Volvo Penta IPS 500 Generator Set

⚠ Calibrate in open water and safe conditions; avoid strong winds or sea-current.

1. Enable docking function.
2. Push both joystick buttons and hold for 5 seconds or more until calibration mode; LEDs flash.
3. Move joystick sideways to an end position; correct boat movement by turning/moving joystick.
4. When boat moves directly sideways, push docking button to store calibration.
5. Release joystick; system returns to normal docking function.

1. Undo bolts on tensioning roller bracket.
2. Remove and change belt if necessary.
3. Tension belt to 70 Nm on tensioning roller square fitting.
4. Secure tensioning roller with bolts torqued to 50 Nm.
5. When warm, undo bolts and repeat belt tensioning procedure.

⚠ Never detach the pressure pipes.

Tools: transparent hose, hand pump

1. Attach transparent hose to air vent valve and lead to receptacle.
2. Open air vent valve and pump fuel with hand pump until fuel is free of air bubbles.
3. Close and tighten air vent valve.
4. Pump another 10 strokes with hand pump.
5. Remove hose and refit protective cap on air vent valve.

⚠ Never over-fill the drive-unit.

1. Open oil filler cap slowly so overpressure disappears.
2. Unscrew draining plug and allow oil to run out.
3. Change the filter.
4. Refit drain plug and a new gasket.
5. Measure correct oil quantity and fill through oil filling hole.
6. Never over-fill the drive-unit.

⚠ Hot oil and hot surfaces can cause burns.

Tools: oil bilge pump

1. Start engine and run to operating temperature 75–95°C, then stop.
2. Connect oil bilge pump to drain pipe and pump up oil.
3. Change oil filter and bypass filter at each oil change.
4. Fill new oil through filler hole; fill 1.5 liters less than total oil volume.
5. Start engine; check oil pressure lamp goes out and no leaks at filters.
6. Stop engine, wait one hour, check oil level and top up if necessary.

⚠ Fire risk. Ensure engine is cold before working on fuel system.

⚠ Do not fill the new filter with fuel before assembly.

Tools: filter wrench

1. Close fuel valve/valves.
2. Clean filter bracket and place vessel under filter.
3. Remove cables from water trap.
4. Unscrew filter; use filter wrench if needed.
5. Clean sealing surfaces; moisten sealing rings with engine oil including inner rubber seal.
6. Screw new filter on by hand until seal touches, then tighten further 1/2 turn.
7. Reinstall water trap cables.
8. Open fuel valve, bleed fuel system, start engine and check for leaks.

⚠ Hot oil and hot surfaces can cause burns.

Tools: filter extractor

1. Place a suitable vessel under the filters.
2. Clean the filter bracket.
3. Unscrew the bypass filter and oil filters with a suitable extractor.
4. Check mating surfaces are clean and no old seal residue remains.
5. Moisten new filter seals with engine oil.
6. Screw filters on by hand until rubber seals touch, then tighten 1/2 to 3/4 turn.
7. Start engine at low idle; check no leakage; check oil level after stopping.

⚠ Risk of water entering; close seawater cock before work.

⚠ Use no steel tools as this will impair electrical protection.

Tools: sandpaper

1. Close seawater cock.
2. Drain seawater system.
3. Remove sacrificial anodes in heat exchanger and intercooler.
4. Check anodes; replace if less than 50% of original size; otherwise clean with sandpaper.
5. Fit anodes with good contact; close drain nipples; open seawater cock; check for leaks.

⚠ Risk for water penetration.

⚠ Impeller will be damaged if lubricants other than glycerin are used.

1. Remove cover from seawater pump and remove impeller.
2. Replace impeller if cracked or defective; replace flange if pump shaft turns by hand.
3. Lubricate pump housing and inside of cover with glycerin.
4. Reinstall impeller using a rotating movement; install seal washers on shaft center.
5. Install cover with a new O-ring.

⚠ Risk for water penetration.

1. Screw off cover and remove seal plate.
2. Lift out and clean the insert.
3. Reassemble the filter.

1. Stop engine and remove starter key.
2. Remove cable from water separator.
3. Place receptacle under fuel filter and unscrew water separator enough to let water run out.
4. Screw in water separator until it bottoms, then a further 1/4 to 1/2 turn.
5. Fasten cable from water separator.

⚠ Make it impossible to start engine when working on propellers.

Tools: special propeller tool

1. Apply water-resistant grease part no. 828250 to splines and thread on both propeller shafts.
2. Install aft propeller, aft nut, locking ring and four socket cap screws; torque 24-28 Nm.
3. Install forward propeller, tighten nut by hand, install locking ring and four socket cap screws; torque 24-28 Nm.
4. Tighten screw D until it bottoms.
5. Push spinner into place by hand.