Volvo Penta Outdrive 280 280dp 285 290 290dp Workshop Service Repair Manual

Drives Workshop Manual 2(0) B C 280, 280-DP, 285, 290, 290-DP SP-A, SP-C, DP-A, DP-B, DP-C

1 General Information ......................................................... 3 Safety Information ........................................................ 3 Introduction ............................................................. 3 Important ................................................................ 3 General Information ..................................................... 6 About the Workshop Manual .................................. 6 Spare parts ............................................................. 6 Repair Instructions ....................................................... 7 Our joint responsibility ........................................... 7 Tightening torques ................................................. 7 Angular torque ....................................................... 8 Lock nuts ................................................................ 8 Strength classes ..................................................... 8 Sealant ................................................................... 8 Safety instructions for fluororubber ........................ 9 Special tools ................................................................... 10 Chemicals .................................................................. 14 Drive models and generations ...................................... 15 Design and function ....................................................... 19 Model 280 .................................................................. 19 Models 290-DP, DP-A, DP-B, DP-C ........................... 20 Removing the sterndrive ............................................... 21 Models 280, 285 and 290 .......................................... 21 Models SP and DP ..................................................... 25 Repair instructions ........................................................ 29 Upper gear housing ................................................... 29 Removal ............................................................... 29 Disassembly, models 280, 285 and 290 .............. 30 Assembly, models 280, 285 and 290 ................... 35 Disassembly, models 290A, SP and DP .............. 46 Assembly, models 290A, SP and DP ................... 50 Drives AQ 280, AQ 280-DP, AQ 285, AQ 290, AQ 290-DP SP-A, SP-C, DP-A, DP-B, DP-C Contents Reconditioning the universal joint ............................. 62 Reconditioning the shift mechanism ......................... 64 Types of shift mechanisms ................................... 64 Shift mechanism type 1 .................................. 64 Shift mechanism type 2 .................................. 66 Shift mechanism type 3 .................................. 68 Intermediate housing ................................................. 73 Reconditioning the intermediate housing, model 280, 285 and 285A ................................... 73 Assembly ........................................................ 75 Reconditioning the intermediate housing, model 290 and 290A ............................................ 77 Assembly ........................................................ 79 Reconditioning the intermediate housing, models SP and DP ............................................... 82 Lower gear ................................................................. 86 Reconditioning the lower gear, models 280, 285, 290 and SP ............................. 86 Disassembly ................................................... 86 Assembly ........................................................ 90 The propeller shaft ......................................... 93 Shimming ........................................................ 94 Final assembly ............................................... 98 Reconditioning the lower gear, models 280-DP, 290-DP and DP ......................... 99 Disassembly ................................................... 99 Inner propellershaft .................................... 102 Outer propeller shaft .................................... 102 Propeller shaft bearing box ......................... 103 Forward gear ............................................... 104 Vertical shaft ................................................ 104 Assembly ..................................................... 105 Shimming the lower gear to the intermediate housing ................................................................... 120 Shimming the upper gear to the intermediate housing ................................................................... 122 Pressure and vaccum testing ................................. 124

2 Contents Installing the sterndrive .............................................. 125 Models 280 and 285 ............................................... 125 Checking and adjusting controls ...................... 127 Checking the retaining pawl when test running ........................................................ 127 Oil filling ............................................................. 128 Propeller installation ......................................... 128 Installing a ‘long hub’ type of propeller ........ 128 Installing a ‘short hub’ type of propeller ....... 128 The duoprop (earlier model) ....................... 129 Changing the direction of the propeller rotation .............................................................. 129 The electro-mechanical sterndrive tilting device (model 280) .................................. 130 Repair instructions ...................................... 130 Reconditioning the tilting device ................. 131 Model 290, SP and DP ........................................... 132 Adjusting the retaining pawl (model 290) ......... 137 Oil filling ............................................................. 137 Propeller installation ......................................... 138 Installing a ‘long hub’ type of propeller ........ 138 Installing a ‘short hub’ type of propeller ....... 138 Changing the direction of the propeller rotation .............................................................. 139 Adjustment of the trim fin ................................... 140 Twin engine installation .................................... 140 Transom shield ............................................................ 142 Changing trim cylinders, model 290, SP and DP ... 142 Chanching steering helmet .................................... 147 Removal ............................................................ 147 Trim system ................................................................. 150 Changing the sending unit ..................................... 150 Changing the trim system gear rack ....................... 151 Changing the trim system gear wheel .................... 153 The power trim pump .............................................. 155 Removing the trim pump from the boat ............. 156 Removing the oil reservoir ................................ 156 Replacing filters ................................................ 156 Removing the electric motor ............................. 157 Installing the elctric motor ................................. 157 Replacing adapter and pump assembly ........... 157 The relief valve assemblies .............................. 158 Installing the trim pump in the boat ................... 158 Venting system .................................................. 158 Test .................................................................... 158 Adjusting the trim instrument .................................. 158 Checking the trim figure .................................... 159 Adjusting the trim figure .................................... 159 Sterndrive extensions ................................................ 160 Installation instructions for 1” and 4” extensions .... 160 The 4” extension ............................................... 160 The 1” extension ............................................... 161 Welding ......................................................................... 162 Parts that cannot be welded ................................... 162 Parts which can be welded ..................................... 162 Repair instructions .................................................. 162 Painting ........................................................................ 163 Preparing the sterndrive ......................................... 163 Painting the underwater hull ................................... 163 Electrical wiring diagrams .......................................... 164 Model 280 Tilting device ......................................... 164 Model 280, Power trim ............................................ 165 Model 290, Power trim (earlier model) ................... 166 Models 290, SP and DP, Power trim (later model).. 167 Technical data ............................................................. 168 Models 280, 280T, 280PT, 285, 285A and 290 ...... 168 Models 280-DP, 280-DP/PT, 290-DP and 290A-DP .......................................................... 170 Models SP-A, SP-A1, SP-A2 and SP-C .................. 173 Models DP-A, DP-A1, DP-A2, DP-B, DP-B1, DP-C and DP-C1 .................................................... 174 References to Service Bulletin .................................. 176

3 Safety Information Introduction The Workshop Manual contains technical data, descriptions, and repair instructions for the designated Volvo Penta products or product versions. Make sure that the correct workshop literature is used. Read the following safety information and the General Information and Repair Instructions in the Workshop Manual carefully before starting service work. As a rule, all service work should be performed on an idle engine. Some work, e.g. certain adjustments, require the engine to be running. Approaching an engine that is running is a safety risk. Remember that loose clothes or long hair can fasten in rotating parts and cause severe injury. A careless movement or dropped tool while working in the vicinity of an engine that is running, can in the worst case lead to injury. Ob- serve caution on hot surfaces (exhaust pipe, turbo, charge air pipe, starter element etc.) and hot fluids in the lines and hoses of an engine that is running, or has just been started. Refit all guards dismantled during service work before starting the engine. Make sure that the warning or information de- cals on the product are always clearly visible. Replace labels that have been damaged or painted over. Never start the engine unless the air filter is fit- ted. The rotating compressor wheel in the turbo can cause severe injury. Foreign objects in the inlet pipe can also damage the machine. Never use starter spray or the like. Explosion risk in the inlet pipe. Risk of personal injury. Avoid opening the coolant filler cap when the engine is hot. Steam or hot coolant can spray out, and built up pressure will be lost. Open the filler cap slowly and release the overpressure in the cooling system if the filler cap or cock must be opened, or if a plug or coolant pipe must be removed when the engine is hot. Steam or hot coolant can flow out in an unpre- dicted direction. Hot oil can cause burn injuries. Avoid skin contact with hot oil. Make sure that the oil system is not pressurised before working on it. Never start, or run the engine with the oil filler cap removed in view of the risk of ejecting oil. Important The following special warning symbols are used in the Workshop Manual and on the product. WARNING! Warns of risk of bodily injury, serious damage to product or property, or that a serious malfunction can occur if the instructions are not followed. IMPORTANT! Used to attract attention to things that can cause damage or malfunction to product or property. NOTE! Used to attract attention to important information, to simplify work procedures or handling. The following list provides an overview of the risks and cautionary procedures that should always be observed. Prevent the engine from being started by dis- connecting the power with the main switch (switches) and locking it (them) in disconnected mode before the service work is begun. Attach a warning sign in the cabin.

4 General Information Stop the engine and close the bottom valve before working on the cooling system. Only start the engine in a well-ventilated area. Exhaust fumes and crankcase gases should be led out of the engine compartment or workshop when working in closed environments. Always use protective glasses for work where there is a risk of splintering, sparks, or splash- ing of acid or other chemicals. The eyes are extremely sensitive, and an injury can cause blindness! Avoid skin contact with oil! Prolonged or fre- quent skin contact with oil can degrease the skin, resulting in irritation, drying out, eczema, and other skin complaints. Used oil is more dan- gerous than new oil from the health care point of view. Use protective gloves and avoid oil drenched clothes and rags. Wash your hands regularly, especially before meals. Use special hand cream to counteract drying out, and to simplify cleaning the skin. The majority of chemicals intended for the product (e.g. engine and timing gear oils, gly- col, petrol and diesel oil) or chemicals for workshop use (e.g. degreasing agent, enamels and solvents) are hazardous to health. Read the instruction on the pack carefully. Always follow the given safety instructions (e.g. the use of breathing protection, protective glasses, or gloves, etc.) Make sure that other personnel are not exposed to hazardous substances, e.g. by inhaling the air. Make sure there is ade- quate ventilation. Handle consumed and sur- plus chemicals in the prescribed manner. Observe extreme caution when tracing fuel leaks in fuel systems and when testing fuel nozzles. Wear protective glasses. The jet from a fuel nozzle has a very high pressure and penetrating force. The fuel can penetrate deep- ly into bodily tissue and cause serious injury. Risk of blood poisoning. All fuels, in similarity with chemicals, are inflammable. Make sure that naked flames, or sparks, cannot lead to ignition. Petrol, certain thinners, and hydrogen from batteries, are extremely inflammable and explosive when mixed with air. Smoking is prohibited! Ventilate well and take the necessary precautions before conducting welding or grinding work in the im- mediate vicinity. Always have a fire extinguish- er handy in the workshop. Make sure that rags drenched in oil and petrol, including old fuel and lubricant filters, are stored safety. Oil drenched rags can in certain conditions self-ignite. Old fuel and oil filters are environmentally hazardous waste, and together with spent lubricant, contaminated fuel, paint residue, solvent, degreasing agent and suds, should be handed in to a waste handling unit for destruction. Batteries must never be exposed to naked flames or electrical sparks. Never smoke in the vicinity of batteries. Hydrogen develops when batteries are charged, which in combination with air forms an explosive gas. This gas is highly inflammable and very explosive. One spark from connecting the batteries incorrectly is sufficient to cause the battery to explode and cause injury. Do not touch the connection when starting (risk of spark) and do not lean over the batteries. Never confuse the plus and minus terminals when fitting the batteries. This can cause serious damage to the electrical equipment. Check the wiring diagram. Always use protective glasses when charging and handling batteries. The battery electrolyte contains strongly corrosive sulphuric acid. On skin contact, wash with soap and plenty of water. If battery acid gets into the eyes, rinse im- mediately with water, and contact a doctor without delay. Stop the engine and switch off the power with the main switch (switches) before working on the electrical system. Adjustment of the clutch should be conducted when the engine is idle.

5 General Information Use the lifting hooks mounted on the engine/ reverse gear when lifting the drive unit. Always check that the lifting equipment is in good con- dition and has the correct capacity for the lift (weight of engine plus reverse gear and extra equipment where appropriate). For safe handling, and to avoid damaging the components mounted on top of the engine, the engine should always be lifted with a lifting bar adjusted to the engine. All chains or wires should run in parallel with each other and as perpendicular to the top of the engine as possible. Special lifting equipment may be required to ensure the right balance and safe handling if other equipment connected to the engine alters its centre of gravity. Never carry out work on an engine only sup- ported by lifting equipment. Never work alone when heavy components are to be dismantled, even when safe lifting (e.g. lockable block and tackle) equipment is used. In most cases, two persons are required even when lifting equipment is used: one to handle the equipment and one to make sure that components are not damaged. When working onboard a boat always make sure in advance that there is sufficient space to allow dismantling in situ, without the risk of personal injury or damage to materials. WARNING! The components in the electrical system and in the fuel system on Volvo Penta products are designed and manufactured to minimise the risks of explosion and fire. The engine must not be run in environments sur- rounded by explosive media. When cleaning with high-pressure wash, observe the following: Never point the jet of water at seals, rubber hoses, or electrical components. Never use the high-pressure function when washing the engine. NOTE! Pressure pipes must not bent, turned, or exposed to other strain. Replace damaged pressure pipes. Always use Volvo Penta recommended fuel. See the instruction handbook. The use of inferi- or quality fuel can damage the engine. The use of inferior fuel in a diesel engine can cause the control rod to jam and the engine to overspeed, with the risk of personal injury or damage to the machine. Inferior fuel can also lead to higher maintenance costs.

6 General Information About the Workshop Manual This Workshop Manual contains technical information, descriptions, and repair instructions for the standard versions of the drive units 280, 280T, 280PT, 285, 285A, 290, 290A, 280-DP, 280-DP/PT, 290-DP, 290A-DP, SP-A, SP-A1, SP-A2, SP-C, DP-A, DP-A1, DP-A2, DP-B, DP-B1, DP-C and DP-C1. The Workshop Manual can show operations carried out on any of the drives listed above. As a result the illustrations and pictures in the manual that show certain parts on the drives, do not in some cases apply to all the drives listed. However the repair and service operations described are in all essential details the same. Where they are not the same this is stated in the manual and where the difference is considera- ble the operations are described separately. The Drive Designations and Series Number (PZ-No.) can be found on the product plate. Please always include both the drive designation and the PZ number in all correspondence. The Workshop Manual is primarily produced for Volvo Penta service workshops and their qualified personnel. It is therefore assumed that persons using this manual have a basic knowledge of marine drive systems, and can perform the relevant work of a mechanical and electrical nature. Volvo Penta continuously develops its products, and therefore reserves the right to introduce modifica- tions. All the information in this manual is based on product data available prior to publication. Any amendments or service methods of essential impor- tance that have been introduced for the product after this date are confirmed in the form of Service Bulle- tins. Spare parts Spare parts for the electrical and fuel systems are subject to different national safety requirements, e.g. U.S. Coast Guard Safety Regulations. Volvo Penta Genuine Spare Parts comply with these requirements. All types of damage resulting from the use of non genuine Volvo Penta spare parts for the product in question will not be regulated by the warranty undertakings of Volvo Penta.

7 Repair Instructions The work methods described in the Workshop Manual are applicable for a workshop environment. The drive has removed from the boat and is installed in an overhaul fixture. Unless otherwise stated reconditioning work which can be carried out with the drive in place follows the same working method. The warning symbols used in the Workshop Manual (see Safety Information for implication), WARNING! IMPORTANT! NOTE! By no means cover everything since the service work is conducted under a wide range of different conditions, and it is obviously impossible to foresee everything. All that can be done is to point out the risks that can occur from incorrect handling when working in a well-equipped workshop with work methods and tools approved by Volvo Penta. Where Volvo Penta special tools can be used for work procedures, these are described in the Work- shop Manual. The object of special tools is to ensure the safest and most rational work method possible. If other tools or work methods are used than those recommended by Volvo Penta, then it is incumbent on the person using them to ensure that there is no risk of personal injury, damage, or malfunction. In some cases, there are special directions and user instructions for the tools and chemicals named in the Workshop Manual. These directions should always be followed even if there is no special mention of them in the Workshop Manual. Most risks can be prevented by means of taking ele- mentary precautions and using common sense. A clean workplace and a clean drive will eliminate many risks of both personal injury and drive malfunction. Above all when working with bearing unions and sealing unions, it is extremely important to prevent dirt or foreign objects from getting in, since this can result in malfunction or reduce the life span of the repair. Our joint responsibility Every engine consists of a large number of co-ordinat- ed systems and components. The deviation of one component from the technical specification can dra- matically increase the impact on the environment from what is otherwise a good engine. It is therefore extremely important to maintain the given tolerances, to implement the correct adjustments where applicable, and to use Volvo Penta Genuine Parts. The time schedule in the engine’s maintenance schedule must be followed. Certain systems, e.g. components in the fuel system, may require special competence and special testing equipment. For environmental reasons certain components are sealed at the factory and must not be worked on by unauthorised persons. Remember that most chemical products when incorrectly used can be damaging to the environment. Volvo Penta recommends the used of biologically de- composing degreasing agents for all cleaning of engine components, unless otherwise stated in the Workshop Manual. When working onboard boats special care must be observed to prevent oils and suds etc. unintentionally ending up the nature, e.g. via the bilge water. Tightening torques Tightening torque for vital unions, which should be tightened with a torque multiplier, are indicated in the Workshop Manual, Technical data, Tightening torques and the manual’s work descriptions. All torque readings are applicable for clean threads, screw heads and mating surfaces. The torque readings re- fer to lightly oiled or dry thread. If lubricants, locking fluids or sealant are required for screw union, then the type is indicated in the work description. For unions where special torque denotations are not indicated, the general tightening torque is applicable ac- cording to the table below. The torque readings are guide values, and unions do not need to be tightened with a torque multiplier.

Volvo Penta Outdrive 280 280dp 285 290 290dp Workshop Service Repair Manual

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