Installation Reference, Volvo Penta IPS 3, Propulsion Unit and Engine -
Using Lifting Hood or Fork lift special tool
Installation reference , Volvo Penta IPS3 Propul-
sion Unit and Engine foundation
Revision:
Document N°: 47701029
Release date: 04-2010
Installation kit
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.
C*
E
F
G
B*
A
D
* not included in the kit
IMPORTANT!
Check that engine chassis no. and propulsion unit
chassis no. are identical.
Chassis no. identification
Chassis no.
Engine
chassis no.
Chassis no.
NOTE!
The Chassis no must
match both drivlines.
IMPORTANT!
Grease the bolts
before attaching.
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.
Select dead-
rise angle on
the special tool
matching the
hull.
Attach the lifting hood using six bolts,
tightening using hand power.
Mount the lifting hood on the IPS unit
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.
4a
Tilt and mount the propulsion unit
Tilt and locate the propulsion unit under the hull
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.
Using the Fork lift
special tool
h
min: 1100 mm
1
2
3
4
5
Installing the engine
WARNING! Always use three lifting eyes
when lifting the engine.
NOTE! Unequal loading can cause
engine vibrations.
Check:
Equal loading on mounts. Check on three points
using setting tool 21244540.
3
4b
5
6
7
1
300 Nm (220
lbf.ft)
Installing the sea water inlet
Seawater filter
Necessary clearance above filter
(for disassembly): 120 mm (5”)
Seawater intake
Install intake in front of engine,
close to keel line.
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.
Connecting the drive shaft
Connecting the oil cooler
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
Tightening torque:
80 Nm (37 lbf.ft)
370±15 mm
(15”±0.6)
IPS side
Engine
side
Tightening torque:
70–80 Nm (52–60 lbf.ft)
Wipe
surfaces
O-ring,
use grese
to keep in
place.
Tightening torque:
48–52 Nm (35–38 lbf.ft)
Tightening torque:
15–20 Nm (11–15 lbf.ft)
Connect the electrical connections
Connect the fuel
Installing the exhaust line
Connecting the fuel pipes and elelctrical connections
B
A
C
NOTE!
Place O-ring in ex-
haust bend
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.
Protective
anode
8
9
10
11
12a
13a
NOTE! Min. distance between
exhaust bend and transom:
50 mm (2”).
IMPORTANT!
Make sure the exhaust hose has no
bends. Refer to figure.
If exhaust riser is used, the exhaust
hose needs to be shortened.
Connect cables to
IPS unit and SUS
Oil temp. and pressure
EVC
bus
cable
SECONDARY (S)
PRIMARY (P)
NOTE! When using jack shaft the exhaust hose might need
support not to bend.
REV. PICKUP
Tightening torque:
70–80 Nm (52–60 lbf.ft)
Calibration
Calibrate 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.
12b
Calibration
Calibrate the propulsion unit positions by using the Laser alignment tool
Inlet hose dimension: 63
mm (2.5”)
Lifting force: Max. 20000 N (4400 lbf)
16 x M14 bolts, placed as in figure.
Tighten all bolts, 3 turns.
Raise the propulsion unit
and attach the bolts
Final torque:
110–120 Nm
(81–89 lbf.
ft)
2
13b
A
B
