unit
chassis no. are identical.
Chassis no.
G
Tilt and mount the propulsion unit
Tilt and locate the propulsion unit under the hull
1 2 3
h
min: 1100 mm
5
4
9
Connecting the oil cooler
B Tightening torque: Tightening torque:
70–80 Nm (52–60 lbf.ft) 80 Nm (37 lbf.ft)
12b
IMPORTANT!
Apply corrosion protection, part no.
9510227, on bonding connections.
Use marine sealant on the through hull
fittings.
IMPORTANT!
- Do not bond the IPS units together.
- Do not bond the IPS to the engine or any other component on board the boat.
- Do not bond any other equipment to the IPS external anode.
- Anode must be isolated from conducting hull material.
3
Put the clamp ring in place
Wipe rubber sealing ring and apply rubber lubricant, Volvo
Penta part no. 3817243. Do this as late as possible before
mounting the propulsion unit.
Put the clamp ring in place in the hull.
IMPORTANT!
Do not use vaseline or grease on o-ring.
Engine
chassis no.
Chassis no.
NOTE!
The Chassis no must
match both drivlines.
5 Raise the propulsion unit 6 Installing the engine
and attach the bolts
WARNING! Always use three lifting eyes
Lifting force: Max. 20000 N (4400 lbf)
when lifting the engine.
16 x M14 bolts, placed as in figure.
Tighten all bolts, 3 turns.
Check:
Equal loading on mounts. Check on three points
using setting tool 21244540.
Final torque:
110–120 Nm
(81–89 lbf.
ft)
10
Installing the exhaust line
B
A Tightening torque: Tightening torque:
70–80 Nm (52–60 lbf.ft) 48–52 Nm (35–38 lbf.ft)
O-ring,
use grese
to keep in
place.
Wipe
surfaces
IMPORTANT!
NOTE! When using jack shaft the exhaust hose might need
Make sure the exhaust hose has no
support not to bend.
bends. Refer to figure.
If exhaust riser is used, the exhaust
hose needs to be shortened.
REV. PICKUP
13a Calibration
Calibrate the propulsion unit positions by using the parallel alignment tool,
Connect cables to EVC
special tool and the VODIA tool in combination with the switch box.
bus
SECONDARY (S)
Please refer to Installation Manual Volvo Penta IPS and VODIA User's Guide.
IPS unit and SUS
cable
Oil temp. and pressure
PRIMARY (P)
Using Lifting Hood or Fork lift special tool
4a Mount the lifting hood on the IPS unit
Select dead-
rise angle on
the special tool
matching the
IMPORTANT!
hull.
Grease the bolts
before attaching.
Attach the lifting hood using six bolts,
tightening using hand power.
7 Installing the sea water inlet
NOTE! Unequal loading can cause
engine vibrations.
300 Nm (220
lbf.ft)
11
Connecting the fuel pipes and elelctrical connections
C Tightening torque: Connect the fuel
15–20 Nm (11–15 lbf.ft)
NOTE!
Place O-ring in ex-
haust bend
NOTE! Min. distance between
exhaust bend and transom:
50 mm (2").
Calibration
13b
Calibrate the propulsion unit positions by using the Laser alignment tool
Wipe rubber sealing ring and apply rubber lubricant, Volvo
Penta part no. 3817243. Do this as late as possible before
mounting the propulsion unit.
Put the clamp ring in place in the hull.
IMPORTANT!
Do not use vaseline or grease on o-ring.
Seawater filter
Necessary clearance above filter
(for disassembly): 120 mm (5")
Seawater intake
Install intake in front of engine,
close to keel line.
Inlet hose dimension: 63
mm (2.5")
Connect the electrical connections