Volvo Penta IPS15 Workshop Manual Group 40 – Marine Propulsion Service & Repair PDF

Description

Volvo Penta IPS15 Workshop Manual – Group 40 Marine Propulsion

This is the full workshop manual for the Volvo Penta IPS15 marine propulsion drive, issued under Group 40. It is written for the technician working on the drive itself – the upper gear, the intermediate housing and connections, the complete lower gear, and the components that sit inside them. Every operation is laid out step by step with the tightening torques, shim calculations, turning-resistance values and gear backlash limits that Volvo Penta specifies for this unit. Publication number 47708467, dated 09-2024.

File Details

• Manual type: Workshop Manual (service and repair)
• Brand: Volvo Penta
• Model: IPS15
• Group: 40 – Marine Propulsion
• Language: English
• Page count: 136 pages
• File format: PDF
• Publication number: 47708467
• Date of issue: 09-2024

Chapters Covered

• General Information – replacement parts, certified engines, colour coding and symbols used in images
• Safety Information – warning levels, mandatory precautions, battery and fuel handling
• Specifications, Power Transmission – general tightening torques, technical data, estimation tables for lower gear shims
• Special Service Tools – the numbered Volvo Penta tools used on IPS15 units
• General – identification plates and product designation
• Check and Fault Trace – oil pressure check with manometer or VODIA
• Drive, Inboard – fitting the drive in the fixture
• Upper Gear, Components – upper gear replacement, clutch disc (reversing gear) replacement, clutch disc package forward/reverse, vertical shaft bearing, gearwheel kit shimming, resolver
• Reducing Valve and Shifting Valves – inspection and replacement
• Lube Oil Pump – replacement and internal inspection
• Servo Steering Units (SUS) – early model and later design replacement
• Slide Washer / Sealing Strip – replacement
• Intermediate Part, Connections – intermediate housing seal replacement, steering spindle check, needle bearing change
• Lower Gear, Complete – full lower gear overhaul, propeller shaft inspection, propeller shaft seals, propellers
• Miscellaneous – water intrusion in transmission, transmission oil replacement

Read together, these chapters give a technician the entire working sequence for the IPS15 drive: strip it down, measure what matters, choose the right shim, and build it back to the tolerances Volvo Penta specifies. The manual is built around Volvo Penta Special Tools, and the tool numbers are called out at each operation so you know exactly what is needed before you start.

What the Workshop Procedures Cover

The upper gear section walks through removing the drive shaft, carrier and companion flange, lifting the upper gear clear, and re-installing it with the steering shaft and resolver wheel correctly aligned. From there the clutch disc package is covered in detail, including the forward/reverse disc pack, piston, springs, hydraulic seals, locking rings and the correct order of steel, friction and spring discs. New fibre discs must be soaked in transmission fluid before installation, and the manual states this clearly.

Shimming is where this manual earns its place. The gearwheel kit shimming procedure shows how to measure clearance between the housing and bearing housing with a feeler gauge, how to read vertical shaft movement with a dial indicator, and how to convert those readings into the correct shim thickness. Gear backlash is checked on both the forward and reverse gear, with marking dye used to confirm the contact pattern sits centrally on the teeth.

The lower gear overhaul is equally complete. It covers removing the end cover and rear gearwheel, pulling the bearing races, pressing bearings on and off the vertical shaft, installing the pinion and pinion nut, and setting rotating torque. Stamped and etched values from the gear kit and bearing box are recorded and fed into the estimation tables, and the manual shows worked examples so the shim arithmetic is easy to follow.

Around the gears, the manual also handles the systems that keep the drive working: the lube oil pump with its relief valve and drive ball, the oil pressure check with a manometer or VODIA, the shifting valves marked Primary and Secondary, the reducing valve, and both generations of the Servo Steering Unit with their resolver connections and cable routing.

Specifications You Can Work To

Torque values appear throughout the procedures rather than in a single distant table. General tightening torques start at 10 Nm for an M6 standard bolt and run to 220 Nm for M16. Component-specific values include the driveshaft connection flange bolts at 85 Nm, the vertical shaft nut at 550 Nm, the input shaft nut at 500 Nm, the pinion nut at 400 Nm, and the steering spindle bolts at 85 Nm. The manual also lists turning resistance for a new input bearing housing at 7 plus or minus 2 Nm, steering spindle at 35 to 50 Nm, and the complete gear at 7.0 plus or minus 1 Nm measured at the vertical shaft.

Gear backlash limits are given as 0.25 to 0.40 mm for the front gear and 0.20 to 0.70 mm for the rear gear. Oil pressure requirements are stated for both new and used drives, at idle and at approximately 1200 rpm. Total weight without propellers is 470 kg, maximum steering angle is plus or minus 34 degrees, and propeller series N and NS are listed.

Transmission Oil and Fluid Data

The manual identifies the correct Volvo Penta transmission oils by part number, with separate listings for North America and the rest of the world, and warns that using anything other than the recommended oil can increase gear shifting delay and shorten transmission life. Total oil quantity for the IPS15-A is given as 23 litres with a 0.5 litre difference between minimum and maximum. The transmission oil replacement procedure covers both the boat-in-water method, using the adapter and hose with a measured insertion depth, and the drained method, along with oil filter change and oil quality sensor recalibration through the display.

Water Intrusion and Fault Tracing

For drives fitted with an oil quality sensor, the manual sets out a full sequence for dealing with water intrusion in the transmission – draining, cleaning the intermediate housing and gear housing, removing and cleaning the oil quality sensor, rinsing hoses and filter bracket, changing the oil filter, finding the cause of the leak, testing for leakage and recalibrating the sensor. Low oil pressure fault tracing lists the probable causes as a blocked strainer, worn oil pump, faulty relief valve or high internal leakage, and the oil pressure check itself is described with both a manometer and VODIA.

Who This Manual Is For

This workshop manual suits a marine technician, workshop or experienced owner working on the Volvo Penta IPS15 drive as a unit – not the engine. The procedures assume the drive is mounted in a work fixture, and the text notes where in-situ work follows the same method. Certified engine requirements, the use of Volvo Penta approved replacement parts, and the safety precautions for fuel, hydraulic and lubrication systems are all set out in the opening sections.

Get the Volvo Penta IPS15 Workshop Manual Today

With this Volvo Penta IPS15 Workshop Manual Group 40 in hand you can strip the upper gear, rebuild a clutch disc pack, calculate lower gear shims, set gear backlash, replace the vertical shaft bearing, service the lube oil pump and diagnose low oil pressure – all to the values Volvo Penta specifies rather than to guesswork. Getting the shim thickness or turning resistance wrong on a drive like this costs far more than the manual does.

The file is delivered instantly as a PDF after payment. No shipping, no waiting, no postal delays. Open it on a laptop, tablet or phone in the workshop, and print the pages you need for the job in front of you.

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