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Volvo Penta 120S-E User Manual

Volvo Penta 120S-E
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-E Specifications

General IconGeneral
Cooling SystemFreshwater cooling
Drive TypeSaildrive
WeightApprox. 120 kg
Power Output20 hp
Bore67 mm (2.64 in) , 67 mm (2.64 in), 72 mm (2.83 in)
Stroke72 mm (2.83 in), 72 mm (2.83 in), 73 mm (2.87 in)

Summary

Workshop Manual

Safety Information

Introduction

Provides context and essential guidelines for service work.

Important Warnings

Highlights special warning signs and safety precautions for users.

General Information

About the Workshop Manual

Details the manual's scope, target audience, and update policy.

Repair Instructions

Our Common Responsibility

Emphasizes correct component specification maintenance and adherence to schedules.

Tightening Torque

Lists torque specifications for fasteners and explains torque-angle tightening methods.

Sealants

Describes types of sealants and locking fluids, and proper application procedures.

Safety Rules for Fluorocarbon Rubber

Outlines safety precautions when handling fluorocarbon rubber at high temperatures.

Special Tools

Other Special Equipment

Chemicals

Lists RTV, anaerobic, and polymer preparations and water-resistant grease.

Design and Function

Reverse Gear MS2

Illustrates the forward and reverse positions of the MS2 reverse gear.

Sailboat Drive 120S

Shows forward and reverse positions of the 120S sailboat drive.

History of Sailboat Drives

Details historical changes and updates for the 120S sailboat drive models.

Disassembly - Upper and Lower Gear Housings, Sailboat Drive

Repair - MS2 Reverse Gear and Upper Gear Housing, Sailboat Drive

Gear Shift Mechanism, Disassembly

Step-by-step guide for disassembling the gear shift mechanism.

Gear Shift Mechanism, Assembly

Step-by-step guide for assembling the gear shift mechanism.

Reverse Gear/Upper Gear Housing, Disassembly

Details the process of disassembling the reverse gear and upper housing.

Input Bearing Seal Housing, Disassembly

Procedures for disassembling the input bearing seal housing.

Upper Bearing Housing, Disassembly

Steps for disassembling the upper bearing housing.

Upper Bearing Housing, Assembly

Steps for assembling the upper bearing housing.

Reverse Gear MS2 Output Gear Housing, Disassembly

Procedures for disassembling the MS2 output gear housing.

Reverse Gear MS2 Output Gear Housing, Assembly

Procedures for assembling the MS2 output gear housing.

Reverse Gear MS2 Slipping Clutch, Disassembly

Steps for disassembling the MS2 slipping clutch.

Reverse Gear MS2 Preload

Details procedures for setting the correct bearing preload.

Reverse Gear MS2 Marking Pattern

Explains how to check and adjust the gear marking pattern for optimal contact.

Gear Housing Checking Marking Pattern and Gear Flank Clearance

Instructions for checking gear flank clearance and marking patterns.

Repair of MS2V Reverse Gear, Angle Gear

Tubular Shaft, Disassembly

Steps for disassembling the tubular shaft.

Pinion, Disassembly

Procedures for disassembling the pinion.

Pinion, Assembly

Steps for assembling the pinion.

Flank Clearance, Checking

Procedures for checking flank clearance and marking patterns for the angle gear.

Repair - Lower Gear Housing, Sailboat Drive

Disassembly of the Drive

Steps for disassembling the drive unit.

Vertical Shaft, Disassembly

Procedures for disassembling the vertical shaft.

Vertical Shaft, Assembly

Steps for assembling the vertical shaft.

Propeller Shaft, Shimming

Details how to calculate and adjust shim thickness for the propeller shaft.

Rear Bearing Housing, Shimming

Explains how to calculate shim thickness for the rear bearing housing.

Pre-load

Instructions for checking and setting the shaft pre-load.

Flank Clearance

Procedures for checking and adjusting flank clearance.

Marking Pattern

Instructions for checking and adjusting the marking pattern.

Model 120S Installation, Lower Gear Housing-Adapter Housing

Steps for installing the lower gear housing and adapter housing for Model 120S.

Pressure Testing

Procedures for pressure testing the drive unit for leaks.

Technical Data

Tightening Torque

Comprehensive list of torque specifications for various components and assemblies.

References to Service Bulletins

Report Form

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