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Installation Reference, Volvo Penta IPS Hull Insert …

7747482 02-2007 Installation Reference, Volvo Penta IPS Hull Plug and Engine Foundation α = Deadrise β = Transom angle Positioning and fitting of hull plug, Twin

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Text of Installation Reference, Volvo Penta IPS Hull Insert …

Template position (X)at different transomangles ( )AnglePosition ( )(X) mm ( )0 5 620 ( )6 10 580 ( )11 15 550 ( )Installation Reference, Volvo Penta IPSHull Insert and Engine FoundationBuilding the engine bedEngine bed positionPositioning andfitting of hull insert1Marking of keel line Outsideof hullNOTE! Keepdraining holesopen. Diam. 25mm (1 )NOTE! Makeengine bed horizontalReinforcement betweeninsert and transomSpecial tool885803 /3594470*DrainingholesDrainingholesDrain ingholesTransomMax. 25 mm (1 )Max. 25 mm (1 )6Fitting of temporary support beamsTemporarysupport beamsInside of hullHoles in hull coin-cide to guide holesin insertGuide holein insertGuide holein hullAligning of inserts to hull79Guideholes inhullEngine mountsposition, D4 and D610Drill and tap holes,M12 (1/2 UNC)Positionahead(cotter pin)Positionastern(cotter pin)Engine mounts po-sition, D4 enginesEngine mounts po-sition, D6 enginesRear engine mountsposition, D4 and D6engines236 mm( )Mark off on hulland drill guide holesin templateDrill pilot holes6 mm (1/4'') in hullTapeOutside of hull3Jackshaft installations only: IMPORTANT! To position thedrive lines in parallel, move mark15 mm ( '') towards the mm( '')Tape8Fiberglass and layerspecificationsPlease refer to the latest version ofinstallation drawings regardinglamination and reinforcement forVolvo Penta tool885803 /3594470*This poster decribes a standard installation ofVolvo Penta IPS units (drive shaft length 385mm/15").Standard installations have a toe-in of 2 .In jack shaft installations the drive lines areset in parallel to the keel line. Jack shaft instal-lations please refer to Installation Reference,publ. no. ! Please refer to the latestversion of installation drawingsregarding lamination and reinforce-ment for Volvo Penta IPS.* Hull plug version* Hull plug versionJack shaft installations11Arrow pointingforwardOutside of hull2Positioning of templateArrow forwardmarkPilot hole6 mm (5/16 )Guide holeGuideholeSpecial tool 3862785Pilot hole 6 mm (5/16 )680 mm ( )665 mm ( )Distance (A) between crank shaft/propulsion unitcenter lines at different deadrise angles, whenusing the (B) between center of hull inserts atdifferent deadrise (B)( )(A) mm ( )(B) mm ( )5 1295 ( )1355 ( )6 1285 ( )1355 ( )7 1270 ( )1350 ( )8 1255 ( )1350 ( )9 1240 ( )1345 ( )10 1225 ( )1340 ( )11 1205 ( )1335 ( )12 1190 ( )1330 ( )13 1175 ( )1325 ( )14 1155 ( )1320 ( )15 1140 ( )1315 ( )16 1120 ( )1310 ( )17 1100 ( )1300 ( )18 1085 ( )1295 ( )19 1065 ( )1290 ( )20 1045 ( )1280 ( )A B XXAB2 2 Standardinstallation, toe-in 2 Stringers between engine bed and insertReinforcement between insert and transomTransomGuide holein hullGuide holein insertInside of hullInsertCut out compasses Pilot holes6 mm (5/16 )Inside of hull5Marking lines andmaking holes in hullNOTE! Mark a line from theguide hole through the pilothole to the back of the line can be used for extraaccuracy for insert holes4Check:Distance from pilot holes (port and starboard) ! Measure at height 340 mm (13 ).If distance is less than 580 mm (23 ) it is recom-mended that the pilot holes and guide hole marksare ! Pay attention to reinforcements,bullkheads 580 mm(23 )340 mm(13 ) Pilot holeMin. 25 mm (1 )Guide holein insertNOTE! Read the Installation Manual D4/D6 Aquamatic DPH/DPR, Volvo Penta IPS, Inboardbefore the installation work of hull insert, engine foundation, IPS propulsion unit and engine ! Make sure all safety precautions are made prior to working procedures, to avoidpersonal injuries and damage on ! Min. center distance (A)IPS 400/500/600: 1045 mm ( )IPS 350: 1030 mm ( )If higher angles are needed do notuse template. Measure accordingto minimum 02-2007Installation Reference, Volvo Penta IPSHull Plug and Engine Foundation = Deadrise = Transom anglePositioning and fitting of hull plug, TwinPositioning and fitting of hull plug, TripleMarking of plug center line measured from transom2Marking of plug center line measured from keel line1C C Positioning and fitting of hull plug, Quadruple ABC Building the engine bed AMarking of plug center line measured from transom2Marking of plug center line measured from keel line1 A = Deadrise = Transom angle = Deadrise = Transom angleMark a straight line parallel to the keel lineat distance A depending on the deadriseof the a straight line parallel to the transomat distance C depending on the transomangle. A A24 755 mm ( )14 655 mm ( )23 745 mm ( )13 645 mm ( )22 730 mm ( )12 635 mm ( )21 720 mm ( )11 630 mm ( )20 710 mm ( )10 620 mm ( )19 700 mm ( )9 610 mm ( )18 690 mm ( )8 605 mm ( )17 680 mm ( )7 600 mm ( )16 670 mm ( )6 590 mm ( )15 660 mm ( )5 585 mm ( ) A A20 1190 mm ( )12 1095 mm ( )19 1175 mm ( )11 1085 mm ( )18 1165 mm ( )10 1080 mm ( )17 1150 mm ( )9 1070 mm ( )16 1140 mm ( )8 1060 mm ( )15 1130 mm ( )7 1050 mm ( )14 1120 mm ( )6 1045 mm ( )13 1105 mm ( )5 1035 mm ( )Mark a straight line parallel to the keel lineat distance A depending on the deadriseof the a straight line parallel to the transomat distance C depending on the of plug center lines measured from keel line1Marking of plug center lines measured from transom2 AB18 640 mm ( )1640 mm ( )17 630 mm ( )1625 mm ( )16 620 mm ( )1610 mm ( )15 610 mm ( )1595 mm ( )14 605 mm ( )1580 mm ( )13 595 mm ( )1570 mm ( )12 585 mm ( )1555 mm ( )11 580 mm ( )1545 mm ( )10 570 mm ( )1535 mm ( )9 565 mm ( )1525 mm ( )8 555 mm ( )1515 mm ( )7 550 mm ( )1505 mm ( )6 540 mm ( )1495 mm ( )5 535 mm ( )1490 mm ( )Mark two straight lines parallel to the keelline at distance A and B depending on thedeadrise of the a straight line parallel to the transomat distance C depending on the special tool 885803 / 3594470* tomeasure up the engine beds. The bedsmust be horizontal. Reinforcements mustbe made between the engine beds and hullplugg lamination and from hull pluglamination to the transom. The beds shallend up against the hull plug lamination bybuilding holes shall be made according tofigure, diameter approx. 25 mm (1 )NOTE! Please refer to the latest version ofinstallation drawings regarding laminationand reinforcement for Volvo Penta IPS.* Hull plug versionWhen the engine beds are designed, makesure that the space for the flywheelhousing, the bottom and sides of thesump, etc. have a recommended clear-ance of at least 20 mm (3/4 ).Use special tool 885803 / 3594470* withthe engine bed drill jig. Place the drill jigagainst the clevis pins for ahead andastern positions engine the bed with holes 6 mm (1/4 ) bydrilling through the drill bushings. Thenremove the special and tap the : M12 (1/2 UNC) or equivalent.* Hull plug versionNOTE! Make engine beds horizontalTo reduce noise and vibration, the enginebed should be filled. Make sure thematerial does not absorb water. Generallyhigh density material (A) is better for noiseand vibration up the engine bed with spacermaterial (A) so that the underside of theengine mountings / engine rubbermountings almost rest against the must be room for flat bars = Spacer materialB = Fiberglass, approx. 10 15 mm ( ")C = Flat bar, galvanized, approx. 10 mm ( "),min. width: 80 mm (3")W = Flat bar widthE = Engine bed min. width: 112 mm ( ")DrainingholesDrainingholesDraininghole sSpecial tool885803 / 3594470*Min. 20 mm(3/4 )Min. 20 mm(3/4 )ABC EWDesign and buildengine beds9Lamination andreinforcement10Engine mountingpositions11Stringers between the engine bed and hullplug lamination:Max. 25 mm (1 )Draining holeMark holesPosition ahead(clevis pin)Position astern(clevis pin)Special tool885803 / 3594470*Engine mountsposition, D4enginesEngine mountsposition, D6 enginesRear enginemounts position,D4 and D6enginesNOTE! Makedraining 25 mm (1 )Fiberglass and layerspecifications8Please refer to the latest version ofinstallation drawings regarding laminationand reinforcement for Volvo Penta ! Pay attention to reinforcements,bulkheads etc. If necessary, the distanceC may need to be increased to clear theexhaust ! Pay attention to reinforcements,bulkheads etc. If necessary, the distanceC may need to be increased to clear theexhaust ! Pay attention to reinforcements,bulkheads etc. If necessary, the distanceC may need to be increased to clear theexhaust of toe-in line370 mm( )Mark a line, at a slight angle, in compari-son to the straight line. At a distance of2000 mm ( ) the end points should be70 mm ( ) apart to create the desired 2 mm( )70 mm( )Marking of toe-in lines3Mark two lines, at a slight angle, in com-parison to the straight lines. At a distanceof 2000 mm ( ) the end points shouldbe 70 mm ( ) apart to create the de-sired 2 mm( )Drill hole on toe-in line4Drill bolt holes on the toe-in line at 240 mm( ) from the center mm( )Drill holes on toe-in lineand mirror the procedure4240 mm( )Drill bolt holes on the toe-in line at 240 mm( ) from the center intersection. Mirror theprocedure for the port side of the hull mm( )Drill holes on toe-in lines4Drill bolt holes on the toe-in lines at 240 mm( ) from the center the procedure5Mirror the procedure for the port side ofthe hull and place a hulltunnel plug. Mark plugcenter line and drillholes5Build a hull tunnel plug according to instal-lation drawings. Mark a plug center bolt holes on the line at 240 mm ( )from the center procedure5Mirror the procedure for the port side ofthe hull IPS plugs and drilladditional holes6Place the IPS plugs according to the drilledholes (A) and bolt the plugs to the hullmold. Mark, drill and bolt additional twoholes (B) for each IPS plugs and drilladditional holes6Place the IPS plugs according to the drilledholes (A) and bolt the plugs to the hullmold. Mark, drill and bolt additional twoholes (B) for each IPS plugs and drilladditional holes6Place the IPS plugs according to the drilledholes (A) and bolt the plugs to the hullmold. Mark, drill and bolt additional twoholes (B) for each result, hullmold7Final result, hullmold7Final result, hullmold7 C0 590 mm ( )1 585 mm ( )2 580 mm ( )3 575 mm ( )4 570 mm ( )5 565 mm ( )6 555 mm ( )7 550 mm ( )8 545 mm ( )9 545 mm ( )10 545 mm ( )11 545 mm ( )12 545 mm ( )13 545 mm ( )14 545 mm ( )15 545 mm ( ) C0 590 mm ( )1 585 mm ( )2 580 mm ( )3 575 mm ( )4 570 mm ( )5 565 mm ( )6 555 mm ( )7 550 mm ( )8 545 mm ( )9 545 mm ( )10 545 mm ( )11 545 mm ( )12 545 mm ( )13 545 mm ( )14 545 mm ( )15 545 mm ( ) C0 590 mm ( )1 585 mm ( )2 580 mm ( )3 575 mm ( )4 570 mm ( )5 565 mm ( )6 555 mm ( )7 550 mm ( )8 545 mm ( )9 545 mm ( )10 545 mm ( )11 545 mm ( )12 545 mm ( )13 545 mm ( )14 545 mm ( )15 545 mm ( )ABBAABBAABBAMin. 25 mm (1 )CMin. 25 mm (1 )CMin. 25 mm (1 )CNOTE! Read the Installation Manual D4/D6 Aquamatic DPH/DPR, Volvo Penta IPS, Inboardbefore the installation work of hull plug, engine foundation, IPS propulsion unit and engine ! Make sure all safety precautions are made prior to working procedures, to avoidpersonal injuries and damage on equipment. IMPORTANT! If the installation is ajack shaft type no toe-in line should bemade. The IPS propulsion units should beinstalled parallel to the keel mm( )70 mm( )Marking of toe-in line3Mark a line, at a slight angle, in compari-son to the straight line. At a distance of2000 mm ( ) the end points should be70 mm ( ) apart to create the desired 2 angle. IMPORTANT! If the installation is ajack shaft type no toe-in line should bemade. The IPS propulsion units should beinstalled parallel to the keel line. IMPORTANT! If the installation is ajack shaft type no toe-in line should bemade. The IPS propulsion units should beinstalled parallel to the keel line. IMPORTANT!Pictures shows a hullmold. IMPORTANT!Pictures shows a hullmold. IMPORTANT!Pictures shows a hullmold.

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