Volvo Penta AQUAMATIC 290-DP Workshop Manual
  1. Manuals
  2. Brands
  3. Volvo Penta Manuals
  4. Outboard Motor
  5. AQUAMATIC 290-DP
  6. Workshop manual

Volvo Penta AQUAMATIC 290-DP Workshop Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the AQUAMATIC 290-DP and is the answer not in the manual?

Questions and answers

Related Manuals for Volvo Penta AQUAMATIC 290-DP

Summary of Contents for Volvo Penta AQUAMATIC 290-DP

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

  • Page 4: Table Of Contents

    Drives AQ 280, AQ 280-DP, AQ 285, AQ 290, AQ 290-DP SP-A, SP-C, DP-A, DP-B, DP-C Contents General Information ............3 Reconditioning the universal joint ......62 Safety Information ............3 Reconditioning the shift mechanism ......64 Introduction ............. 3 Types of shift mechanisms ........
  • Page 5 Contents Installing the sterndrive ..........125 Installing the elctric motor ......... 157 Models 280 and 285 ..........125 Replacing adapter and pump assembly ... 157 Checking and adjusting controls ...... 127 The relief valve assemblies ......158 Checking the retaining pawl when Installing the trim pump in the boat ....

  • Page 6: General Information

    Approaching an engine that is running is a scriptions, and repair instructions for the designated safety risk. Remember that loose clothes or Volvo Penta products or product versions. Make sure long hair can fasten in rotating parts and cause that the correct workshop literature is used.
  • Page 7 General Information Stop the engine and close the bottom valve be- All fuels, in similarity with chemicals, are inflam- fore working on the cooling system. mable. Make sure that naked flames, or sparks, cannot lead to ignition. Petrol, certain thinners, and hydrogen from batteries, are ex- Only start the engine in a well-ventilated area.
  • Page 8 Use the lifting hooks mounted on the engine/ WARNING! The components in the electrical reverse gear when lifting the drive unit. Always system and in the fuel system on Volvo Penta check that the lifting equipment is in good con- products are designed and manufactured to dition and has the correct capacity for the lift minimise the risks of explosion and fire.

  • Page 9: General Information

    All types of damage resulting from the use of 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. non genuine Volvo Penta spare parts for the product in question will not be regulated by the warranty The Workshop Manual can show operations carried undertakings of Volvo Penta.

  • Page 10: Repair Instructions

    The warning symbols used in the Workshop Manual implement the correct adjustments where applicable, (see Safety Information for implication), and to use Volvo Penta Genuine Parts. The time schedule in the engine’s maintenance schedule must WARNING! be followed.

  • Page 11: Angular Torque

    General Information Size Tightening torque, Nm (lb.ft) Safety instructions for M5 ............(4.4) fluororubber M6 ............(7.4) M8 ............(18.4) Fluororubber is a common material used in sealing M10 ............ (36.9) rings for shafts and O-rings. M12 ............ (59.0) Hydrofluoric acid is formed when fluororubber is M14 ............

  • Page 12: Safety Instructions For Fluororubber

    Workshop Manual: properties but of other manufacture, should be used ® during the service work. Volvo Penta part no. 1161053-2 (alternative Loctite 243) When using sealant and locking fluids it is important Volvo Penta part no.1161351-0 (alterantive Loctite ®...

  • Page 13: Special Tools

    Special tools In all cases where it has been practically possible tools have been punched with their tool number, excluding the last digit. The last digit (after the hyphen) is a check number. 839643 854668 873058 884140 884143 884161 884168 884241 884259 884263...
  • Page 14 Special tools 884267 884283 884298 884311 884312 884316 884348 884381 884385 884386 884387 884483 884502 884521 884789 884792 884573 884793 884267-6 Tool, dismantling vertical shaft 884386-4 Sleeve, dismantling and installing gear wheels in upper gear 884283-3 Drift for the installation of sealing rings in propeller bearing housing and of propeller 884387-2 Attachment plate for upper gear housing...
  • Page 15 Special tools 884794 884795 884796 884797 884798 884799 884801 884802 884803 884806 884807 884830 884831 884832 884874 884932 884933 884936 884938 884941 8 84831-9 884794-9 Puller, forward bearing race remover, low- Press fixture, bearing race remover, low- 884795-6 Bearing install tool, lower 884832-7 Drift set, tube gear race remover, lower 884796-4...
  • Page 16 Special tools 884975 884976 884978 884982 885008 885009 885043 885127 885143 885146 885148 885149 885153 885192 885197 885207 885208 885209 885226 885227 884975-4 Installation tool 885148-7 Pin remover, intermediate 884976-2 Protection sleeve 885149-5 Drilling jigg, duoprop, lower 884978-8 Trim cylinder removal tool, intermediate 885152-9 Kit containing tools 884387 and 885153 884982-0...

  • Page 17: Chemicals

    Spring gauge/scale, upper 3850608-5 Snap ring plyers, upper 9991801-3 Standard shaft 3855876-3 Tool, new type of propeller nut 9992520-8 Stand Chemicals Volvo Penta part no.: 1141570-0 Sealant for drives 1161053-2 Thread locking compound 1161099-5 Sealing compound 1161351-0 Bushing installation adhesive...

  • Page 18: Drive Models And Generations

    Drive models and generations AQ 280 AQ 280T Power trim/tilt Oil: Ratio: Oil: Ratio: Same as engine 1.61:1 Same as engine 1.61 Qty: 2.6 liters (2.74 qts) 1.89:1 Qty: 2.6 liters (2.74 qts) 2.15:1 AQ285 AQ 280 PT AQ 285A Power trim Electro mechanical tilt Power steering...
  • Page 19 Drive models and generations AQ 280-DP/PT AQ 280-DP Dual hydraulic cylinders Ratio: Ratio: Oil: Oil: 1.95:1 1.95:1 API GL-5, SAE 90 API GL-5, SAE 90 2.30:1 2.30:1 Qty: 2.7 liters (2.85 qts) Qty: 2.7 liters (2.85 qts) AQ 290 AQ 290-DP AQ 290A AQ 290A-DP Transom shield...
  • Page 20 Drive models and generations SP-C SP-A2 Sliding sleeve (steel) Sliding sleeve (steel) Sliding sleeve (brass) Cover Intermediate housing Gear set Cover Hydraulic cylinder Hook up fork Support plate Sliding sleeve (brass) Gear set Oil: Ratio: Same as engine 1.61:1 (all SP-C drives) Oil: Ratio: 1.89:1...
  • Page 21 Drive models and generations DP-B1 DP-C Sliding sleeve (steel) Cover Cover Ball bearing Intermediate housing Universal joint Hydraulic cylinder Intermediate housing Hook up fork Transom shield Oil: Ratio: Oil: Ratio: Fully synthetic 1.78:1 Fully synthetic 1.78:1 API GL-5 SAE 75W–90 1.95:1 API GL-5 SAE 75W–90 1.95:1...

  • Page 22: Design And Function

    Design and function Model 280 Section through the sterndrive 1. Steering arm 2. Electro-mechanical tilting device 3. Steering yoke 4. Rubber cushion 5. Universal joint 6. Steering helmet 7. Input gear 8. Forward/reverse gear 9. Forward/reverse cone 10. Upper gear housing 11.

  • Page 23: Models 290-Dp, Dp-A, Dp-B, Dp-C

    Design and function Models 290-DP, DP-A, DP-B, DP-C Section through the sterndrive, showing model DP 1. Transom shield 2. Trim cylinder 3. Hook up fork 4. Steering yoke 5. Steering helmet 6. Universal joint 7. Input gear 8. Forward/reverse gear 10.

  • Page 24: Removing The Sterndrive

    Removing the sterndrive Models 280, 285 and 290 Alt 2 Alt 1 1. Remove the propeller of the Singleprop sterndrive according to the picture. A-propeller 2. Remove the propellers of the Duoprop sterndrive B-propeller according to the picture. (The picture shows the earlier model.) NOTE! Never mix propellers from different drives.
  • Page 25 Removing the sterndrive 3. Remove the Allen-head bolts holding the zinc ring and remove it. 5b. Sterndrive model 290: Remove the cover over the shift mechanism and disconnect the shift cable from the shift plate and remove the swivel. Remove the screws holding the locking plate, then push the locking plate down.
  • Page 26 Removing the sterndrive WARNING! Never start working on the rubber WARNING! Never start working on the stern- bellows of the sterndrive until you have secured drive rubber bellows or on the hydraulics until it in its raised position and then in a way which the sterndrive is securely locked in its raised definitely keeps it up.
  • Page 27 Removing the sterndrive 8b. Sterndrive model 290: Remove the two locking screws holding the shaft journals in the transom shield. Support the sterndrive from underneath and 7b. Sterndrive model 290: Remove the steering hel- met and the universal joint rubber bellows from the up- knock out the shaft journals using a brass drift or per gear housing (1), the exhaust bellows from the in- some similar tool.

  • Page 28: Models Sp And Dp

    Removing the sterndrive Models SP and DP 1. Disconnect power to prevent accidental starting. 4. Move control to forward gear. 2. Move control to reverse. 5. Remove the aft line cutter, forward propeller nut, and forward propeller. Return the shift control to neu- tral.
  • Page 29 Removing the sterndrive 7. Remove the cotter pin and washer from the shift 9. Remove the two screws (1) holding the steering pin cable end. Remove the end pivot pin from the cable. to the upper gear head (2). Using two M6 screws (3) 30 mm or longer, install into the threaded holes of the steering pin.
  • Page 30 Removing the sterndrive 885143 885143 11. Remove the cotter pin on the trim cylinder pin. Re- 13. Remove the clamp on the raw water hose. Re- move the trim cylinder pin. Raise the drive manually move the raw water hose. Remove special tool and insert special tool 885143.
  • Page 31 Removing the sterndrive 885146 15. Install special tool 885146 and remove the stern- drive from the transom shield.

  • Page 32: Repair Instructions

    Repair instructions Upper gear housing Removal 1. Place a drain pan under the sterndrive. Remove the 3. Remove two retaining nuts from upper gear head drain plug (1) and drain oil from drive. Reinstall the studs. drain plug after the oil has drained. 2.

  • Page 33: Disassembly, Models 280, 285 And 290

    Repair instructions Disassembly, models 280, 285 and 290 3. Remove the 7 screws holding the lower gear hous- ing to the intermediate housing. Use a rubber mallet and knock the housings carefully apart. Lift off the splines sleeve (1). 1. Remove the shift rod (1) from the shift plate (2). Re- NOTE! On sterndrives of later manufacture the 4 big- move the screws (3) and the nuts (4) holding the in- ger-sized screws are installed with stainless steel...
  • Page 34 Repair instructions 5. Remove the 4 screws holding the shift mechanism and remove the mechanism. 7. Remove the 4 screws holding the gear housing cov- NOTE! Be sure to remove the shift shoe (1) with the er and remove the cover. shift mechanism.
  • Page 35 Repair instructions 11. Remove the needle bearings (1) and the spacer 9. Lift out the upper gear and the bearing box as well rings (2) from the upper and lower gear sets. as the engagement sleeve. NOTE! The needle bearings are matched in pairs and must not be mixed! 884259 884386...
  • Page 36 Repair instructions 884265 884386 15. Remove the collar washer (1) from the double 13. Press out the bearings of the bearing sleeves. bearing box. Use special tools 884386 and 884265. NOTE! Take care of the shims (2). Input gear (Double bearing box) 16.
  • Page 37 Repair instructions 18. If required press off the roller bearing (1) from the gear using a knife puller. The bearings (1) and (4) can be changed separately. When changing the out- er races of the bearings, these must be ”knocked” off.

  • Page 38: Assembly, Models 280, 285 And 290

    Repair instructions Assembly, models 280, 285 and 290 NOTE! When assembling the upper gear housing it is very important that the gears are correctly positioned in relation to each other. This applies not only to the backlash between the gear teeth but also to the gear teeth contact.
  • Page 39 Repair instructions Forward and reverse gears 884265 884168 5. Measure the depth of the recess in the collar wash- er “E” and add to this measurement a number of 7. Lubricate the bearings (1) and press the bearings shims (5) that the measurement “B” is obtained. into their respective bearing boxes (2).
  • Page 40 Repair instructions Shimming the forward and reverse gears Method 1 11. Only the decimal values of the “B” and “C” di- mensions are stamped into the upper gear housing. The nominal value for both “B” and “C” is 61.00 mm (2.40”).
  • Page 41 Repair instructions Checking the gear backlash and NOTE! When calculating the shim thickness for the forward and reverse gears, remember: contact pattern The upper gear housing nominal dimension has two values. If the stamped number is 50 or more, use the lower nominal value, 61.00 mm.
  • Page 42 Repair instructions 884387 15. Brace the special tool 884387 in a vice and install 17. Install the clamp ring and the cover with sufficient the gear housing in the tool. number of shims to ensure a proper compression of the bearings. There must be a clearance (1) between the housing and the clamp ring.
  • Page 43 Repair instructions 19. When the correct backlash has been obtained, 21. Dismantle the gear set and compare the contact dismantle the double bearing box and the clamp ring. pattern to that of the picture “A”. This picture shows In order to obtain a clear picture of the contact pat- the desired pattern for the drive side of the forward tern, the gear teeth are coated with a thin coating of and reverse gear.
  • Page 44 Repair instructions Final assembly 23. If the dye pattern reflects a contact pattern as shown in picture “C” the shim thickness underneath the drive gear (double bearing box) must be increased. The drive then moves away from the center. NOTE! If the drive is moved in or out respectively, also the gears must be moved in or out in order to maintain the correct backlash.
  • Page 45 Repair instructions 884830 5. In order to obtain the correct axial shaft clearance 3. Install the needle bearings (1) and the spacer ring there are 3 left hand threaded nuts (1) with different (2) between the bearings in the lower gear and insert steps available.
  • Page 46 Repair instructions 9991801 884312 8. Remove the recessed washer and the shims in it. 7. Measure the shim thickness between the clamp Press the new sealing ring against the collar in the ring and the gear housing as follows: double bearing box, with the open part against the Hold the double bearing box as indicated in the picture bearing.
  • Page 47 Repair instructions 12. Apply Volvo Penta part no. 1161099-5, Permatex ® 10. Install the shims and the 2 new O-rings on the double bearing box. no. 3 on the surfaces between the clamp ring and gear housing. Install the double bearing box along with the universal joint in the gear housing.
  • Page 48 Repair instructions 14. Coat the contact surface with Volvo Penta part no. 1141570-0 sealant and install the sealing ring (1) in a way that the sealing for the front right hand screw aligns with the corresponding recess in the cover.

  • Page 49: Disassembly, Models 290A, Sp And Dp

    Repair instructions Disassembly, models 290A, SP and DP NOTE! The illustrations show drives model DP, but the working methods are the same as for models 290A and SP. 3. Loosen and remove the 4 allen head bolts holding the double bearing box. 884264 884830 1.
  • Page 50 Repair instructions 7. Remove the left hand thread nut on the vertical shaft. Use special tool 884830 and the spline shaft as a counter-hold while removing the nut. 5. Remove the 4 screws holding the gear housing cov- 8. Lift out the upper bearing assembly along with the sliding sleeve and the spring.
  • Page 51 Repair instructions 884259 SP & DP 290A 884938 11b. Drives without intgrated bearings: Press out the bearings from the bearing sleeves. Use special tools 884938 and 884265. 10. Remove the needle bearings (1) from the upper and lower gear cup assemblies. Model 290A only: Also remove the spacerring (2).
  • Page 52 Repair instructions 884263 3850608 15. Turn over the double bearing box and press out 13. Use special tool 3850608 to remove the locking the seal ring along with the roller bearing. Use special ring (1), remove the shoulder washer (2). tool 884263.

  • Page 53: Assembly, Models 290A, Sp And Dp

    Repair instructions Assembly, models 9991801 290A, SP and DP 884933 NOTE! When assembling the upper gear housing it is very important that the gears are correctly positioned in relation to each other. This applies not only to the backlash between the gear teeth but also to the gear teeth contact.
  • Page 54 Repair instructions 884263 9991801 884932 884938 2. Install the bigger roller bearing on the gear wheel by 4. Press down the sealing ring to the shoulder. Use pressing it on. Use special tool 884263. special tool 884932 with handle 991801 and special tool 884938.
  • Page 55 9985494. Pre-stressing new bear- ings: 10–15 N (2,20–3,30 lbs). NOTE! Apply thread locking compound, Volvo Penta Prestressing used bearings: 7,5–10 N (1,6–2,2 lbs). ® part no. 1161053-0 or Loctite 243 on the screw.
  • Page 56 Repair instructions Forward and reverse gears 884265 884168 8a. Drives without integrated bearings: 9. Always start by adjusting the forward gear. If the previously dismantled gears are to be used, it is im- Lubricate the bearings (1) and press the bearing into portant not to mix forward and reverse gears with each their respective bearing boxes (2).
  • Page 57 Repair instructions Shimming the forward and reverse gears Method 1 12. Only the decimal values of the “B” and “C” di- mensions are stamped into the upper gear housing. The nominal value for both “B” and “C” is 61.00 mm (2.40”).
  • Page 58 Repair instructions Checking the gear backlash and NOTE! When calculating the shim thickness for the forward and reverse gears, remember: contact pattern The upper gear housing nominal dimension has two values. If the stamped number is 50 or more, use the lower nominal value, 61.00 mm.
  • Page 59 Repair instructions 884387 885153 16 a. Drives with integrated bearings 18. Use sufficient number of shims to create clear- From models SP-A1 and DP-A1 on ance of max. 0.1 mm (0.004”) between the top cover and the upper gear housing as shown in the picture. Brace the special tool 884387 plate and ring 885153 Install the cover and tighten the cover screws.
  • Page 60 Repair instructions 20. Remove the double bearing box when the correct 22. Dismantle the gear set and compare the contact backlash has been obtained. pattern to that of the picture “A”. This picture shows the desired pattern for the drive side of the forward To gain a clearer picture of the contact pattern, coat and reverse gear.
  • Page 61 Repair instructions Final assembly 24. If the dye pattern reflects a contact pattern as shown in picture “C” the shim thickness underneath the drive gear (double bearing box) must be in- creased. The drive then moves away from the cent- NOTE! If the drive is moved in or out respectively, 1.
  • Page 62 Repair instructions SP & DP 290A 290A SP & DP 3. Install the needle bearings (1) and the spacer ring 5. Place the upper gear wheel with the calculated (2, model 290A only) between the bearings in the shims in the gear housing. Install the needle bearings lower gear and insert the shaft in the gear.
  • Page 63 Repair instructions 7. Measure the clearance between the nut and the 9. Coat the surfaces between the double bearing box bearing. The axial clearance should be 0.1–0.5 mm, and the gear housing with sealing compound, Volvo ® 0.00394–0.0197"). If it should not be possible to ob- Penta part no.
  • Page 64 Repair instructions 11. Coat the cover with sealant, Volvo Penta part no. 12. Insert the calculated shims and tighten the cover. 1141570-0 and install the sealing ring (1) so that the NOTE! The front, right hand screw is a hollow screw,...

  • Page 65: Reconditioning The Universal Joint

    Repair instructions Reconditioning the universal joint 3. Try to ease out the bearing using a pair of pliers or 1. Remove the locking rings (1) holding the needle ® bearing in the yoke. Channel Lock pliers. If this is unsuccessful the bear- ing can be driven out by using a hammer and a drift NOTE! To avoid having the locking rings “jump out”...
  • Page 66 Repair instructions 5. Use a small amount of water resistant EP bearing grease, Volvo Penta part no. 1161246-2, to retain the needle bearings in the cap. Push the spider through the yoke in one direction to allow the needle bearing to align with the spider.

  • Page 67: Reconditioning The Shift Mechanism

    Repair instructions Reconditioning the shift mechanism Shift mechanism type 1 Types of shift mechanisms For the models 280, 290, 285, 285A and 290A there are 3 different types of shift mechanism. The first type was installed up to and including serial no PZ 2829528.
  • Page 68 6. Install the spring (1), the shift shoe (2) and the lock it with the load pin (3). Make sure that the load O-ring (3) and coat the contact surfaces with sealing pin centers in the excentric piston. compound, Volvo Penta part no. 1161099-5 or ® Permatex no. 3.

  • Page 69: Shift Mechanism Type 2

    Models 290 and 290A: Add one more shim to the screw (1). Coat the shim/shims and the screw with sealing compound, Volvo Penta part no. 1161099-5, or 8. Knock out the load pin (1, figure above) and pull out ®...
  • Page 70 11. Install the spring (1), the sliding shoe (2) and the 9. Lubricate the sealing ring abundantly and install it O-ring (3) and coat the contact surfaces with sealing with the steel edge (small clearance) facing inwards compound, Volvo Penta part no. 1161099-5, or the gear housing. Permatex ®...

  • Page 71: Shift Mechanism Type 3

    Models 290 and 290A: Add one more shim to the screw (1). When the adjustment is done, coat the shims and the screw with sealing compound, Volvo Penta part no. ® 1161099-5, or Permatex no. 3 and tighten the screw.
  • Page 72 Repair instructions 19. Tap the eccentric piston lightly on a wooden sur- face to remove the spring pin (1). Inspect the eccen- tric piston for scoring, distortion, or damage that may cause it to leak or bind in the housing. 16.
  • Page 73 23. Install a new O-ring (3) and insert the spring (2) and the sliding shoe (1). Coat the contact surface with Volvo Penta part no. 1141570-0 sealant. 25. Set the shift mechanism in a position between forward and neutral or between reverse and neutral.
  • Page 74 Models 290 and 290A: Add one more shim to the screw. When the adjustment is done, coat the shims and the screw with sealing compound, Volvo Penta part no. ® 1161099-5, or Permatex no. 3 and then tighten the screw.
  • Page 75 After the proper amount of shims have been estab- lished add one more shim to the shimming screw. Coat the shimming screw threads with Volvo Penta sealing compound, part no. 1161099-5, and install. Tighten the shimming screw to 14–16 Nm (10–12 lb.ft.).

  • Page 76: Intermediate Housing

    Repair instructions Intermediate housing Reconditioning the intermediate housing, model 280 and 285 3. Remove the plastic washers (1) and the wear wash- er (2). 1. Remove the 2 screws holding the hose connection (1) on the yoke. Remove the hose connection and the gasket.
  • Page 77 Repair instructions 884259 7. Dismantle the axial bearing race. Use special tools 884140 and 884143. Also replace the O-rings (1). One at each end of the tube. 5. Press out the bushing (1). Use special tool 884259. 6. Should the shift yoke need to be replaced, remove the cotter pin (1).

  • Page 78: Assembly

    Repair instructions Assembly Oil all moving parts and the screws prior to as- sembly. 10. Paint the retaining pawl with a thin layer of ‘touch-up paint’. Painting is hard to do when the pawl is assembled. The picture reflects an assembled retaining pawl. 9991801 884259 9.
  • Page 79 Be very careful during the installation of the steering spindle in order to avoid damaging the lower sealing ring. 13. Glue the bushing to the yoke. Use bushing installation adhesive, Volvo Penta part no. 11161351-0 or Loctite ® 603 . The flange must be turned downwards against the retaining pawl.

  • Page 80: Reconditioning The Intermediate Housing

    Repair instructions Reconditioning the intermediate housing, model 290 and 290A 16. Install the shift yoke (3) and push in the shaft (2) and lock it with the cotter pin (1). NOTE! A washer must be installed on either side of the cotter pin.
  • Page 81 Repair instructions 9991801 884259 5. Should the shift yoke be in need of being replaced, remove the cotter pin (1). Then pull out the shaft (2) and remove the shift yoke (3). 3. Press out the sealing rings and the needle bearing. Use special tools 884259 and 9991801.

  • Page 82: Assembly

    Repair instructions 7. If necessary the retaining pawl is dismantled as fol- 9. Paint the retaining pawl with a thin layer of lows: ”touch-up paint”. Painting is hard to do when the pawl is assembled. Remove the shaft journals (42). Remove the spring (43) the spring (40) and the springs (44).
  • Page 83 Repair instructions 11. Press in both sealing rings. Use special tool 13. Place the yoke and the wear washer (1) on the in- 884259. termediate housing and push in the steering spindle (2) as far as to hold the wear washer. NOTE! The sealing rings are to seal against water and thus have to be installed ”facing”...
  • Page 84 18. Install the shift yoke (3) and push in the shaft (2) yoke. Coat the surfaces with sealing compound, and lock it with the cotter pin (1). ® Volvo Penta part no. 1161099-5 or Permatex no. 3. NOTE! Install a washer on each side of the cotter pin!

  • Page 85: Reconditioning The Intermediate Housing, Models Sp And Dp

    Repair instructions Reconditioning the intermediate housing, models 9991801 SP and DP 884259 3. Press out the lower steering spindle bushing. Use special tools 884259 and 9991801. 1. Remove the 2 screws holding the hose connection. Remove the hose connection and the gasket. 9991801 9991801 884311...
  • Page 86 Repair instructions 9991801 884259 5. Should the shift fork require replacement, remove 7. Grease the lower hook up fork bushing with Volvo the cotter pin (1). Remove the shaft (2) and remove Penta part np. 828250-1 water resistant grease. Using the shift yoke (3).
  • Page 87 10. Push the steering spindle (1) through the interme- 12. Install the O-ring and the hose connection on the yoke. Use a small amount of Volvo Penta part no. diate housing exhaust port (2) stopping short of the 828250-1 water resistant grease to hold the O-ring in upper hook up fork bushing.
  • Page 88 Repair instructions 13. Install the shift yoke (3). Align the shift yoke with the shaft hole in the intermediate housing. Push the shaft (2) through and lock it with a new cotter pin (1).

  • Page 89: Lower Gear

    Repair instructions Lower gear Reconditioning the lower gear, models 280, 285, 290 and SP Disassembly The propeller shaft 885192 884830 9992520 3. Use special tool 884830 and install the lower gear upside down. 1. Install the suspension fixture 885192 in stand 884161 99922520 and brace the lower unit in the stand.
  • Page 90 Repair instructions 884168 5. Remove the 6 nuts holding the washer (1) and 7. Press off the gear wheel and the bearing from the knock the propeller shaft out of the bearing housing. propeller shaft simultaneously. Use special tool Use a copper mallet or its equivalent in order not to 884168.
  • Page 91 Repair instructions 9. Knock out the 2 sealing rings (1) off the propeller bearing housing. 11b. Models 280, 290 of later manufacture: Lift the gear housing off the special tool and place it back in the work stand. Remove the nylock® nut with a hook spanner wrench.
  • Page 92 Repair instructions 884381 884143 13. Lift out the pinion (1) and the needle bearing wash- 15. Press (knock) off the outer ring of the needle bear- er (2). ing. Use special tools 884381 and 884143. Insert the tool from underneath and the shaft from above. NOTE! The needle bearing is a full needle type of bearing with loose needles (3).

  • Page 93: Assembly

    Repair instructions Assembly Oil all moving parts and the screws prior to as- sembly. 884316 17. Should the needle bearing of the propeller shaft be damaged, use special tool 884316 to remove it. In- sert the puller into the needle bearing in a way that the barbs of the puller end up at the backside of the needles.
  • Page 94 Repair instructions 884266 5. Install the spacer pad (1) on the ball bearing and 3. Grease abundantly the outer race (1) with grease press on the roller bearing. Use special tool 884266. and insert the 27 needles, well cleaned, into the ring letting the grease hold them.
  • Page 95 Repair instructions 6b. Models 280, 290 of later manufacture: Install the 8. Install the vertical shaft with a 0.35 mm (0.14") thick spacer ring and tighten the plastic insert locknut. thick shims package (1) consisting of a paper shim Use a hook spanner wrench. 0.25 mm (0.01") between two metal shims 0.05 mm (0.002") each.

  • Page 96: The Propeller Shaft

    Repair instructions The propeller shaft 884140 884143 10. Remove the conical roller bearing race in the inter- mediate housing (if the old bearing can still be used). 12. Install the oil deflector (1) and the locking ring (2) Use special tools 884140 and 884143. on the gear wheel (3).

  • Page 97: Shimming

    Repair instructions 884263 884265 16. Install the locking washer (1) and the round nut (2). Tighten the nut and lock it with the locking washer (3). 14. Press on the gear wheel on the propeller shaft. Use special tools 884265 and 884263. Shimming Method 1 884168...
  • Page 98 Repair instructions Method 2 2. The gear length is fixed at 5.85 mm (0.230"). Add 3. Insert the 0.2 mm (0.008") shim (1) in the propeller or subtract the plus or minus marking of the gear bearing housing. This is a value of experience. wheel.
  • Page 99 Repair instructions 5. Install the propeller shaft with its bearing box in the gear housing. Tighten the screws with a torque of 40 Nm (29.5 lb.ft.). NOTE! The two O-rings (1) on the bearing housing should not be installed. 7. If the backlash is found not to be correct, adjust as follows: If the method 1 has been used: If the backlash is too small, increase the shim thickness underneath...
  • Page 100 Repair instructions 884830 11. Should the contact pattern correspond to that of picture “B”, reduce the shim thickness for the vertical shaft and the propeller shaft. 9. Install special tool 884830 onto the splines end and turn the gear in the set direction of rotation, clockwise for left handed propeller.

  • Page 101: Final Assembly

    1. Dismantle pinion and gear and clean parts from ing. Coat the contact surfaces and the screws with marking dye and then assemble with the calculated sealing compound, Volvo Penta part no. 1161099-5 or shims. Then install the spacer ring, the locking ring ®...

  • Page 102: Reconditioning The Lower Gear, Models 280-Dp, 290-Dp And Dp

    Repair instructions Reconditioning the lower gear, models 280-DP, 290-DP and DP 885192 Disassembly 1. Clean the sterndrive externally. 9992520 4. Install the suspension fixture 885192 in stand 99922520 and brace the lower unit in the stand. 2. Drain the oil by removing the screw (1), if not al- ready drained in previous steps.
  • Page 103 Repair instructions 10. Install special tool 885197 on the inner propeller shaft. 7. Remove the two Allen-head screws from the propel- ler bearing housing. Key width: ”. 884802 884789 11. Install special tool 884802 over the inner propeller 884161 shaft. Add the washer and nut from tool 885197. The slot in the end of the tool should face the pinion gear.
  • Page 104 Repair instructions 13. Remove the nut from the pinion gear. 14b. NOTE! Sterndrives model 280 and 290 of earlier manufacture have a lock washer (1) and a round nut Use a 23 mm wrench. (2) instead of a Nylock nut. Knock down the locking ®...

  • Page 105: Inner Propellershaft

    Repair instructions Inner propeller shaft 884797 16. Remove the pinion gear and the front gear from the lower unit housing. The forward gear should be free to remove from the housing with the forward bear- ing attached to the gear. 19.

  • Page 106: Propeller Shaft Bearing Box

    Repair instructions 23. Remove the inner needle bearing and seals using special tools 884803 and 884143. Install special tool 884789 to protect the propeller shaft threads. NOTE! If you only want to replace the seals, it is still easier to remove the seals along with the bearings. 21.

  • Page 107: Forward Gear

    Repair instructions Vertical shaft 884796 9991801 25. Remove the outer bearing race using special tools 27. Use a knife puller to remove the bearings one by 884796 and handle 9991801. one or together. IMPORTANT! Center the tool carefully. Locate a IMPORTANT! Use spline socket 3850598 to pair of wooden blocks underneath the bearing protect the splines when pressing off the...

  • Page 108: Assembly

    Repair instructions NOTE! When calculating the shim thickness for the lower unit gears, remember: The lower unit gear housing nominal dimension has two values: If the stamped number is 50 or more, use the lower nominal value: 60.00 mm. If the stamped number is 49 or less, use the higher nominal value: 61.00 mm.
  • Page 109 Repair instructions 3. The nominal measurement of the forward gear is 39.50 mm. The tolerance (±) is engraved on the gear. All engraved numbers are decimal millimeters. In this instance, “-10” equals -0.10 mm. The real measure- ment of the gear is 39.50 - 0.10 = 39.40 mm. 884793 Add the height of the forward roller bearing to the real measurement of the forward gear:...
  • Page 110 Repair instructions 884793 884263 8. Press a new inner bearing race onto the vertical shaft. Use special tool 884793. 884799 6. Use special tool 884263 to press the gear and bear- ing assembly onto the propeller shaft. Use special tool 884799 to protect the bearing.
  • Page 111 Repair instructions 11a. Sterndrives model 280 and 290 of earlier man- ufacture: Install the thick spacer ring (1), the locking washer (2) and the round nut (3) on the vertical shaft. NOTE! Install the nut with the even side facing up- wards.
  • Page 112 Repair instructions 14. The nominal measurement of the vertical shaft is 217.75 mm. This measurement is added to the cal- culated pinion measurement of 59.95 mm. This com- bined distance equals 277.70 mm, as illustrated be- low: Add: Vertical Shaft Nominal 217.75 mm Pinion Calculated +59.95 mm...
  • Page 113 Repair instructions 18. Hold the pinion nut with a 23 mm socket. Use spe- cial tool 884830, or 3850598 as an alternative, and a torque wrench. Torque the vertical shaft to 110 Nm (81.5 lb.ft.). 20. Find the stamping “C” on the bearing box. In this WARNING! Be careful not to allow the case, “C”=25.
  • Page 114 Repair instructions 23. Add the gear measurement to the bearing nominal Shimming the outer propeller shaft dimension. Add: Gear measurement 39.60 mm Nominal bearing height + 20.75 mm Total aft gear dimension 60.35 mm Now subtract the total aft gear dimension from the bearing box location.
  • Page 115 Repair instructions 27. Now add the front and rear gear shims. Add: Forward gear shims 0.60 mm 884797 Aft gear shims + 0.31 mm 0.91 mm Add nominal value + 120.00 mm 120.91 mm The shim thickness is obtained by subtracting: Subtract: 121.51 mm 25.
  • Page 116 Repair instructions 32. Apply marking dye on the convex side of the aft 884806 gear. Place the calculated shims for the intermediate bearing and the intermediate bearing on the inner pro- peller shaft. Install special tool 885197 onto the threads until the tool bottoms. 29.
  • Page 117 Repair instructions 884348 37. Using a depth gauge, measure “B” in special tool 884348. Subtract measurement “A” from measure- ment “B”. B – A = positive result ( clearance dimension) B – A = negative result (preload) 35. Grease the bearing box and install on the lower Tolerances: Max.
  • Page 118 Repair instructions Checking preload Checking backlash Propeller Nut 39. After calculating the shims required according to points “A” and “B”, place the calculated shim on top of the bearing race and install special tool 884830 on the vertical shaft. Use torque gauge 9999177 and 41.
  • Page 119 Repair instructions 884795 43. Move the dial indicator gauge to the outer nut. Measure the backlash of the rear gear the same way as the front gear. The clearance should be 0.15– 0.27 mm (0.006–0.010”), which is 0.20–0.35 mm (0.008–0.014”) at the gear. 45.
  • Page 120 Repair instructions Final assembly 47. If the contact pattern is toward the root of the tooth and at the big end, the shims should be in- creased under the front and rear roller bearing (1, fig- ure under point 44). To maintain correct bearing preload, reduce the shims under the intermediate bearing (3) by a corresponding amount.
  • Page 121 Repair instructions 884975 884976 6. Insert the protective ring 884976 into the outer propeller shaft seals so that the seal lips are protected during installation. 3. Grease the new seal rings and install in the propel- ler shaft. Turn the steel edge (1) facing forward. Use special tool 884975.
  • Page 122 9. Install new O-rings (1) on the bearing box. Coat the 12. Install the zinc ring on the lower gear housing. entire sealing surface and O-rings with Volvo Penta Check to make sure that the contact surfaces are clean and there is a good electrical contact.

  • Page 123: Shimming The Lower Gear To The Intermediate Housing

    (1) on the vertical shaft with the groove in the up position. Coat the contact surfaces with a B – A = positive result ( clearance dimension) thin coating of Volvo Penta part no. 1141570-0 seal- B – A = negative result (preload) ant.
  • Page 124 Repair instructions 5. Use new screws and washers. Coat the screw threads with thread locking compound, Volvo Penta part no. 1161053-2, or Loctite ® 243. Tighten the 4 larger screws diagonally and in se- quence with a torque wrench to 38 Nm (28 lb.ft.). Use special tool 885008.

  • Page 125: Shimming The Upper Gear To The Intermediate Housing

    0.06 mm shim to preload the upper gear head bearing. Apply a light coating of Volvo Penta part no. 1141570 1. Measure the distance from the bottom of the upper sealant to the mating surfaces of the intermediate gear housing to the top of the outer bearing race (A).
  • Page 126 Repair instructions 7. Install the shift linkage rod, washer and cotter pin. 5. Install the O-ring (1) on the upper gear. WARNING! Always use a new cotter pin. Never reuse a cotter pin that has been removed. 885009 885008 6. Install the upper gear housing on the intermediate housing.

  • Page 127: Pressure And Vaccum Testing

    Repair instructions Pressure and vacuum testing Before filling the drive with gear oil, it must be pres- a) Connect a pressure tester 3810152 to the drain hole sure and vacuum tested to verify proper sealing during and pressurise the drive to 21–35 kPa. Turn the pro- assembly.

  • Page 128: Installing The Sterndrive

    Repair instructions Installing the sterndrive Models 280 and 285 There are 2 types of exhaust bellows. One type with 2. Check to make sure that the hole in the suspension an exhaust valve and one without. The exhaust bel- yoke for the push rod is chamfered. The chamfer lows with an exhaust valve installed should be used should be 1 mm ×...
  • Page 129 Repair instructions 4. Hang the hose clamp for the rubber bellows of the universal joint on the “neck” of the gear housing. Grease the splines of the universal joint and those of the shaft with grease. Push the sterndrive gently against the drive shaft.

  • Page 130: Checking And Adjusting Controls

    Lock the thrust sleeve and the counter nut with locking compound, Volvo Penta part no. 1161053-2. Check that the retaining pawl touches the under- side of the adjusting pin. If it doesn’t probably...

  • Page 131: Oil Filling

    Repair instructions Installing a ‘short hub’ type of Oil filling propeller (B) 1. Install the oil drain plug with a new O-ring. Grease the propeller shaft with a thin layer of 2. Tilt the sterndrive to the full up position. Remove grease.

  • Page 132: The Duoprop, Earlier Model

    Repair instructions The Duoprop, earlier model Changing the direction of the Check the speed range of the relevant boat and select propeller rotation the correct propeller. See Propeller recommenda- tions . NOTE! The propellers are supplied matched in pairs and must not be mixed. Install the propellers as follows: Grease the propeller The upper gear is designed in a way it does not have shaft and install the fishing line deflector (1) and the...

  • Page 133: The Electro-Mechanical Sterndrive Tilting Device (Model 280)

    Repair instructions Install the overload circuit breaker as follows: The electro-mechanical Install the overload circuit breaker (1) on the tran- sterndrive tilting device, som, close to the sterndrive tilting device. Remove the minus wire (earth), (blue), from the flywheel model 280/285 housing sufficiently to allow the wire to be connected to the overload circuit breaker and then back to the flywheel housing.

  • Page 134: Reconditioning The Tilting Device

    Repair instructions 1c. Mechanical fault Checking after reconditioning Check to make sure that the cover does not press Check after the installation that the tilt and retaining against the limit switch by removing the cover and pawl mechanism function properly. When tilting, the testing the function of the tilting device.

  • Page 135: Model 290, Sp And Dp

    Repair instructions Models 290, SP and DP 1. Install the exhaust bellows on the transom shield. 3. Remove the locking screw and remove the sus- Turn the hose clamp so that the tightening screw pension pin. Grease the suspension pins with Volvo ends up at two o’clock with the head pointing down- Penta low temperature grease 1161417-9 and install in wards.
  • Page 136 Repair instructions 885146 5. Remove the cover over the shift mechanism. 7. Install the plastic bushings (1) in the holes (2) of Hang a hose clamp on the sterndrive and install the the suspension yoke. yoke on the sterndrive. Then lift up the sterndrive and hang it in the tool 885146.
  • Page 137 Tighten the locking screws. Prior to the tightening of the screws, grease them with low temperature grease, Volvo Penta part no. 1141644-3. NOTE! Don’t forget the washer under the screw heads.
  • Page 138 Repair instructions 885143 13. Pull down the retaining pawl and lift up the stern- 15. Check to make sure that all bellows and hoses drive sufficiently to allow the installation of special have been installed correctly and well tightened. tool 885143 between the transom shield and the sus- Tilt the sterndrive and turn it fully both ways and pension yoke.
  • Page 139 Grease the attachment (2) with low temperature grease, Volvo Penta part no. 1161417-9. Install the attachment in the helmet bushing with the recessed holes vertical (one hole over the other).

  • Page 140: Adjusting The Retaining Pawl (Model 290)

    Repair instructions Oil filling 1. Install the oil drain plug with a new O-ring (1). Adjusting the retaining pawl, model 290 Set the control lever in the ‘Forward’ position and check that the lever (8) does not touch the hous- ing.

  • Page 141: Propeller Installation

    Repair instructions Propeller installation Locking the propeller cone on sterndrives of earlier Install the spacer ring (2). manufacture is done by a folding washer and on stern- Install and tighten the propeller cone (1). drives of later manufacture by a locking screw through Install and tighten the center bolt (6).

  • Page 142: Changing The Direction Of The Propeller Rotation

    Repair instructions Changing the direction of the propeller rotation, SP drives On the propeller hub there is a ‘L’ for left hand rotating and a ‘R’ for right hand rotating propeller. Also the size of the propeller is stamped into the hub, for instance 15×19 where 15 denotes the diameter in inches and 19 the pitch, also in inches.

  • Page 143: Adjustment Of The Trim Fin

    Repair instructions Adjustment of trim fin The trim fin is factory set at 5 ° towards port side. Af- ter installation the adjustment of the trim fin should be checked and, if necessary, corrected according to figures below. This is a basic adjustment. An exact adjustment can only be done after a test run with the servo unit disconnected.
  • Page 144 Repair instructions NOTE! that later propellers, both A and B propellers, are painted black. To identify the two types, the rear propeller has a sticker on the front end of the hub. Propellers with a green/yellow sticker (A propellers) shall only be used with diesel engines. Propellers with a red/yellow sticker (B propellers) shall only be used with petrol/gasoline engines.

  • Page 145: Transom Shield

    Transom shield Trim cylinders, later models Changing trim cylinders, models 290, SP and DP 1. Remove the sterndrive when the boat is on land. Also remove the exhaust bellows and the universal joint bellows. Remove if necessary barnacles etc and clean the shield.
  • Page 146 The dowel pin will then be pushed out and the was removed. trim cylinder can be removed. Use grease nipple, Volvo Penta part no. 940194. 884978 7. Remove the locking bolt for the trim cylinder dowel 9. If the dowel pin will not come out by using a grease pin.
  • Page 147 Transom shield 11. Always use a new O-ring (1) on the dowel pin dur- ing reassembly. Check the pin hole and pin for scratches or other damage. Position (2) is the locking bolt. IMPORTANT! The transom must have cutouts called for on the transom template to allow suffi- cient clearance for the pins to be removed.
  • Page 148 For more information on electrochemical corrosion, con- sult publication 7733534-7 Marine Electrical Systems available from Volvo Penta parts. 15b. Starboard cylinder: Install the plastic plug (D). Install the sterndrive according to chapter Installing the Sterndrive .
  • Page 149 Transom shield Trim cylinders, all models Trim Trim pump, pump, Trim later earlier pump, model model earlier model IMPORTANT! The hydraulic pump must be in- stalled vertically, as reflected by the picture. 16. Remove the oil filler/indicator plug to check the oil level.

  • Page 150: Chanching Steering Helmet

    Transom shield Changing steering helmet Steering Fork Steering Helmet 21. Loosen the tiller arm set screw using a 5/32 allen wrench. To ensure the integrity of the steering system the steering helmet is not serviceable as a separate part from the steering fork. If there is a problem with the steering helmet or the steering fork, they must be re- placed as a unit.
  • Page 151 Transom shield 25. Make sure the square/the splines on the steering fork and the tiller arm are aligned. 23. Install a new bushing (8) into the new steering fork. 26. Using a rubber mallet tap on the steering fork into position 24.
  • Page 152 Transom shield 28. Install a new seal (9) and O-ring (7) on the gear wheel. Install the trim sending unit, gear wheel and gear rack. See chapter Trim System .

  • Page 153: Trim System

    Trim system Changing the sending unit 3. Install the sending unit housing into the steering 1. Lower the sterndrive to the full down position. Turn shaft on the transom shield. Rotate the sending unit the helm full starboard. Using a 13 mm wrench, re- slightly to align the drive coupling with the gear wheel.

  • Page 154: Changing The Trim System Gear Rack

    Trim system Changing the trim system gear rack 5. -4 should be shown in the instrument window for a 12º transom angle. Move the sending unit in either direction until the correct number is displayed on the trim gauge. Other transom angle settings are as fol- lows: Transom angle Instrument indication...
  • Page 155 Trim system 3. Turn the gear wheel until the tooth with a white re- cessed marking appears. 6. Install the screw and carefully tighten. NOTE! It is recommended that a new screw be used whenever the gear rack is removed. WARNING! Do not overtighten the screw.

  • Page 156: Changing The Trim System Gear Wheel

    Trim system Changing the trim system gear wheel 1. Remove the sterndrive according to the section in- stallation and removal. 8. -4 should be shown in the instrument window for a 12º transom angle. Move the sending unit in either direction until the correct number is displayed on the trim gauge.
  • Page 157 4. Grease the new gear wheel shaft and O-ring liberal- 6. Push the steering helmet into position with the ly with Volvo Penta Propeller shaft grease 828250-1. marked tooth of the gear wheel engaging the first Install the new gear wheel with the marked tooth point- notch of the gear rack.

  • Page 158: The Power Trim Pump

    Trim system 8. After all adjustments are made, tighten the trim sender bracket hold down screw. Be sure the sending unit does not move when the bracket is tightened. The power trim pump The parts illustrated are those available as replace- ment parts or complete assemblies.

  • Page 159: Removing The Trim Pump From The Boat

    Trim system Removing the trim pump from the Removing the oil reservoir boat Turn off the main battery switch. Disconnect the trim pump wiring harness, ground cable from the fly- wheel housing, and the positive (+) cable from the starter motor. Remove the center bolt (1), together with the O-ring (2) and sleeve (3) that holds the plastic reservoir, us- ing an 8 mm socket.

  • Page 160: Removing The Electric Motor

    Trim system Replacing adapter and pump assembly To install a new filter, place a 5/8" socket over the fil- ter and gently tap it down using a hammer. Removing the electric motor The adapter and pump assembly contain no servicea- ble parts and are replaced as a complete unit.

  • Page 161: The Relief Valve Assemblies

    Trim system Venting system The relief valve assemblies Reconnect main battery switch and operate the trim If the original factory fitted valves have to be re- pump (system is self-bleeding). Re-check the oil level moved, this will alter the factory setting, and new and add if necessary.

  • Page 162: Checking The Trim Figure

    Trim system Checking the trim figure 4. The instrument, when trimmed down and with a known transom angle, shows the following figures, 1. Turn the ignition key to the ignition position (the see table below: lights are on). Transom angle Instrument indication 10°...

  • Page 163: Sterndrive Extensions

    Re- move the splines sleeve. Coat the contact surface with a sealant, Volvo Penta part no. 1141570-0. Use the 3 new O-rings and the oil NOTE! When installing a 1" extension the washers will pipe from the extension kit.

  • Page 164: The 1" Extension

    Sterndrive extensions The 1" extension Tightening torques – see the picture! Install the cover over the shift mechanism. Coat the contact surfaces with a sealant. Use the 3 new O-rings and the oil pipe from the extension kit. In- If the paint has been damaged, use touch-up paint to stall the extension on the lower gear housing.

  • Page 165: Welding

    (i.e. shaft. near bearing locations). Always use Volvo Penta The lower unit housing on the cavitation plate and welding electrode 839643-4 when making any weld- the exhaust channel except around the bearing ing repairs to the sterndrive or transom shield.

  • Page 166: Painting

    Leave an area of 10 mm (1/2”) around craft. In these cases ask your Volvo Penta dealer the shield unpainted. for advice about alternative methods.

  • Page 167: Electrical Wiring Diagrams

    Electrical wiring diagrams R 1.5 Model 280, tilting device R 1.5 Down References: Diesel 1. Relay box 2. Relay 3. Limit switch 4. Push rod, retaining pawl 5. Connector 6. Electrical motor 7. Switch 8. Warning light 9. Key switch 10.

  • Page 168: Model 280, Power Trim

    Electrical wiring diagrams Model 280, Power trim Down Ground IV/SB GN/R Attach to flywheel housing GN/Y To engine fuse battery side Power lead Battery 1. Pump motor 6. Trim gauge 2. Relay 7. Sender 3. Fuse 8. Relay 4. Switch 9.

  • Page 169: Model 290, Power Trim Earlier Model

    Electrical wiring diagrams Model 290, Power trim Earlier model Cable colour codes 1. Oil pump 2. Fuse 55 amps = red 3. Trim sender = black 4. Trim indicator 5. Switch = green 6. Switch-relay, position ”Beach” = blue 7. Connection instrument panel 8.

  • Page 170: Models 290, Sp And Dp, Power Trim Later Model

    Electrical wiring diagrams Models 290, SP and DP, Power trim Later model 1. Oil pump 2. Fuse 55 amps 3. Trim sender 4. Trim indicator 5. Switch 6. Switch-relay, position ”Beach” 7. Connection instrument panel 8. Instrument lighting 9. Throttle hook-up (optional) 10.

  • Page 171: Technical Data

    Technical data Models 280, 280T, 280PT, 285, 285A and 290 General Data Type designation ..............Aquamatic 280, 285 & 290 Shift Mechanism ..............Self adjusting Silent Shift type of cone clutch, servo assisted disengagement. Direction of rota- tion adjustable. Maximum propeller diameter ...........
  • Page 172 Input gear in double bearing box, run-in gears, 290A ....7.5–10 N (1.65–2.2 lb.) Alt. Volvo Penta oil for petrol or diesel engines. See Owners Manual. Early production drives were filled with engine oil and have that recommendation in the Owner’s Manual. Late production drives have ATF oil filled.

  • Page 173: Models 280-Dp, 280Dp/Pt, 290Dp And 290A-Dp

    Technical data Models 280-DP, 280DP/PT, 290DP and 290A-DP General Data Type designation ..............Aquamatic DuoProp Shift mechanism ..............Self adjusting Silent Shaft type of cone clutch, servo assisted disengagement. Direction of rota- tion adjustable. Maximum propeller diameter ........... 16" Maximum tilt angle, approx ............. 60°...
  • Page 174 Technical Data Lubricating system Pump, type ................Circulation pump for distribution of oil to all lubri- cating points Oil quality ................API GL5 Viscosity ................. SAE 90 or 80W90 Oil quantity, approx ..............2.7 liters (2.8 US Qts.) Oil quantity, 1" extension, approx........... 2.7 liters (2.8 US Qts.) Oil quantity, 4"...

  • Page 175: Models Sp-A, Sp-A1, Sp-A2 And Sp-C

    Technical data Models SP-A, SP-A1, SP-A2 and SP-C GeneralData Type designation ..............Aquamatic SP-A, SP-A1, SP-A2 & SP-C Shift mechanism ..............Self adjusting Silent Shaft type of cone clutch, servo assisted disengagement. Maximum Propeller diameter ........... 16” Maximum tilt angle, approx............. 60"...
  • Page 176 Technical Data Tightening torques Lb. ft. Upper nut on vertical shaft (upper gear) ........Tightening universal joint ............Assembly double bearing box - gear housing ......Assembly of top cover to upper gear housing ......Lower nut on vertical shaft ............Bearing box with propeller shaft in gear housing ......

  • Page 177: Models Dp-A, Dp-A1, Dp-A2, Dp-B, Dp-B1, Dp-C And Dp-C1

    Technical data Models DP-A, DP-A1, DP-A2, DP-B, DP-B1, DP-C and DP-C1 General Data Type designation ..............Aquamatic DUOPROP Shift mechanism ..............Self adjusting Silent Shaft type of cone clutch, servo assisted disengagement. Maximum tilt angle, approx ............. 60" Power Trim & tilting device ............. “Power Trim”...
  • Page 178 Technical Data Tightening torques Lb. ft. Upper nut on vertical shaft (upper gear) ........Tightening universal joint ............Assembly double bearing box - gear housing ......Assembly of top cover to upper gear housing ......Lower nut on vertical shaft ............Bearing box with propeller shaft in gear housing ......

  • Page 179: References To Service Bulletin

    References to Service Bulletins Group Date Concerning ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 180 From: ....................................................................Refers to publication: ............................. Publication No.: ............. Date of issue: ..............Proposal/motivation: ....................................................................................................................................................................................................................................................................................................................Date: ..............Signed: ............. AB Volvo Penta Technical Information Dept. 42200 SE-405 08 Göteborg Sweden...

Table of Contents

Save PDF