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Volvo Penta 120S-D User Manual

Volvo Penta 120S-D
88 pages
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MS2, MS2B-A, MS2B-L, MS2A-D
MS2A-E, MS2L-D, MS2L-E, MS2V
120S, 120S-B, 120S-C, 120S-D, 120S-E
Workshop manual
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Table of Contents

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Volvo Penta 120S-D Specifications

General IconGeneral
Engine Model120S-D
Engine TypeDiesel
Power Output120 hp
Number of Cylinders4
Stroke90 mm
Max RPM4000
Cooling SystemFreshwater cooling
Fuel SystemDirect injection

Summary

Safety Information and Precautions

Introduction to Safety

Provides an overview of the workshop manual's safety information and general instructions.

Important Warning Signs

Details the meaning of warning signs like WARNING!, IMPORTANT!, and NOTE! used in the manual.

General Information for Workshop Manual Users

About This Workshop Manual

Explains the manual's scope, target audience, and reliance on product data availability.

Volvo Penta Original Spare Parts

Stresses the importance of using genuine Volvo Penta spares for warranty and safety.

Repair Instructions and Guidelines

Our Common Responsibility in Repair

Highlights the importance of maintaining technical specifications and using correct procedures.

Tightening Torque Specifications

Details tightening torques for vital fasteners and general torque values.

Sealants and Their Application

Describes various types of sealants and locking fluids used in engine assembly.

Special Tools for Repair Procedures

Lists and illustrates specialized tools required for specific repair operations.

Special Equipment and Chemicals

Design and Function Overview

History of Sailboat Drives

Outlines historical development and changes in sailboat drive models.

Disassembly of Gear Housings

Provides step-by-step instructions for disassembling upper and lower gear housings.

Repair of MS2 Reverse Gear and Upper Housing

Gear Shift Mechanism Disassembly and Assembly

Detailed steps for dismantling and reassembling the gear shift mechanism.

Reverse Gear Housing Disassembly

Instructions for disassembling the main reverse gear and upper housing components.

Input Bearing Housing Installation

Guide for installing the input bearing housing, including shims and bearing races.

Flank Clearance Measurement

Procedures for measuring and adjusting gear flank clearance.

Marking Pattern Check

Instructions on how to apply marking dye and check gear tooth contact patterns.

Repair of MS2V Reverse Gear and Angle Gear

Tubular Shaft Disassembly

Step-by-step guide for removing the tubular shaft and related components.

Pinion Disassembly and Assembly

Procedures for dismantling and reassembling the pinion and its bearings.

Angle Drive Final Assembly

Instructions for assembling the angle drive and connecting it to the reverse gear.

Repair of Lower Gear Housing and Sailboat Drive

Disassembly of the Drive Unit

Steps for dismantling the lower gear housing and drive components.

Vertical Shaft Assembly

Guide for assembling the vertical shaft, including bearings and ferrules.

Propeller Shaft Shimming Procedures

Methods for calculating and installing shims for propeller shaft alignment.

Flank Clearance Checking

Process for measuring and adjusting flank clearance on the propeller shaft.

Marking Pattern Analysis

Instructions for analyzing gear marking patterns to ensure correct tooth contact.

Technical Data

References to Service Bulletins

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