PDF

Installation E
IPS 3 1(1)
IPS 900, 1050, 1200

Content
Safety Information ...................................................................................... 2
General Information .................................................................................... 5
Installation Tools and Documentation ...................................................... 8
Special Tools .......................................................................................... 10
Engine Characteristics ............................................................................. 13
Engine Application Ratings .................................................................. 13
Engine Performance .............................................................................. 14
Arrangement and Planning ...................................................................... 16
Engine Placement .................................................................................. 16
Engine Room .......................................................................................... 19
Sound Absorption .................................................................................. 28
Electrochemical Corrosion ................................................................... 31
Installation ................................................................................................. 49
Volvo Penta IPS ...................................................................................... 49
Fiberglass Hull Constructions ............................................................ 49
Aluminium Hull Constructions ........................................................... 72
Engine Foundation ............................................................................... 73
Propulsion Unit Installation ................................................................ 78
Engine Installation ............................................................................... 84
Extension Shaft .................................................................................... 88
Exhaust System ................................................................................... 90
Cooling System .................................................................................... 92
Fuel System .......................................................................................... 101
General ................................................................................................ 101
Fuel Tanks .......................................................................................... 102
Piping .................................................................................................. 104
Fuel pressure ...................................................................................... 106
Lubrication System .............................................................................. 108
Electrical System ................................................................................. 109
Batteries .............................................................................................. 110
Alternator ............................................................................................ 117
Voltage Supply ................................................................................... 118
Connection ......................................................................................... 119
Fire Extinguishing System .................................................................. 127
Power Take-off ..................................................................................... 129
Calibration and Settings ......................................................................... 130
IPS Calibration ...................................................................................... 130
Launching and Sea Trial ........................................................................ 133
Alphabetical index .................................................................................. 139
47705785 05-2014 © AB VOLVO PENTA 1

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. ous to inhale. Use an exhaust extractor to lead
Carefully read the chapters Safety precautions exhaust fumes away from the exhaust pipe and crank-
and General information in the manual before case ventilator when the engine is run in a confined
servicing or running the engine. space.
The following types of special warning messages can Always wear protective goggles if there is a risk
be found in this manual and on the engine: of splinters, sparks and splashes from acid or other
chemicals. Eyes are extremely sensitive and injury
WARNING! may result in loss of sight!
Indicates a hazardous situation which, if not avoided,
could result in death or serious personal injury. Avoid getting oil on the skin! Prolonged or
repeated contact with oil may lead to the disappear-
IMPORTANT! ance of the skin's natural oils. This will cause irritation,
Indicates a situation which, if not avoided, could result dry skin, eczema and other skin problems. Old oil is
in property damage. more hazardous to health than new. Use protective
gloves and avoid oil-soaked clothes and rags. wash
NOTICE! Important information that facilitates the regularly, especially before meals. Use special skin
work process or item. creams that facilitate cleaning and prevent the skin
from drying out.
Set out below is a list of risks that must always be
borne in mind and the safety precautions that must Most chemical used in the product (engine and
always be taken.
reverse gear oil, glycol, gasoline and diesel) or chem-
Plan ahead so that there is always sufficient icals intended for use in the workshop (degreasing
agents, paints and solvents) are health hazards. Read
space for safe installation and (future) disassembly.
the instructions on the product packaging carefully!
Lay out the engine compartment (and other compart-
Always follow safety instructions (the use of protective
ments such as the battery compartment) so that all
masks, protective goggles, gloves etc.). Make sure
service points are accessible. Make sure not to come
that other personnel are not inadvertently exposed to
into contact with rotating components, hot surfaces or
hazardous substances, e.g. in the air they breathe.
sharp edges when checking and servicing the engine.
Ensure good ventilation. Hand in used and surplus
Make sure that all equipment (e.g. pump drives, com-
chemicals to a recycling station.
pressors) has protective covers.
Take extreme care when searching for fuel sys-
Make sure the engine cannot be started while
tem leaks and testing injectors. Wear protective gog-
work is in progress by not connecting the electrical
gles. The spray from an injector is at very high pres-
system or by switching off electrical power to the
sure and fuel can force its way into tissue and cause
engine at the main switches and locking them in the
a serious risk of blood poisoning (septicemia).
OFF position. Erect a warning sign at the helm station.
Stop the engine and disconnect the power at the
main switches before working on the electrical sys-
tem.
2 47705785 05-2014 © AB VOLVO PENTA

Safety Information
Coupling adjustments must be made with the Do not open the engine coolant filler cap (fresh-
engine stopped. water cooled engines) when the engine is hot. Steam
or hot coolant may be ejected when system pressure
Use the lifting eyes installed on the engine/ is released. Open the filler cap slowly and release the
reverse gear when lifting off the drive. Always check system pressure carefully (freshwater cooled
that the lifting equipment is in good condition and has engines). Hot coolant may spray out if the filler cap or
the capacity to lift the engine (engine weight including drain tap is opened, or if a plug or coolant pipe is
reverse gear and any auxiliary equipment installed). removed from a hot engine.
If the engine has auxiliary equipment that has Hot oil can cause burns. Avoid getting oil on the
altered its center of gravity, special lifting devices may skin. Be sure to release the pressure from the lubri-
be required to obtain the correct balance for safe han- cation system before starting work on it. Never start
dling. or run an engine without the oil filler cap attached.
There is a risk of oil being ejected.
Never work on an engine that is suspended in an
engine hoist. If the boat is in the water – stop the engine and
close the seawater tap before working on the system.
It is mandatory that no work be carried out on a
running engine. There are however adjustments that All fuels, and many chemicals, are flammable.
require the engine to be run. Approaching a running Make sure they are not exposed to open flames or
engine is a safety risk. Loose clothes and long hair sparks. Gasoline, certain solvents and hydrogen from
can catch in rotating parts and cause serious injury. A batteries are extremely flammable and explosive in
careless movement or a dropped tool may result in the right concentration in air. No Smoking! Make sure
injury when working in the vicinity of a running engine. the workplace is well ventilated and take the neces-
Be careful to avoid hot surfaces (exhaust pipes, tur- sary safety precautions before welding or grinding in
bochargers, charge air manifolds, start elements etc.) the vicinity. Always have a fire extinguisher accessible
and hot liquids in pipes and hoses on engines that are at the workplace.
running or recently stopped. Re-install all protective
covers that were removed during maintenance work Store oil, fuel-soaked rags and old fuel and oil
before starting the engine. filters in the correct manner. Oil-soaked rags may
ignite spontaneously in certain conditions. Old fuel
Make sure that all warning and information decals and oil filters are harmful to the environment and must
on the product are always visible. Change decals that be handed to a recycling station for destruction.
are damaged or painted over
Make sure the battery compartment is built
Turbocharged engines: never start the engine according to current safety standards. Never allow
without the air cleaner installed. The rotating com- open flames or electrical sparks in the vicinity of the
pressor turbine in the turbocharger can cause severe batteries. Never smoke in the vicinity of the batteries.
injury. Foreign objects that enter the inlet ducts can Batteries give off hydrogen gas during charging,
also cause mechanical damage. which may combine with air to form an explosive mix-
ture. The gas mixture is extremely volatile and easily
Never use start spray in the air intake. The use ignited. Incorrect battery connection may cause
of such products may result in an explosion in the inlet sparks which in turn may cause an explosion. Do not
manifold. Risk of injury. change the battery connections when attempting to
start the engine (risk for sparks) and do not lean over
the batteries.
47705785 05-2014 © AB VOLVO PENTA 3

Safety Information
Make sure that the positive (+) and negative (–) Always use fuels recommended by Volvo Penta.
battery cables are correctly connected to the corre- Refer to the Operator's Manual. Poor quality fuel may
sponding battery terminals. Wrong connection may damage the engine. Poor fuel quality in a diesel
cause severe damage to electrical equipment. Refer engine may cause the fuel control mechanism to bind
to the wiring diagram. which will lead to engine overspeeding with the risk of
engine damage and personal injury. Low fuel quality
Always wear protective goggles when charging may also lead to higher service costs.
or handling batteries. Battery electrolyte contains
highly corrosive sulfuric acid. Wash immediately with Use an adjustable lifting beam to provide a safe
soap and copious amounts of water if battery electro- lift and to avoid damage to components on the top of
lyte comes into contact with the skin. Flush immedi- the engine. All chains and cables must run parallel
ately with water and seek medical attention if battery and be as square as possible to the top of the engine.
acid gets in the eyes.
Never work alone when installing heavy compo-

nents, even when using safe lifting equipment e.g.
lockable blocks. Most lifting devices require the two
people, one to take care of the hoist and the other to
make sure no components catch or are damaged.
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.
4 47705785 05-2014 © AB VOLVO PENTA

General Information
General Information
About this installation manual Removal of complete engine assembly
This publication is intended as an installation guide for In the event of a requirement to remove the entire
Volvo Penta marine diesel engines for IPS installa- engine assembly from the vessel, it is the responsi-
tions. The publication is not exhaustive and does not bility of the boat builder to arrange reasonable means
cover all conceivable installations, but should be con- for removal and re-installation.
sidered as a recommendation and guidance accord-
ing to Volvo Penta norms. Detailed installation instruc- Reasonable means that the engine assembly can be
tions accompany most accessory kits. lifted in and out within a moderate amount of time
using normal resources and methods available to the
The recommendations are the result of many years of industry. In this way costs and operational down-time
practical experience from all over the world. If it is are kept to a minimum. 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.
It is Volvo Penta policy to avoid unreasonable instal-
It is the responsibility of the installer to ensure that lations that increase extra costs for boat owners dur-
installation is carried out in a satisfactory manner, that ing the lifetime of the boat.
the installation is in good operable condition, that
approved materials and accessories are used and Plan the installation carefully
that the installation fulfills all current instructions and
regulations. Great care must be taken when installing engines and
their components if they are to function perfectly.
This installation manual is intended to be used by pro- Make sure that the correct specifications, drawings
fessionally qualified and skilled personnel. It is there- and other data are available before work is begun.
fore assumed that those persons using the manual This facilitates correct planning and installation right
have fundamental knowledge of marine propulsion from the start.
systems and are capable of carrying out the associ-
ated mechanical and electrical work. Plan the engine compartment so that it will be easy to
perform routine service that involves changing com-
Volvo Penta continually improves it products and ponents. Compare the engine service manual to the
reserves the right to make changes. All the informa- original drawings where dimensions are stated.
tion in this manual is based on product specifications
available at the time of publication. After this date all When installing engines, it is extremely important that
important product modifications that change installa- no dirt or foreign objects enter the fuel, cooling, inlet
tion methods will be communicated via service bulle- or turbo systems, as this may cause faults or the
tins. engine to seize. Because of this, systems must be
sealed. Clean supply lines and hoses before they are
connected to the engine. Remove the protective caps
from the engine when an external system is con-
nected.
47705785 05-2014 © AB VOLVO PENTA 5

General Information
Certified engines From June 16 1998, all leisure craft and certain asso-
ciated equipment that is marketed and used within the
A certified engine means that the engine manufac- EU must be provided with a CE label confirming ful-
turer guarantees that both new engines and those in fillment of safety requirements established by the
operation fulfill legislation and regulations. The engine 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 in support of the directive's objective regarding uni-
must be observed during installation: form safety requirements for leisure craft within the
• Service on injection pumps, pump settings and EU.
injectors must always be carried out by an
Lifeboats and boats used in commercial navigation
authorized Volvo Penta workshop.
are approved by classification societies in the country
• The engine may not be modified in any way where the boat is registered.
except with accessories and service kits devel-
oped for the purpose by Volvo Penta. Mutual responsibility
• The installation of exhaust pipes and air intakes Every engine consists of a large number of compo-
(ventilation ducts) in the engine compartment nents working in unison. If one component deviates
must be carefully planned as their design may from technical specifications it may lead to the engine
influence exhaust emissions. having a significantly greater impact on the environ-
• Seals may only be broken by authorized per- ment. It is therefore essential that adjustable systems
sonnel. are set correctly and that genuine Volvo Penta parts
are used.
IMPORTANT!
Certain systems (e.g. the fuel system) may require
Only use genuine Volvo Penta parts. If non-Volvo special professional expertise and test equipment.
Penta parts are used it will mean that Volvo Penta For environmental reasons, some components are
is no longer able to take responsibility for the factory sealed. No work may be performed on sealed
engine fulfilling certification requirements. Volvo parts by unauthorized personnel.
Penta will not reimburse damages and costs arising
from the use of non-Volvo Penta spare parts. Remember that most chemical products can harm the
environment if they are used in the wrong manner.
Seaworthiness Volvo Penta recommends the use of bio-degradable
de-greasing agents for cleaning engine components,
It is the responsibility of the boat builder to meet all
unless the service manual states otherwise. When
safety requirements applicable in the market where
working onboard take especial care to ensure that oil
the boat is sold. For example, in the U.S.A. US Fed-
and spills are collected for handing to a re-cycling sta-
eral Regulations for pleasure boats specify require-
tion and not unintentionally pumped into the environ-
ments. Requirements applicable in the EU are descri-
ment with bilgewater.
bed below. In other markets, contact the competent
national authority for information and detailed descrip-
tions of safety requirements.
6 47705785 05-2014 © AB VOLVO PENTA

General Information
Metric Conversion Chart

Metric to American or UK units: American or UK to metric units:
To convert Multiply To convert Multiply
From To with From To with
Length mm in. 0.03937 in. mm 25.40
cm in. 0.3937 in. cm 2.540
m ft. 3.2808 ft. m 0.3048
Area mm² sq. in. 0.00155 sq. in. mm² 645.3
m² sq.ft. 10.76 sq. ft. m² 0.093
Volume cm³ cu. in. 0.06102 cu. in. cm³ 16.388
l, dm³ cu. ft. 0.03531 cu. ft. l, dm³ 28.317
l, dm³ cu. in. 61.023 cu. in. l, dm³ 0.01639
l, dm³ imp. gallon 0,220 imp. gallon l, dm³ 4.545
l, dm³ U.S. gallon 0.2642 U.S. gallon l, dm³ 3.785
m³ cu. ft. 35.315 cu. ft. cm³ 0.0283
Power N lbf 0.2248 lbf N 4.448
Weight kg kg lb. 2.205 lb. kg 0.454
Power kW hp (metric)(1) 1.36 hp (metric) (1) kW 0.735
kW bhp 1.341 bhp kW 0.7457
kW BTU/min 56.87 BTU/min kW 0.0176
Tightening Nm lbf ft 0.738 lbf ft Nm 1.356
torque
Pressure Bar psi 14.5038 psi Bar 0.06895
MPa psi 145.038 psi MPa 0.006895
Pa mm Wg 0.102 mm Wg Pa 9.807
Pa in Wg 0.004 in Wg Pa 249.098
kPa in Wg 4.0 in Wg kPa 0.24908
mWg in Wg 39.37 in Wg mWg 0.0254
Energy kJ/kWh BTU/hph 0.697 BTU/hph kJ/kWh 1.435
Effort kJ/kg BTU/lb 0.430 BTU/lb kJ/kg 2.326
MJ/kg BTU/lb 430 BTU/lb MJ/kg 0.00233
kJ/kg kcal/kg 0.239 kcal/kg kJ/kg 4.184
Fuel cons. g/kWh g/hph 0.736 g/hph g/kWh 1.36
g/kWh lb/hph 0.00162 lb/hph g/kWh 616.78
Moment of kgm² lbft² 23.734 lbft² kgm² 0.042
inertia
Flow, gas m³/h cu.ft./min. 0.5886 cu.ft./min. m³/h 1.699
Flow, fluid m³/h US gal/min 4.403 US gal/min m³/h 0.2271
Speed m/s ft./s 3.281 ft./s m/s 0.3048
mph knots 0.869 knots mph 1.1508
Temperature Celsius Fahrenheit °F=9/5 x °C Fahrenheit Celsius °C=5/9 x (°F–
+32 32)
1) All catalog output data specified in horsepower refers to metric horsepower.
47705785 05-2014 © AB VOLVO PENTA 7

Installation Tools and Documentation

Publications
Installation manuals
Instal Manuals are available for the EVC system, for exam-
lation ple.
BE
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.
8 47705785 05-2014 © AB VOLVO PENTA

3 Posters
EVC-C
Refer to posters for the design of hull inserts, lamina-
tions, drive unit installation and the installation and cal-
ibration of the EVC system.
P00008985
VODIA
The VODIA diagnostic tool is used for reading fault
VODIA codes in clear text during diagnosis work. It can also
be used for setting EVC parameters.
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

p0006256 Network or contact Volvo Penta to order.
Chemicals
There is a large range of chemicals available from
Volvo Penta.
Some examples:
• Oil and coolant
• Sealing compound and grease
• Touch-up paint
Refer to Volvo Penta Spare Parts & accessories.
An
t if ouli n g
P0004585
47705785 05-2014 © AB VOLVO PENTA 9

Installation Tools and Documentation, Special Tools
Special Tools
P0010517 P0010518
P0010505
3849633 Drill jig 3594503 Drill jig 21110860 Lifting tool

Location of engine bed and Lamination of hull inserts and Attaching device for propulsion
engine mount positions (hull the location of engine beds unit when lifting by hoist
inserts) (complete with molding tools).
P0010506
p0010872
3849664 Lifting tool 3887101 Break-out box 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
10 47705785 05-2014 © AB VOLVO PENTA

Other Special Equipment
VODIA
p0005125
P0004349
p0008375
88890074 Multimeter 88820047 VODIA, diagnostic 9998339 Manometer

tool Measuring fuel feed pressure
PDA only
P0004580
9998493 Hose 21504294 Reference elec-

Used in combination with trode
9998339 Manometer. Measuring electrochemical cor-
rosion
47705785 05-2014 © AB VOLVO PENTA 11

Chemical products
P0001874 P0001871
828250 Grease alt. 1381065 Corrosion protec- 3817243 Rubber lubricant

21347121 Grease (400 gr) tion
12 47705785 05-2014 © AB VOLVO PENTA

Engine Characteristics, Engine Application Ratings
Engine Characteristics
Engine Application Ratings
The engines covered by this manual are used mainly
in three different operating conditions: Rating 3, Rating
4 and Rating 5, as described below.
Rating 3
Light Duty Commercial
For commercial vessels or craft with high demands on
speed and acceleration. For planing or semi-planing
boats in cyclical operation with operational time less
than 2000 hours per year.
Typical boats: high speed passenger vessels (HSLC),

patrol and emergency boats, pilot boats and supply
boats.
Full power could be utilized maximum 2 hour per 12

hours operation period. Between full load periods,
engine speed should be reduced at least 10% from the
obtained full load engine speed.
Rating 4
Special Light Duty Commercial
For light planing and semi-planing craft in commercial
boats with operational time less than 800 hours per
year. Recommended speed at cruising = 25 knots.
Typical boats: patrol and emergency boats.
Full power could be utilized maximum 1 hour per 12

hours operation period. Between full load periods,
engine speed should be reduced at least 10% from the
obtained full load engine speed.
Rating 5
Recreational Craft Application
This power is intended for pleasure craft applications,
operated by owners for their recreation. It can be used
for high speed planing crafts in commercial applica-
tions with special limited warranty, see warranty and
service book. Operated for less than 400 hours per
year (Marine Leasure 300h/year).
NOTICE! Time between major overhaul is subject to a

number of factors including duty cycle, loads, speed,
lubrication, maintenance, temperature, contamination
and others. Volvo Penta recommend continuous oil
analysis.
For IPS different (shorter) repair intervals must be con-
sidered, see instruction manual.
47705785 05-2014 © AB VOLVO PENTA 13

Engine Characteristics, Engine Performance
Engine Performance
Marine engine power is specified, just like automobile
and truck engines, according to one or more power
norms. Power is specified in kW or hp, always at a
rated rpm.
Most engines provide the power specified on the con-

dition that they have been tested in the conditions the
power norms state, and have been broken in properly.
According to ISO standards, tolerances are normally
±5 %, which is a reality that must be accepted for ser-
ies-produced engines.
Power measurement
Engine manufacturers normally measure engine
power at the flywheel, but before power reaches the
propeller, losses occur in the drive train and propeller
shaft bearings. These losses amount to 4–6 %.
All major marine engine manufacturers determine

engine power according to ISO 8665 (supplement to
ISO 3046 for pleasure boats). If an exhaust system is
not included, engine tests are performed with a back
pressure of 10 kPa (1.45 psi).
1 Engine performance
A
Engine power is affected by a number of different fac-
tors. Among the most important are air pressure, out-
3
B door temperature, humidity, fuel calorific value and
4 C exhaust back pressure. Deviations from normal values
affect diesel and gasoline engines in different ways.
Diesel engines use large amounts of air for combus-

5 tion. If the mass of air is reduced, the first sign is an
6
increase in black exhaust smoke. The effects of this
are especially noticeable at the planing threshold when
the engine must produce maximum torque.
If the deviation differs significantly from normal air flow,

the diesel engine will lose power. In the worst case the
loss may be so great that torque is insufficient for the
2 boat to overcome the planing threshold.
P0004571
Point A is where the indicated engine power is equal

Connection between performance-influencing factors in inboard
engines
to the power acting on the propeller. Volvo Penta IPS
drive units have defined propeller sizes that are dimen-
1 Power sioned for engine characteristics.
2 rpm
3 Power loss due to atmospheric conditions
4 Loss due to large propeller
5 Critical area
6 Indicated rpm
14 47705785 05-2014 © AB VOLVO PENTA

Engine Characteristics, Engine Performance
Other factors that influence performance

It is important to keep exhaust back pressure low.
Power losses caused by back pressure are directly
proportional to the increase in back pressure, which
also increases exhaust temperature.
Boat weight is another important factor that influences

speed. Increased boat weight has a great influence on
speed, especially on planing or semi-planing hulls. A
new boat that is tested with half full fuel and water tanks
and without a load, may lose 2-3 knots when it is driven
fully loaded with fuel, water and equipment for the voy-
age.
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.
47705785 05-2014 © AB VOLVO PENTA 15

Arrangement and Planning, Engine Placement
Arrangement and Planning

Engine Placement
Engine Inclination
To ensure the engine receives lubrication and cooling
in a satisfactory manner, it is important that maximum
engine inclination is not exceeded. Engine inclination
must therefore be checked.
Be careful to avoid the front of the engine's being lower

than the flywheel, i.e. an exaggerated negative incli-
nation that may impair engine lubrication and cooling
system venting.
Each engine type has a maximum permissible engine

inclination while the boat is under way. This inclination
includes both the installation angle and the increase in
trim angle the boat attains when moving at speed
through the water.
A
A Engine inclination with the boat at rest.
B Boat trim angle under way.
C Total engine inclination under way, maximum per-
missible inclination (A+B).
B
A boat's weight distribution is affected by the choice of
C
driveshaft length.
P0010566
See technical data for limit values.
16 47705785 05-2014 © AB VOLVO PENTA

Weight Distribution
The location of the longitudinal center of gravity is of
great importance for trim angle at top speed etc. Gen-
erally speaking, a fast boat should have its center of
gravity further aft than a slower boat.
The center of gravity has great influence on a boat's

static and dynamic stability. It is therefore important to
consider CoG position both when the boat is laden and
empty.
A It is important that heavy components such as engines,

fuel and water tanks and batteries be located such that
the best possible trim is achieved when the boat is in
the water, and generally that as low a vertical CoG as
possible is attained.
Fuel and water tanks must be located longitudinally as

close to the center of gravity as possible in order that
the center of gravity is not moved when water and fuel
B
levels change.
P0005314
It is an advantage not to locate the fuel tanks in the

Figure A shows an installation with good weight distribution. vicinity of the hot engine compartment. If possible, the
Figure B shows an incorrect installation with poor trim angle as the
result.
batteries must be located in a separate, well-ventilated
section.
It is always the boat designer and/or boat builder who

is responsible for the final result.
47705785 05-2014 © AB VOLVO PENTA 17

Clearance Around Propulsion Units

Objects that protrude from the hull bottom cause tur-
bulence. If such are present in the vicinity of the drive
units, propeller propulsion ability will be impaired.
A Place no objects inside the dashed lines.
B
A min. 3000 mm (118")
B
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
18 47705785 05-2014 © AB VOLVO PENTA

Arrangement and Planning, Engine Room
Engine Room
Accessibility for Maintenance
When the engine installation is designed, great
emphasis must be placed on engine service accessi-
bility. Also make sure that the complete engine can be
lifted out without damage to the boat.
NOTICE! There must also be sufficient space for

A sound-dampening materials. The recommended min-
imum distance from sound-dampening materials is
180 mm (7") (A) and 200 mm (8") (B); see illustration.
P0011626
Removal of complete engine assembly

If it is necessary to remove the entire engine assembly
from the vessel, it is the responsibility of the installer
(boat builder) to arrange reasonable means for
removal and re-installation. This means removal within
a moderate amount of time using normal 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.
Considering the great demand placed on boatyards

etc. during high season, the boat builder's instructions
must be followed.
47705785 05-2014 © AB VOLVO PENTA 19

P0013934
General maintenance Repairs

Items that usually require maintenance accessibility: Items that may require maintenance accessibility:
• Coolant • Removal of injectors, cylinder head, radiator etc.
• Oil change and filling (engine, drive) • Removal or exchange of electrical components
• 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
20 47705785 05-2014 © AB VOLVO PENTA

Engine Room Ventilation

Engine performance
Diesel engines require a surplus of air. Deviations from
normal values first present themselves as more black
smoke than usual. This may be especially noticeable
at the planing threshold when the engine must deliver
the highest possible torque.
If deviations from normal values are great, the diesel

engine will lose power. The power loss may be so great
that a planing boat is unable to overcome the planing
threshold.
In order for the engine to function properly and provide

full power, it is absolutely essential that both inlet and
outlet air ducts are dimensioned and installed cor-
rectly.
Two main conditions must be met:

A The engine must receive sufficient air (oxygen) for
fuel combustion.
B The engine compartment must be ventilated such
that the temperature can be kept at an acceptably
low level.
Ventilation is also important to keep the temperature

of electrical and fuel systems low, and to guarantee
normal engine cooling.
Ventilation must also be suitably adapted if crew mem-

bers will be present in the engine compartment.
NOTICE! Current national safety regulations and leg-

islation must be followed. Each classification society
has its own rules that must be followed when so
required.
Engine power at high altitudes above sea level

In most cases marine engines are used at, or close to,
sea level. However, there are lakes at high altitudes
above sea level.
Operations at high altitudes involve a power loss owing

to a drop in air density (and thereby oxygen levels) as
altitude increases. This will result in the development
of smoke and the turbocharger running at abnormally
high rpm with increased wear.
However, power loss is not significant below approx.

500 m (1640 ft) above sea level. At altitudes in excess
of 500 m (1640 ft) above sea level, power loss is
around 0.1% per 100 m (328 ft).
Volvo Penta IPS 800/900 are not suitable for opera-

tions above 1 500 m (5,000 ft).
47705785 05-2014 © AB VOLVO PENTA 21

Dimensioning of air intake and ducts
The following basic facts must be considered in

calculations when planning an installation:
• All combustion engines, regardless of manufacture
or type, require a certain amount of oxygen (or air)
for the combustion process. However, diesel
engines work with a somewhat larger air surplus
than gasoline engines.
• Furthermore, all engines emit a certain amount of
heat to the surroundings, i.e. the engine compart-
ment.
• Heat radiation is smaller on modern, compact
engines than on older, less compact engines. Mod-
ern engines enjoy a great advantage in this.
Ducts and pipes for inlet and outlet air

It is an advantage if ducts and pipes for inlet and outlet
air can be planned as early as the design stage, as they
can then be built into the hull or superstructure. This
eliminates the requirement for separate ducts.
It is relatively simple to design a system for providing

the engine with a sufficient quantity of combustion air,
but significantly more difficult to ventilate heat radiation
away.
The engine draws in air efficiently and naturally takes

it from whatever direction it can. If inlet and outlet ducts
are too small, the engine will draw in air from both ducts
and no ventilation air will be expelled through the outlet
duct. This will create dangerously high temperatures in
the engine compartment.
Most of the engine heat radiation must be carried away

from the engine compartment. It is a mandatory
requirement to keep engine compartment temperature
below the maximum permissible limit.
22 47705785 05-2014 © AB VOLVO PENTA

Fans
Normally an extraction (suction) fan must be installed
in the outlet duct to ventilate the engine compartment
more efficiently and thus keep engine compartment
temperature low.
Conversely, fans may never be installed in the inlet

duct as this may lead to engine compartment over-
pressure, with the risk of gases or air leaking into other
parts of the boat.
For diesel engines the fan may very well be thermostat

controlled; it must start at an engine compartment tem-
perature of around +60 °C (+140 °F), measured in the
engine compartment.
NOTICE! Fan hose connections for diesel engines

must be located as high up in the engine compartment
as possible to carry away hot air, while as low as pos-
sible for gasoline engines to carry away fumes.
Engine compartment temperature

It is important that inlet temperature be kept as low as
possible bearing in mind that engine performance fig-
ures apply at a test temperature of +25 °C (+77 °F).
Temperature
≤25°C (77 °F) Full power
>25°C (77 °F) Power loss 1 % per 10°C
Inlet air temperature at the air filter may not be higher

than +25 °C (+77 °F) to obtain full power. During sea
trials the temperature in the air filter must not be higher
than 20 °C (36 °F) above the outside temperature.
Engine surface temperature is rather high at certain

points. Certain individual engine components such as
charge regulators and relays must therefore be instal-
led on bulkheads or other locations where the temper-
ature is relatively low.
Maximum temperature at electrical component

installation locations is 70 °C (158 °F). However, the
starter motor and alternator have their given locations.
Engine compartment pressure

Volvo Penta recommends that the negative pressure
in the engine compartment does not fall below 0.5 kPa
(0.07 psi) at full speed. A slight negative pressure in
the engine compartment is not harmful and it prevents
gases from being forced out of the engine compart-
ment into other boat spaces.
47705785 05-2014 © AB VOLVO PENTA 23

Engine air consumption

The engine consumes a certain amount of air during
the combustion process. This requires the inlet duct to
have a certain internal cross-sectional area.
This area can be calculated using the formula:

A = 1.9 × engine power
A = Area in cm2
Engine power in kW
The value applies to inlets, without obstacles, that are

up to 1 m (3.3 ft) with only one 90-degree bend. The
bend radius must be at least twice the duct diameter.
If longer ducts or more bends are used, the area must

be corrected by multiplying with the coefficient in the
Coefficient of bends table.
Coefficient of bends
Duct length, m (ft.)
Quantity 1 (3.3) 2 (6.6) 3 (9.8) 4 (13.1) 5 (16.4)
bends
1 1 1.04 1.09 1.13 1.20
2 1.39 1.41 1.43 1.45 1.49
3 – 1.70 1.72 1.74 1.78
Engine compartment ventilation

In addition to its air consumption, the engine radiates
heat. Heat radiation must be carried away from the
engine compartment in order to keep the temperature
down to permissible values.
The same dimensions must be chosen for the outlet

and inlet channels in order to achieve low flow speeds
and low noise levels.
Ventilation inlet/outlet area is calculated according

to the following formula:
Area (cm2) = 1.65 × engine power (kW)
These values must be corrected in accordance with

table 1 in regard to bends and duct length.
Outdoor temperature is assumed to be +30 °C (86 °F).

Correction factors in table Correction factor must be
used where applicable.
Correction factor
Outer temperature °C (°F) Correction factor
+20 (68) 0.7
+30 (86) 1.0
+40 (104) 1.4
24 47705785 05-2014 © AB VOLVO PENTA

Choice of fan
The fan must be dimensioned for airflow according to
the following:
Outlet air (m3/min) = 0.07 × engine power (kW)
The total pressure increase at the fan must be 10 mm

(0.39") water gauge (100 Pa).
These two values, flow and total pressure increase, are

sufficient for selecting a fan. If the fan is installed
directly on the bulkhead, i.e. without a connecting duct,
the total pressure increase value may be reduced by 7
mm (0.28") water gauge (70 Pa). This means that a
somewhat smaller fan may be used.
Calculation of air ducts

Example 1: IPS1050, 588 kW (800 hp)
Calculation of areas for one 588 kW 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 × 588 = 1117
cm2 (173.1 sq.in)
No corrections according to tables Coefficient of

bends and Correction factor. The area 1117 cm² (173,1
sq.in) gives a duct diameter of 377 mm (14,8") for each
engine (2√(area/π)).
Multiply by the number of engines to calculate the area

of the engine compartment inlet duct.
Ventilation:
1 Air intake: Area = 1.65 × 588 = 970 cm2 (150.4
sq.in). This gives a diameter of 304 mm (12.0") for
a single engine.
2 Air outlet: Area = 1.65 × 588 = 970 cm2 (150.4
sq.in). This gives a diameter of 304 mm (12.0") for
a single engine.
3 Extraction fan capacities: 0.07 × 588 = 41.2
m3/min (1455 ft3/min).
4 Multiply each sum by the number of engines to cal-
culate the area and fan capacity for a common
engine compartment.
47705785 05-2014 © AB VOLVO PENTA 25

Example 2: IPS1200, 662 kW (900 hp)

Area calculations for one engine with a 2 m (6.6 ft) long
duct, 2 bends and an outside temperature of +20 °C
(+68 °F).
Air consumption:
Area for engine air consumption: 1.9 × 662 = 1258
cm2 (195 sq.in).
Correction for duct length and bends = 1.41 from Coef-

ficient of bends.
This gives 1.41× 1258 = 1773.5 cm2 (274.9 sq.in). The

area 1773.5 cm2 (274.9 sq.in) corresponds to a duct
diameter of 475 mm (18.7").
Multiply by the number of engines to calculate the area

of the engine compartment inlet duct.
Ventilation:
1 Inlet, engine compartment: Area = 1.65 × 662 =
1092 cm2 (169.2 sq.in). This corresponds to a duct
diameter of 373 mm (14.7").
2 Outlet, engine compartment: Area = 1.65 × 662
= 1092 cm2 (169.2 sq.in). This corresponds to a
duct diameter of 373 mm (14.7").
3 Correction, inlet and outlet: Air temperature = 0.7
from Correction factor, plus a correction for duct
length and bends = 1.41 from Coefficient of bends.
This gives 0.7 × 1.41 × 1092 = 1078 cm2 (167 sq.in).
This corresponds to a duct diameter of 370 mm
(14.6") for each inlet and outlet.
4 Extraction fan capacities: 0.07 × 662 (kW) = 46.3
m3/min (1635 ft3/min).
5 Multiply each sum by the number of engines to cal-
culate the area and fan capacity for a common
engine compartment.
26 47705785 05-2014 © AB VOLVO PENTA

Location of ventilators and air inlets

NOTICE! Air inlets and outlets may never be located
on the transom. Air in this area mixes with water and
exhaust fumes, and must never be allowed into the
boat.
Air inlet function

Air inlets and outlets must function well even in bad
weather and must therefore have efficient water traps.
For the most part noise insulation must be built in.
Air inlets and outlets must be located as far away from

each other as possible so that an effective through flow
is achieved.
If inlets and outlets are too close to each other air is

able to recirculate, which will provide inadequate ven-
tilation.
5 Location of air ducts
3
Ducts or pipes for engine air supply must be run to a
place as close to the air filter as possible, but with a
minimum distance of 20–30 cm (8–12") in order to def-
4 initely prevent water from entering the engine. Refer to
the illustrations.
1
The inlet ventilation duct for diesel engines must be led
in far down into the engine compartment, but not so far
down that any bilge water is able to block air supply.
The outlet duct must be located diametrically opposite
2 on the other side of the engine installation.
All ducts and pipes must be run such that there is the
P0004733 least possible flow resistance. Bends may not be
sharp, but must be moderately rounded. The minimum
1 Engine air filter
radius is double the diameter. Obstacles or constric-
2 Inlet duct, engine compartment tions must always be avoided.
3 Exhaust
The ducts must be cut obliquely at the ends to provide
4 Water trap best flow.
5 Extraction fan
Always take any local regulations into account.
If it is not possible to arrange drainage, ventilation

hoses must be bent upwards somewhat in order to
form a gooseneck that prevents seawater forcing its
way into the engine compartment. Remember to build
the engine compartment as spaciously as possible to
facilitate engine service.
P0004734
47705785 05-2014 © AB VOLVO PENTA 27

Arrangement and Planning, Sound Absorption
Sound Absorption
The drive assembly must be installed so that noise and
vibrations are minimized. The noise that occurs is party
airborne noise and partly structural noise (vibrations).
Structural noise
Engine vibrations are transferred to the hull via the
engine mounts and engine bed. Other transfer routes
are through the transmission and propeller system,
exhaust pipes, coolant pipes, fuel pipes and electrical
and control cables.
Propeller pressure waves are transmitted through the

water to the hull. Propeller drive pulses are transferred
to the hull via support brackets, bearings and seals.
Airborne noise
This section concerns airborne noise from the engine
compartment. The most important method of reducing
airborne noise from the engine compartment is to seal
it properly. Further noise reductions can be achieved
by laying sound insulation material and by designing
noise baffles in the air inlets.
The engine installation must be noise insulated to pro-

vide as low a noise level as possible. Build noise baf-
fles into the engine compartment. There are different
types of noise baffles to choose from. The illustration
shows a type that also provides drainage.
It is important to ensure that the insulation material is

sufficiently thick.
1
The greatest possible care must be taken to screen the
noise source as much as possible. Screen off the entire
bulkhead down to the hull, but leave a little gap so that
bilge water does not force its way into the insulation
material.
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
28 47705785 05-2014 © AB VOLVO PENTA

Make sure that there is sufficient space for inspections,

service and repairs and for engine movement during
operations before the insulation material is installed.
Also make sure that all covers are properly insulated.
Examples of insulation material design are shown

below. This type of insulation material is glued to the
frame.
P0006333
1
1
2
3
3 4
P0004739
P0004740
Insulation material installed on wood (plywood): Insulation material installed on GRP:

1 Wood (plywood) 1 GRP
2 Flameproof absorbent layer 2 Iron/PVC, thickness 2.5 mm (0.1”)
3 Flameproof, reflective and noise insulating foil 3 Flameproof absorbent layer
4 Flameproof, reflective and noise insulating foil
NOTICE! The insulation materials look different

depending on the material the frame is made of - GRP
or wood.
47705785 05-2014 © AB VOLVO PENTA 29

When electrical cables are run through a bulkhead, it

is advantageous to run them through a conduit or
grommet that can be sealed properly. This also pro-
tects the cable against wear.
P0004741
Bulkhead bushings
Fuel hoses that are run through bulkheads must be

protected by grommets. The grommet seals and pro-
tects the hose against sharp edges that may cause
leaks.
Other lines such as electrical and battery cables can

be run through a rubber hose or a special 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
30 47705785 05-2014 © AB VOLVO PENTA

Arrangement and Planning, Electrochemical Corrosion
Electrochemical Corrosion
General
NOTICE! Refer to the Service handbook Corrosion
measurement, DPH/DPR & IPS for further information.
Corrosion theory
Corrosion in water is always electrochemical in nature.
This means that a weak electric current occurs at the
same time as chemical reactions takes place. Two
chemical reactions are required to make a metal cor-
rode, an oxidation reaction (metal dissolving) and a
reduction reaction (generally oxygen consuming). Oxi-
dation is referred to as an anode reaction and reduc-
tion is referred to as a cathodic reaction. In an oxidation
reaction, electrons are freed which are transported in
the metal to another point, where they are consumed
in a cathodic reaction.
Electrons are thus transported in the metal from the

anode to the cathode. This causes a weak DC current
Fe Fe2+ +2 e- ANODE in the opposite direction. An electric circuit must be
closed. This is achieved by the transport of ions in the
water.
O2 + H2O + 2 e 2 OH-
CATHODE
P0011416
Anodic and cathodic reactions must always balance

each other, which means that the electrons released
at the anode must be consumed at the cathode. If the
anodic and cathodic reactions occur evenly distributed
across the entire surface, general corrosion occurs.
I The depth of attack then becomes basically equal
across the entire surface. This commonly occurs on
steel and bronze.
P0011417
47705785 05-2014 © AB VOLVO PENTA 31

If the anodic and cathodic reactions occur at different

points, local corrosion occurs, i.e. deeper attack at cer-
tain points. The attacks on materials which can be pas-
sivated, such as stainless steel and aluminum are gen-
erally localized. There are different types of local cor-
rosion. The most common types of attack on stainless
steels and aluminum are pitting corrosion and crevice
corrosion.
In addition to these local attacks, attack can be caused

by galvanic corrosion or stray currents. In areas where
rapid water flow occurs, damage cause by cavitation
can also occur.
If we ignore attacks related to material defects, the fol-

lowing types of corrosion can occur:
- General corrosion.
- Pitting.
- Crevice corrosion.
- Galvanic corrosion.
- Stray current corrosion.
- Cavitation.
A brief description of each type of corrosion is given

below.
General corrosion
General corrosion is the most common type of corro-
sion. This results in even attack across all or large parts
of the surface.
In seawater, mild steel and bronze are subject to gen-

eral corrosion, but not stainless steel. In stationary
seawater, the corrosion rate of mild steel is about 0.1
mm/year (0.3 mm/year at the waterline) unless the
steel is protected by cathodic protection. Bronze is ini-
tially attacked at a rate of 0.05 mm/year, but after some
time the corrosion rate falls to a low level, since the
corrosion products (black, brown) have a protective
effect. Green/blue corrosion products are a sign of
higher corrosion rates and that the protective layer has
p0011418
not been developed.
Aluminum can be subject to a certain amount of gen-

eral corrosion in rapidly flowing water, but not in sta-
tionary water.
32 47705785 05-2014 © AB VOLVO PENTA

Pitting corrosion
Pitting corrosion can occur on stainless steel and alu-
minum. The attack is caused by localized breakdown
of the passive oxide film on the metal surface. In nat-
ural water, it is generally chloride ions that initiate the
attack. The risk increases with rising water tempera-
tures. There is a number of aluminum alloys with very
good resistance to corrosion by seawater. If these are
connected together with more noble metals, they will
be attacked due to galvanic corrosion, however.
Very high levels of chromium and molybdenum are

required, above all, to make stainless steel fully resist-
p0011419
ant to the risk of pitting corrosion. If there is weak
cathodic protection (sacrificial anodes), excellent pro-
tection against pitting corrosion can be obtained on
simpler steels. Alloys of lower grades than 316 should
be avoided, however.
Crevice corrosion
An attack in the gap between two metal surfaces, or
between one metal surface and another materials is
called crevice corrosion. A so-called oxygen depletion
cell is formed when oxygen transport into the crevice
is lower than oxygen transport out to the cell opening.
Separate anodic and cathodic surfaces are formed.
The cathodic process, which requires access to oxy-

gen, is formed in the gap opening and the anodic proc-
ess, metal dissolving, takes place inside the gap. Crev-
ice corrosion can occur on most metals, but the risk is
greatest on metals that can be passivated, such as
aluminum and stainless steel.
p0011420 Deposit corrosion is closely related to crevice corro-

sion. It takes place under deposits and marine fouling
such as barnacles.
47705785 05-2014 © AB VOLVO PENTA 33

Galvanic corrosion
Metals From To Galvanic corrosion is probably the most common
Graphite +0,19 +0.25V type of corrosion. It occurs when two metals of dif-
ferent nobility are in electric contact and are sub-
Stainless steel 18‑8, Mo, ±0,00 -0.10 V
merged in the same body of water at the same time.
in passive state *
The least noble metal is corroded.
Stainless steel 18‑8 in ‑0,05 -0.10 V
passive state *
Information about the nobility of different metals is
Nickel ‑0,10 -0.20 V obtained from galvanic potential tables which have
Nickel-aluminum-bronze -0,13 -0.22 V been prepared in various fluids, such as seawater.
Lead ‑0,19 -0.25 V See table to the left:
Silicon bronze (Cu, Zn, Si, ‑0,26 -0.29 V There are four factors which influence the serious-
Mn, Sn) ness of galvanic corrosion in each individual case.
Manganese bronze (Cu, ‑0,27 -0.34 V These are:
Zn, Si, Mn, Sn)
- Area relationship between the anode (less
Aluminum brass (Cu, Zn, ‑0,28 -0.36 V noble metal) and the cathode (more noble
Al) metal). If the anode is small in relation to the
Solder (Pb, Sn) ‑0,28 -0.37 V cathode, the depth of attack will be greater than
Copper ‑0,30 -0.57 V if the situation was reversed.
Tin ‑0,31 -0.33 V - Conductivity of the water. Seawater conducts
Red brass (Cu, Zn) ‑0,30 -0.40 V electricity better than fresh water, and corrosion
takes place at a greater rate.
Yellow brass (Cu, Zn) ‑0,30 -0.40 V
Aluminum bronze ‑0,31 -0.42 V - Potential difference between the two metals. A
large potential difference increases the power
Stainless steel 18‑8, Mo, ‑0,43 -0.54 V
behind the process.
in active state **
Stainless steel 18‑8 in ‑0,46 -0.58 V - Lower corrosion rate can be obtained if the
active state ** more noble metal can be passivated. This
means that stainless steel is more noble than
Cast iron ‑0,60 -0.71 V copper, but the galvanic corrosion will be more
Steel ‑0,60 -0.71 V severe on aluminum when connected to copper
Aluminum alloy ‑0,76 -1.00 V than when connected to stainless steel.
Galvanized iron and steel ‑0,98 -1.03 V
Zinc ‑0,98 -1.03 V In seawater, total galvanic corrosion counted in
grammes of metal, will be greater than in water which
Magnesium and magne- ‑1,60 -1.63 V
is not so salt. The greatest depth of corrosion on a
sium alloy consumed
metal can be equally large in brackish or fresh water.
The better conductivity of seawater means that the
* Metals are in a passive state when they have a thin, attack will be distributed evenly across the entire sur-
corrosion inhibiting coating. 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.
34 47705785 05-2014 © AB VOLVO PENTA

1 The following should be considered, to counteract

galvanic corrosion:
- Do not connect metals which are far away from
each other in the galvanic potential table.
- Insulate different metals from each other by
cathode anode using plastic or rubber (must not contain graph-
ite).
2 - Paint the structure. The surface of both metals
should be painted. If painting is restricted to only
the less noble metal, heavy galvanic corrosion
could occur on surfaces where there is paint
damage. The reason for this is that the cathode/
anode relationship will be unfavorable.
cathode anode - Install cathodic protection.
P0011421
1 Seawater
2 Fresh water
Stray current corrosion

1200 As we learned in the corrosion theory chapter, corro-
1000 sion occurs when a DC current flows into the water
from a metal surface. Similar stray currents from the
cm3/Ampere
800
drive can occur if there is a fault in the boat’s electrical
600 system, such as if couplings are exposed to dirt and
400 moisture, components are incorrectly installed or dam-
aged. Stray currents can come from shore current
200
installations or adjacent boats. All metals, except a few
0 noble metals, are corroded by stray currents. Corro-
CU AC
FE DC
FE AC
AL DC
CU DC
AL AC
sion rates can be very high.
The sacrificial anodes on the drive are not dimen-

P0011422
sioned to counteract any stray currents. If stray cur-
rents occur, the anodes will be consumed very quickly
and the drive will be attacked.
Aluminum is particularly vulnerable to stray currents. If

the current density on the surface is high, corrosion can
also occur when there is a stray inwards current. AC
currents can also cause damage. 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.
47705785 05-2014 © AB VOLVO PENTA 35

Corrosion protection
Drives are protected from corrosion by a number of
measures.
- Alloys which are resistant to salt water.
- Avoidance of unsuitable combinations of metals.
Where appropriate, a favorable relationship
between anode and cathode is established.
- High quality surface treatment.
- Cathodic 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.
Cathodic protection is arranged by supplying a weak

DC current from an anode to the protected object. The
current which leaks in counteracts the corrosion cur-
rent. The higher the protection current, the lower is the
rate of corrosion.
Zn
P0011424
The current required for protection can be generated

in two ways. These are either with sacrificial anodes or
by applying a current. If sacrificial anodes are used, the
current is generated by connecting the protected
object with a less noble metal (anode). The difference
in electric potential creates a protective galvanic cur-
rent. It can be said that corrosion is transferred to the
Zn anode, which is why they are referred to as sacrificial
anodes.
P0011425
36 47705785 05-2014 © AB VOLVO PENTA

If a current is applied, this is supplied from an external

source (rectifier, battery).
The materials used in sacrificial anodes are zinc, alu-

minum, magnesium and iron. Please note that special
alloys are used, to meet the following requirements:
- No passivation, i.e. they do not stop supplying cur-
rent.
- Even consumption.
- Low polarization tendency, i.e. they retain a suffi-
P0011426 cient potential difference to the object.
- Low self-corrosion.
Only use original anodes. Never paint over the anodes.
Iron anodes can be used to protect stainless steel and

bronze objects. Magnesium anodes can be used in
fresh water where the current supplied by zinc anodes
may not be enough in some cases. 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.
47705785 05-2014 © AB VOLVO PENTA 37

Definitions Protection against electrochemical

Single-pole system corrosion
In a single-pole system the actual engine block is In order to avoid galvanic corrosion to underwater
used as the negative ground return for all components components such as hull fittings, swim ladders etc., it
on the engine block. is important that they be protected. Volvo Penta rec-
ommends connecting all components to a protection
Two-pole system anode (normally made of zinc) installed on the
In a two-pole system each electrical component on transom. Trim tabs may have their own protection.
the engine has an insulated direct current ground NOTICE! Volvo Penta's recommended active protec-
return. The alternator, starter motor and all sensors/ tion against corrosion is the ACP system; read more
senders are electrically insulated from the engine in the ACP chapter.
block and are supplied without a braided ground strap
installed between the starter motor and engine block. NOTICE! Normally, the system connecting individual
The engine block is not connected to the battery neg- components must not have any contact with the neg-
ative terminal (-). ative circuit in the boat electrical system.
All IPS engines are two pole.
Local recommendations, e.g. ABYC, may state that
Isolation transformer the battery negative terminal be connected to the gal-
vanic circuit. If the galvanic circuit is connected to the
A transformer with galvanically separated input and
battery negative terminal (-), the engine block must
output windings.
also be connected by a cable of a capacity sufficient
The isolation transformer separates galvanic shore to conduct current at engine start; refer to the descrip-
power from the boat and reduces the risk for galvanic tion in ABYC chapter E-11.
corrosion and stray current corrosion as described in
IMPORTANT!
ABYC circuit diagram 8 and text E-11.7.2.2.1.4 thru
5. Corrosion damage caused by stray currents will not If there is a risk for galvanic corrosion and stray cur-
be compensated for under warranty. rent corrosion, an isolation transformer must be instal-
led.
Ground fault circuit interrupter (GFCI)
Volvo Penta IPS drive units are manufactured in a
A health and safety protection device, the GFCI cuts
nickel aluminum bronze alloy and are protected
the current to a circuit when current to ground
against corrosion by two anodes. One is installed in
exceeds a predetermined value.
the exhaust system (iron) and the other on the
Spark generation between live conductors and transom (aluminum). The drive unit has an underwa-
ground may occur at relatively low currents and will ter surface are that exceeds 1 m2 (10.8 ft2).
not trip circuit breakers. Moreover, very low currents
may also constitute a danger for personnel. A GFCI IMPORTANT!
must be installed on the other side of the isolation The anodes must not be painted over.
transformer as ground fault protection in the boat.
IMPORTANT!
GFCI tripping sensitivity and tripping times must meet
local standards. Do not connect Volvo Penta IPS units to each other.
A GFCI located on the other side of the isolation trans- IMPORTANT!

former safeguards ground fault protection in the boat. Do not connect the Volvo Penta IPS units to the
This is supplement to ABYC E-11 that ensures a engine or any other components on board.
higher level of protection against electric shock.
IMPORTANT!
Do not connect any other equipment to the Volvo
Penta IPS transom-mounted anode.
NOTICE! The above recommendations do not conflict

with ABYC E-11, in particular paragraphs 11.18.1 and
11.17.2.3.
IMPORTANT!
In steel and aluminum installations it is important to
ensure good insulation between the Volvo Penta IPS
unit and the hull. Volvo Penta disclaims responsibility
for any hull corrosion.
For advice regarding the prevention of dangerous sit-

uations as a result of electrostatic discharges or light-
38 47705785 05-2014 © AB VOLVO PENTA

ning, refer to the applicable literature published by

national and international standards organizations
such as the International Electrotechnical Commis-
sion and American Boat and Yacht Council.
Special publications IEC 60092-507:2000 Electrical

installation in ships Part 507: Pleasure craft, and ABYC
Standards and guidelines H-33 and E-4 may provide
guidance.
Painting a Volvo Penta IPS drive unit

A Volvo Penta recommends that the drive units be
B painted. This will reduce anode consumption as the
bronze surface exposed to water is reduced signifi-
cantly by external painting. In order for the paint to
adhere to the drive unit a suitable base coat is recom-
mended before anti-fouling paint is applied. Painting
drive units is also useful in areas with much marine
fouling.
IMPORTANT!
Do not paint in the groove (A) between the drive unit
and the hull (does not apply to metal boats where the
inside of the IPS hole is painted with antifouling paint).
IMPORTANT!
Do not paint the white plastic part (B).
P0006329
47705785 05-2014 © AB VOLVO PENTA 39

Shore supply and alternator installation

Example of an installation with isolation
transformer
For installation, refer to local regulations.
Single phase, 240 VAC system

16 15
21 19 17
24 23 22 20 18
14
5 6 7
4 8
1 2 3 9
11 12 13
10
P0004769
1 Phase
2 Zero
3 Protective ground
4 2-pole, 3-wire grounded contact and female socket
5 Shore side
6 Boatside
7 Transformer shield
8 Alternator circuit breaker
9 Alternator (accessory)
10 To DC negative buss and ground plate, boat
11 Phase
12 Zero
13 Protective ground
14 240 VAC ground, female socket
15 240 V AC apparatus
16 Separate circuit breaker (typical)
17 GFCI
18 Changeover switch, land / alternator
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
40 47705785 05-2014 © AB VOLVO PENTA

Two-phase, 120/240 VAC primary, 120/240 VAC secondary

18
19
27 26 25 24 23
22 21 20
17
6
5 7 8
9
1
2 34 10 12 13 14 15
P0004770 11 16
1 Phase
2 Zero
3 Phase
4 Protective ground
5 3-pole, grounded pin-type connector and 4-conductor socket
6 Shore side
7 Boatside
8 Transformer shield
9 Circuit breaker, alternator
10 Alternator (accessory)
11 To DC negative buss and ground plate, boat
12 Phase
13 Zero
14 Phase
15 Protective ground
16 240 VAC apparatus
17 120 VAC ground, female socket
18 120 VAC apparatus
19 Separate circuit breaker (typical)
20 GFCI
21 Changeover switch, land / alternator
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
47705785 05-2014 © AB VOLVO PENTA 41

Recommendations 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. Shore
Installations should be carried out according to figures
power ground protection must always be connected
above.
to the shore power connection box ground. Shore
Single phase, shows a single-phase installation for
power ground protection in the boat must be galvan-
240 VAC or 120 VAC.
ically separated.
Two-phase, shows an installation with a 240 VAC
input, 120/240 VAC output.
WARNING!
The figures are based on ABYC E-11 diagrams 8 and Work on the low voltage circuits in the boats should
11 but require a GFCI and an isolation transformer. be done by a person with electrical training or
The figures are considered to be best practice and knowledge. Installation or work on land current
follow recommendations from ABYC and ISO, and equipment must only be done by a competent
offer protection against electrochemical corrosion and electrician, in accordance with local regulations for
electric shock. mains electricity.
The safety-related components are important for the
following reasons:
Battery charging
Battery chargers directly connected to a shore con-
Isolation transformer nection must be of the type “Full Transformer” (gal-
Refer to Arrangement and Planning page 38 for fur- vanically separated windings) in order to reduce the
ther information. risk for galvanic corrosion and stray current corrosion.
GFCI
Refer to Arrangement and Planning page 38 for fur-
ther information.
Ground plate
A common ground plate below the waterline must be
connected to the AC/DC electrical system in order to
guarantee crew safety.
42 47705785 05-2014 © AB VOLVO PENTA

Prevention of stray current during

installation
Correct installation reduces the risk of stray current
throughout boat service life.
• All DC circuits must have an insulated ground
return.
• All joints in the system such as connectors, connec-
tor rails etc., must be installed such that they are not
exposed to moisture or bilge water. The same
applies to switches and fuse holders etc.
• Cables must be run as high as possible above bilge
water level. If a cable must be run such that it is
exposed to water, it must be run in a watertight
sheath, and the connectors must also be watertight.
• Cables that may be exposed to wear must be instal-
led in self-draining conduits, sheaths, cable chan-
nels or similar.
• For information regarding the installation of batteries
and main switches, refer to the
Installation page 110 and Alternator
connnections page 117 chapters.
• Engines and drivetrains may not be used as ground
connections for radio, navigation or other equipment
where separate ground cables are used.
• All separate ground cables (ground cables for radio,
navigation equipment, echo sounders etc.) must be
connected to a common grounding point, e.g. a
cable that in normal circumstances does not func-
tion as a ground return for the equipment.
• When shore power (120/230 V) is connected,
ground protection must not be connected to the
engine or any other grounding point in the boat. The
ground protection must always be connected to the
shore power connection box ground.
• Converters such as battery chargers connected to
shore power, must have ground protection con-
nected on the input side (120/230 V), but the nega-
tive connection on the output side (12/24 V) must
not be connected to ground protection without being
galvanically separated.
WARNING!
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.
47705785 05-2014 © AB VOLVO PENTA 43

Checking Protective Anodes

Volvo Penta IPS drive units are protected against gal-
vanic corrosion by two anodes. One is installed in the
exhaust system (iron) and the other on the transom
(aluminum).
IMPORTANT!
Make sure the anode has good metallic contact with
the drive unit. Never paint the protection anodes.
IMPORTANT!
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.
IMPORTANT!
The anode must be insulated from the hull if the latter
is made of conductive material such as aluminum or
steel.
P0006328
Propellers
The propellers are made of the same material as the
drive units and are electrically connected to them.
Paint the IPS propellers

Volvo Penta recommends the propellers to be painted.
This will reduce anode consumption as the bronze sur-
face exposed to water is reduced significantly by exter-
nal painting. In order for the paint to adhere to the pro-
pellers a suitable base coat is recommended before
antifouling paint is applied. Any high-speed marine
antifouling should be chosen, Prop-Speed recom-
mended.
44 47705785 05-2014 © AB VOLVO PENTA

ACP
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. If the batteries begin to discharge, the
ACP switches from primary to secondary protection.
The IPS is then protected by the consumption of a
sacrificial zinc anode installed in the ACP unit on the
transom.
When the primary protection is in use, a small quantity

of chlorine gas is produced by the ACP; if desired it can
be switched off temporarily. The ACP then switches
over to secondary protection.
The ACP reverts automatically to normal mode after 4
hours; earlier reversion can be arranged in the settings
menu (see below) or when ignition is switched on.
Boats equipped with ACP have a zinc anode integrated

into the ACP unit; see illustration.
When ACP is used, the regular anode protection must

not be installed on the transom.
P0008993
NOTICE! The anode (iron) in the exhaust pipe must
remain.
47705785 05-2014 © AB VOLVO PENTA 45

Checking electrochemical
corrosion
Tools:
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)(1) is con-

nected to 88890074 Multimeter. The multimeter is
used to measure the difference in potential.
p0005125 NOTICE! If another multimeter is used, it must have an

accuracy of 1 mV.
88890074 Multimeter
Depending on the method used, the results provide an
average voltage for the whole measured object, e.g. a
shaft, or the voltage an individual component produ-
ces.
Examples of such measuring points are rudders and

water inlets etc.
NOTICE! The reference electrode may be used in

water with varying salt levels, or in freshwater.
The process measures the difference in potential

between the measured object and the reference elec-
trode. The reference electrode has a known constant
electrode potential. Thus the measured difference in
potential is always related to a special reference elec-
trode and the same electrolyte, i.e. the same water and
water temperature. Water flow must always be the
same if the results from different measurements are to
be compared.
1. Ideally, do not combine the blue 885156 calomel electrode with

the amber 21504294 Ag/AgCl electrode. In such cases the 40 mV
must be added to the measured value from the Ag/AgCl electrode
when comparing with the calomel electrode.
46 47705785 05-2014 © AB VOLVO PENTA

Measurement theory
The protection anode works by emitting an electrical
current – protective current – in order to counteract
corrosion current. When the protective current
increases and corrosion current is reduced, the poten-
tial of the protected object is also reduced. When a
given potential is reached, the corrosion current dis-
appears and the object has complete cathodic protec-
tion.
Thus a given electrode potential for the metal serves

as a guide to when cathodic protection is active and
whether it is sufficient. The reference electrode is able
to measure whether the protective potential is provided
for.
Checking galvanic currents, reference

electrode, Volvo Penta IPS
Connect 21504294 Reference electrode to
88890074 Multimeter.
Connect the multimeter to a suitable screw in contact

with the drive unit. Set the multimeter for DC current
measurement.
Carefully remove the protective sleeve from the refer-

ence electrode. The protective sleeve is filled with a
saturated salt solution (NaCl). Clean the tip with a
clean paper napkin or similar before replacing after
measuring.
Dip the electrode in the water near the drive unit. The
result is an average value for the drive unit. The result
must be lower than -450 mV in seawater/brackish
water and -150 mV in freshwater.
If the result exceeds this (i.e. the value is closer to zero

than -350 mV and -50 mV respectively), the drive units
do not have sufficiently good cathodic protection. Dis-
connect the connection between the aluminum anode
and the drive unit.
If the potential only changes slightly, the aluminum

anode is either consumed, or has poor contact. Install
a new anode. The iron anode in the exhaust system is
not as critical. 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.
47705785 05-2014 © AB VOLVO PENTA 47

Measuring drive unit insulation

First check that no connections have been made to the
drive unit, i.e. that the drive unit has not been con-
nected to the boat's protective system. If this is the
case, the connections must be removed. Connect
measuring wires to unpainted parts that are in good
contact with the drive unit and engine block. Set the
multimeter for DC current measurement. Note the
value.
Then connect a 9 V battery between the drive unit and

the engine block. Remove the battery after around 10
seconds. 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.
48 47705785 05-2014 © AB VOLVO PENTA

Installation, Volvo Penta IPS
Installation
Volvo Penta IPS
Fiberglass Hull Constructions
General
About Volvo Penta's demands for hull
construction
Normal scantling rules (e.g., ISO 12215) focus on var-
iables such as propeller thrust, steering forces, mass
of machinery, etc.
The Volvo Penta IPS hull requirements focus on ensur-

ing an adequate structure to keep the hull intact in a
hard grounding where the drives are designed to shear
off under certain conditions. Extensive full scale testing
and calculations conducted by Volvo Penta show that
forces generated in an underwater collision or ground-
ing are more than 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. The strength of the hull structure is depend-
ant upon a number of factors including shape, fiber-
glass quality and strength, type and quality of resin,
lamination conditions, laminator skill, etc. The ultimate
responsibility to ensure that all Volvo Penta IPS hull
are produced consistently with these requirements
rests exclusively with the boat builder.
47705785 05-2014 © AB VOLVO PENTA 49

Lamination
Types of fiber glass

Fiber glass is available in many variations, orientations
and weights. There are also many types of resins avail-
able. The key to a well-functioning matrix is to choose
resin and fiberglass that are suited to one another.
Abbreviations
E E-glass
L Longitudinal (0°)
P0009095 T Transverse (90°)
LT 0°/90° biaxial
E-LTM BX +45°/-45° biaxial or double diagonal
A Chopped strand mat
Avoiding secondary bonding in the

lamination
Secondary bonding occurs when a new layer of fiber-
glass is added to a fiber glass layer that has already
cured. This secondary bonding becomes a weak link in
the hull. The new layer will not bond adequately if the
cured layer is not first sanded and washed clean from
contaminants.
Examples of when secondary bonding may occur

P0009094
The first half of the total number of layers is laid on a
Friday and left to cure over the weekend. There is a
E-BXM
heat wave over the weekend with higher temperatures.
Work continues on Monday with the remaining layers

added to those that have almost fully cured. If the
existing layer is not sanded and washed clean from
contaminants, secondary bonding will occur.
Core material
IMPORTANT!
The core material must have a density of 100 kg/m3
(6,2 lb/ft3) or more.
IMPORTANT!
The use of hull core materials in general use does not
deviate from instructions regarding Volvo Penta IPS
reinforcements.
50 47705785 05-2014 © AB VOLVO PENTA

Premolded Hull Inserts and Hull

Mold Plugs
Hull mold plugs (1) are recommended. Hull penetration
inserts (2) for finished molded hulls may be necessary
1 in some cases for technical production reasons. When
using hull molding plugs, refer to the Placement and
Mounting of Hull Plug, Twin Installation page 56
chapter. When using hull molding inserts, refer to the
Placement and Mounting of Hull Inserts page 52
chapter.
All necessary drawings regarding the location, calcu-

lation and design of inserts, reinforcements and engine
beds are supplied by Volvo Penta.
Use the installation posters included in the engine

2 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
47705785 05-2014 © AB VOLVO PENTA 51

Placement and Mounting of Hull

Inserts
Ready-molded hull inserts are used for prototype hulls,
one-off manufacture or engine change to IPS. These
inserts are not recommended for series production.
1 Begin by marking up the keel line as a clear ref-
erence line.
Engine positions
Engines and drive units must be parallel, regardless of
drive shaft length.
NOTICE! The engine axis must be straight in order to

minimize vibrations. Deviations may not exceed ±4°.
P0004600
52 47705785 05-2014 © AB VOLVO PENTA

2 Mark out a straight line parallel to the keel at a

distance of (A), which is governed by hull bottom
angle (α).
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
Bottom angle Distances
(α) (A) mm (in.)
5° 739 (29.1)
6° 747 (29.4)
7° 756 (29.8)
8° 765 (30.1)
9° 774 (30.5)
10° 784 (30.9)
11° 794 (31.3)
12° 804 (31.6)
13° 814 (32.1)
14° 825 (32.5)
15° 836 (32.9)
16° 847 (33.4)
17° 859 (33.8)
P0010870
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)
NOTICE! After installation, the distance between the

upper gear case center must be at least 1250 mm
(49.2"). However, short distances limit joystick func-
tionality.
3 The exhaust elbow must have at least 50 mm

(2") clearance (A) from the transom. At a height
A of 415 mm (16") (C) the distance to the transom
must be at least 820 mm (32.3").
Mark out a point on the line at a distance from the

transom that leaves sufficient space for the
exhaust elbow and drill a 6 mm (1/4") guide hole.
NOTICE! Bear in mind the location of reinforce-
P0012201 ments, bulkheads etc. It may be necessary to
increase the distance to the transom to provide
A Min. 50 mm (2") clearance for the exhaust elbow.
B 770 mm (30.3")
C 415 mm (16")
D Hole
47705785 05-2014 © AB VOLVO PENTA 53

4 Drill another guide hole for hull plug alignment as

illustrated, located 675 mm (26.6") further forward
on the line that runs parallel with the keel.
675mm
(26.6”)
P0015312
5 The pre-molded insert will fit in a cutout with a

diameter of: 1300 mm (51.2"). Attach a cord or
similar of length 650 mm (25.6") to the aft hole.
Attach a pen to the other end and mark out a cir-
cle.
6 Mirror the entire procedure on the opposite side
of the hull.
P0015311
7 Cut out the hull insert hole around the marked

circle.
54 47705785 05-2014 © AB VOLVO PENTA

8 Install temporary support beams from the outside

of the hull.
P0002348
1 9 Place the inserts in the cut-outs. Align them so

that the guide hole in the insert coincides with the
2 guide hole in the hull and the marking line.
Temporarily install the insert in the hull.
NOTICE! Check that the inserts are correctly

3 aligned with the hull.
5
4
6 7
p0011413
1 Transom
2 Guide hole in insert
3 Insert
4 Guide hole in hull
5 Guide hole in insert
6 Inside of hull
7 Marking line
Grinding
1 Grind down the joint where the inside of the hull meets
the insert to a 1:12 (approx. 5°) slope equivalent to
around half the hull thickness. Also grind the outside
of the hull joint and laminate it so that the transition is
smooth.
P0011587
2
1 Pre-molded hull insert

2 Hull
47705785 05-2014 © AB VOLVO PENTA 55


Plug, Twin Installation
NOTICE! The illustration shows a hull mold.
Mark out a straight line parallel to the keel at a distance

of (A), which depends on hull bottom angle (β).
In order to achieve the recommended CC-distance

between engines of 1400 mm (55.1"), the following
applies:
Distance (A) measured from the keel to the

plug centerline at varying bottom angles
(β) (A) mm (in.)
5° 739 (29.1)
6° 747 (29.4)
7° 756 (29.8)
8° 765 (30.1)
9° 774 (30.5)
A 10° 784 (30.9)
11° 794 (31.3)
12° 804 (31.6)
13° 814 (32.1)
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)
56 47705785 05-2014 © AB VOLVO PENTA

Mark out a line from the keel line parallel with the
transom. Distance (C) = 850 mm (33.5").
NOTICE! Bear in mind the location of reinforcements,

bulkheads etc. It may be necessary to increase the
C distance to the transom to provide clearance for the
exhaust elbow.
P0015314
The exhaust elbow must have at least 50 mm (2")

clearance (A) from the transom. At a height of 415
A mm (16") (C) the distance to the transom must be at
least 820 mm (32.3").
P0006126
A Min. 50 mm (2")
B 770 mm (30.2")
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") guide holes on the intersecting lines.
P0010559
47705785 05-2014 © AB VOLVO PENTA 57

Mirror the procedure

Mirror the procedure for the port side of the hull mold.
P0010560
Installing the protective template and hull

plugs
Drill out the guide holes to 20 mm (0.79"). Enlarge the
protective template holes by breaking away the inner
plastic parts (see illustration). Locate the protective
template above the hull plug and then bolt it to the
mold.
P0015313
P0010561
58 47705785 05-2014 © AB VOLVO PENTA


Plug, Triple Installation
Mark out a straight line parallel to the keel at a distance

of (A), which is governed by hull bottom angle (ß).
In order to achieve the recommended CC-distance

between engines of 1400 mm (55.1"), the following
applies:
Distance (A) from the keel to the plug cen-

A
terline at varying bottom angles
(β) (A) mm (in.)
5° 1442 (56.8)
p0006134
6° 1451 (57.1)
7° 1461 (57.5)
8° 1472 (58.0)
9° 1483 (58.4)
10° 1495 (58.8)
11° 1507 (59.3)
12° 1519 (59.8)
13° 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)
NOTE! After installation, the distance between the

tionality.
47705785 05-2014 © AB VOLVO PENTA 59

transom. Distance (C) = 850 mm (33.5")

exhaust elbow.
P0015314

least 820 mm (32.3").
P0006126
A Min. 50 mm (2")
B 770 mm (30.2")
C 415 mm (16")
D Marking

6 mm (0.24") pilot holes on the intersecting lines.
Mirror the procedure for the port side of the hull.
P0010559
60 47705785 05-2014 © AB VOLVO PENTA

Build and position a tunnel plug in the hull

Mark out the plug center line and drill holes.
Build the hull tunnel plug according to the installation

drawings. Mark out a centerline for the plug. Use the
template again to drill four holes in the tunnel plug.
P0010562
Installing the hull plugs and protective

template
mold.
P0015313
P0010563
47705785 05-2014 © AB VOLVO PENTA 61


Plug, Quad Installation
Mark out a straight line parallel to the keel at the dis-

tances (A and B), which are governed by hull bottom
angle.
B In order to achieve the recommended CC-distance

A between engines of 1400 mm (55.1"), the following
applies:
Distances (A and B) measured from the

keel to the plug centerline at varying bot-
P0006145 tom angles
Bottom angle Distances Distances
(β) (A) mm (in.) (B) mm (in.)
5° 739 (29.1) 2144 (84.4)
6° 747 (29.4) 2155 (84.8)
7° 756 (29.8) 2167 (85.3)
8° 765 (30.1) 2179 (85.8)
9° 774 (30.5) 2192 (86.3)
10° 784 (30.9) 2206 (86.8)
11° 794 (31.3) 2220 (87.4)
12° 804 (31.6) 2235 (88.0)
13° 814 (32.1) 2251 (88.6)
14° 825 (32.5) 2268 (89.3)
15° 836 (32.9) 2285 (90.0)
16° 847 (33.4) 2304 (90.7)
17° 859 (33.8) 2323 (91.5)
18° 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)
NOTICE! After installation, the distance between the

tionality.
62 47705785 05-2014 © AB VOLVO PENTA

transom. Distance (C) = 850 mm (33.5").

exhaust elbow.
P0015314

least 820 mm (32.3").
P0006126
A Min. 50 mm (2")
B 770 mm (30.2")
C 415 mm (16")
D Marking

6 mm (0.24") pilot holes on the intersecting lines.
P0010559
47705785 05-2014 © AB VOLVO PENTA 63

Mirror the procedure for the port side of the hull mold.
P0010564
Installing the protective template and hull

plugs
mold.
P0015313
P0011230
Laminating the hull

Special requirements zone
The hull must be reinforced in the area around the drive
unit holes according to the following requirements:
B
A 950 mm (37.40") (twin installation)
B 850 mm (33.46")
C 600 mm (23.62") along the transom
A
D at least 30 mm (1.2"), with a glass content of 45%
of which max. 20% CSM.
C
P0014274
64 47705785 05-2014 © AB VOLVO PENTA

NOTICE! The lamination specifications are independ-

ent of whether hull mold plugs or pre-molded hull
inserts are used. If hull inserts are used the insert
thickness is added to the above thickness require-
ments.
IMPORTANT!
Each layer of fiberglass matting must overlap its pred-
P0013987 D ecessor in the transition between the hull bottom and
the hole side walls.
Avoid secondary bonding (refer to Lamina-
tion page 50). It is unlikely that the full 30 mm (1.2")
thickness can be laminated in a single step. Contact
the resin supplier regarding time frames and sugges-
tions for intermediate lamination thicknesses in order
to avoid secondary bonding and excessive tempera-
tures.
Laminating the hull

1. Basic hull
Specifications regarding hull bottom (or equivalent)
laminations should also continue up onto the IPS plug.
This is achieved by alternately laying mats on the hull
bottom and around the plug as described below.
Laminate the hull bottom, stern and sides. Mats that
run along the hull must extend a little way up the sides
of the plugs. This can be achieved by snipping tabs in
the mats at the points where they extend up onto the
plugs.
P0013988
It is possible to wrap mats in the sections around the

plug in order to build up the laminate, while also over-
lapping against the hull bottom layer. Alternate with
mats that run all the way up the plugs and others that
wrap around it. Make sure that the edge of each layer
does not coincide with an edge from a previous layer.
NOTICE! Fiberglass mats with ±45° fiber directions,

i.e. E-BXM, will be easier to conform to the plugs' V
grooves than mats with 0/90° fiber directions, i.e. E-
LTM.
P0013989
47705785 05-2014 © AB VOLVO PENTA 65

2. Reinforced area
Laminate the thicker areas around the drive unit holes
when the basic hull thickness has been achieved. Lay
strips of matting from the top of the plug and out onto
the hull bottom. Lay each strip offset in a circular pat-
tern that continually builds up the laminate. Increase
the length of the matting strips by 50 mm (2") (A) per
layer to achieve the best bond with the hull. Also over-
lap in the transition between the plugs.
P0013991
C
P0014274
End result. Note that the illustration only shows half the hull.
66 47705785 05-2014 © AB VOLVO PENTA

Engine Foundation
Engine bed design
General
The engine beds must be horizontal athwartships.
IMPORTANT!
The engine axis must be straight in order to minimize
vibrations. It is extremely important that driveshaft
flanges be kept parallel. Deviations may not exceed
±4°.
C Build the engine bed up to the following dimensions:
A B
A Minimum 116 mm (4.6")
B 690 mm (27.2")
C 810 mm (31.9")
P0015334
Engines should have a clearance of at least 20 mm

(3/4"). Make sure to leave space for protruding parts.
A 335 mm (13.2")
B 336 mm (13.2")
P0013874 B
47705785 05-2014 © AB VOLVO PENTA 67

A Construction
2 Build up the bed until it touches the drilling jig along the
3
entire length of the stay.
B
Use a suitable core material and laminate according to
applicable standards (e.g. ISO 12215). Build a galvan-
ized iron strip into the laminate for the engine mounts.
1 Also build in drainage channels so that bilge water is
able to run down to the bilge pump.
1 Core material
2 Fiberglass
P0011754
3 Iron strip
A min. 80 mm (3.1")
B 10 mm (0.4")
1 Drain hole
If the drain hole (1) in the molded hull insert is blocked
2 with fiberglass it must be drilled out. Drill corresponding
1 holes if hull plugs have been used. Diameter: 15 mm
(0.6").
2 Also drill drain holes (2) at suitable points in the rein-
forcement beams. Diameter: 20 mm (0.8").
p0013976
68 47705785 05-2014 © AB VOLVO PENTA

Construction of reinforcing beams

General
Thickness requirements
1
Laminate all of the beams in the structure to a thick-
t ness of t =12 mm or t = 15 mm; refer to the description
for each stage for details.
2
The first mat laid should continue out at least 50 mm
(2") on either side of the beam. Overlap each new layer
by at least 50 mm (2").
Fill the edge (2) between the beam material (1) and the
hull with caulking to a radius of at least R 25 mm (1")
P0014398 B before laminating.
Note that the reinforcement beams around the hole
must be distributed evenly.
Construction
The first beams
The outer beam will be around X = 100 mm (3.9") wide
and Y = 250 mm (9.8") high (measured on the outside
of the hull). The outer beams must be laid on top of the
30 mm laminated area. The size of the engine bearers/
stringers is governed by the size and location of the
engine mounting feet; refer to the installation drawings.
t=12mm
t=12mm t=15mm
P0014275
t=12mm
Note: The figures show only half the hull for the sake of clarity.
Create the beams between the hole and the stern at

an angle of 30° up toward the stern.
47705785 05-2014 © AB VOLVO PENTA 69

t=12mm Thwartships beam

Make an athwartship beam that runs parallel with the
hull bottom angle and which is higher than the out-
board fore-and-aft beam (perpendicular height from
hull bottom angle approx. 305 mm (12")).
If the thwartships beam is moved forward (max. 300

mm (11.8")) it must still be laid on top of the 30 mm
(1.18") thick lamination layer. This means the require-
ment area will increase in size.
Make a recess/groove in the beam to make room for

the driveshaft between the engine and the drive unit.
Suggested size of the recess/groove:
P0014276
A: 415 mm (16.3")
r
r: 200 mm (7.8")
H
A
P0014010
t=15mm Reinforcement beams around the hole

Build a further 6 reinforcement beams spaced equidis-
tantly around the hole. The beams must be around 130
mm (5.1") wide and G = 185 mm (7.3") high measured
on the outside of the hull surface. Angle the beams up
toward the stern at 30°.
P0014277
P0014453
70 47705785 05-2014 © AB VOLVO PENTA

t=15mm Beams between the holes

Build two beams; one that runs from the transom to the
main athwartships rib, 100 mm (3.9") wide and 400 mm
(15.7") high measured on the outside of the hull and
the other to attach the IPS ring to the athwartships ribs,
130 mm (5.1") wide and 185 mm (7.3") high measured
from the outside of the hull surface.
End result
When all of the reinforcement beams are in place and
laminated the end result should appear as illustrated
below.
P0014278
P0014413
Twin installation
P0014525
Triple installation
P0014524
Quad installation
47705785 05-2014 © AB VOLVO PENTA 71

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.
72 47705785 05-2014 © AB VOLVO PENTA

Engine Foundation
Maximum Water Level
E
C B
A
CL
P0015329
Checking the water level in the design

study
Distance between the crankshaft centerline and the
engine top cover (E):718 mm (28.3"). The distances
specified below may not be exceeded regardless of
load conditions.
Distance to the water level from the crank-

shaft centerline (CL)
A (no riser) Max. 250 mm (9.84") (1)
B (riser) Max. 475 mm (18.7") (2)
1) A riser is required if the dimension is exceeded.
2) If this dimension is exceeded a special riser must be made.
NOTICE! Standard exhaust elbow to be installed with

min. C = 15°.
NOTICE! The riser should be installed at a 45° angle.
47705785 05-2014 © AB VOLVO PENTA 73

Checking water level after launch

NOTICE! Risk of water ingress. 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.
A B
CL
P0011336
Water level below engine top cover

A (no riser) Min. 468 mm (18.4") (1)
B (riser) Min. 243 mm (9.6") (2)
1) A riser is required if the dimension is not reached.
2) If this dimension is not reached a special riser must be
made.
74 47705785 05-2014 © AB VOLVO PENTA

Engine Foundation
Installing a drilling jig
Build up the engine bed until it fits along a drilling jig
attached to the hull plug/insert.
Refer to the Installation Tools and Documenta-

tion page 10 chapter for the tool number for each type
of installation.
Alternative 1: Hull plugs

Locate the drilling jig stay in the hull plug attachment
fittings and secure it with a pin.
P0013974
Alternative 2: Pre-molded hull inserts

Install the special tool by setting its counter piece inside
the insert and bolting it to the drilling jig plate. Make
very sure that the drilling jig is properly secured in the
insert.
P0015321
47705785 05-2014 © AB VOLVO PENTA 75

Holes for engine mounts

Fit the pins for the special tool in the forward and aft
engine mount holes for the engine model concerned.
Slide the drilling jig so that it is up against the pins. Drill
6 mm (1/4") pilot holes through the tool drill bushings
into the bed.
P0013975
1 Pin for aft engine mounts

2 Pin for forward engine mounts
3 Drill bushings
NOTICE! Drill through the holes that are marked with

the engine model concerned.
Undo the special tool retaining bolts. Use the T-bolt to

remove the special tool. Screw in the upper tool.
P0014284
76 47705785 05-2014 © AB VOLVO PENTA

Continue to screw until the lower tool protrudes. Be

prepared to catch the plug's lower part. Remove the
plug's upper part.
Drill and tap the engine mount holes with thread size
M16 (5/8" UNC).
P0014288
1 Drain hole
If the drain hole (1) in the molded hull insert is blocked
2 with fiberglass it must be drilled out. Drill corresponding
1 holes if hull plugs have been used. Diameter: 15 mm
(0.6").
2 Also drill drain holes (2) at suitable points in the rein-
forcement beams. Diameter: 20 mm (0.8").
p0013976
47705785 05-2014 © AB VOLVO PENTA 77

Propulsion Unit Installation
Propulsion Unit
IMPORTANT!
The emergency steering tool kit must be delivered with
the boat.
Checking chassis ID
It is important to check that the power steering unit
(SUS) chassis ID (1) and engine chassis ID (2) are
1 identical. The engine chassis ID is located on the
engine cover, and the SUS chassis number is on a
decal on the outside of the packaging and on the top
of the SUS.
NOTICE! Do not assemble the equipment together if

1 2 the numbers do not correspond; the engine and power
steering will not work together.
P0004630
Installation
1 Dry off the upper rubber ring and apply lubricant
part # 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.
P0015336
78 47705785 05-2014 © AB VOLVO PENTA

Lifting the drive unit

Lift the drive unit into the hull with the aid of a fork lift
or hoist.
Alternative 1: Lifting using a block and tackle
2 Dry off the lower rubber ring and apply lubricant

part # 3817243. Position the rubber ring on the
drive unit drive leg.
3 Fit 21110860 Lifting tool to the drive unit.
P0010520
4 Connect the lifting device through the hull to the

lifting eye in the tool that best positions the drive
unit at an angle suitable for the hull design.
5 Lift the drive unit until it is up against the hull.
Maximum lifting force: 20 000 N (4400 lbf).
P0010521
47705785 05-2014 © AB VOLVO PENTA 79

Alternative 2: Lifting by fork lift
6 Connect 3849664 Lifting tool to a fork lift accord-

ing to the tool instructions. Fit the drive unit into
the tool.
7 Make sure the drive unit installation point in the
hull (H) is at least 1100 mm (44") above ground
level.
8 Dry off the lower rubber ring and apply lubricant
part # 3817243. Position the rubber ring on the
drive unit drive leg.
p0010522
9 Tilt the drive unit down and position it immediately

below the hull installation point.
10 Tilt the drive unit up to its installation angle and
lift it up slowly through the hull until it is in even
contact. Maximum lifting force: 20 000 N (4400
lbf).
P0015332
80 47705785 05-2014 © AB VOLVO PENTA

Installation
11 Before installation grease the bolts with Volvo
Penta waterproof grease, part # 828250. Distrib-
ute all of the 16 M14 bolts and tighten each bolt
in clockwise sequence three turns. Then tighten
the bolts to 110–120 Nm (81–89 lbf.ft) in the same
order.
P0015337
47705785 05-2014 © AB VOLVO PENTA 81

Propeller
NOTICE! Propeller appearance may vary between dif-
ferent propeller sizes owing to different suppliers.
Installation
Tools:
3863070 Allen key socket
3
4
P0001856
828250
P0010527
1 Clean and brush waterproof grease, Volvo Penta

part # 828250 (also available in tubes, 21347121)
onto both propeller shaft splines and threads.
2 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.
Tighten using special tool 3863070 Allen key
24-28 Nm socket.
Tightening torque: 24–28 Nm (17.7–20.7
lbf.ft).
3 Fit the forward propeller (3). Install the nut (4) and
tighten it by hand until it bottoms. Turn the nut so
that the holes coincide and insert the six bolts.
Tighten using special tool 3863070 Allen key
socket.
lbf.ft).
P0011228
82 47705785 05-2014 © AB VOLVO PENTA

4 Press on the propeller cone (5) by hand. Apply

Volvo Penta locking fluid 1161053 or Loctite 242
to the center bolt and tighten.
lbf.ft).
Loctite 242
24-28 Nm
P0011229
47705785 05-2014 © AB VOLVO PENTA 83

Engine Installation
General
Preparing the engine
NOTICE! Before the engine is installed, installation of
fuel, steering and electrical systems must be as com-
plete as possible.
IMPORTANT!
Always use all lifting lugs when lifting the engine.
Fit auxiliary equipment and accessories such as aux-

iliary alternator, hot water take-off, power take-off etc.
to the engine before it is installed.
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 cocks, etc. are closed.
Fill oil and coolant. Carry out a leakage check.
P0013875a
Engine Mountings
H Check that the engine beds are level before installing
according to the description in the appropriate instal-
V lation manual. The engine should be placed in the boat
and adjusted maintaining an even pressure on the
engine cushions. Carry out a check measurement of
cushion compression after 12 hours.
Use no other type of engine cushions than those devel-

oped especially for the engine type to be installed.
Adjust the height using the adjuster nut (1).

A NOTICE! The maximum height of 125 mm (4.9") may
V not be exceeded
P0015318
A = Nominal height (without spacer): 117 ±10 mm (4.5 ±0.4")

V = Lateral adjustment ±7 mm (0.28")
84 47705785 05-2014 © AB VOLVO PENTA

Check the distances B1 and B2. The difference may

not exceed 3 mm (0.12") at any mount.
B1 B2
P0014286
View from side
Also check dimensions C1 and C2 at the engine cush-

ion sides. The difference may not be greater than 1.5
mm (0.06").
Angle displacement between the engine bed plane and
the engine brackets is corrected by adjusting the bed
planes below the engine cushion feet.
C1 C2
P0015320
View from front or rear
NOTICE! Check that the rubber cushions are installed

such that they are not subject to any preload or side
forces once the engine is installed.
P0014296
47705785 05-2014 © AB VOLVO PENTA 85

The two forward mounts must be loaded equally, as

must the two aft mounts.
Measure engine mount compression (B) on each side.

The difference between port and starboard sides may
not exceed 1 mm (0.04").
B Compare lateral alignment between the forward and
aft engine mount pairs. Adjust as necessary.
Carry out alignment in relation to the drive unit. Tighten

the upper nut on each engine mount; use a counter-
hold on the underside. Check that the engine beds are
parallel; check engine mount loads.
After checking engine mount loads tighten the upper

nuts on all four engine mounts. Tightening torque,
adjuster nuts: 300 Nm (220 lbf.ft)
Tightening torque, engine bed bolts:
120 ±5Nm (88.5 ±4 Ibf.ft). This requires a flat base
P0014296 with integrated steel plates. Check with the boat
builder how the bed must be built up; also refer to
Maximum Water Level page 73.
Propulsion Unit
Connecting the drive shaft
1 Install the drive shaft coupling from the engine to
the drive unit by pulling it out and fitting the four
bolts and washers to the drive unit shaft.
2 Check the flange-to-flange drive shaft distance as
1 illustrated. The length of the shaft should be 370
±15 mm (15"±0.6). Adjust the engine as neces-
sary.
NOTICE! If a longer drive shaft must be used,

refer to General page 88.
IMPORTANT!
2 Check the direction of the two spline coupling
arrows (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!
3 Tighten the bolts to 70–80 Nm (52–60 lbf.ft).
P0015319
86 47705785 05-2014 © AB VOLVO PENTA

4 Install the drive shaft cover on the drive unit.

Tighten the eight cover bolts to 70–80 Nm (52–
60 lbf.ft).
P0013979
Oil cooler
1 Connect the drive unit oil lines to the oil cooler.
Tightening torque: 80 Nm (59 lbf.ft)
2 Clamp hoses at the rear engine mounting and fix
them using cable ties.
P0014299
47705785 05-2014 © AB VOLVO PENTA 87

Extension Shaft
General
It can be advantageous in some installations to move

the engine forward in the boat e.g. to keep the stern
deck level so that the boat can be used for fishing, etc.,
or to move the CoG forward. To achieve this a jack-
shaft may be used between the sterndrive and the
engine.
When the jackshaft is installed, the boat must be on

dry land with the engine and drive unit in position.
IMPORTANT!
The engine and drive unit must be installed parallel
with the keel.
WARNING!
Working with or approaching a running engine is a
safety risk. Watch out for rotating components and hot
surfaces.
Stop the engine before work on the jackshaft is begun.

Do not run the engine with safety covers removed.
Installation
The driveshaft can be ordered in various lengths (A);

installed lengths as follows:
A
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")
P0004660
88 47705785 05-2014 © AB VOLVO PENTA

Safety cover
In addition to the drive shaft cover installed on the drive
unit, it is advisable to install a safety cover on the
remaining section of the jackshaft.
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.
P0010909
Harnesses and hoses

Electrical supply harnesses engine–SUS and oil
hoses from the oil cooler to the transmission are
included in the jackshaft installation kit.
NOTICE! Make sure that the oil hoses are installed

correctly; refer to Oil cooler page 87.
Exhaust hoses are available in standard sizes and

must be ordered separately according to drive shaft
length.
Exhaust hose diameter: 125 mm (5")
Installation instructions
P0006211
For further information, refer to the installation instruc-
tions included in the jackshaft kit.
47705785 05-2014 © AB VOLVO PENTA 89

Exhaust System
Exhaust Outlet
1 Clean the mating surfaces on the gear case and
exhaust outlet.
2 Install the exhaust outlet using eight bolts. Use
grease to secure the O-ring in place. Tighten to
70–80 Nm (52–60 lbf.ft).
3 Install the exhaust elbow with a new O-ring. Insert
the six bolts and screw them in a few turns.
P0007473
IMPORTANT!
Check that no steel spirals protrude from the hose.
4 Determine exhaust hose length: measure the dis-

tance between the exhaust elbow and the engine
exhaust pipe. Add 200 mm (7.87") for end over-
laps.
5 Use the hose clamp to mark around the entire
circumference of the hose. Saw off the hose and
clip off the steel spirals.
P0007513
90 47705785 05-2014 © AB VOLVO PENTA

6 Slide the exhaust hose onto the exhaust elbow so

that it overlaps by 100 mm (3.94") and fasten with
two hose clamps.
Slide the other end of the hose onto the engine
exhaust pipe so that it overlaps by 100 mm (3.94")
and fasten with two hose clamps.
Tighten the four clamps to 15–20 Nm (11–15
lbf.ft).
7 Tighten the exhaust elbow bolts to 48–52 Nm
(35–38 lbf.ft).
P0010526
8 Make sure the exhaust hose does not sag. When

installing a longer drive shaft, support the hose as
Min.45 necessary.
Min.15
P0014300
The exhaust elbow must be inclined by at least 45%. The riser must be inclined at least
15%.
IMPORTANT!
Y Minimum distance (Y) between exhaust elbow and
inside of transom: 50 mm (2").
P0006190
47705785 05-2014 © AB VOLVO PENTA 91

Cooling System
General
Only coolant specified by Volvo Penta may be used;
refer to the owner's manual. Coolant type affects
engine cooling performance and its corrosion protec-
tion.
ant
Cool
92 47705785 05-2014 © AB VOLVO PENTA

Raw Water System

Water circulation from the seawater system cools:
• engine coolant
• exhaust
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
The seawater inlet is included in the IPS system deliv-
ery. In the case of steel hulls, the same material the
boat is made from may be used. If the materials in the
hull and seawater inlet are dissimilar, it may be nec-
essary to electrically insulate the inlet from the hull to
avoid galvanic corrosion.
A The seawater inlets, sea cocks and strainers must
have sufficiently high flows to avoid capacity losses
and a consequent reduction in water supply to the
pump. The pressure differential at the seawater pump
inlet may not exceed 30 kPa (4.35 psi).
The seawater inlet must fit a hose with an internal

diameter of 63 mm (2.5"). The strainer must have a
flow area of at least 32.5 cm2 (5.04 sq.in).
B Seawater inlets must be located deep enough so that

they remain underwater even when the boat rolls or
P0008187 moves through heavy seas.
IMPORTANT!
Seawater inlets must therefore be installed forward of
the engines, close to the keel. Avoid locating the
intakes in line with the propellers.
Install the inlets with their openings (strainers) facing

forward.
Brush a suitable sealant, e.g. silicone rubber, on the

sealing surfaces. Tighten the inlet using the nut (2).
3
4 Install the sea cock and hose union (3). Use a non-
hardening sealant.
2 IMPORTANT!
Always use two hose clamps on all hose unions in the
1 seawater system. Align the hose clamp screws (4) as
illustrated.
The seawater line must have gradual bends to avoid

P0008188 unnecessary stresses and flow restrictions. Use rein-
forced rubber hose that can withstand negative pres-
1 Strainer sure.
2 Nut
3 Hose union and sea cock
4 Hose clamps
47705785 05-2014 © AB VOLVO PENTA 93

IMPORTANT!
The hose between the seawater filter and the engine
must not be under tension; a certain flexibility must be
allowed. If the hose passes through a bulkhead or sim-
ilar it must be protected against chafing.
Seawater filter
During operations in shallow areas and harbors, etc. it
is impossible to prevent particles, sludge and sand
from entering the seawater inlet. These contaminants
can be caught by filters in the suction line. A seawater
filter contributes to longer pump service life and also
prevents engine damage that may occur due to insuf-
ficient cooling in the charge air cooler or heat
exchanger.
The seawater filter must be installed in an accessible

location forward of the engine at least 200 mm (8”)
above the water line of a laden boat, e.g. on an easily
accessible bulkhead.
Seacock inlet diameter:

63 mm (2½")
Seawater pump outlet diameter:

63 mm (2½")
A Clearance for removal of filter cartridge (A):

300 mm (1 ft)
Seawater pump pipe union, diameter:

63 mm (2½")
P0012202
60,0 The graph shows the capacity of a standard filter. If the

Pressuer drop (kPa)
50,0
water is heavily contaminated it may be necessary to
install a filter with extra large capacity. The graph for a
40,0 filter with greater capacity must be the same as or
30,0
beneath the standard graph.
20,0
10,0
0,0
0 100 200 300 400 500 600 700 800 900 1000
Flow (l/min)
P0014023
94 47705785 05-2014 © AB VOLVO PENTA

Freshwater System
General Mixture ratio

Freshwater circulates through the engine cooling
ducts and heat exchanger with the aid of a centrifugal WARNING!
pump. All coolant is hazardous and harmful to the
environment. Do not consume. Coolant is flammable.
As long as the coolant is cold the thermostat is closed,
which prevents the coolant from passing through the NOTICE!
heat exchanger. The coolant passes instead through
a bypass line back to the suction side of the pump. IMPORTANT!
This means the engine quickly reaches its working The coolant must be mixed with clean water. Use
temperature. The thermostat also controls correct distilled/deionized water. The water must fulfill
temperature under low power and loads. requirements specified by Volvo Penta; refer to Water
Quality.
Coolant IMPORTANT!
We recommend “Volvo Penta Coolant VCS”, ready It is extremely important that the system be filled with
mixed (yellow) or “Volvo Penta Coolant VCS”, con- the correct coolant concentration. Mix the liquids in a
centrate (yellow) mixed with clean water according to separate, clean container before filling the cooling
specifications; refer to Water quality. Only coolant of system. Check that the liquids mix properly.
this grade is suitable and approved by Volvo Penta.
IMPORTANT!
Coolant must be used all year round. This is in order
to ensure that the engine has the proper corrosion
protection even though there may never be any risk
of freezing. Future warranty claims related to the
engine and accessories may be declined if the wrong
coolant has been used, or if the instructions for cool-
ant mixture have not been followed.
”Volvo Penta Coolant VCS, concentrated” is a con-

centrated coolant that must be mixed with water. It
has been developed to function optimally in Volvo
Penta engines and it provides excellent protection
against corrosion, cavitation and freeze damage.
”Volvo Penta Coolant VCS, ready mixed” is a ready

mixed coolant comprising 40% ”Volvo Penta coolant”
and 60% water. This concentration protects the
engine from corrosion, cavitation damage and the risk
of freezing down to -28 °C (18 °F).
47705785 05-2014 © AB VOLVO PENTA 95

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").
Install the auxiliary hot water circuit so that its highest

point is at least 50 mm (2") (A) lower than the fluid
level in the expansion tank. If this is not possible, a
separate expansion tank must be installed. Refer to
the next section.
P0013879
Shut-off cocks
Volvo Penta recommends that shut-off valves are
installed on both the inlet and outlet sides of the auxil-
iary circuit. Locate the taps as close to the engine as
possible.
96 47705785 05-2014 © AB VOLVO PENTA

Extra expansion tank

The engine's fresh water system, including the heat
1 4 exchanger, contains 48 liter (12.68 US gal). An exter-
nal circuit may increase this volume by up to 15 liter
(3.96 US gal) without the need for an auxiliary expan-
3 sion tank.
A
If the volume is expanded further, or if an additional
circuit is located above the engine, the cooling system
must be equipped with a larger auxiliary expansion
tank. Hot water circuits and cabin heating are two
examples of auxiliary circuits.
The auxiliary expansion tank must be located so that

it is easily accessible for level checks and filling.
The venting hoses (1) may not be run below their

respective engine connection points.
Height (A) Type of pressure cap

m ft kPa (psi)
– 2,0 (– 6.5) 75 (10.9)
2 2,0 – 5,0 ((6.5 – 16.5) 50 (7.3)
5,0 – 7,0 (16.5 – 23.0) 30 (4.4)
7,0 – 10,0 (23.0 – 33.0) Open system
P0015338
1 Vent hose
2 Hot water heater
3 Min. coolant level
4 Pressure cap
A Min. marking height above the valve cover or above the exter-
nal circuit's highest point.
3 Expansion tank volume must be 15% of cooling system

total capacity.
1 Of this volume:
MAX 5% is intended for coolant expansion when it is hot

(expansion volume) (1)
MIN 5% is intended for the difference between the MAX.

and MIN. levels
2 5% is reserve capacity (2)
The engine expansion tank must have a separate vent-

ing line to the auxiliary tank connected below the MIN.
level. The hose must withstand temperatures of up to
115 °C (240 °F).
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 vent-
ing when coolant is filled.
47705785 05-2014 © AB VOLVO PENTA 97

Venting the system

7 In most cases, as in the system illustrated, the system
is self-venting to the expansion tank. If an auxiliary
system does not vent normally to the expansion tank,
a separate venting nipple (4) must be installed at the
highest point for maximum venting.
H
4 1
P0013881
1 Cabin heater with defroster unit

2 Return water to engine
3 Outlet from engine
4 Venting nipple
5 Hot water heater
6 Hose warmer with pump
7 Expansion tank
H: Min. 50 mm (2")
98 47705785 05-2014 © AB VOLVO PENTA

Water Quality
ASTM D4985:
Total solid particles <340 ppm

Total hardness <9.5° dH
Chloride <40 ppm
Sulfate <100 ppm
pH value 5.5–9
Silica (as per ASTM D859) <20 mg SiO2/l
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, CODMn (acc. <15 mg KMnO4/l
ISO8467)
47705785 05-2014 © AB VOLVO PENTA 99

Coolant Level, Checking and

Topping Up
Filling with coolant
NOTICE! Coolant must be filled when the engine is
stopped and cold.
Top up coolant to the correct level through the filler

opening on the expansion tank. Fill slowly at first,
around 10–15 l/min (2.5–4.0 US gal/min) so that dis-
placed air is given the opportunity to flow out through
the filler hole.
Cooling system volume without auxiliary circuits:

48 liter (12.7 US gal)
1 Fill the system until it is completely full, including
the expansion tank. The coolant level must be
about 50 mm (2") below the expansion tank pres-
sure cap sealing surface.
P0013904
2 Start the engine and let it run for about 1 h.
3 Stop the engine and let it cool.
4 Check the coolant level and top up as necessary.
External systems:
If external systems are connected to the engine cooling
system, the system valves must be open and system
units vented during filling. Special venting nipples may
be installed in the external circuits; this applies espe-
cially to systems located above the engine.
IMPORTANT!
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.
100 47705785 05-2014 © AB VOLVO PENTA

Installation, Fuel System
Fuel System
General
2 1 Fuel tank
3
2 Filler cap
A A 3 Vent line
4 Suction line
5 Inspection cover
8
6 Remotely operated fuel shut-off valve
5
6 7 Fuel level sensor
7
8 Return line
9 Bottom plug
A Nipple in installations with a rubber

hose
4
P0004674 9
The installation of fuel system components such as fuel tank, NOTICE! There may be local legislation that
taps, fuel pipes and auxiliary fuel filters etc., must be carried always sets aside engine manufacturer liter-
out very carefully in order to ensure sufficient fuel to the engine ature and recommendations.
and that the requirements for perfect sealing and fire safety
are met. In Europe, materials and installation of fixed
fuel systems must fulfill the requirements of
Plan the locations of the tanks carefully before starting work. ISO 10088. In the USA the installation must
Use quality taps to avoid leakage. A leaking fuel system fulfill the requirements of the ABYC and
always entails great risk of functional faults and fire. USCG.
Use first-class quality components. When working on the fuel system, it is impor-
tant to keep it clean and free from dirt.
Ideally, the taps must be installed on the outside of the engine
compartment, or be remotely operable.
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.
47705785 05-2014 © AB VOLVO PENTA 101

Fuel Tanks
If possible, the tanks must be located so that they are
on the same level as, or a little higher than, the engine.
If they are placed lower consideration must be given to
the maximum feed pump suction height of 1.5 m (4.9
ft). Note that the suction height must be measured from
the suction line lower opening, i.e. 25 mm (1") above
the tank bottom. More information about fuel lines and
suction heights can be found in the Fuel System,
Piping page 104 chapter.
If the tanks are located lower than the level permitted

by the feed pump suction height, fuel must first be
pumped up to a day tank using a hand pump or electric
pump. In this case, return fuel must be led back to the
day tank.
Twin tanks must be cross-connected at the base by a

pipe equipped with shut-off taps. The lower cross-con-
nection pipe must have an inner diameter of at least 25
mm (1") so that the tanks can be filled from one side of
the boat. It is acceptable to use alternative fuel tank
shapes if these are adapted to the installation geome-
try. Regardless of the shape chosen it is important to
design the tank such that there is a lower section from
P0004677 which water and sludge can be drained off.
WARNING!
Hot fuel can cause burns.
Return fuel may have a temperature of up to 100°C

(212 °F). If a plastic tank is used, check how heat
resistant the material is.
IMPORTANT!
All tanks must be equipped with at least one slosh baf-
fle per 150 l (37 US gal) volume. Check to see if there
are special restrictions regarding volumes and slosh
baffles.
P0004675
102 47705785 05-2014 © AB VOLVO PENTA

Filling and ventilation connections may not be located

on the sides of the tank.
The fuel tanks have connections for filling, ventilation,

suction lines, return lines and fuel level sensors and an
inspection hole with cover. The suction and return lines
must always be separated as illustrated.
A shut-off valve must be fitted to the suction line as

close to the tank as possible. The shut-off valve may
be remotely controlled by cable or similar. Some mar-
kets require electrically controlled shut-off valves.
Diesel engine return lines must be run back to the bot-

tom of the tank in order to prevent air entering when
the engine is stopped.
P0004676
Place the tank on a soft base. Do not mount the tank
on wooden blocks or other type of uneven base as this
may cause uneven loading with the attendant risk of
fatigue cracks in the tank.
Install the tank in the boat. Secure the tank with clamps
to prevent it from moving in heavy seas. The fuel tank
should be located by itself in a cool space in order to
avoid fuel being heated or spread to other parts of the
boat in the event of a leak.
In boats where space is limited, the tank may be

shaped in order to fit under the aft deck or similar
space.
The tank must be well ventilated. The tank ventilation

line (1) must have an inner diameter of 12 mm (1/2").
Run the hose with an upward bend inboard in the boat
in order to prevent water entry.
The deck filler (2) must be designed such that it

accepts hose connections of at least 50 mm (2.0")
diameter. The hose between the deck filler and the
tank must overlap the hose connections at both ends
by at least 75 mm (3.0") and be secured using two
hose clamps at each end. The hose clamps must be
made of corrosion free material.
No common ground conductor for the fuel tank, fuel

filler, etc. is normally required for diesel installations.
However, regional authorities may require this for all
boats.
P0004678
IMPORTANT!
1 Vent line
Install the filler and ventilation hoses so that no sags
2 Deck filler (gland) (3) are formed where fuel is able to collect.
3 Prohibited sag
IMPORTANT!
The fuel filler and ventilation must be installed such that
overfilling is prevented and that fuel cannot enter the
air inlets.
47705785 05-2014 © AB VOLVO PENTA 103

Piping
Fuel System, Piping

Install tanks and clamp lines securely close to the bot-
tom of the boat to avoid heat radiation.
Distance between pipe and fuel tank as illustrated:
A 25 mm (1")
B 300 mm (12")
C 10 mm (0.4")
IMPORTANT!
Pipes should be of material that is corrosion resistant
in a marine environment. Avoid copper pipes between
the tank and the engine. Use two hose clamps.
A C
P0013918
Rubber hoses
The illustration shows the most common type of fuel
line connections. Check that correctly sized approved
hoses are used.
Refer to the table below for required minimum internal

rubber hose diameter.
Diameter, feed line 10 mm (3/8")

Diameter, return line 7 mm (0.275")
P0010574
Max. suction height 1.5 m (4.9 ft.)
If the tank is installed lower than the engine the dis-

tance between the engine valve cover and the tank's
lowest fuel level may not be greater than 2 m (6.6 ft).
If the tank is installed higher than the engine the dis-
tance between the engine valve cover and the tank's
highest fuel level may not be greater than 1.5 m (4.9
ft).
NOTICE! Some classification societies and other

authorities do not allow rubber hoses as fuel lines, or
require such hoses to meet certain specifications.
Check to see if the boat will be used in such areas.
Fasten the fuel lines using clamps. Distance between

clamps: approx. 300 mm (12").
104 47705785 05-2014 © AB VOLVO PENTA

Stainless steel pipes

The illustration shows the transition from flexible fuel
hose (1) to a pipe (2).
2
1
1
A C
P0013919
Refer to the table below for required minimum external

pipe diameter.
Line length <6 m (19.7 ft.) >6 m (19.7 ft.)

Diameter, 10 mm (3/8") 12 mm (1/2")
feed line
Diameter, 7 mm (3/8") 7 mm (3/8")
return line
Max. suction height 2 m* (6.56 ft.) 2 m* (6.56 ft.)
P0015359
* from the top of the engine (valve cover)
47705785 05-2014 © AB VOLVO PENTA 105

Fuel pressure
Fuel Feed Pressure, Check

Low feed pressure may be the result of a blocked fuel
filter, an underdimensioned system, a defective over-
flow valve or a defective feed pump.
IMPORTANT!
The overflow valve may not be adjusted. Replace the
valve if necessary.
Connect 9998494 Hose and 9998339 Manometer to

the venting nipple (1) at the front of the top of the
engine.
Increase engine speed and then reduce it. Read off

when the engine is idling. The feed pressure must be
at least 100 kPa (14.5 psi).
P0011415
106 47705785 05-2014 © AB VOLVO PENTA

Fuel pre-filter
The filter must be installed on the feed pump suction
side, between the feed pump and the fuel tank. It must
be placed vertically between the fuel tank bottom and
the feed pump in order to reduce resistance in the feed
line.
Install the filter vertically on a bulkhead or bracket

where it is not affected by engine revolutions and such
that it is as protected as possible from an engine com-
partment fire. The location must also facilitate inspec-
tions and filter insert changes.
Due to the system design, the fuel flow is slightly higher

than the consumption of the engine. Select a fuel pre-
filter capable of a fuel flow of minimum 200 liters/
hour.
NOTICE! Separate fuel filters for each engine is

required.
NOTICE! Depending on filter type, free space above

the filter of 130–260 mm (5–10") is required for filter
insert changes.
NOTICE! Fuel pre-filters with glass bowls may not be

installed in boats that are to be CE marked.
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.
47705785 05-2014 © AB VOLVO PENTA 107

Installation, Lubrication System
Lubrication System
Draining the Engine
Engine oil may cause harm to the environment. Be
sure to collect drained oil.
Oil drain pump

An electrical oil drain pump is available as an acces-
sory. The pump is installed in a suitable location using
a bracket. Pump direction may be changed by switch-
ing polarity.
Oil hoses
Oil hoses should have a shut-off tap or only be con-
nected at oil changes in order to avoid the risk of inad-
vertent drainage.
P0010246
108 47705785 05-2014 © AB VOLVO PENTA

Installation, Electrical System
Electrical System
General
The electrical installation must be planned very care-
fully and installed with the greatest of care. Strive for
simplicity when designing the electrical system.
Cables and connectors used in the installation must be

approved for marine use. The cables must be run in
conduits and securely fastened.
IMPORTANT!
Cables between engine and boat must be clamped
both on the engine and in the boat so that they are not
damaged by vibrations.
Be careful not to run cables too close to engine hot

spots or close to other heat sources. The cables must
not be subjected to mechanical wear. Where neces-
sary, run cables through conduits.
Strive to minimize the number of joints in the system.

Make sure that the cables and particularly the joints are
accessible for inspection and repair.
There must be a circuit diagram in the boat covering

the entire system. This will considerably simplify fault
tracing and the installation of further equipment.
IMPORTANT!
Make sure that all components used are suitable for
marine environments. Take care to ensure that no
joints in the engine compartment are located far down.
IMPORTANT!
Supply cables – batteries, alternators, distributors,
starter motors and heavy loads must be installed sep-
arately from the 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.
Two-pole electrical system

IPS engines have two-pole electrical systems with
insulated ground returns. In a two-pole system each
electrical component on the engine has an insulated
direct current ground return.
IMPORTANT!
Do not ground any cables to the engine block.
Power supply
IMPORTANT!
Large power consumers such as capstans and similar
must be connected to a separate auxiliary battery and
not to the start batteries.
47705785 05-2014 © AB VOLVO PENTA 109

Batteries
Battery terminology
Capacity
Capacity is measured in ampere hours (Ah). Start bat-
tery capacity (Ah) is normally specified as the battery
20-hour capacity, i.e. the battery will be discharged by
a constant current over 20 hours until it reaches a final
voltage of 1.75 V per cell. For example: If a battery is
able to produce 3 A over 20 hours, its capacity is 60
Ah.
The ampere value at cold start (CCA) measures bat-

tery start capacity. The SAE (Society of Automotive
Engineers) specifies the following test: A battery at a
temperature of -18 °C (0 °F) must be able to provide
current equivalent to the ampere value during a 30-
second cold start with a constant voltage level above
1.2 V per cell or 7.2 V for a 12 V battery. There are
other CCA tests defined by DIN, JIS, and ETN, etc.
These tests give other CCA values than the SAE test.
Battery capacity is influenced by temperature. Battery

capacity is specified at +20 °C (68 °F). Cold signifi-
cantly reduces a battery's ability to release energy. The
following table shows capacity differences at +20 °C
(68 °F) and -18 °C (0 °F).
Temperature +20 °C (68 °F) -18 °C (0 °F)

Capacity 100 % 50 %
70 % 35 %
40 % 25 %
If the boat has several batteries, the following connec-

tion method must be used:
Series connection:
When two 12 V batteries are connected in series, boat
system voltage will be 24 V.
IMPORTANT!
Always check boat system voltage before connection.
Engines may be in 12 V or 24 V configurations.
The batteries must be identical in respect of:

• Type
• Voltage
• Capacity
• Age
IMPORTANT!
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.
110 47705785 05-2014 © AB VOLVO PENTA

Two batteries connected in series provide the same

capacity, but double the voltage. During charging,
each battery takes current from the charger. The total
battery voltage may not exceed the battery voltage
stated on the charger.
When two 12 V batteries are connected in series and

one of the batteries has a shorted cell, the voltage of
P0004708
the two batteries will be around 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.
Batteries, Installation
Install the batteries in a box with a tight-fitting lid. Ven-
tilate the box with 25 mm (1") hoses (1). The ventila-
tion hoses must lead to the outside of the boat in order
to release the flammable gas the batteries produce.
1 The batteries must be securely strapped down.
WARNING!
Risk of fire and explosion. Never allow an open flame
or electric sparks near the battery or batteries.
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
47705785 05-2014 © AB VOLVO PENTA 111

Starting Group Battery Capacity

The batteries below are recommended for start of
engines at the stated temperatures. The list applies to
both 12 V and 24 V applications.
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 IPS installations.
Lowest Min. battery capacity (SAE)

temperature
+5 °C (41 °F) 800 CCA and 115 Ah
-5 °C (23 °F) 900 CCA and 120 Ah
Main switch
A main switch must be installed on the positive side.
When the cables are run through bulkheads both the
positive and negative cables must be fitted with rubber
bushings. Locate the main switch on the outside of the
engine compartment, but as close to the engine as
possible in order to reduce cable length.
P0004714
Technical requirements, main switch

Nominal capacity
Normal volt- Continuous Under 5 sec. Under 5.5 Operating Standard Protection
age min. temperature, rating
max.
≤48 V 150 A 1 000 A 450 A +85 °C SAE marine IP 66
+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.
112 47705785 05-2014 © AB VOLVO PENTA

Charge distributor
Example
The charge distributor automatically charges two bat-
8 tery circuits, independently of each other. One circuit
4
is used to start the engine and the other circuit for other
5 electrical equipment.
This means that if the service battery is discharged the

6 engine will still be able to be started with the start bat-
tery.
3 1
1 Start battery
2 Service battery
3 Sensor cable
2
4 Consumer
7 5 Charge distributor
6 Battery changeover switch
P0015540
7 Start motor
8 Alternator
Cross-over Switch
The use of a battery changeover switch between the
service battery and the start battery is recommended.
3
1 Start battery
2 Service battery
- - 3 Battery changeover switch

+ +
1 2
4 Start motor
-
4
P0015381
47705785 05-2014 © AB VOLVO PENTA 113

Starting Battery Cable Area

Volvo Penta recommends cable cross-sections
according to the table below in order to provide suffi-
cient power from the battery to the starter motor.
NOTICE! The list applies to both 12 V and 24 V sys-

tems.
Measure the total cable length from the battery pos-

itive terminal (+) via the main switch to the starter motor
positive connection (+), and from the starter motor
3 negative connection (-) back to the battery negative
+ + - terminal (-).
1
- 2 Then select the recommended cable area according to
table below for both the negative cable (-) and the
positive cable (+).
Because the cable must absorb generated heat, the

P0015387
cross-sectional area must be no less than 50 mm²
1 Battery (0.076 in.2).
2 Start motor
3 Main switch
The total start battery cable length and cable cross section in temperature class 70 °C
(158 °F)
Total length of positive (+) and negative (-)
7,3 (24) 9,7 (32) 12,4 (41)
cables, max. length m (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.) 12 (0.47) 14 (0.55) 16 (0.63) 18 (0.71)
114 47705785 05-2014 © AB VOLVO PENTA

Battery Charging
IMPORTANT!
Always connect the battery charger directly to the bat-
tery positive (+) and negative (-) terminals.
For charge voltages and charging times, refer to the

battery manufacturer instructions.
When a battery charger is used in a 12 V system bat-

tery voltage increases to around 13.8–14.4 V. Charg-
ing at high speed with high gas generation may result
in the following:
• Battery service life is reduced
• Capacity is reduced
• There is a risk of shorting in the battery
P0002111
• There is an explosion risk
The following parameters govern charging time dura-
tion:
• How discharged the battery was at commencement
of charging
• Charger capacity (how much current a charger is
able to supply)
• Battery size (capacity in Ah)
• Battery temperature. A longer charging time is
required when a battery is cold. A battery is not able
to receive a high charge current at low tempera-
tures.
It is better to charge at 10 A for 5 hours than at 50 A

for 1 hour, even though the total charge is 50 Ah in both
cases. The battery may have difficulty in accepting a
high charge current.
WARNING!
Explosion hazard. Batteries contain and give off an
explosive gas which is highly flammable and explosive.
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.
47705785 05-2014 © AB VOLVO PENTA 115

Charge state
Charge state is the level to which the battery is
charged. This state can be measured either by meas-
uring the specific gravity of the battery acid in each cell,
or by measuring the voltage in each cell without a load.
The latter cannot be done on modern batteries as the
cell electrical connections are sealed and not accessi-
ble for measuring.
Measuring the voltage across the terminals provides

entirely incorrect information if one of the cells is defec-
tive. 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.
116 47705785 05-2014 © AB VOLVO PENTA

Alternator
Alternator connnections
S W B+ Battery positive (+)
B- Battery negative (-)
S Sensor cable
D
D Magnetization
W Rpm (not used)
B-
B+
P0004716
47705785 05-2014 © AB VOLVO PENTA 117

Voltage Supply
Terminal boxes for electricity supply are located on the
starboard side of the engine. Connect the positive and
negative cables and secure all the way to the SUS.
Attach the power cables using cable ties.
IMPORTANT!
Brush corrosion protection, part # 9510227 onto all
connections.
The negative cable (-) from the battery is connected to

the engine negative terminal (-) (white cable in illus-
tration).
The positive cable (+) from the battery is connected to

the engine positive terminal (+) (black cable in illustra-
tion).
P0013920
118 47705785 05-2014 © AB VOLVO PENTA

Connection
Connections to Starter Motor

Connection of battery cables, 2-pole
system to the junction box on the D13 for
supply to the SUS.
the negative terminal (-) on the box (white cable in
illustration).

the positive terminal (+) on the box (black cable in illus-
tration).
Tightening torque
Positive terminal (+): 16–20 Nm (11.8–14.8 lbf.ft)
Negative terminal (-): 22-26 Nm (16.2-19.2 lbf.ft)
p0014245
Connection of battery cables, 2-pole

system to the D11 starter motor for supply
to the SUS.
the starter motor negative terminal (-) (white cable in
illustration).

the starter motor positive terminal (+) (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)
P0018137
Refer to the Installation page 110 chapter for dimen-
sioning of start batteries and cables.
47705785 05-2014 © AB VOLVO PENTA 119

Standard installation
The start battery is connected via a main switch to the
starter motor. The cables between the alternator and
the starter motor are factory installed.
System with separate service battery

The batteries are connected via a charge distributor
between the alternator and the starter motor. When the
total cable length between the alternator and the start
battery is changed, the existing engine power cable
must be replaced with new cables with appropriate
cross-sectional areas. Connect the sensor cables from
the alternator to the service battery arrays.
1 Locate the red power cable, (a), 16 mm2 (6 AWG),
between the alternator and the starter motor.
Remove and insulate the cable at both ends.
Secure the ends with cable ties or similar to prevent
vibration damage.
2 Calculate the total length that will be required for the
new cables b, c and d. Determine the necessary
1 Start battery cross-sectional cable area with the aid of the table
below. Negative cable cross-sectional areas must
2 Service battery
be at least the same as the positive cables.
3 Sensor cable
3 Install a new (preferably red) power cable (b)
between the alternator and the charge distributor.
Also make new (preferably red) power cables (c
and d) between the charge distributor and the bat-
teries.
Total cable length and cable area from alternator to battery

Total length for cables b, 2.0 3.2 5.0 7.0 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 10 16 25 35 50 70 95 120

(AWG) (8) (6) (4) (2) (0) (00) (000) (0000)
120 47705785 05-2014 © AB VOLVO PENTA

Twin installation 24 V, two separate

service battery arrays
(Tolerant system in case of fault in one installation)
Recommended installation
• Separate start battery arrays for each engine (driv-
etrain).
• Connect the sensor cable from the alternators to the
service battery arrays.
• NOTICE! No equipment connected to start battery
array.
• Two separate service battery arrays.
Navigation equipment is connected to the port side
service battery.
NOTICE! Navigation equipment must not be con-
nected to the start battery array.
• Capstans and other large power consumers are
connected to the starboard side service battery (II).
This prevents voltage drop in equipment connected
to the port service battery, such as navigation instru-
ments.
NOTICE! Large power consumers must have a sep-
arate switch that is connected directly to the service
1 Alternator battery positive terminal (+).
2 Sensor cable • All other equipment such as lamps, fans, fridges
3 3-way charge distributor (not Volvo Penta accessory)
etc., (navigation equipment excepted) may be con-
nected to the port or starboard service battery.
5 Accessories (normal consumers), not navigation equipment Tolerant system in case of fault in one installation
6 Start battery
If a short circuit occurs in one of the drivetrains, this will
not affect the other drivetrain.
7 Service batteries I and II
8 Capstans etc. (major power consumers)
9 Starter motor
47705785 05-2014 © AB VOLVO PENTA 121

Twin installation 24 V, one separate

service battery array
(Tolerant system in case of fault in one installation)
Alternative installation
• Separate start battery arrays for each engine (driv-
etrain).
• Connect the sensor cable from the alternators to the
service battery arrays.
• One separate service battery array.
• All equipment, large power consumers and lamps,
fans, fridge etc. are connected to the service battery
array.
NOTICE! Large power consumers must have a sep-
arate switch that is connected directly to the service
battery positive terminal (+).
Certain sensitive navigation equipment may cease
to function temporarily if it is connected to the same
battery array as a large consumer.
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.
1 Alternator
2 Sensor cable
3 3-way charge distributor (not Volvo Penta accessory)
5 Accessories (normal consumers)
6 Start battery, port
7 Service battery
9 Starter motor
10 Start battery, starboard
11 Navigation equipment (24 V: max 7.5 A (180W))
122 47705785 05-2014 © AB VOLVO PENTA

Auxiliary alternator, 12 V or 24 V, twin

installations
Example
• Keep 12 V and 24 V systems separate.
• Connect the sensor cables to the correct voltage
group, 12 V or 24 V.
NOTICE! Large power consumers must have a sepa-

rate switch that is connected directly to the service bat-
tery positive terminal (+).
1 Alternator
2 Sensor cable
3 Accessories 12 V/24 V
5 Connect to start array, negative (-)
47705785 05-2014 © AB VOLVO PENTA 123

External accessories
P0004723
1 Ground cable junction box (-)

2 Fuse box (+)
3 Junction box, lanterns
Before auxiliary equipment such as navigation equip- Install the electrical system control panel close to the
ment, auxiliary lighting, radio, echo sounders etc. are instrument panel, in an easily accessible place that
installed, their total power consumption must be accu- is not exposed to moisture.
rately calculated in order to ensure that boat charging
capacity is sufficient. If a 230 V system is installed, this part of the electrical
panel must be clearly marked.
The above schematic shows how equipment may be NOTICE! Make sure that all components used are
installed in the boat. Fasten the cables to brackets at suitable for marine environments. 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.
124 47705785 05-2014 © AB VOLVO PENTA

Calculate the supply cable area

Note that power supply cable length and area (A+, A-)
depends on the number of accessories connected.
• Add all the accessories (power consumers).
• Measure the total length of the supply cable (A+,
A-) on the positive (+) and negative (-) sides.
• Refer to the chart Calculating cable
area page 126. The chart shows supply cable area.
P0004724
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 126.
- +
P0004723
47705785 05-2014 © AB VOLVO PENTA 125

Calculating cable area

1 Load
12V 24V
1 1 A Length (m)
A B C D A B C D B Surface (mm²)
30 30
700 4000 C Current (A)
25 70 25
50 600 120 150
20
50
500 20
95
3000 D Output (W)
40
35 70
400 100
15 25 15 50
30
2000
35 80
16 300
10 10 25 1500
20 60
10
8 200 8 16 50
6 15
40 1000
6 6 10
4 150
800
5 5 6 30
2,5 10
4 100 4 4 600
1,5 8
20 500
3 1 80 3 2,5
6
0,75 1,5 400
5 60 15
1
2 50 2 300
4
0,75
1,5 40 1,5 10
0,5 3
200
8
30 0,5
1 1 150
2 6
0,8 20 0,8 5
P0004726
AWG – American Wire Gauge Example: If a 12 V fridge consumes 70 W and the dis-
AWG mm² (std) mm² sq. in tance between the terminal block and the fridge is four
meters, draw a straight line between 8 (4 x 2) on the
18 0,75 0,82 0.0013
meter scale and 70 on the consumer scale.
16 1,5 1,31 0.0020
14 2,5 2,08 0.0032 The line dissects the area scale in the 2.5 space; 2.5
12 4 3,31 0.0051 corresponds to the area required (2.5 mm2).
10 6 5,26 0.0082
8 10 8,37 0.013 The calculation is based on the maximum permissible
6 16 13,29 0.021 voltage drop in all cables between the positive con-
5 16 16,76 0.026 nection to the consumer and back to the negative
4 25 21,14 0.033 connection.
3 25 26,65 0.041
Total voltage drop when applying the above
2 35 33,61 0.052
table:
0 (1/0) 50 53,46 0.083
00 (2/0) 70 67,40 0.104 12 V system 0.4 V
000 (3/0) 95 84,97 0.132
24 V system 0.6 V
0000 (4/0) 120 107,16 0.166
126 47705785 05-2014 © AB VOLVO PENTA

Installation, Fire Extinguishing System
Fire Extinguishing System

Separate relay and connection
Fault codes will appear if the fire-extinguishing system
input is activated:
Red alarm/buzzer
• Flash code 299
(internal fault in EVC system)
VODIA/EVC display fault

• Serious communication fault, PCU
PSID 200, FMI: 8
• Serious communication fault, PCU
PSID 200, FMI: 9
• Internal ECU communication fault, PCU
SID 231, FMI: 2
p0014263 For further information refer to the EVC system litera-
ture.
Recommended installation
Active (+) at stop (energized to stop)

1 Pin 1 R (+)
2 Pin 2 SB (-)
87a
30 3 Accessory cable kit, 10 m (3.5 ft.)
87
4 Fire extinguishing system
(+)86 (-) 85 5 Main switch (+) or accessory relay (ignition switch)
1
2
3
4 5
P0011567
47705785 05-2014 © AB VOLVO PENTA 127

Installation, Fire Extinguishing System
Alternative installation
Inactive (+) when closed (energized to run)
85 NOTICE! If there is a requirement for a pause function
on the relay with an active positive (+) from the fire
shut-off system when the engine is running, and no
87a active positive (+) to switch off the system, the cables
must be connected in the relay base as illustrated.
Terminal 85 is connected to the battery (-) and terminal

30 +86 to the fire alarm unit.
87 + 86
P0011569
87 is not used.
The illustration shows a circuit diagram of an energized

circuit.
87a 1 Pin 1 R (+)
30 2 Pin 2 SB (-)
87
3 Accessory cable kit, 10 m (3.5 ft.)
(+)86 (-) 85 4 Fire shut-off unit
5 From main switch (+)
Do not use accessory relay for EVC
1
2
3
5
P0011568 4
128 47705785 05-2014 © AB VOLVO PENTA

Installation, Power Take-off
Power Take-off
The engine has surplus power equivalent to 200 Nm
(148 lbf.ft) at 600 rpm, which is normally used for accel-
eration. Some of this surplus may be used for power
take-off with the risk of the boat losing some perform-
ance.
Large consumers for low speed maneuvering should

not be installed. Winches and stabilizers consume less
owing to their duration of use.
47705785 05-2014 © AB VOLVO PENTA 129

Calibration and Settings, IPS Calibration
Calibration and Settings

IPS Calibration
Requirements
• The boat may not be in the water.
• The batteries must be fully charged or connected to
2 an external charging device.
1
• No people or objects may be present inside the drive
leg operating area.
VODIA
Calibration is performed by the OEM (manufacturer)

4 3 2 1
ENGINE ENGINE ENGINE ENGINE
SB SBC QUAD PTC PT

X SB TRIPLE C PT
X X TWIN SB PT
and consists of two parts:

AUTOMATIC SWITCHBOX(ASB)
Drivline positioning and Parallel alignment.
Further information regarding Volvo Penta IPS drive

unit calibrations and settings can be found in the
VODIA system.
IMPORTANT!
If a factory-set calibration or drive leg parallelism cali-
bration has not been performed, no gear can be
engaged.
2 Connect 21287382 Break-out box (1) to the engine

diagnostics connectors. Also connect
3838619 VODIA, diagnostic tool (2) to the junction box.
VODIA
1
The junction box allows switching between drive legs
4
ENGINE
3
ENGINE
2
ENGINE
1
ENGINE
during work progress. Select OEM in the VODIA menu
and follow the instructions.
SB SBC QUAD PTC PT
X SB TRIPLE C PT
X X TWIN SB PT
Drivline positioning
Drivline positioning determines driveline position rela-

tive to the other drivelines.
• Select Drive leg position, calibration in the diag-
nostics tool.
• Follow the instructions on the screen.
IMPORTANT!
2 This operation must always be followed by the Parallel
calibration of drive legs procedure.
VODIA
1
4 3 2 1
ENGINE ENGINE ENGINE ENGINE
SB SBC QUAD PTC PT

X SB TRIPLE C PT
X X TWIN SB PT
P0015943
130 47705785 05-2014 © AB VOLVO PENTA

Calibration of lower gear case parallelism
The procedure is used to set the the lower gear cases

parallel to one another and the boat's keel.
The boat may not be in the water. A junction box and

a special tool for drive center positioning are required
for this procedure. The junction box is connected to the
engine diagnostic systems and the VODIA tool.
The drive legs are calibrated by following the IPS pro-

cedures in the VODIA system.
Twin installation
1 Fit 21406897 Calibration tool to the drive unit pro-
peller shafts with the light sources facing inwards.
2 Switch on power and turn the tool so that the
points of light are at the same height as the light
sources.
3 Adjust the drive unit angles until both points of
light meet the light sources.
P0010873
Triple and quad installations

Calibrate the drives according to the sequence in the
illustrations.
1 2
1 2 3
P0013907
Detailed drive leg calibration instructions can be found

in the VODIA tool.
47705785 05-2014 © AB VOLVO PENTA 131

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.
Steering angle settings

It is the boatbuilder's responsibility to choose the most
suitable steering angle settings for the particular boat
model in consultation with the Volvo Penta represen-
tative. The setting must be evaluated by means of a
test run of the first boat of a given model manufactured.
Settings are made using the VODIA tool.
There are four settings:
Maximum
Usually provides the smallest turning radius. This set-
ting is used for special sports boats that can cope with
aggressive steering angles.
Medium high (standard setting)

The most common setting, well able to utilize IPS unit
maneuverability.
Medium low
For applications where the boat is relatively suscepti-
ble to heeling, but in which the IPS system's maneu-
verability is still prioritized.
Minimum
For boats with high CoG and with a great inclination to
heel and where aggressive maneuvering is not a pri-
ority.
At low speeds, all settings provide the same steering

characteristics.
132 47705785 05-2014 © AB VOLVO PENTA

Launching and Sea Trial

Launching and Starting
Checks before launching
• Check that all valves and taps at hull fittings are
closed.
P0004753
Checks after launching

Check the following before starting the engine.
IMPORTANT!
Recommendations for oil, fluids and grease: refer to
the Operator's Manual.
Check leakage risks

• Check taps.
• Check hull fittings.
Engine
• Top off lubrication oil.
• 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
47705785 05-2014 © AB VOLVO PENTA 133

Drive unit
• Check the level of the gear lubricant and top up as
necessary. Open the oil filler cap (1) so that excess
pressure is released. Undo the oil dipstick (3) with
the aid of a standard 1/2" extension (2).
• 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)

• Carry out auto configuration (refer to the EVC sys-
tem installation manual)
• Verify that complete calibration has been made
(refer to the EVC system installation manual)
• Start the EVC display(s) and check functionality
• Check any fault codes
P0007397
4 IPS 2/3 drive unit

4, Connect breather hose
5, Water in oil sensor
P0019801
134 47705785 05-2014 © AB VOLVO PENTA

Starting the Engine (Cold Start)

WARNING!
Never use start spray or similar agents to start an
engine. This may cause an explosion in the inlet mani-
fold. Danger of personal injury.
IMPORTANT!
Also refer to the Operator's manual for information on
how to start the engine.
General
The throttle must always be in the neutral position
before start. The engine control system ensures that
the engine receives the correct amount of fuel, even
when the engine is cold.
The engine is pre-heated by the control unit, which also

allows the start motor to crank a few revolutions before
fuel is injected. The colder the engine is, the more rev-
olutions the engine is cranked. 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.
47705785 05-2014 © AB VOLVO PENTA 135

Starting the engine

Gear selection
Put the gear in neutral by moving the control levers to
the neutral position at all helm stations.
Turn the ignition on.
P0017799
Start using the start button

Depress the start button. Release the start button as
soon as the engine starts. Note that if you start the
engine from another helm station, the ignition key at
the main helm station must be in the I position. Abort
the start attempt if the engine does not start within 20
seconds.
P0017771
Overheating protection
If the starter motor is allowed to run for its maximum
activation time, the circuit will be disconnected to pro-
tect the starter motor from overheating. Allow the
starter motor to cool for at least five minutes (if possi-
ble) before making a new start attempt.
136 47705785 05-2014 © AB VOLVO PENTA

After starting
Read off the instruments and warm up the engine

1 First allow the engine to idle for ten seconds and
then check that the instruments and displays are
showing normal values.
2 Check that there are no alarms displayed and that
none of the warning lamps are flashing.
3 Then warm up the engine at low rpm with low load
so that it reaches normal operating temperature
before full power is demanded.
NOTICE! Never rev up the engine when it is cold.
Temporary disengagement
The gearshift function can be disconnected so that the
control lever only affects engine revolutions.
1 Move the lever to the neutral position.
2 Press the control “Throttle Only” button or the neu-
tral button (N) on the helm station panel.
3 Release the button. The N symbol on the control
will light up to confirm that the shift function is dis-
engaged.
To exit neutral mode, press the button again.
CAUTION!
Take care not to engage the gear by mistake.
Checks at idle
• Check for leaks in the fuel and cooling systems.
Hoses and pipes.
• Check that instruments and gauges are functional
and show the correct values
• Check that all equipment such as lanterns, instru-
ments etc. is functioning normally.
Check idle revolutions

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.
47705785 05-2014 © AB VOLVO PENTA 137

Sea Trail
Check during boat test run:
• Instruments: engine rpm, oil pressure, coolant tem-
perature and battery charging.
• Any occurrence of water, coolant, oil or fuel leaks in
the engine installation.
• The ability to achieve rated engine speed (refer to
the Operator's Manual) in a fully laden boat.
Check across the entire speed range:

• That engine compartment temperature is below
max; refer to the Engine compartment ventilation
P0008525 chapter.
• 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 130.
138 47705785 05-2014 © AB VOLVO PENTA

Alphabetical index
A G
Accessibility for Maintenance................................... 19 General............................. 31, 49, 84, 88, 92, 101, 109
Accessory Battery.................................................. 112 General Information.................................................... 5
ACP.......................................................................... 45 H
Alternator connnections.......................................... 117 Hot water connections.............................................. 96
Aluminium Hull Constructions.................................. 72
Arrangement and Planning....................................... 16 I
Installation................................................. 49, 0 , 88
B Installation Tools and Documentation........................ 8
Batteries................................................................. 110 IPS Calibration....................................................... 130
Batteries, Installation.............................................. 111
Battery Charging.................................................... 115 L
Laminating the hull................................................... 64
C Lamination................................................................ 50
Calibration and Settings......................................... 130 Launching and Sea Trial........................................ 133
Charge distributor................................................... 113 Launching and Starting.......................................... 133
Checking electrochemical corrosion......................... 46 Lubrication System................................................. 108
Checking Protective Anodes.................................... 44
Chemical products.................................................... 12 M
Chemicals................................................................... 9 Main switch............................................................. 112
Clearance Around Propulsion Units......................... 18 Maximum Water Level.............................................. 73
Connection............................................................. 119 Metric Conversion Chart............................................. 7
Connections to Starter Motor................................. 119 O
Construction of reinforcing beams............................ 69 Oil cooler.................................................................. 87
Coolant Level, Checking and Topping Up.............. 100 Other Special Equipment......................................... 11
Cooling System........................................................ 92
P
Corrosion theory....................................................... 31
Piping..................................................................... 104
Cross-over Switch.................................................. 113
Placement and Mounting of Hull Inserts................... 52
D Placement and Mounting of Hull Plug, Quad
Draining the Engine................................................ 108 Installation................................................................ 62
E Placement and Mounting of Hull Plug, Triple
Electrical System.................................................... 109 Installation................................................................ 59
Electrochemical Corrosion....................................... 31 Placement and Mounting of Hull Plug, Twin
Engine Application Ratings...................................... 13 Installation................................................................ 56
Engine Characteristics............................................. 13 Power Take-off....................................................... 129
Engine Foundation....................................... 67, 73, 75 Premolded Hull Inserts and Hull Mold Plugs............ 51
Engine Inclination..................................................... 16 Propeller................................................................... 82
Engine Installation.................................................... 84 Propulsion Unit................................................... 78, 86
Engine Mountings..................................................... 84 Propulsion Unit Installation....................................... 78
Engine Performance................................................. 14 Publications................................................................ 8
Engine Placement.................................................... 16 R
Engine Room............................................................ 19 Raw Water System................................................... 93
Engine Room Ventilation.......................................... 21
S
Exhaust Outlet.......................................................... 90
Safety Information...................................................... 2
Exhaust System....................................................... 90
Sea Trail................................................................. 138
Extension Shaft........................................................ 88
Sound Absorption..................................................... 28
External accessories.............................................. 124
Special Tools............................................................ 10
Extra expansion tank................................................ 97
Starting Battery Cable Area.................................... 114
F Starting Group Battery Capacity............................. 112
Fiberglass Hull Constructions................................... 49 Starting the Engine (Cold Start)............................. 135
Fire Extinguishing System...................................... 127
V
Freshwater System.................................................. 95
VODIA........................................................................ 9
Fuel Feed Pressure, Check.................................... 106
Voltage Supply....................................................... 118
Fuel pre-filter.......................................................... 107
Volvo Penta IPS....................................................... 49
Fuel pressure......................................................... 106
Fuel System........................................................... 101 W
Fuel System, Piping............................................... 104 Weight Distribution................................................... 17
Fuel Tanks.............................................................. 102
47705785 05-2014 © AB VOLVO PENTA 139

Report form
Do you have any complaints or other comments about this manual? Please make
a copy of this page, write your comments down and post it to us. The address is at
the bottom of the page. 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
47705785 English 05-2014

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Installation E

IPS 900, 1050, 1200

47705785 05-2014 © AB VOLVO PENTA 1

2 47705785 05-2014 © AB VOLVO PENTA

47705785 05-2014 © AB VOLVO PENTA 3

Never work alone when installing heavy compo-

The components in the electrical system, ignition

4 47705785 05-2014 © AB VOLVO PENTA

47705785 05-2014 © AB VOLVO PENTA 5

6 47705785 05-2014 © AB VOLVO PENTA

Metric Conversion Chart

47705785 05-2014 © AB VOLVO PENTA 7

Installation Tools and Documentation

8 47705785 05-2014 © AB VOLVO PENTA

The tool is very practical for fault tracing as it is possible

Refer to VODIA information at Volvo Penta Partner

47705785 05-2014 © AB VOLVO PENTA 9

3849633 Drill jig 3594503 Drill jig 21110860 Lifting tool

3849664 Lifting tool 3887101 Break-out box 21406897 Calibration tool

3863070 Allen key socket

10 47705785 05-2014 © AB VOLVO PENTA

Other Special Equipment

88890074 Multimeter 88820047 VODIA, diagnostic 9998339 Manometer

9998493 Hose 21504294 Reference elec-

47705785 05-2014 © AB VOLVO PENTA 11

828250 Grease alt. 1381065 Corrosion protec- 3817243 Rubber lubricant

12 47705785 05-2014 © AB VOLVO PENTA

Typical boats: high speed passenger vessels (HSLC),

Full power could be utilized maximum 2 hour per 12

Typical boats: patrol and emergency boats.

Full power could be utilized maximum 1 hour per 12

NOTICE! Time between major overhaul is subject to a

47705785 05-2014 © AB VOLVO PENTA 13

Most engines provide the power specified on the con-

All major marine engine manufacturers determine

Diesel engines use large amounts of air for combus-

If the deviation differs significantly from normal air flow,

Point A is where the indicated engine power is equal

14 47705785 05-2014 © AB VOLVO PENTA

Other factors that influence performance

Boat weight is another important factor that influences

Boats made from fiberglass reinforced plastic absorb

47705785 05-2014 © AB VOLVO PENTA 15

Arrangement and Planning

Be careful to avoid the front of the engine's being lower

Each engine type has a maximum permissible engine

16 47705785 05-2014 © AB VOLVO PENTA

The center of gravity has great influence on a boat's

A It is important that heavy components such as engines,

Fuel and water tanks must be located longitudinally as

It is an advantage not to locate the fuel tanks in the

It is always the boat designer and/or boat builder who

47705785 05-2014 © AB VOLVO PENTA 17

Clearance Around Propulsion Units

Clearance between hull and Ips drive unit is 9 mm

18 47705785 05-2014 © AB VOLVO PENTA

NOTICE! There must also be sufficient space for

Removal of complete engine assembly

Considering the great demand placed on boatyards

47705785 05-2014 © AB VOLVO PENTA 19

General maintenance Repairs

20 47705785 05-2014 © AB VOLVO PENTA

Engine Room Ventilation