Volvo Penta SX-M DP-SMSMTDSMTD1 Sterndrive Transom Shield Workshop Manual_60454787 – PDF DOWNLOAD

Volvo Penta SX-M DP-SMSMTDSMTD1 Sterndrive Transom Shield Workshop Manual_60454787 – PDF DOWNLOAD

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Volvo Penta SX-M DP-SMSMTDSMTD1 Sterndrive Transom Shield Workshop Manual_60454787 – PDF DOWNLOAD

Language : English
Pages : 270
Downloadable : Yes
File Type : PDF
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Volvo Penta SX-M DP-SMSMTDSMTD1 Sterndrive Transom Shield Workshop Manual_60454787 – PDF DOWNLOAD

Sterndrive
SX-M, SX-MTD
DP-SM, DP-SMTD, DP-SMTD1
Transom Shield
SX-M, SX-MLT, SX-MACLT,
SX-MHP, SX-MDA, SX-MDB

Good Service Practice:

Service required for this product is generally one of three kinds:
• Normal care and maintenance – which includes putting a new
stern drive into operation, storing engines, lubrication, and care
under special operating conditions such as salt water and cold
weather.
• Operating malfunctions – due to improper engine or drive
mounting, propeller condition or size, boat condition, or the malfunction
of some part of the engine. This includes engine servicing
procedures to keep the engine in prime operating condition.
• Complete disassembly and overhaul – such as major service
or rebuilding a unit.
It is important to determine before disassembly just what the trouble is
and how to correct it quickly, with minimum expense to the owner.
When repairing an assembly, the most reliable way to ensure a good
job is to do a complete overhaul on that assembly, rather than just to
replace the bad part. Wear not readily apparent on other parts could
cause a malfunction soon after the repair job. Repair kits and seal kits
contain all the parts needed to ensure a complete repair, to eliminate
guesswork, and to save time.
Repair time can also be minimized by the use of special tools. Volvo
Penta Special Tools are designed to perform service procedures
unique to the product that cannot be completed using tools from other
sources. They also speed repair work to help achieve service flat rate
times. In some cases, the use of substitute tools can damage the part.
Note! Do not operate engine out of water even momentarily. If
operated in test tank, use proper test wheel. Failure to do
so can damage water pump, overheat engine, or allow
excessive engine RPM.
Preparation for Service :

Proper preparation is extremely helpful for efficient service work. A
clean work area at the start of each job will minimize tools and parts
becoming misplaced. Clean an engine that is excessively dirty before
work starts. Cleaning will occasionally uncover trouble sources. Obtain
tools, instruments and parts needed for the job before work is started.
Interrupting a job to locate special tools or repair kits is a needless
delay.
Use proper lifting and handling equipment. Working on stern drives without proper
equipment can cause damage and personal injury.
Always use clean fresh fuel when testing engines. Troubles can often
be traced to the use of old or dirty fuel.

TABLE OF CONTENTS:

Volvo Penta SX-M DP-SMSMTDSMTD1 Sterndrive Transom Shield Workshop Manual_60454787 – PDF DOWNLOAD

General Information…………………………………………. 5
Sterndrive Lubrication – SX Models………………………… 8
Adding Lubricant to Sterndrive………………………… 8
Sterndrive Oil Capacity………………………………. 8
Draining and Filling Sterndrive……………………….. 8
Sterndrive Lubrication – DP-S Models………………………. 10
Adding Lubricant to Sterndrive………………………… 10
Sterndrive Oil Capacity………………………………. 10
Draining and Filling Sterndrive……………………….. 10
Power Trim/Tilt-Fluid Level…………………………… 11
Off -Season Storage Preparations – All Models………………. 11
Painting……………………………………………. 11
Preparation for Boating After Storage………………….. 12
Gimbal Bearing and Inspect Universal Joint bellow……….. 12
Recommendations For Antifouling Paints…………………. 13
Painting The Stern Drive With Antifouling Paint…………. 14
Paints For Stern drives………………………………. 14
Painting The Hull With Antifouling Paint……………….. 14
Metric Conversion Chart………………………………. 15
Periodic Maintenance Chart……………………………. 18
Transom Shield Assembly – SX-M……………………………….. 19
Special Tools…………………………………………… 20
Trim/Tilt Cylinder Removal……………………………….. 20
Trim/Tilt Cylinder Installation…………………………… 22
Pivot Housing Removal……………………………………. 23
Pivot Housing Disassembly………………………………… 25
Pivot Housing Assembly…………………………………… 26
Pivot Housing Installation……………………………….. 26
Gimbal Ring Removal……………………………………… 28
Gimbal Ring Disassembly………………………………….. 30
Gimbal Ring Assembly…………………………………….. 31
Gimbal Ring Installation…………………………………. 32
Trim Sender Adjustment…………………………………… 35
Gimbal Housing Disassembly……………………………….. 36
Water Hose and Bellows Removal………………………… 36
Anode Replacement……………………………………. 36
Trim Sender Removal………………………………….. 37
Water Tube Removal…………………………………… 37
Hydraulic Lines and Manifold Removal…………………… 38
Steering, Gimbal Bearing and Seal Removal………………. 39
Gimbal Housing Cleaning and Inspection…………………. 39
Gimbal Housing Assembly………………………………….. 40
Steering Bearing, Gimbal Bearing and Seal Installation…… 40
Hydraulic Lines and Manifold Installation………………. 41
Trim Sender Installation……………………………… 43
Water Tube Installation………………………………. 44
Water Hose Installation………………………………. 44
U-joint and Exhaust Bellows Installation……………….. 45
Gimbal Housing Removal…………………………………… 46
Shift Cable Sleeve Replacement………………………… 47
Transom and Exhaust Seal Replacement…………………… 48
Gimbal Housing Installation………………………………. 49
Torque Specifications……………………………………. 52
Sealants, Lubricants, and Adhesives……………………….. 53
Service Chart…………………………………………… 54
Transom Shield Assembly SX-MHP……………………………….. 55
Special Tools…………………………………………… 56
Sealants, Lubricants and Adhesives………………………… 56
Trim/Tilt Cylinder Installation…………………………… 58
Pivot Housing Removal……………………………………. 59
Pivot Housing Assembly…………………………………… 62
Pivot Housing Installation……………………………….. 62
Gimbal Ring Removal……………………………………… 64
Gimbal Ring Disassembly………………………………….. 67
Gimbal Ring Assembly…………………………………….. 67
Gimbal Ring Installation…………………………………. 68
Trim Sender Adjustment…………………………………… 71
Gimbal Housing Disassembly……………………………….. 72
Anode Replacement……………………………………….. 72
Trim Sender Removal……………………………………… 73
Water Tube Removal………………………………………. 73
Hydraulic Lines and Manifold Removal………………………. 74
Steering Bearing, Gimbal Bearing and Seal Removal…………… 75
Gimbal Housing Cleaning and Inspection…………………….. 75
Gimbal Housing Assembly………………………………….. 76
Steering Bearing, Gimbal Bearing and Seal Installation…… 76
Hydraulic Lines and Manifold Installation………………. 77
Trim Sender Installation……………………………… 79
Anode and Sensor Housing Installation………………….. 80
Water Tube Installation………………………………. 80
Water Hose Installation………………………………. 80
U-joint and Exhaust Bellows Installation……………….. 81
Gimbal Housing and Transom Plate Removal……………….. 82
Shift Cable Sleeve Replacement………………………… 83
Transom and Exhaust Seal Replacement…………………… 84
Gimbal Housing and Transom Plate Installation…………… 85
Torque Specifications……………………………………. 87
Sealants Lubricants, Adhesives……………………………. 88
Service Chart…………………………………………… 89
Upper Gear Housing………………………………………….. 91
Special Tools…………………………………………… 92
Sealants, Lubricants and Adhesives………………………… 92
Sterndrive Removal………………………………………. 93
Sterndrive Disassembly…………………………………… 93
Upper Gear Housing Disassembly………………………… 94
Shift Actuator Housing Removal………………………… 95
Pinion Bearing Carrier Removal………………………… 95
Output Gear Removal………………………………….. 96
Upper and Lower Output Gear Disassembly………………… 99
Universal Joint Replacement……………………………100
universal joint Installation…………………………..101
Pinion Bearing Carrier Disassembly……………………..102
Upper Housing Stud Replacement…………………………105
Upper Gear Housing Oil Screen………………………….105
Shimming Thrust Plates………………………………..105
Shift Linkage Disassembly……………………………..107
Water Passage Plate Service……………………………108
Shift Linkage Assembly………………………………..108
Pinion Bearing Carrier Assembly………………………..109
Upper and Lower Output Gears Assembly…………………..114
Lower Output Gear Shimming…………………………….115
Upper Output Gear Shimming…………………………….116
Pinion Bearing Carrier Shimming………………………..117
Upper Gear Housing Assembly……………………………….118
Lower Output Gear and Shaft Assembly……………………118
Lower Output Gear Installation…………………………119
Cone Clutch Installation………………………………121
Upper Output Gear Installation…………………………122
Shimming Vertical Movement Of Upper Driveshaft…………..123
Pinion Bearing Carrier Installation…………………….124
Top Cover Shimming……………………………………125
Checking Gear Lash……………………………………125
Lower Gear…………………………………………..126
Upper Gear…………………………………………..126
Correcting Gear Lash………………………………….127
Checking the Gear Teeth Contact Pattern…………………130
Final Assembly of Upper Gear Housing……………………131
Shift Actuator Housing Disassembly……………………..132
Shift Actuator Housing Assembly………………………..134
Shift Actuator Housing Installation…………………….136
Shimming Shift Actuator Housing………………………..136
Assembly of Sterndrive………………………………..138
Pressure and Vacuum Testing Sterndrive………………….139
Pressure Testing……………………………………..140
Vacuum Testing……………………………………….140
Sterndrive Filling……………………………………140
Specifications…………………………………………..144
Sealants, Lubricants and Adhesives…………………………145
Service Chart……………………………………………146
SX Lower Gearcase……………………………………………147
Special Tools……………………………………………148
Lower Gearcase Removal……………………………………149
Lower Gearcase Disassembly………………………………..150
Propshaft Bearing Housing Service………………………150
Seal and Bearing Removal………………………………151
Seal and Bearing Installation………………………….151
Propshaft Bearing Removal……………………………..152
Propshaft Bearing Installation…………………………153
Intermediate Driveshaft and Water Tube Guide Removal……..153
Driveshaft and Gear Removal……………………………154
Pinion Bearing Removal………………………………..157
Driveshaft Bearing Removal and Installation……………..157
Pinion Shimming………………………………………158
Lower Gearcase Assembly…………………………………..160
Propshaft Gear – Bearing Installation…………………..161
Propshaft Gear Shimming……………………………….161
Propshaft Gear – Bearing Cup Installation……………….162
Pinion Bearing Installation……………………………163
Driveshaft and Gear Installation……………………….164
Setting Initial Rolling Torque…………………………165
Initial Propshaft Bearing Housing Shimming………………166
Setting Final Rolling Torque…………………………..167
Gear Lash Checking……………………………………167
Checking Gear Contact – SX Lower Unit…………………..168
Final Propshaft Bearing Housing Shimming………………..170
Propshaft Bearing Housing – Retainer Installation………..171
Lower Gearcase Installation……………………………172
Pressure and Vacuum Testing Sterndrive………………….174
Sterndrive Filling……………………………………175
Specifications…………………………………………..177
Sealants, Lubricants and Adhesives…………………………178
Service Chart……………………………………………179
DP-S Lower Gearcase………………………………………….181
Gearcase Retaining Plate………………………………….182
Special Tools……………………………………………183
Propeller Shaft Runout………………………………..184
Lower Gearcase Removal……………………………………184
Lower Gearease Disassembly………………………………..186
Propeller Shaft Housing Propeller Shaft Removal………….186
Inner Propeller Shaft Removal………………………….187
Water Tube Guide and Anode Removal……………………..188
Driveshaft and Pinion Removal………………………….189
Gearease Bearing and Race Removal………………………190
Lower Driveshaft Bearing………………………………190
Pinion Bearing……………………………………….190
Forward Bearing Race………………………………….191
Propeller Shaft Housing Service……………………………191
Outer Propeller Shaft Service……………………………..193
Forward Gear Service………………………………….196
Driveshaft Service……………………………………197
Magnet Service……………………………………….198
Upper Housing Stud Replacement…………………………199
Pinion Shimming………………………………………199
Forward Gear Shimming…………………………………200
Outer Propeller Shaft Shimming…………………………202
Oil Screen Service – Upper Housing……………………..206
Exhaust Cover Service…………………………………206
Lower Gearcase Assembly…………………………………..207
Gearease Bearing and Race Installation………………….207
Forward Bearing Race………………………………….207
Pinion Bearing……………………………………….207
Lower Driveshaft Bearing………………………………208
Driveshaft and Pinion Installation……………………..209
Setting Initial Rolling Torque…………………………210
Propeller Shaft Housing and Propeller Shaft Installation….211
Setting Final Rolling Torque…………………………..214
Checking Tooth Contact Pattern…………………………216
Adjusting Tooth Contact Pattern and Gear Lash……………217
Final Assembly…………………………………………..218
Lower Gearcase Installation……………………………….219
Pressure and Vacuum Testing……………………………221
Sterndrive Filling……………………………………222
Anode – Testing and Replacement………………………..224
Specifications…………………………………………..225
Sealants, Lubricants and Adhesives…………………………226
Service Chart……………………………………………227
Sterndrive Removal and Installation……………………………229
Sealants, Lubricants and Adhesives…………………………229
Sterndrive Removal……………………………………….229
Sterndrive Installation…………………………………..232
Check and Adjust Trim Sending Unit……………………..237
Shift and Throttle Cable Installation…………………..237
Check Remote Control Shift Cable Stroke…………………237
Shift Cable Installation………………………………238
Throttle Cable Installation……………………………241
Trim/Tilt Hydraulic System……………………………………243
Sealants, Lubricants and Adhesives…………………………243
Special Tools……………………………………………243
System Description……………………………………….244
Reservoir – Checking, Filling and Bleeding………………….244
Troubleshooting – General…………………………………244
Troubleshooting With In-Line Pressure Tester………………..245
How to Install Tester…………………………………….245
System Hydraulic Tests……………………………………245
Test No. 1 – Complete Up Circuit…………………………..245
Test No. 2 – Pump Isolation, Up Circuit…………………….246
Test No. 3 – Complete Down Circuit…………………………246
Test No. 4 – Pump Isolation, Down Circuit…………………..246
Servicing Motor and Pump………………………………….247
Removing Motor and Draining Reservoir…………………..247
Separation of Reservoir and Motor………………………248
Separation of Pump and Manifold………………………..251
Installation of Pump………………………………….251
Installation of Motor and Reservoir…………………….252
Installation of Pump Assembly………………………….253
Servicing Trim/Tilt Cylinders……………………………..254
Filling and Bleeding Dry System………………………..258
Trim Cylinders…………………………………………..258
Trim Motor and Reservoir………………………………258
Hydraulic Pressure Specifications………………………….259
Propellers………………………………………………….261
Sealants, Lubricants and Adhesives…………………………261
Special Tools……………………………………………261
Propeller Selection – SX Models……………………………261
Propeller Removal and Installation – SX Models………………262
Left-Hand Rotation – SX Models…………………………….264
Propeller Selection – DP-S………………………………..264
Propeller Removal and Installation – DP-S Models…………….265
Condition of Boat Bottom………………………………….266
Bottom Painting………………………………………….266
Boat Trailers……………………………………………266
Boat Trim – SX and DP-S…………………………………..267
Propeller Hub Replacement…………………………………267
High Altitude Operation…………………………………..267