Volvo Penta IPS 3 Installation Reference Manual

Installation Reference, Volvo Penta IPS 3, Propulsion Unit and Engine - Using Lifting Hood or Fork lift special tool

Installation reference , Volvo Penta IPS3 Propul­sion 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 dead­rise 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 rub­ber 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 dis­tance. Adjust engine if needed.
If drive shaft have been disassem­bled 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 ex­haust 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