Installation Reference, Volvo Penta IPS 2, Propulsion Unit and Engine - Using Lifting Hood or Fork lift special tool

NOTE! Read the “Installation Manual Volvo Penta IPS” before the installation work of IPS propulsion unit and engine is started.Other electrical installations, please refer to

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 addition, all cables and hoses must be correctly located and clamped.

G

Water in Oil sensor cable

Tightening torque: 20 Nm (14.7 lbf.ft)

See instruction 7749163 included in the anode kit.

Make sure the breather hose has a constant drop and does not sag.

See EVC Installation manual for:General EVC settings and calibrationsJoystick calibrationSlip calibrationWater in Oil sensor calibration

Installation reference, Volvo Penta IPS Propul-sion Unit and Engine foundationRevision: ADocument N°: 47705819Release date: 05-2014

Inlet hose dimension: 63 mm (2.5”)

Seawater filterNecessary clearance above filter (for disassembly): 120 mm (5”)

Seawater intakeInstall intake in front of engine, close to keel line.

BTightening torque: 70–80 Nm (52–60 lbf.ft)

A Tightening torque: 48–52 Nm (35–38 lbf.ft)

Tightening torque: 15–20 Nm (11–15 lbf.ft)

C

IMPORTANT!Make sure the exhaust hose has no bends. Refer to figure. If exhaust riser is used, the exhaust hose needs to be shortened.

Mount the protective anode

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.

IMPORTANT!Apply corrosion protection, part no. 9510227, on bonding connections.Use marine sealant on the through hull fittings.

Connect cables to IPS unit

Oil temp. and pressure

PRIMARY (P)

Tightening torque: 70–80 Nm (52–60 lbf.ft)

NOTE! When using jack shaft the exhaust hose might need support not to bend.

Jackshaft lengthL-install700–800 mm1100–1200 mm1500–1600 mm1900–2000 mm2400–2500 mm

Tilt and mount the propulsion unit Tilt and locate the propulsion unit under the hull

4bPut the propulsion unit on the special toolRemove the Clamp ring and rubber sealing ring from the propulsion unit.Apply rubber lubricant on sealing ring, Volvo Penta part no. 3817243.

REV. PICKUP

Tightening torque: 70–80 Nm (52–60 lbf.ft)

Tightening torque: 80 Nm (37 lbf.ft)

Wipe surfaces

O-ring, use grese to keep in place.

NOTE! Min. distance between exhaust bend and transom: 50 mm (2”).

Protective anode

NOTE!Place O-ring in exhaust bend

EVC bus cable

SECONDARY (S)

1 2 3

4 5

Using the Fork lift special tool

h min: 1100 mm300 Nm (220 lbf.ft)

1 Installation kit

A

E

B*

F

C* D IMPORTANT!Check that engine chassis no. and propulsion unit chassis no. are identical.

Chassis no. identification

Chassis no.

Engine chassis no.

Chassis no.

2

NOTE!The Chassis no must match both drivlines.

Mount the lifting hood on the IPS unitPut the clamp ring in placeWipe 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.

4a

IMPORTANT!Grease the bolts be-fore attaching.

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.

Select deadrise angle on the spe-cial tool matching the hull.

Attach the lifting hood using six bolts, tightening using hand power.

3

Lifting force: Max. 20000 N (4400 lbf)16 x M14 bolts, placed as in figure.Tighten all bolts, 3 turns.

5 Raise the propulsion unit and attach the bolts

Final torque:110–120 Nm(81–89 lbf.ft)

Installing the sea water inlet7 8Installing the engine

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

6 NOTE! Unequal loading can cause engine vibrations.

Check:Equal loading on mounts. Check on three points using setting tool 21244540.

Check: Drive shaft flange-to-flange distance. Adjust engine if needed.If drive shaft have been disassembled us marking for proper assebly.Aligning of arrows.

A

370±15 mm (15”±0.6)

Connecting the drive shaft

B

9 Connecting the oil cooler10A Installing the exhaust line11Calibrate the propulsion unit positions by using the parallel alignment tool, special tool and the VODIA tool in combination with the switch box. Please refer to Installation Manual Volvo Penta IPS and VODIA User’s Guide.

12a 13a

13b

12b

IPS sideEngine side

Calibration before launch

Calibrate the propulsion unit positions by using the Laser alignment tool

Connect the voltage supply cables

Connect the fuel hoses

Connecting the fuel hoses and electrical connections

10B Installing the ventilation kit

*tools not included in the kit

Calibration after launching

Note the locations of Secondary and Primary solenoid connextions.