Page 1 Installation IPS 2 1(1) IPS650, IPS800, IPS950...
Page 3: Table Of Contents
Alternator .................... 130 Voltage Supply ................... 131 Connection ..................132 Fire Extinguishing System ..............140 Calibration and Settings ................. 142 IPS Calibration ..................142 Launching and Sea Trial ................ 148 Alphabetical index .................. 155 47704162 10-2014 © AB VOLVO PENTA...
Page 4: Safety Information
Safety Information This installation manual contains information required Only start the engine in well-ventilated areas. for the correct installation of your Volvo Penta prod- Remember that exhaust fumes are toxic and danger- uct. Check that you have the correct manual.
Page 5 Risk of injury. start the engine (risk for sparks) and do not lean over the batteries. 47704162 10-2014 © AB VOLVO PENTA...
Page 6 The components in the electrical system, ignition system (gasoline engines) and fuel system on Volvo Penta products are designed and manufactured to minimize the risk of fire and explosion. Do not run engines in areas where there are explosive materials.
Page 7: General Information
For the sake of high demands necessary or desirable to depart from recommended at high season on yards, the vessel manufacturers routines, Volvo Penta is happy to offer assistance in instruction should be followed. finding a solution for the installation in question.
Page 8: Certified Engines
European Parliament and European commission in must correspond to the unit used for certification. In the Recreational Craft Directive. These normative order for Volvo Penta to be able to declare that standards are reflected in the standards established engines fulfill environmental legislation, the following...
Page 9 0.2271 Speed ft./s 3.281 ft./s 0.3048 knots 0.869 knots 1.1508 Temperature Celsius Fahrenheit °F=9/5 x °C Fahrenheit Celsius °C=5/9 x (°F– 1) All catalog output data specified in horsepower refers to metric horsepower. 47704162 10-2014 © AB VOLVO PENTA...
Page 10: Installation Tools And Documentation
Manuals are available for the EVC system, for exam- ple. P0014255 Installation instructions There are installation instructions included with most kits. Drawings Drawings are included in kits and additional drawings are available electronically from Volvo Penta. 47704162 10-2014 © AB VOLVO PENTA...
Page 11 The tool is very practical for fault tracing as it is possible to see the values the EVC nodes are reading and sending. Refer to VODIA information at Volvo Penta Partner Network or contact Volvo Penta to order. p0006256 Chemicals There is a large range of chemicals available from Volvo Penta.
Page 12: Special Tools
21406897 Calibration tool Position device when lifting by Used together with the VODIA Drive unit alignment (complete fork lift tool for calibrating IPS units pair) P0001856 3863070 Allen key socket Torque tightening propeller retainer rings 47704162 10-2014 © AB VOLVO PENTA...
Page 13 P0004580 p0008375 88890074 Multimeter 88820047 VODIA, diagnostic 9998493 Hose tool Used in combination with 9998339 Manometer. PDA only P0008329 21244540 Measuring tool 9998339 Manometer Measuring engine mount com- Measuring fuel feed pressure pression 47704162 10-2014 © AB VOLVO PENTA...
Page 14 Installation Tools and Documentation, Special Tools Chemical products P0001874 P0001871 828250 Grease alt. 1381065 Corrosion protec- 3817243 Rubber lubricant 21347121 Grease (400 gr) tion 47704162 10-2014 © AB VOLVO PENTA...
Page 15: System Information
System Information, EVC System Information Refer to the Installation EVC installation manual for EVC system installation instructions. 47704162 10-2014 © AB VOLVO PENTA...
Page 16: Engine Characteristics
Operated for fewer than 300 hours per year. Full power may be utilized for max 1 hour per 12 hour period. Between full-throttle periods, engine revolutions must be reduced by at least 10% from full rpm. 47704162 10-2014 © AB VOLVO PENTA...
Page 17: Engine Performance
P0004571 Point A is where the indicated engine power is equal Connection between performance-influencing factors in inboard to the power acting on the propeller. Volvo Penta IPS engines drive units have defined propeller sizes that are dimen- Power sioned for engine characteristics.
Page 18 Boats made from fiberglass reinforced plastic absorb water when they are afloat which means they become heavier over time. Marine fouling is an often-over- looked problem that greatly affects boat performance. 47704162 10-2014 © AB VOLVO PENTA...
Page 19: Arrangement And Planning
B Boat trim angle under way. C Total engine inclination under way, maximum per- missible inclination (A+B). A boat's weight distribution is affected by the choice of driveshaft length. P0010566 See technical data for limit values. 47704162 10-2014 © AB VOLVO PENTA...
Page 20 Place no objects inside the dashed lines. A min. 3000 mm (118") B min. 400 mm (16") C min. 50 mm (2") P0006153 Clearance between hull and Ips drive unit is 9 mm (+ 5 mm - 2 mm) P0019672 47704162 10-2014 © AB VOLVO PENTA...
Page 21: Engine Room
This means: within reasonable time using nor- mal resources and methods available to the industry to limit costs and operational downtime. It is Volvo Penta policy to avoid installations that involve extra costs for boat owners during the lifetime of the boat.
Page 22: General Maintenance
Filter changes (oil, fuel, air and crankcase • Removal of flywheel and vibration damper breather) • Measurement at diagnostic points • Drivebelt change and adjustment/tensioning • Removal of valve cover • Changing impeller, seawater pump • Water filter, cleaning 47704162 10-2014 © AB VOLVO PENTA...
Page 23 500 m (1640 ft) above sea level, power loss is around 0.1% per 100 m (328 ft). Volvo Penta IPS 650, 800 and 950 engines are not suitable for operations above 1,500 m (5,000 ft). 47704162 10-2014 © AB VOLVO PENTA...
Page 24 NOTICE! Fan hose connections for diesel engines must be located as high in the engine compartment as possible to carry away hot air, while for gasoline engines as low as possible to carry away fumes. 47704162 10-2014 © AB VOLVO PENTA...
Page 25 70 °C (158 °F). However, the starter motor and alternator have their given locations. Engine compartment pressure Volvo Penta recommends that negative pressure in the engine compartment not fall below 0.5 kPa (0.07 psi) at full speed. A slight negative pressure in the engine...
Page 26 Outdoor temperature is assumed to be +30 °C (86 °F). Correction factors according to the Correction factor table must be used where applicable. Correction factor Outside temperature °C Correction factor (°F) +20 (68) +30 (86) +40 (104) 47704162 10-2014 © AB VOLVO PENTA...
Page 27 7 mm (0.28") water gauge (70 Pa). This means that a somewhat smaller fan may be used. 47704162 10-2014 © AB VOLVO PENTA...
Page 28 Arrangement and Planning, Engine Room Calculation of air ducts Example 1: IPS650, 375kW (510 hp) Calculation of areas for one 375kW engine with an unlimited airflow and an outside temperature of +30 °C (+86°F). Air consumption: The following is obtained for each engine: Area for engine air consumption: 1.9 ×...
Page 29 3 Extraction fan capacities: 0.07 × 459 = 32.1 /min (1091 ft /min). 4 Multiply each sum by the number of engines to cal- culate the area and fan capacity for a common engine compartment. 47704162 10-2014 © AB VOLVO PENTA...
Page 30 4 Extraction fan capacities: 0.07 × 533 (kW) = 36 min (1271 ft /min). 5 Multiply each sum by the number of engines to cal- culate the area and fan capacity for a common engine compartment. 47704162 10-2014 © AB VOLVO PENTA...
Page 31 Remember to build the engine compartment as spaciously as possible to facilitate engine service. P0004734 47704162 10-2014 © AB VOLVO PENTA...
Page 32: Sound Absorption
Cracks and openings etc. must be carefully sealed with insulation material. In cases where the engine is instal- led beneath the deck, all bulkheads and decks must be insulated. P0004735 Engine compartment noise baffles 47704162 10-2014 © AB VOLVO PENTA...
Page 33 Flameproof, reflective and noise insulating foil Flameproof absorbent layer Flameproof, reflective and noise insulating foil NOTICE! The insulation materials look different depending on the material the frame is made of - GRP or wood. 47704162 10-2014 © AB VOLVO PENTA...
Page 34 PVC pipe (installation pipe) built into the hull. Any gaps between the pipes and the cables can be sealed with insulating material or sealing compound. P0006334 Fuel hose protected by a grommet 47704162 10-2014 © AB VOLVO PENTA...
Page 35: Electrochemical Corrosion
The depth of attack then becomes basically equal across the entire surface. This commonly occurs on steel and bronze. P0011417 47704162 10-2014 © AB VOLVO PENTA...
Page 36 Aluminum can be subject to a certain amount of gen- eral corrosion in rapidly flowing water, but not in sta- tionary water. 47704162 10-2014 © AB VOLVO PENTA...
Page 37 Deposit corrosion is closely related to crevice corro- p0011420 sion. It takes place under deposits and marine fouling such as barnacles. 47704162 10-2014 © AB VOLVO PENTA...
Page 38: Galvanic Corrosion
This coating is not face. In fresh water, there will be more local attack present in the active state. close to the point of contact. ** Still water. 47704162 10-2014 © AB VOLVO PENTA...
Page 39 The AC corrosion rate for aluminum is 30% of the rate for DC. The cor- responding rates for steel, copper and zinc are much lower, at 1 %. Please refer to the figure to the left. 47704162 10-2014 © AB VOLVO PENTA...
Page 40: Corrosion Protection
- Carefully designed electrical system. - Recommendations to minimize external interfer- ence. Recommendations from Volvo Penta and anti fouling manufacturers must be followed. In addition, the mate- rial must be resistant to the alkali that is formed on cathodically protected surfaces.
Page 41 Please note that magnesium anodes give overprotection to aluminum in seawater. There is no risk of overprotection of alu- minium if zinc or aluminum anodes are used for pro- tection. 47704162 10-2014 © AB VOLVO PENTA...
Page 42 Moreover, very low currents IMPORTANT! may also constitute a danger for personnel. A GFCI Do not connect Volvo Penta IPS units to each other. must be installed on the other side of the isolation transformer as ground fault protection in the boat.
Page 43 Standards and guidelines H-33 and E-4 may provide guidance. Painting a Volvo Penta IPS drive unit Volvo Penta recommends that drive units be painted in cases where the boat is used in waters where anode consumption is higher than acceptable. This will...
Page 44 19 Encapsulated single-phase 1:1 isolated transformer with metal shield 20 Main switch, shore power, with overvoltage protection 21 Power supply (isolated electrically from boat) 22 Connector, shore power cable 23 Shore supply cable 24 Shore connection 47704162 10-2014 © AB VOLVO PENTA...
Page 45 22 Encapsulated single-phase 1:1 isolated transformer with metal shield 23 Main switch, shore power, with overvoltage protection 24 Power supply (isolated electrically from boat) 25 Connector, shore power cable 26 Shore power cable 27 Shore connection 47704162 10-2014 © AB VOLVO PENTA...
Page 46: Shore Power
Shore power In regard to personal safety and equipment care, When shore power (120/230 V) is connected, shore Volvo Penta provides the following recommendations power ground protection must not be connected to the for the installation of AC shore power: engine or any other grounding point in the boat.
Page 47 Work on the low voltage circuits in the boats should be done by a person with electrical training or knowledge. Installation or work on land current equipment must only be done by a competent electrician, in accordance with local regulations for mains electricity. 47704162 10-2014 © AB VOLVO PENTA...
Page 48 Do not connect Volvo Penta IPS units to each other. Not valid for ACP, see more about ACP. IMPORTANT! Do not connect the Volvo Penta IPS units to the engine or any other components on board. IMPORTANT! Do not connect any other equipment to the Volvo Penta IPS transom-mounted anode.
Page 49 Arrangement and Planning, Electrochemical Corrosion Volvo Penta ACP (Active Corrosion Protection) pro- tects against galvanic corrosion by controlling an elec- tric current that is monitored by the EVC. It is preferable to connect the boat to shore supply, if such is available. If shore power is unavailable, ACP utilizes the batteries, as it is connected to the boat's 12 V/24 V system.
Page 50 88890074 Multimeter 21504294 Reference electrode Measuring galvanic current and stray current in water Volvo Penta has developed a method for measuring 21504294 Reference electrode galvanic current and stray current in water using a ref- erence electrode. 21504294 Reference electrode (Ag/AgCl) is con- nected to 88890074 Multimeter.
Page 51 Check it the next time the boat is taken out of the water. If the potential is has changed a more accurate analy- sis should be carried out. Repeat the measurement for the other drive unit. 47704162 10-2014 © AB VOLVO PENTA...
Page 52 Read off the multimeter value. If the value is high, >0.2 V, and then falls away quickly, the insulation between the drive unit and engine block is sufficient. Repeat the measurement for the other drive unit. 47704162 10-2014 © AB VOLVO PENTA...
Page 53: Installation
10 times higher than protection afforded by following traditional scantling rules. IMPORTANT! The Volvo Penta IPS is designed to function as an integrated part of the hull and laminate structure. The strength of the entire system is dependant on the inte- grated strength of the IPS and the hull and laminate structure.
Page 54 The core material must have a density of 60 kg/m (3.8 lb/ft ) (aka 60H) or more. IMPORTANT! The use of hull core materials in general use does not deviate from instructions regarding Volvo Penta IPS reinforcements. 47704162 10-2014 © AB VOLVO PENTA...
Page 55 Volvo Penta. Use the installation posters included in the engine delivery for dimensioning requirements. Other draw- ings are available electronically from Volvo Penta. For further design guidelines, refer to ISO12215 Hull con- struction and scantlings. P0011945...
Page 56 After installation, the distance between the upper gear case center must be at least 1200 mm (47.2"). At a distance of 1400 mm (55.1"), the following applies: Distance (A) measured from the keel to the insert centerline at varying bottom angles. 47704162 10-2014 © AB VOLVO PENTA...
Page 57 It may be necessary to increase the distance to the transom to provide clearance for the exhaust elbow. P0012201 Min 50 mm (2") 750 mm (30") C 415 mm (16") D Hole 47704162 10-2014 © AB VOLVO PENTA...
Page 58 Attach a pen to the other end and mark out a cir- cle. Mirror the entire procedure on the opposite side of the hull. Cut out the hull insert hole around the marked circle. P0015311 47704162 10-2014 © AB VOLVO PENTA...
Page 59 Temporarily install the insert in the hull. NOTICE! Check that the inserts are correctly aligned with the hull. Transom Guide hole in insert Insert Guide hole in hull Guide hole in insert Inside of hull Marking line 47704162 10-2014 © AB VOLVO PENTA...
Page 60 1075 (31.7) 0,9 (0.035) E-LTM (0°/90°) 1075 (31.7) 0,9 (0.035) E-LTM (0°/90°) 1075 (31.7) 0,9 (0.035) E-LTM (0°/90°) 1075 (31.7) 0,9 (0.035) Final lamination requirements: ≥ 25 ≥ 26 875 (792.8) ≥ 25 (1) 47704162 10-2014 © AB VOLVO PENTA...
Page 61 The bonding surfaces of the pre-molded ring must be lightly grinded (even if it is already grinded when sup- plied from Volvo Penta) and cleaned from surface con- taminates before it is used. P0011587 Hull insert...
Page 62 (C) minimum 50 mm (2”) from the previous layer. P0012013 Outside hull lamination Grind a wedge from outside in hull. Laminate the tran- sition and grind to a smooth area. P0011594 47704162 10-2014 © AB VOLVO PENTA...
Page 63 Adjust core dimensions to meet final requirements. A 137 mm (5.7”) B 157 mm (6.2”) P0012187 Inner lamination, see Lamination of Hull Inserts page 58. Ring core Outer lamination, see Lamination of Reinforcement Beams page 76 47704162 10-2014 © AB VOLVO PENTA...
Page 64 Fill transitions between the ring and hull/insert with putty. Use putty with high fiberglass content. The filling radius should be at least 12 mm (0.5”). Continue from Lamination of Reinforcement Beams page 76. P0012213 47704162 10-2014 © AB VOLVO PENTA...
Page 65 14° 825 (32.5) p0006134 15° 836 (32.9) 16° 847 (33.4) 17° 859 (33.8) 18° 871 (34.3) 19° 883 (34.8) 20° 896 (35.3) 21° 909 (35.8) 22° 923 (36.3) 23° 937 (36.9) 24° 951 (37.4) 47704162 10-2014 © AB VOLVO PENTA...
Page 66 Min 50 mm (2") 750 mm (30") 415 mm (16") Marking Drill holes along the lines Use the template from tool 3594503 Drill jig to drill four 6 mm (0.24") pilot holes on the intersecting lines. P0010559 47704162 10-2014 © AB VOLVO PENTA...
Page 67 Place the plugs over the holes. Enlarge the template hole by breaking away the inner plastic parts. Place the template on the plug and drill 20 mm (0.79") holes. Attach the plugs with four screws. P0010565 P0010561 47704162 10-2014 © AB VOLVO PENTA...
Page 68 1533 (60.3) 14° 1546 (60.9) 15° 1561 (61.4) 16° 1575 (62.0) 17° 1591 (62.6) 18° 1607 (63.3) 19° 1624 (63.9) 20° 1641 (64.6) 21° 1659 (65.3) 22° 1678 (66.0) 23° 1697 (66.8) 24° 1717 (67.6) 47704162 10-2014 © AB VOLVO PENTA...
Page 69 Drill holes along the lines Use the template from tool 3594503 Drill jig to drill four 6 mm (0.24") pilot holes on the intersecting lines. Mirror the procedure on the port side of the hull. P0010559 47704162 10-2014 © AB VOLVO PENTA...
Page 70 Place the plugs over the holes. Enlarge the template hole by breaking away the inner plastic parts. Place the template on the plug and drill 20 mm (0.79") holes. Attach the plugs with four screws. P0010565 P0010563 47704162 10-2014 © AB VOLVO PENTA...
Page 71 871 (34.3) 2343 (92.2) 19° 883 (34.8) 2364 (93.1) 20° 896 (35.3) 2386 (93.9) 21° 909 (35.8) 2409 (94.8) 22° 923 (36.3) 2433 (95.8) 23° 937 (36.9) 2458 (96.8) 24° 951 (37.4) 2484 (97.8) 47704162 10-2014 © AB VOLVO PENTA...
Page 72 B 750 mm (30") C 415 mm (16") D Marking Drill holes along the lines Use the template from tool 3594503 Drill jig to drill four 6 mm (0.24") pilot holes on the intersecting lines. P0010559 47704162 10-2014 © AB VOLVO PENTA...
Page 73 Place the plugs over the holes. Enlarge the template hole by breaking away the inner plastic parts. Place the template on the plug and drill 20 mm (0.79") holes. Attach the plugs with four screws. P0010565 47704162 10-2014 © AB VOLVO PENTA...
Page 74 0,9 (0.035) E-LTM (0°/90°) 1075 (31.7) 0,9 (0.035) 25.1 Final lamination requirements: ≥ 25 ≥ 26 875 (792.8) ≥ 25 (1) ≥ 31 175 (919.7) ≥ 30 (1.2) ≥ 29 1) Quadruple installations only 47704162 10-2014 © AB VOLVO PENTA...
Page 75 First layer Place mats around the inserts, that are extended (A) 100 mm (4”) out from mold plug. A mat overlap of min- imum 50 mm (2”) on the plug must be applied. P0012012 47704162 10-2014 © AB VOLVO PENTA...
Page 76 Before the ring is placed, fill the V-groove in the hull mold plug with putty. Use a putty mix with high fiber- glass content. IMPORTANT! Putty must not be used in the V-groove before previ- ous lamination steps are completed. 47704162 10-2014 © AB VOLVO PENTA...
Page 77 Fill transitions between the ring and hull/insert with putty. Use putty with high glass fiber content. The filling radius should be at least 12 mm (0.5”). A 137 mm (5.4”) B 157 mm (6.2”) P0011745 47704162 10-2014 © AB VOLVO PENTA...
Page 78 Layer # 1 Lay a layer of mats that extend (A) at least 100 mm (4") out from the ring. Allow each mat to overlap the adjacent mat by at least 50 mm (2"). P0012015 47704162 10-2014 © AB VOLVO PENTA...
Page 79 Allow the new layer to extend beyond (B) the layer below by at least 50 mm (2") out from the ring. NOTICE! Allow the mats to reach up onto the stern if this is possible. P0012016 47704162 10-2014 © AB VOLVO PENTA...
Page 80 The beams must be sufficiently long to make contact with both rings and the inside of the hull. Spackle the joins around the beams to facilitate lami- nation. Use a spackle mixture with a high fiber glass content. P0011713 47704162 10-2014 © AB VOLVO PENTA...
Page 81 Place eleven further layers, each overlapping the previ- ous with 50 mm (2”) in all directions. IMPORTANT! Drainage holes in any reinforcement beam must not have a diameter larger than 25 mm (1”). P0011714 47704162 10-2014 © AB VOLVO PENTA...
Page 82 Zones of Requirement Zon A Zon B Within zone A, both Volvo Penta requirements found Zone B refers to the lamination of the reinforcement in Lamination of Hull Inserts page 58 and Lamination rings and the reinforcement beams. See require-...
Page 83: Aluminium Hull Constructions
Aluminum hull structures for IPS Drawings and directions on how to fasten the alumi- num ring to the hull are included in the installation kit. Contact the Volvo Penta sales organization for further documentation and digital information. 47704162 10-2014 © AB VOLVO PENTA...
Page 84: Engine Foundation
1) A riser is required if the dimension is exceeded. 2) If this dimension is exceeded a special riser must be made. NOTICE! The riser provides a 115 mm (4.5”) height increase at the recommended 45° installation angle. 47704162 10-2014 © AB VOLVO PENTA...
Page 85 NOTICE! Risk of water entry. Have a transparent hose ready. 1 Disconnect the water hose at the water inlet. 2 Attach the transparent hose to the connection. 3 Measure from the engine cover down to the water- line. 47704162 10-2014 © AB VOLVO PENTA...
Page 86 Deviations may not exceed ±4°. Build the engine bed up to the following dimensions: A 120 mm (4.7") B Min 590 mm (23.2") C 700 mm (27.6") D 115 mm (4.5") P0011752 P0011752 47704162 10-2014 © AB VOLVO PENTA...
Page 87 Slide the drilling jig so that it contacts the pins. Drill 6 mm (1/4") pilot holes through the tool drill bushings into the bed. The outer holes are for D13 engines, the inner for D11 engines. 47704162 10-2014 © AB VOLVO PENTA...
Page 88 Drill equivalent holes if hull plugs have been used. Diameter: 15 mm (0.6"). Also drill drain holes (2) at suitable points in the rein- forcement beams. Diameter: 25 mm (1"). P0011758 47704162 10-2014 © AB VOLVO PENTA...
Page 89: Propulsion Unit Installation
# 3817243. Do this as late as possible before drive unit installation. IMPORTANT! Do not use petroleum jelly or grease. Lay the clamping ring in place on the inside of the IPS ring. p0012230 47704162 10-2014 © AB VOLVO PENTA...
Page 90 Hoist the drive unit until it is in even contact with the hull. Maximum lifting force: 20 000 N (4400 lbf). P0010521 47704162 10-2014 © AB VOLVO PENTA...
Page 91 Mounting Grease and install all 16 M14 bolts and tighten each bolt three turns in a clockwise sequence. Then tighten the bolts to 110–120 Nm (81–89 lbf.ft) in the same order. P0010523 47704162 10-2014 © AB VOLVO PENTA...
Page 92 3863070 Allen key socket P0001856 828250 P0010527 Clean and brush waterproof grease, Volvo Penta part # 828250 (also available in tubes, 21347121) onto both propeller shaft splines and threads. Install the aft propeller (1). Then install the aft nut (2) and tighten it by hand until it bottoms. Turn the nut so that the holes coincide and insert the six bolts.
Page 93 Installation, Volvo Penta IPS Press on the propeller cone (5) by hand. Apply Volvo Penta locking fluid 1161053 or Loctite 242 to the center bolt and tighten. Tightening torque: 24–28 Nm (17.7–20.7 lbf.ft). Loctite 242 24-28 Nm P0011229 47704162 10-2014 © AB VOLVO PENTA...
Page 94: Engine Installation
NOTICE! All engines and reverse gears are supplied by Volvo Penta without engine oil and coolant. Check that the bottom plugs are in position and that coolant and hot water drain taps etc. are closed.
Page 95 Tools: 21244540 Measuring tool Install the engine mounts on the engine brackets in accordance with the following: Brush Volvo Penta grease part # 828250 onto the threads. Lift the engine by attaching a lifting device to both engine lifting eyes.
Page 96 (1). The illustration shows the correct posi- tion: the arrows point toward each other. If the spline coupling is incorrectly installed there is a great risk of vibration problems! Tighten the bolts to 70–80 Nm (52–60 lbf.ft). 47704162 10-2014 © AB VOLVO PENTA...
Page 97 Also refer to Engine Founda- tion page 84. Oil cooler Connect the drive unit oil lines to the oil cooler. Tightening torque: 80 Nm (59 lbf.ft) P0009909 47704162 10-2014 © AB VOLVO PENTA...
Page 98: Extension Shaft
Do not run the engine with safety covers removed. Installation The driveshaft can be ordered in various lengths (A); installed lengths as follows: 700–800 mm (27.5–31.5") 1100–1200 mm (43.5–47") 1500–1600 mm (59–63") 1900–2000 mm (75–79") 2400–2500 mm (94.5–98.5") 47704162 10-2014 © AB VOLVO PENTA...
Page 99 Example of jackshaft safety cover Jackshaft shaft safety covers are not supplied by Volvo Penta. These covers must be made by the boat builder and designed according to local regulations and appli- cable legislation.
Page 100: Exhaust System
Add 200 mm (7.87") for end over- laps. Use the hose clamp to mark around the entire circumference of the hose. Saw off the hose and clip off the steel spirals. P0007513 47704162 10-2014 © AB VOLVO PENTA...
Page 101 P0014300 The exhaust elbow must be inclined by at least 45%. The riser must be inclined at least 15%. IMPORTANT! Minimum distance (Y) between exhaust elbow and inside of transom: 50 mm (2"). P0006190 47704162 10-2014 © AB VOLVO PENTA...
Page 102: Cooling System
Volvo Penta Spare Parts Accessories. Make enough to guarantee that cooling performance is not sure that parts not supplied by Volvo Penta do not affected by fouling and repainting even after a long reduce or impede pressures and flows in the engine.
Page 103 The water is drawn in through an intake in the hull and is led via a filter to the engine. From there the water enters the exhaust hose and leaves via the IPS drive. Volvo Penta cooling systems are designed for max seawater temperatures of 32 °C (90 °F). Seawater inlet...
Page 104 Clearance for removal of filter cartridge (A): 200 mm (4.72”) If the water is heavily contaminated it may be neces- sary to install a filter with extra large capacity. Seawater pump pipe union, diameter: P0012202 63 mm (2½") 47704162 10-2014 © AB VOLVO PENTA...
Page 105 P0010525 The anti-siphon valve must be installed at least 500 mm (20") (B) above the waterline of a loaded boat. The valve is not supplied by Volvo Penta. 47704162 10-2014 © AB VOLVO PENTA...
Page 106: Freshwater System
(a 60% glycol mixture reduces the freezing point to We recommend “Volvo Penta Coolant, Ready Mixed”, -54 °C). Never mix more than 60% concentrate (Volvo or “Volvo Penta Coolant” (concentrated) mixed with Penta Coolant) in the coolant mixture as this reduces pure water according to specifications;...
Page 107 Hot water connections Hot water connections may be made to the thermostat housing (outlet) and the circulation pump (inlet). The unions supplied by Volvo Penta are intended for hoses with and inner diameter of 16 mm (5/8”). P00011345 Install the auxiliary hot water circuit so that its highest point is at least 50 mm (2") (A) lower than the fluid level...
Page 108 2.0 – 5.0 (6.5 – 16.5) 50 (7.3) The venting hoses (1) may not be run below their 5.0 – 7.0 (16.5 – 23.0) 30 (4.4) respective engine connection points. 7.0 – 10.0 (23.0 – 33.0) Open system 47704162 10-2014 © AB VOLVO PENTA...
Page 109 The engine pressure cap must be replaced with a sealed cap. The regular engine venting hose from the thermostat housing may be connected to the auxiliary expansion tank below the MIN level to facilitate venting when coolant is filled. 47704162 10-2014 © AB VOLVO PENTA...
Page 110 5 Hot water heater 6 Heater 7 Expansion tank If an auxiliary system does not vent normally to the expansion tank, a separate venting nipple (4) must be H: Min 50 mm (2") installed. 47704162 10-2014 © AB VOLVO PENTA...
Page 111 Silica (as per ASTM D859) <20 mg SiO P0002094 Iron (as per ASTM D1068) <0.10 ppm Manganese (as per ASTM D858) <0.05 ppm Conductivity (as per ASTM <500 µS/cm D1125) Organic content, COD (acc. <15 mg KMnO ISO8467) 47704162 10-2014 © AB VOLVO PENTA...
Page 112 Do not start the engine until the system is completely filled with coolant. WARNING! Do not open the coolant filler cap when the engine is hot. Steam or hot fluid could spray out, causing severe burns. 47704162 10-2014 © AB VOLVO PENTA...
Page 113: Fuel System
Fuel may be divided up between several tanks in order to keep the center of gravity low and also to allow adjustment of the fore-and-aft CoG. If the tanks are to be built in, the surrounding space must have good ventilation. 47704162 10-2014 © AB VOLVO PENTA...
Page 114: Fuel Tanks
IMPORTANT! An auxiliary fuel filter with water separator must be installed for use with all Volvo Penta engines. If a day tank is installed the return line must run to the day tank.
Page 115 Fuel temperatures and flows must be taken into account by the boatbuilder when selecting the fuel tank. For example if a fuel cooler is necessary on the return line to avoid excessive temperatures in the selected tank. 47704162 10-2014 © AB VOLVO PENTA...
Page 116 In boats where space is limited, the tank may be shaped in order to fit under the aft deck or similar space. P0004677 47704162 10-2014 © AB VOLVO PENTA...
Page 117 (3) are formed where fuel is able to collect. Prohibited U-bend IMPORTANT! The fuel filler and ventilation must be installed such that overfilling is prevented and that fuel cannot enter the air inlets. 47704162 10-2014 © AB VOLVO PENTA...
Page 118: Piping
Check to see if the boat will be used in such areas. Fasten the fuel lines using clamps. Distance between clamps: approx. 300 mm (11.8"). 47704162 10-2014 © AB VOLVO PENTA...
Page 119 <6 m (19.7 ft.) >6 m (19.7 ft.) Diameter, 10 mm (3/8") 12 mm (1/2") feed line Diameter, 10 mm (3/8") 10 mm (3/8") return line Max suction height 2.0 m (6.5 ft.) 2.0 m (6.5 ft.) 47704162 10-2014 © AB VOLVO PENTA...
Page 120: Fuel Pressure
Double filters The double fuel pre-filter has a pressure gauge that shows pressure-drop. Flow may be directed through the left, right or both filters, which makes filter insert replacement possible when the engine is running. 47704162 10-2014 © AB VOLVO PENTA...
Page 121: Lubrication System
P0010246 Viscosity Select the viscosity according to the table. The temperature values refer to stable ambient tem- peratures. * SAE 5W/30 refers to synthetic or semi-synthetic oils. 47704162 10-2014 © AB VOLVO PENTA...
Page 122: Electrical System
EVC buss cable and the control unit cables in Volvo Penta IPS installations. Positive (+) and negative cables (-) must be secured adjacent to one another, not separately.
Page 123: Batteries
Batteries may not be subjected to different loads (equipment must subject both batteries to load – not just one). A small power consumer, such as a radio connected to only one battery can quickly destroy both batteries. 47704162 10-2014 © AB VOLVO PENTA...
Page 124 23 V. Example: When two 12 V batteries, each with a capacity of 88 Ah, are connected in series, voltage will be 24 V and the total capacity 88 Ah. 47704162 10-2014 © AB VOLVO PENTA...
Page 125 Batteries that are not sealed may only be installed in the engine compartment if they are installed in a sep- arate, sealed and well-ventilated battery box. Battery gas is highly inflammable and extremely volatile. P0004705 47704162 10-2014 © AB VOLVO PENTA...
Page 126 NOTICE! Battery capacity drops by around 1% per degree Celsius from +20 °C (68 °F), which must be taken into consideration in extreme temperatures. IMPORTANT! A common start battery array is not permitted for Volvo Penta ISP installations. Lowest Min. battery capacity (SAE) temperature +5 °C (41 °F)
Page 127: Main Switch
+185 °F J1171 Accessory Battery The use of a separate battery array for service power consumption is mandatory. Volvo Penta recommends the use of a charge distrib- utor to charge the service batteries. IPS800 47704162 10-2014 © AB VOLVO PENTA...
Page 128 Battery changeover switch Cross-over Switch The use of a battery changeover switch between the service battery and the start battery is recommended. 1 Start battery 2 Service battery 3 Battery changeover switch 4 Start motor P0015381 47704162 10-2014 © AB VOLVO PENTA...
Page 129 (ft.) Cable area, mm² (AWG) 70 (00) 95 (000) 120 (0000) Comparison cable cross section (mm²) – diameter (mm) according to Volvo standard (SS IEC 228) Cross section, mm² (AWG) 50 (0) 70 (00) 95 (000) 120 (0000) Core diameter approx., mm (in.)
Page 130 A short circuit, open flame or spark could cause a vio- lent explosion. Ventilate well. IMPORTANT! Never switch off power to the battery charger before the connections are removed. 47704162 10-2014 © AB VOLVO PENTA...
Page 131 Instead, battery acid specific gravity must be measured using a battery acid hydrometer. Specific gravity differs with temperature. The lower the temper- ature the higher the specific gravity. 47704162 10-2014 © AB VOLVO PENTA...
Page 132: Alternator
Installation, Electrical System Alternator Alternator connnections Battery positive (+) Battery negative (-) Sensor cable Magnetization Rpm (not used) P0004716 Extra Alternators Refer to the Power Transmission chapter for informa- tion regarding auxiliary alternators. 47704162 10-2014 © AB VOLVO PENTA...
Page 133: Voltage Supply
The connections for voltage supply are located on the flywheel housing. Connect to the positive and negative cables and secure all the way to the SUS using cable ties. IMPORTANT! Brush corrosion protection, part # 1381065 onto all connections. 47704162 10-2014 © AB VOLVO PENTA...
Page 134: Connection
(+) (black cable in illustration). Tightening torque Positive terminal (+): 16–20 Nm (11.8–14.8 lbf.ft) Negative terminal (-): 22–26 Nm (16.2–19.2 lbf.ft) Refer to the Installation page 121 chapter for dimen- sioning of start batteries and cables. 47704162 10-2014 © AB VOLVO PENTA...
Page 135 Total length for cables b, 10.0 14.0 19.0 24.0 c and d; max length, m 24 V alternator (6.6) (10.5) (16.4) (23) (32.8) (45.9) (62.3) (78.7) (ft.) Cable area, mm² (AWG) (00) (000) (0000) 47704162 10-2014 © AB VOLVO PENTA...
Page 136 All other equipment such as lamps, fans, fridges Sensor cable etc., (navigation equipment excepted) may be con- 3-way charge distributor (not Volvo Penta accessory) nected to the port or starboard service battery. Battery changeover switch Tolerant system in case of fault in one installation...
Page 137 Tolerant system in case of fault in one installation If a short circuit occurs in one of the drivetrains, this will not affect the other drivetrain. Alternator Sensor cable 3-way charge distributor (not Volvo Penta accessory) Battery changeover switch Accessories (normal consumers) Start battery, port Service battery Capstans etc.
Page 138 NOTICE! Large power consumers must have a sepa- rate switch that is connected directly to the service bat- tery positive terminal (+). Alternator Sensor cable Accessories 12 V/24 V Capstans etc. (major power consumers) Connect to start array, negative (-) 47704162 10-2014 © AB VOLVO PENTA...
Page 139 Spray all electrical short intervals and mark the cables at fuse boxes and equipment with water repellent spray. junction boxes (1-3) with each cable consumer such as communication radio, fridge, lanterns etc. 47704162 10-2014 © AB VOLVO PENTA...
Page 140 Calculate cable area for power consumers • Measure the distance from the terminal block to the accessory. Multiply the distance by two. • • Then calculate the cable area according to the chart Calculating cable area page 139. P0004723 47704162 10-2014 © AB VOLVO PENTA...
Page 141 Total voltage drop when applying the above 33,61 0.052 table: 0 (1/0) 53,46 0.083 00 (2/0) 67,40 0.104 12 V system 0.4 V 000 (3/0) 84,97 0.132 24 V system 0.6 V 0000 (4/0) 107,16 0.166 47704162 10-2014 © AB VOLVO PENTA...
Page 142: Fire Extinguishing System
1 Pin 1 R (+) 2 Pin 2 SB (-) 3 Accessory cable kit, 10 m (3.5 ft.) 4 Fire extinguishing system 5 Main switch (+) or accessory relay (ignition switch) (+)86 (-) 85 P0011567 47704162 10-2014 © AB VOLVO PENTA...
Page 143 1 Pin 1 R (+) 2 Pin 2 SB (-) 3 Accessory cable kit, 10 m (3.5 ft.) 4 Fire shut-off unit (+)86 (-) 85 5 From main switch (+) Do not use accessory relay for EVC P0011568 47704162 10-2014 © AB VOLVO PENTA...
Page 144: Calibration And Settings
Below is an overview of the calibration routines together with a description of how the required special tools must be used. Further information regarding Volvo Penta IPS drive unit calibrations and settings can be found in the VODIA system. IMPORTANT!
Page 145 Calibration and Settings, IPS Calibration Calibration, lower gear case factory setting Volvo Penta IPS units are always calibrated when they leave the factory or warehouse. Factory setting cali- bration is only required when a unit has been exchanged or when an important part of the system has been changed, e.g.
Page 146 Using the 3849622 Calibration tool Twin installation Press the tool's plastic cylinders into the drive leg exhaust outlets (1). NOTICE! The plastic cylinders must be pressed all the way in to the bottom of the exhaust outlets. P0001800 47704162 10-2014 © AB VOLVO PENTA...
Page 147 When the rod (2) can be easily slid through the cylinder holes, the drive legs are parallel to one another and the keel. NOTICE! The cylinders must remain in place, i.e. all the way in to the bottom of the exhaust outlets. P0001803 47704162 10-2014 © AB VOLVO PENTA...
Page 148 VODIA tool. Quadruple installation Reporting calibration to the VODIA website Connect to the VODIA website and report Volvo Penta IPS calibration after the procedure is completed. If the calibration has been reported, no new calibration is required after future updates.
Page 149 Minimum For boats with high superstructure and with a great inclination to heel and where aggressive maneuvering is not a priority. At low speeds, all settings provide the same steering characteristics. 47704162 10-2014 © AB VOLVO PENTA...
Page 150: Launching And Sea Trial
Check the status of drain taps and plugs. P0006343 • Fill with coolant; refer tothe Coolant Level, Checking and Topping Up chapter. Fuel system • Fuel level • Filters and taps • Venting, venting valve 47704162 10-2014 © AB VOLVO PENTA...
Page 151 Replace the dipstick but do not screw it down before reading off. IMPORTANT! The Volvo Penta IPS unit must be stopped for at least 12 hours before a correct oil level check can be made. Instrument and control system (EVC system) •...
Page 152 This increases the tem- perature in the combustion chambers, which guaran- tees a safe start and reduces starting smoke. Idle speed is also controlled by engine temperature and is somewhat higher after a cold start. 47704162 10-2014 © AB VOLVO PENTA...
Page 153: Starting The Engine
Allow the starter motor to cool for at least five minutes (if possi- ble) before making a new start attempt. 47704162 10-2014 © AB VOLVO PENTA...
Page 154 Idle revolutions depend on engine type. Refer to the EVC system installation manual if idle revolutions must be adjusted. Checks when engine is stopped Press the stop button on the start/stop panel. 1 Check engine oil levels. 2 Check coolant levels. 47704162 10-2014 © AB VOLVO PENTA...
Page 155 Engine compartment ventilation chapter. P0008525 Check that no abnormal noise or vibrations occur. • • Check that the chosen steering matrix corresponds to the desired boat characteristics; refer to Calibra- tion and Settings page 142. 47704162 10-2014 © AB VOLVO PENTA...
Page 157: Alphabetical Index
Special Tools............10 Fuel pre-filter............118 Starting Battery Cable Area........127 Fuel pressure............118 Starting Group Battery Capacity......124 Fuel System............111 Starting the Engine (Cold Start)......150 Fuel System, Piping..........116 SUS................ 131 47704162 10-2014 © AB VOLVO PENTA...
Page 158 System Information..........13 Viscosity..............119 VODIA................ 9 Voltage Supply............131 Volvo Penta IPS............51 Weight Distribution........... 18 Zones of Requirement..........80...
Page 159 We would prefer you to write in English or Swedish. From: ...................................................................... Refers to publication: ............................... Publication no.: ..............Issued: ..............Suggestion/reasons: ........................................................................................................................................................................................................................................................................................................................Date: ............. Name: ............AB Volvo Penta Technical Information SE-405 08 Göteborg Sweden...

This manual is also suitable for:

Ips800 Ips950

Volvo IPS650 Installation Manual

Quick Links

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Summary of Contents for Volvo IPS650

This manual is also suitable for:

Table of Contents