Transmission and Driveline. Section 2A - Transmission and Driveline
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1 Trnsmission nd Driveline Trnsmission nd Driveline Tle of Contents Section 2A - Trnsmission nd Driveline 2 A Generl Informtion...2A-2 Ger Rtio Selection...2A-2 Engine nd Propeller Shft Instlltion Angle...2A-2 Propeller Shft Rottion nd Spcing on Dul Instlltions...2A-2 Propeller Blde Tip Clernce...2A-3 Propeller Shft Coupling...2A-3 Propeller Shft...2A-4 Propeller Shft Log Sel Connections...2A-4 Trnsmissions...2A-8 Ger Rtios...2A-8 Model Offerings nd Identifiction...2A-9 Propeller Rottion...2A-12 ZF Mrine Trnsmissions DTS...2A-14 Products without Emissions Control...2A-14 Products with Emissions Control...2A-15 Remote Control nd Shift Cle...2A APRIL 2008 Pge 2A-1
2 Trnsmission nd Driveline Generl Informtion Ger Rtio Selection The trnsmission ger rtio nd propeller must provide the optimum mtch etween the engine nd the ot ppliction. Ger rtio nd propeller selection re ffected y numerous fctors including engine horsepower, WOT RPM, hull design, propeller clernce, ot weight, nd other fctors. Severl computer progrms re ville to ssist in nlyzing ll of these vriles nd selecting the proper propeller nd ger rtio. Typiclly, higher reduction trnsmission coupled with slower turning, lrger dimeter propeller provides the est efficiency for lrger, hevier ots. Conversely, lower reduction trnsmission nd smller dimeter, fster turning propeller will generlly provide superior performnce on lighter, fster pplictions (35 mph nd ove). Engine nd Propeller Shft Instlltion Angle Mount the trnsmission nd engine so tht the ngle reltive to horizontl is within the rnge shown on the instlltion drwings. As generl rule, the propeller shft ngle should position properly sized propeller t lest one propeller dimeter elow the wterline. Instlling the engine with the front end too high cn cuse erte the trnsmission fluid nd engine oil. Tke specil cre on 5.7 MPI nd 6.2 MPI V drive pplictions with propeller shft ngles of less thn 9 to void wter reversion prolems through the exhust system. See Exhust System. The exhust elow outlets will hve less thn their prescried mount of downwrd slope with the exhust elows instlled in their norml orienttion. On these pplictions, reverse the exhust elows to get the proper slope. The engine cn e otined from the fctory with this orienttion. NOTE: 5.7 MPI, 6.2 MPI, nd 8.1 model hve n incresed slope in the exhust elow outlets nd cn ccommodte ny propeller shft ngle within the specified rnge in V Drive pplictions, without the need to reverse the elow. Propeller Shft Rottion nd Spcing on Dul Instlltions For est performnce, set up the ot so the propellers rotte outwrd when looking from the stern. As generl rule, insufficient spcing reduces efficiency nd increses virtion. Shft spcing must provide the minimum distnces etween engines s specified in the following tle to llow for servicing. c d d c - Inwrd propeller rottion - Outwrd propeller rottion c - RH rottion d - LH rottion Pge 2A APRIL 2008
3 Minimum Distnce Between Engine Centerlines Trnsmission nd Driveline Model Mesurement Propeller Blde Tip Clernce All Except 8.1 H.O. nd Horizon mm (33 in.) 8.1 H.O. nd Horizon mm (37.5 in.) IMPORTANT: Sufficient clernce is required etween the propeller lde tips nd the ot ottom to prevent wter hmmering ction ginst the hull. Insufficient clernce cn generte excessive noise, virtion, nd cvittion. A clernce of 10 15% of the propeller dimeter is typicl for most ots % of propeller dimeter minimum Propeller Shft Coupling Since the engine hs flexile mounts, some provision must e provided in the propeller shft nd coupling to ccommodte for slight engine movement. On recretionl ots, this is typiclly provided y flexile stuffing ox nd single strut ering. In these cses, rigid propeller shft coupling cn e used. Purchse rigid propeller shft couplings with the engine or through Mercury Precision Prts nd Accessories. Alignment with these couplings is criticl. See Section 3 Engine. To minimize virtion, provide minimum distnce of 20 times the propeller shft dimeter etween the trnmission output flnge nd the first fixed ering. If this distnce is not ville, use flexile coupling. Flexile couplings provide virtion isoltion nd re more tolernt to engine mislignment. They lso reduce the need for periodic relignment of the engine. If using n ftermrket coupling, the flnge must conform with the specifictions on the instlltion drwing. The trnsmission output flnges comply with: Velvet Drive 71C nd ZF 45C SAE J756 Type 410. All other trnsmissions SAE J756 Type 5. All coupler olts must e SAE Grde 8 (Metric Grde 10.9) or etter, with shoulder (grip length) long enough to pss through the coupler nd trnsmission output flnge. Tighten ll coupler olts to specifiction APRIL 2008 Pge 2A-3
4 Trnsmission nd Driveline Propeller Shft Description Nm l-in. l-ft Coupler olts The required propeller shft dimeter cn vry significntly depending on the mteril used, strut nd ering design, engine horsepower, nd shft RPM. Informtion is ville from the propeller shft mnufcturer nd in mrine hndooks for selecting the proper dimeter. Sufficient shft dimeter is criticl for durility nd minimizing virtion. As guideline, the propeller shft should e minimum of 1/14 the dimeter of the propeller. Propeller Shft Log Sel Connections NOTICE Incorrectly instlling the wter supply hose to the shft log sel cn cuse incresed exhust system corrosion or sumersion or freeze dmge due to siphoning. Position nd securely fsten the wter supply hose with portion of the hose ove the engine exhust elows. Route the propeller shft log sel hose so tht portion of the hose extends ove the top of the engine exhust elows to prevent siphoning ction when the engine is not running. Securely fsten the hose to mintin its proper position. 8.1 MODELS WITHOUT EMISSIONS CONTROL 1. Attch the shft log sel cooling hose to the reducer fitting on the end of the strord exhust mnifold. IMPORTANT: Do not remove the reducer fitting, even if you re not using the shft log sel. The reducer fitting hs een crefully sized to mintin the proper pressure lnce in the cooling system Propeller shft log sel connection 8.1 models without emissions control - Reducer fitting 8.1 MODELS WITH EMISSIONS CONTROL 1. Attch the shft log sel cooling wter hose to the ccess port in the reducer fitting, locted on the poppet vlve underneth the exhust mnifold. There is reducer fitting on the port nd strord mnifolds. Pge 2A APRIL 2008
5 Trnsmission nd Driveline IMPORTANT: Do not remove the reducer fitting, even if you re not using the shft log sel. The reducer fitting hs een crefully sized to mintin the proper pressure lnce in the cooling system Shft log sel ccess port 8.1 models with emissions control 2. Route the shft log sel hose so tht portion of the hose extends ove the top of the engine exhust elows. 3. Fsten the hose securely to keep it properly positioned. 5.7 MPI AND 6.2 MPI MODELS WITHOUT EMISSIONS CONTROL A fitting is instlled t the fctory into the proper port on the port exhust elow Propeller shft log sel connection 5.7L nd 6.2L models without emissions control - Shft log sel fitting APRIL 2008 Pge 2A-5
6 Trnsmission nd Driveline 5.7 MPI WITH EMISSIONS CONTROL Engines with sewter cooling - V drive loction Engines with closed cooling - Inline loction IMPORTANT: If not using shft log sel, this fitting must remin plugged. 1. Remove the plug from the exhust port elow. 2. Instll the reducer fitting, shipped with the prts g, to the pplicle loction. 3. Attch the shft log sel cooling wter hose to the reducer fitting. 4. Route the propeller shft log sel hose so tht portion of the hose extends ove the top of the engine exhust elows. 5. Fsten the hose securely to keep it properly positioned. Pge 2A APRIL 2008
7 Trnsmission nd Driveline SCORPION MODELS WITHOUT EMISSIONS CONTROL A rss plug is instlled t the fctory into the proper port on the port exhust elow. In line models - Brss plug V-Drive models IMPORTANT: If not using shft log sel, this fitting must remin plugged. SCORPION 350 WITH EMISSIONS CONTROL A fitting is instlled t the fctory into the proper port on the port exhust elow. Shft log sel fitting IMPORTANT: If not using shft log sel, this fitting must remin plugged. 1. Attch the shft log sel cooling wter hose to the reducer fitting. 2. Route the propeller shft log sel hose so tht portion of the hose extends ove the top of the engine exhust elows. 3. Fsten the hose securely to keep it properly positioned APRIL 2008 Pge 2A-7
8 Trnsmission nd Driveline Trnsmissions Ger Rtios Tow Sports Tow Sports 5.7 TKS Tow Sports 5.7 MPI Scorpion 350 Scorpion 377 Inord 5.7 TKS Inord 5.7 MPI Horizon MPI Horizon H.O. Horizon 8.1 Velvet Drive Ger Rtios Wlter V-Drive Ger Rtios ZF Mrine Ger Rtios 71C 72C 5000A 5000V 45C 71C 45C 63A 63IV 80A 1.0:1 1.0:1 1.0:1 1.0:1 1.0:1 1.46:1 1.46:1 1.0:1 1.0:1 1.0:1 1.0:1 1.0:1 1.25:1 2.8:1 1.25:1 2.8:1 1.25:1 2.8:1 2.7:1 2.7:1 2.7:1 IMPORTANT: 8.1 H.O., nd Horizon 8.1 Models using Velvet Drive 72C 1.0:1R V Drive instlltion only, used with level mounted engine coupled to drive shft with forwrd fcing exhust elows. 2.8:1 Pge 2A APRIL 2008
9 Model Offerings nd Identifiction VELVET DRIVE 71C AND 72C TRANSMISSIONS Trnsmission nd Driveline On ll Velvet Drive In Line 71C nd 72C series trnsmissions, the ger rtio in FORWARD ger is mrked on the identifiction plte. Trnsmission output flnge rottion in FORWARD ger is indicted on decl on the trnsmission cse. Trnsmission rottion is descried when viewed from the rer of trnsmission. c 7424 Velvet Drive 71C nd 72C trnsmissions - Identifiction plte - Ger rtio (in FORWARD ger) c - Output flnge rottion decl (in FORWARD ger) VELVET DRIVE 5000 SERIES TRANSMISSIONS On the Velvet Drive 5000A nd 5000V trnsmissions, the identifiction plte indictes ger rtio, seril numer, nd model A 8 down ngle 5000V 12 V-drive APRIL 2008 Pge 2A-9
10 Trnsmission nd Driveline Identifiction plte ZF MARINE 630 AND 800 SERIES TRANSMISSIONS On the ZF Mrine Down Angle nd V Drive trnsmissions, the identifiction plte indictes ger rtio, seril numer, nd model V-drive 8 down ngle Identifiction plte Pge 2A APRIL 2008
11 ZF MARINE/HURTH 45C Trnsmission nd Driveline The trnsmission identifiction plte is locted on the top rer of the trnsmission Identifiction plte ZF Mrine/Hurth 45C WALTER V-DRIVE TRANSMISSIONS On the Wlter V Drive trnsmissions, the identifiction plte indictes ger rtio, seril numer, nd model Identifiction plte Wlter RV 36 V Drive APRIL 2008 Pge 2A-11
12 Trnsmission nd Driveline Propeller Rottion ZF MARINE 630 AND 800 AND VELVET DRIVE 5000 SERIES TRANSMISSION The ZF Mrine 630, ZF Mrine, nd Velvet Drive 5000 Series trnsmissions re full power reversing trnsmissions, llowing stndrd LH rottion engine (viewed from flywheel end) to e used for oth propeller rottions. Propeller rottion (output flnge rottion) is determined y shift cle ttchment t the remote control. d c e 7648 Velvet Drive 5000A 8 down ngle d f g Velvet Drive 5000V V Drive - Direction of shift lever enggement (towrd flywheel) - Trnsmission input shft rottion direction (LH) c - Trnsmission output shft rottion direction (LH s viewed t propeller) d - Direction of shift lever enggement (wy from flywheel) 7649 e - Trnsmission output shft rottion direction (RH s viewed t propeller) f - Trnsmission output shft rottion direction (LH s viewed t propeller) g - Trnsmission output shft rottion direction (RH s viewed t the propeller) Pge 2A APRIL 2008
13 Trnsmission nd Driveline d c e 7650 ZF Mrine 630A nd 800 down ngle trnsmissions d c e 7651 ZF Mrine 630V V drive trnsmissions - Direction of shift lever enggement (towrd flywheel) - Trnsmission input shft rottion direction (LH) c - Trnsmission output shft rottion direction (RH s viewed t propeller) d - Direction of shift lever enggement (wy from flywheel) e - Trnsmission output shft rottion direction (LH s viewed t propeller) VELVET DRIVE 71C AND 72C TRANSMISSIONS NOTICE An incorrect propeller cn dmge the trnsmission. Ensure tht the rottion of the propeller mtches tht listed on the output flnge rottion decl. Alwys instll the correct rottion propeller nd drive the ot forwrd using forwrd ger APRIL 2008 Pge 2A-13
14 Trnsmission nd Driveline The 1:1 ger rtio version of this trnsmission hs LH output flnge rottion when in forwrd ger. This is the sme s the engine rottion nd is referenced from the rer of the engine. A LH rottion propeller must e used on these pplictions (except Wlter V drive ppliction where the rottion is estlished y the ger ox). The trnsmission cn only e operted under full power when in the forwrd ger position. Velvet Drive 71C nd 72C trnsmission - Output flnge rottion decl - Direction of rottion in forwrd ger ZF Mrine Trnsmissions DTS Products without Emissions Control The oil temperture sensor for the ZF Mrine trnsmissions with electronic shift is not instlled t the fctory. An llen plug is instlled in the port for shipping. The oil temperture sensor is provided in prts g ZF Mrine trnsmission DTS (oil temperture sensor not instlled) Pge 2A APRIL 2008
15 Trnsmission nd Driveline Remove the llen plug nd instll the oil temperture sensor. Connect the wire connections, of the hrness, to the oil temperture sensor. Products with Emissions Control ZF Mrine trnsmission DTS (oil temperture sensor instlled) - Oil temperture sensor - Oil temperture sensor wire connections On the ZF Mrine Trnsmissions, the trnsmission identifiction plte indictes ger rtio, seril numer, nd model. Trnsmission output shft rottion nd propeller rottion required (in forwrd ger) re indicted on decl on the trnsmission cse. Trnsmission rottion is descried when viewed from the rer of trnsmission. Remote Control nd Shift Cle Trnsmission identifiction plte See Section 9 Instrumenttion nd Controls APRIL 2008 Pge 2A-15
16 Trnsmission nd Driveline Notes: Pge 2A APRIL 2008
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