Manual, Stepdrive for 290

PRM Marine Transmissions Installation & Service Manual StepDrive

Installation & Service Manual

2-Speed Automatic Transmission for retro fitting to:

Volvo 290DP drive leg, versions C, D and E.

© Newage Transmissions Ltd, 2004. All rights reserved. No part of this publication may be reproduced without the written Permission of the copyright owner.


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Congratulations on your purchase of

Foreword The PRM StepDrive has been specifically designed for retro fitting to the Volvo Penta 290-DP drive leg, issues C, D and E. Provided it is correctly installed and maintained it should provide a long and trouble free life, and giving the owner the following advantages over the existing single speed drive:

? Improved acceleration ? Reduced creep speed ? Smoother FWD / REV selection ? Improved fuel economy, less smoke and less vibration.

This Workshop Manual is intended primarily for StepDrive dealers and therefore assumes a basic knowledge of marine drive systems and electrical competence with Volvo engine installations. It is of utmost importance that the instructions are followed to ensure that the unit operates as intended. Newage Transmissions Ltd continuously develops its products, and as such reserves the right to modify StepDrive as required; any amendments deemed pertinent to the Manual will be introduced via service bulletins. Newage Transmissions Ltd can accept no responsibility under warranty or otherwise for any loss or damage resulting from failure to observe these instructions. To avoid prejudicing your rights under war ranty, do not undertake any repair or other work on the gearbox during the warranty period without first contacting Newage Transmissions Ltd or an authorised distributor for advice. In the event of failure, you should do this via the StepDrive distributor who supplied the gearbox; if this is not possible, you should notify Newage Transmissions Ltd. direct, quoting the serial number.


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Content

1 GENERAL INFORMATION ........................................................................................................................... 1 1.1 SERVICE PARTS............................................................................................................................................... 1 1.2 PRE-DELIVERY TEST....................................................................................................................................... 1 1.3 IDENTIFICATION .............................................................................................................................................. 1 1.4 TECHNICAL OVERVIEW OF STEP DRIVE ....................................................................................................... 2

1.4.1 Control.................................................................................................................................................... 2 1.4.2 Hydraulics.............................................................................................................................................. 3 1.4.3 StepDrive Layout...................................................................................................................................5

2 INSTALLING STEPDRIVE ............................................................................................................................. 6 2.1 REMOVING THE STERNDRIVE........................................................................................................................ 6 2.2 PARTS REQUIRED............................................................................................................................................. 7 2.3 DISASSEMBLY OF DRIVE LEG........................................................................................................................ 7 2.4 SHIMMING FOR THE STEP DRIVE ................................................................................................................... 8 2.5 BUILDING STEP DRIVE INTO THE LEG .......................................................................................................... 9

2.5.1 Assembling to the Lower Section........................................................................................................ 9 2.5.2 Assembling to the Upper Section......................................................................................................10 2.5.3 Joining the StepDrive.........................................................................................................................11 2.5.4 Refitting the Sterndrive.......................................................................................................................12

2.6 ONBOARD.......................................................................................................................................................14 2.6.1 Helm Controls......................................................................................................................................14 2.6.2 Switch Box............................................................................................................................................15 2.6.3 Engine Compartment..........................................................................................................................17 2.6.4 Outside the boat...................................................................................................................................19

3 TESTING..............................................................................................................................................................20 3.1 POST ASSEMBLY TESTING............................................................................................................................20

4 WARRANTY.......................................................................................................................................................21 4.1 VALIDITY PERIOD.........................................................................................................................................21 4.2 STEP DRIVE PRODUCT ...................................................................................................................................21 4.3 LIMITATION OF LIABILITY...........................................................................................................................22 4.4 ITEMS NOT SUPPLIED BY NEWAGE..............................................................................................................22 4.5 ADVICE ...........................................................................................................................................................22 4.6 ILLUSTRATION OF WARRANTY COVER......................................................................................................22 4.7 TRANSFERABLE WARRANTY.......................................................................................................................23 4.8 STOLEN STEP DRIVE UNIT............................................................................................................................23

5 SERVICING ........................................................................................................................................................24

6 PARTS LIST........................................................................................................................................................25 6.1 STEP DRIVE GENERAL ASSEMBLY – MAIN GEARBOX .............................................................................25 6.2 STEP DRIVE GENERAL ASSEMBLY – TOP MANIFOLD..............................................................................27 6.3 MAINSHAFT ASSEMBLY...............................................................................................................................29 6.4 LAYSHAFT ASSEMBLY.................................................................................................................................30 6.5 SOLENOID HOUSING ASSEMBLY.................................................................................................................31 6.6 PUMP MANIFOLD ASSEMBLY......................................................................................................................32 6.7 NON-RETURN VALVE SUB-ASSEMBLY .....................................................................................................33 6.8 SOLENOID COVER ASSEMBLY.....................................................................................................................33 6.9 RELIEF VALVE ASSEMBLY..........................................................................................................................34 6.10 FILTER KIT (MT0516-KIT).........................................................................................................................34 6.11 INSIDE THE BOX .............................................................................................................................................35 6.12 STEP DRIVE FAULT FINDING CHART ..........................................................................................................38


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Table of Figures Figure 1 – Serial Plate ______________________________________________________________ 1 Figure 2 – Control Box ______________________________________________________________ 2 Figure 3 – Hydraulics Schematic_______________________________________________________ 3 Figure 4 – Cooling Flow Schematic ____________________________________________________ 4 Figure 5 – Power Flow through StepDrive _______________________________________________ 5 Figure 6 – Ratio equation ____________________________________________________________ 5 Figure 7 – ‘O’ rings for Volvo Bottom Gear Housing _______________________________________ 9 Figure 8 – Photo showing even spreading of Loctite 518 sealant _______________________________ 9 Figure 9 – ‘O’ Rings for Volvo Top Gearbox_____________________________________________ 10 Figure 10 – Photo showing even spreading of Loctite 518 sealant_____________________________ 10 Figure 11 – ‘O’ rings for StepDrive joining______________________________________________ 11 Figure 12 – Photo showing even spreading of Loctite 518 sealant_____________________________ 11 Figure 13 – Painted and Anti-fouled Drives. _____________________________________________ 13 Figure 14 – Example of Switch box location._____________________________________________ 15 Figure 15 - Connecting the plug for the Switch Box________________________________________ 16 Figure 16 - Template for Switch Box ___________________________________________________ 16 Figure 17 – Installation guide________________________________________________________ 17 Figure 18 – Alternator wiring (diesel engines) ____________________________________________ 18 Figure 19 – Example of cable run, ‘P’ clips and gland mounting. _____________________________ 19 Figure 20 – Copy of Warranty Registration Form - send to Newage ___________________________ 23


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1 General Information

1.1 Service Parts

The comprehensive illustrated parts list found at the back of this manual gives full information and ordering procedure.

1.2 Pre-delivery Test

Before the StepDrive leaves the factory, every gearbox is subjected to a final test and inspection which includes the following:

1. Flush clean. 2. Pressurise the StepDrive assembly, and check for deterioration of pressure to

Volvo’s recommendation, inc vacuum test. 3. Fill with oil. 4. Check for noise levels. 5. Check ‘drag torque’ during running. 6. Record oil flow in cooling circuit. 7. Record time to working temperature. 8. Activate gear change solenoid. 9. Reverse rotation. 10. Record oil pressure @ 1500rpm in forward & reverse, reduction & direct drive.

1.3 Identification

Every PRM Marine Transmission is fitted with an identification plate before it leaves the factory, which on StepDrive is located on the back face of the main gearcase. It will be observed that there are two lines of numbers, the top line being the serial number & works order number and the bottom line being the product structure number (the serial number and order number below are examples).

Figure 1 – Serial Plate

C 9 1 9 4 0 0 R 0 1 1 6 2 S D 2 9 0 C

P R M N E W A G E C O V E N T R Y

M A D E I N E N G L A N D


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1.4 Technical Overview of StepDrive

The automatic two-speed gearbox will always start off in the low gear (reduction), which has an exact ratio of 1.31 to 1 (in addition to the standard drive ratio). This reduction gear will reduce the creep/idle speed of the boat, and hence give more thinking and manoeuvring time, with the added benefit of less vibration as the engine is under reduced load, and not labouring. As the boat begins to accelerate, the reduction gear reduces the amount of engine torque required to rotate the prop, hence taking the load off the engine and allowing it to accelerate at a greater rate. When the boat is planing and the drag forces reduce, the gearbox then changes gear automatically taking the drive back to the original leg ratio, hereon referred to as direct drive. This has the advantage of not only better acceleration, but also better fuel economy as the duration of time under acceleration is reduced; as is the load on the engine during this inefficient time period. It has also been noticed that with less ‘over fuelling’ there will also be less black smoke. It is also possible that on some installations the pitch of the propeller can be increased to achieve a higher top speed. NOTE: This is only possible if the original prop selection was a compromise of top speed against acceleration, typically on pre-KAD engines.

1.4.1 Control

The gear change itself is controlled by a 2-position, 4-way solenoid spool valve and coil that is triggered by the electrical control system (one control system per boat). When the ignition is turned on, the gearbox will automatically receive a signal to move the spool valve to the reduction position, however StepDrive gear selection is not physically activated until the gearbox has system pressure. The pressure is provided by the internal gear pump, which is rotated when the Volvo cone clutch gearbox has been engaged (Fwd or Rev). This design feature allows the cone clutch gearbox to be used without the inertia of the prop magnifying any backlash/noise, with the hydraulics then giving a smoother take up.

Figure 2 – Control Box

The control system requires a simple 12-volt electrical supply (taken from the alternator) and a signal from the alternator pulse terminal (on twin installations only a single reading is required). This should generally be set to change gear at maximum engine power (max rpm), although this is slightly variable dependent upon each vessel (mass, beam displacement etc).

Engine Compartment mounted Control Box featuring: - Fault light (RED) - On/off indicator (GREEN / ORANGE) - Change point adjuster:

- Clockwise = increase rpm - Anti-clockwise = decrease rpm (Approx 100rpm = 1 turn)

Alternator terminal connectors

Cable attachment for helm mounted ‘On/Off’ Switch Box with indicator light

StepDrive Signal Cables


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1.4.2 Hydraulics

StepDrive is a hydraulic gearbox, which is fitted after the Volvo cone clutch gearbox, and driven by the output of the cone clutch drive. This allows the forward / reverse mechanism to be selected without the inertia of the propeller, reducing the lurch that can be present, with the hydraulics then giving a smooth take-up. Fundamentally the hydraulics serve two main functions:

1. To give the required clutch pressure to either the ‘reduction’ or ‘direct drive’ multi plate wet clutches. This pressure is set by Newage Transmissions at the factory. The oil circuit consists of a 100?m suction strainer (that should be cleaned when the leg is serviced), a series of non-return valves (NRV), a two-gear pump, pressure relief valve (530-550psi), 25?m pressure filter (to be replaced when serviced) and 4way solenoid spool valve (12 volt). The excess oil is then passed from the relief valve to the cooling circuit.

Figure 3 – Hydraulics Schematic


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2. The cooling circuit is vital to the longevity of the gearbox; cold oil is pumped (via strainer, NRV’s and relief valve) from below the water line/cavitation plate, directly in to the bottom bearing of the Volvo cone clutch gearbox (or ‘top box’). There is also an additional oil flow circuit that cools the StepDrive gearbox itself. Both these circuits join a common path back below the water level as illustrated below:

Figure 4 – Cooling Flow Schematic


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1.4.3 StepDrive Layout

The StepDrive is a twin parallel vertical axis layshaft design gearbox. It comprises of two constant mesh ‘Clutch gears’ and two constant mesh ‘Pinion gears’. The Mainshaft clutch gear is driven from the Volvo cone clutch output shaft, with the layshaft continuously driving the StepDrive hydraulic pump.

LAYSHAFT CLUTCH GEAR

LAYSHAFT PINION GEAR

MAINSHAFTPINION GEAR

MAINSHAFTCLUTCH GEAR

INPUT TO STEPDRIVE

STEPDRIVE OUTPUT

PUMP DRIVE

Figure 5 – Power Flow through StepDrive

When the StepDrive ‘reduction’ is engaged (at low rpm), the Layshaft clutch is actuated, locking the layshaft clutch gear to the layshaft pinion gear; the power is therefore transmitted via the reduction ratio on the pinion gears, as indicated by the white arrow. Direct drive is achieved by locking the mainshaft clutch gear to the mainshaft pinion gear, as shown with the black arrow. This effectively locks the shaft solid and hence has no gearing losses/transmission errors.

The 4-gear mesh sets the overall reduction ratio of the gearbox, and is calculated as follows:

1:31.139

50x

44

45

GearPinion Layshaft

GearPinion Mainshaft x

GearClutch Mainshaft

GearClutch Layshaft ??

T

T

T

T

Figure 6 – Ratio equation


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2 Installing StepDrive

2.1 Removing the Sterndrive

This should be done in accordance with the guidelines in the Volvo Penta Workshop Manual, but the procedure has been summarised below:

1. Disconnect the power to prevent accidental starting 2. Move the control lever to reverse 3. Loosen the propeller cone lock bolt 4. Move the control lever to forward gear 5. Remove the aft line cutter, forward propeller nut, and forward propeller. Return

the shift control to neutral. 6. Remove the shift linkage cover on the leg. 7. Remove the cotter pin and washer from the shift cable end, and remove the end

pivot pin from the cable. 8. Loosen the screw holding the shift cable clamp and release shift cable. 9. Remove the 2 screws holding the steering pin to the upper gear head. Using 2

M6 screws 30mm long (or longer), install into the threaded holes of the steering pin. As the screws are turned in, the steering pin will be forced out of the steering pin socket and steering helmet bushing.

10. Using Volvo tool (884573), remove the clamp around the u-joint bellows. 11. Remove the cotter pin on the trim cylinder pins. Remove the trim cylinder pins.

Raise the drive manually and insert Volvo tool onto the ‘H’ bracket (885143). 12. Remove the exhaust bellows from the drive. 13. Remove the clamp on the raw water hose. Remove the raw water hose. Now

remove the ‘H’ bracket support tool and lower the drive. 14. Install Volvo Penta support bracket (885146) and remove the sterndrive from the

transom shield (remove pivot pins with bolts). This is based on units not fitted with the ‘Hook -up’ mechanism. It is not possible to directly fit StepDrive to these types of stern drives (without modifications) for the following reasons:

? The output bearing of the early Volvo cone clutch gearbox is not compatible with the StepDrive. *

? The Vertical drive shaft to the lower section is a different length and not compatible with StepDrive. *

? The StepDrive exhaust ducting is located where the Hook -up mechanism fits, i.e. a new ‘H’ bracket and ram set is required.

* Depending upon demand, the necessary modifications will be made to the StepDrive to allow installation on DP drives preceding model C.


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2.2 Parts required

The StepDrive gearbox replaces the centre section of the 290DP drive leg. To complete the installation the drive must be removed from the boat and moved to a clean and dry area. In addition to the Volvo 290DP drive to be converted, the following parts will be required:

? StepDrive Gearbox, inc: - StepDrive Gearbox and plastic top cover - General Parts kit - ‘O’ ring kit - Assembly kit

? Volvo shims for the Cone Clutch output ball bearing (not supplied) ? Volvo shims for the lower leg input tapered roller bearing (not supplied) ? Consumables such as Paint, Anti-foul, grease, medium strength thread lock, silicone etc

(not supplied).

? In addition to these essential items, it is recommended that the normal service items be replaced as required (anodes, bellows etc).

In the event of the small electrical box mounted on the top of StepDrive becoming damaged, or failure of the spool valve or coil; Loctite Super Lube (available from Newage Spares Dept) will be required when assembling to protect the internals against water ingress. An installer for a new build should not require this grease.

2.3 Disassembly of Drive leg

Once the sterndrive has been removed from the boat in accordance with the guidelines set by Volvo Penta, the drive leg can now be disassembled as follows:

1. Place a suitable container under the sterndrive, remove the dipstick and remove the oil drain plug from the bottom of the duo-prop housing. Reinstall the drain plug after the oil has been drained.

2. Examine the condition of the oil for signs of excessive heat (black), which may indicate the drive has been slipping, or has significant wear. If the oil is of white colour, it is likely that the drive was not sealed correctly, or has sustained damage to the joint faces. This will need investigating and curing prior to fitting StepDrive.

3. Remove the cotter pin and washer from the gearshift linkage, and remove the linkage. This should be stored in a suitable container for the owner, as it will not be required for the StepDrive installation.

4. Remove the two 3/8” UNC nuts from the upper gear head studs, and the two 3/8” UNC cap head bolts to remove the gear head, using a rubber mallet if required. NOTE: Retain all shims, as these will be required to calculate the new shims for the StepDrive.

5. Remove the seven bolts fixing the lower gear housing to the intermediate housing (retaining all washers if present), and lift apart using a rubber mallet if required. The internal splined shear tube should be removed and placed with the linkage (see point 3). Again, all shims must be retained.

6. The intermediate housing will not be required, however the ‘H’ bracket, steering spindle, hose connection (and gasket), sealing rings and needle roller bearings/washers are retained for the StepDrive installation.

7. Remove the two bolts fixing the plastic hose connection, and remove with gasket. 8. Remove the yoke by driving out the steering spindle using Volvo Penta tools

(884311 & 9991801).


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2.4 Shimming for the StepDrive

With the Volvo 290DP drive spit into the three fundamental parts, remove the bearing cup from the underside of the centre section (using pinch bars), and measure the bearing bore depth (ensuring the shims have been removed) with a depth-micrometer. Then measure the depth of the same bearing bore on the StepDrive gearcase. The StepDrive depth should be same or greater than the original housing; the difference should be made up by the addition of shims. If the exact shimming size is not available, up to 0.002” pre-load is acceptable, but there should be no float.

1) Old centre section bottom bearing bore depth = w 2) StepDrive bottom bearing bore depth = x

x - w = Additional Shim size required

Repeat the above procedure for the output bearing of the Volvo top box by measuring the depths of the old and new bores. As this bearing is a ball bearing, if the exact size cannot be achieved, 0.002” (2 thou) float is acceptable.

1) Old centre section top bearing bore depth = y 2) StepDrive top bearing bore depth = z

z - y = Additional Shim size required

Note, this shimming procedure is identical to replacing a standard Volvo 290DP centre section, and requires no additional special tooling. See your Volvo Penta drive workshop manual for further shimming details.


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2.5 Building StepDrive into the Leg

Once the shimming has been calculated, the gearbox can now be assembled to the remaining Volvo components. Firstly, remove the ‘H’ bracket from the old centre section, and fit to the StepDrive gearbox as described in the Volvo workshop manual. Note it is possible that this may need to be re-shimmed to minimise free play using Volvo shims (0.7, 0.8 and 0.9mm).

2.5.1 Assembling to the Lower Section

? Clean the surfaces with an oil repellent solvent, and check for any lumps, bumps or burrs. ? Starting with the Volvo lower housing, insert the two studs (04805125S from Fastener Kit

MT0518) into the housing to meet with the holes marked X on StepDrive (illustration), using a medium strength thread locking agent (not supplied).

? Using Loctite 518, create a continuous thin bead around the bearing, mounting holes and oil return hole, and also around the exhaust ducting (all on the Volvo lower unit). Using a brush, dab and spread this evenly to create the gasket, see figure 9.

? Place ‘O’ rings into position with grease; one in StepDrive gearbox recess, and one in Volvo lower unit groove.

? Lower the StepDrive gearbox assembly on to the top of the Volvo lower housing, taking care not to disturb/move the ‘O’ rings.

? Tighten the 5 cap screws and 2 nuts to the recommended Volvo tightening torque.

NOTE: Actual ‘O’ rings are not coloured, but are refereed on page 34.

Figure 7 – ‘O’ rings for Volvo Bottom Gear Housing

Figure 8 – Photo showing even spreading of Loctite 518 sealant

X


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2.5.2 Assembling to the Upper Section

? The existing Volvo studs (2 off) attached to the cone clutch gear housing should be retained, and checked that they do not protrude further than 39mm from the mounting face.

? Clean the mating surface with an oil repellent solvent, and check for any lumps, bumps or burrs.

? Use the ‘O’ rings provided (within MT0519; 04309930V & 04302530V), and grease into position as shown below (colours refer to actual size colour chart in section 6.11).

NOTE: Actual ‘O’ rings are not coloured

Figure 9 – ‘O’ Rings for Volvo Top Gearbox

? Apply the Loctite 518 sealant with a continuous thin bead around the underside of the

Volvo cone clutch gearbox, around the bearing, mounting holes and oil return aperture. Care should be taken to ensure that the sealant makes no contact with the bearing. Spread this evenly by using a brush to dab and spread the gasket.

? Lower the manifold onto the Volvo gear housing, using the studs for guidance, and ensuring that the ‘O’ ring remain in the correct position. NOTE: The original Volvo bush/insert is not required in the hole marked ‘Y’.

? Insert the two new cap screws, and fit the new washers and nuts to the studs (supplied in the fastener kit MT0518)

? Tighten in standard ‘opposite’ pattern to the correct tightening torque (specified by Volvo).


Y

Morse cable shown for later reference only


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2.5.3 Joining the StepDrive

? Check pump spline ? Check faces clear from lumps bumps and burrs and oil contamination ? Place ‘O’ rings using grease

NOTE: Actual ‘O’ rings are not coloured; colours refer to section 6.11

Figure 11 – ‘O’ rings for StepDrive joining

? Apply a thin bead of Loctite 518 to the face around the ‘O’ ring apertures, and spread evenly by dabbing with a brush, as illustrated below.

? Lower the top assembly onto the main gearbox, using the rear-mounting stud as a guide. ? Fasten the seven bolts and single nut to the correct tightening torque (28Nm)



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2.5.4 Refitting the Sterndrive

? Check for casting flash on exhaust bellow location groove. ? Repeat Volvo refitting instructions as normal.

Take care not to damage the electrical cable in the process. ? Mask off the transom, bellows etc, wash off any oil, grease or dirt using thinners or similar

and paint the StepDrive with Volvo paint and or anti-foul. There is no necessity for priming as the gearbox is ‘chromated’.

? Assemble the linkage parts as illustrated below, using a Loctite thread locking agent on

the ball joint thread (as indicated ), and ensure the split pin on the Volvo selector mechanism is bent to secure fitment.

o The pivot bolt and nyloc nut ‘A’ (for the fwd/rev crank; MT9041) should be done

up sufficiently to ensure rotation, but not give any axial movement or ‘wobble’ of the crank.

o Screw the loose clevis ‘B’ onto the end of the Morse cable thread, to approximately the correct position, NOTE this will need to be adjusted and attached after section 2.6 of this manual.

? Once the Morse cable has been ‘slid’ to the top of the slot in the bracket (C), and the

bracket securely fastened to the gearbox, use one of the M6 button head screws (3 supplied loose) and stainless steel nut to stop it from sliding out of position.

? Upon completion of section 2.6, assembled all remaining linkage parts (in neutral), check

both split pins, and grease all pivot points and push/pull rod of the cable. Fit top cover with the two remaining M6 button head screws, and securely tighten.

? The gearbox top cover can now also be anti-fouled (optional), and the protective film over

the serial plate removed; this should be grease for protection. The Volvo Penta sticker maybe purchased and added to the top cover (at additional cost).

A

C

B


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NOTE: Do not fill with oil until the unit has been air tested (see section 3). Props should only be installed when all dynamic testing has been completed.

Figure 13 – Painted and Anti-fouled Drives.


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2.6 Onboard

2.6.1 Helm Controls

Due to the configuration of the StepDrive gearbox, the actuation point on the brass crank of the Volvo cone clutch gearbox has been swapped to operate on the opposite end. For this reason the helm control will need to be changed to ensure that the cable follows the following rule:

Cable PULL = Forward Cable PUSH = Reverse

This will usually entail removing the helm lever body from the boat, and swapping the point of cable attachment to the opposite side of the fulcrum.

NOTE: Failure to complete this will result in the boat going in the opposite direction relative to the lever position


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2.6.2 Switch Box

As seen in section 1.4.1 (Control), a switch box is supplied for turning StepDrive on and off (this is not essential to the operation of the gearbox, and should not be confused with manual control of ratio selection). Note, when in the ‘Off’ position the sterndrive will have the same ratio as standard, and draw no electrical current. The location of this switch panel is not important but for simplicity and easy access Newage Transmissions Ltd recommend that it is fitted to the dashboard where possible. If this is not possible it can be mounted remotely, but this is dependent upon the cable length (cable is approximately 10 meters) and should be checked first. The switch box features water resistant switches, and the electrical circuit is sealed in a potting compound to ensure reliability. The panel itself is Aluminium and has been protected to limit oxidation in salt-water environments. The design of the switch box dictates that it must be mounted on a flat surface, and when completed it will be 3mm proud of the mounting surface (the thickness of the Aluminium plate). This will require an area where the dashboard can be drilled to create an aperture (see template below) for the electrical box and cabling. The panel should be secured to the dashboard using the fasteners supplied (2.8mm pilot hole), or suitable alternatives. (To avoid accidental switching, allow sufficient clearance from other controls).

NOTE: Ensure the area below the mounting surface is clear from obstruction/electrical cables.

Figure 14 – Example of Switch box location.


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Connecting the electrical plug (after feeding through hull to the control box)

Figure 15 - Connecting the plug for the Switch Box

-------------------------------------------------------------------------------------------------------------------------- Template fo r hole

Figure 16 - Template for Switch Box

The electrical contacts should be orientated so that the two location flats are pointing downwards with the black plastic plug in the shown position.

Rubber grommets

Note: the cable colours should correspond to the mating plug on the Control Box.


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2.6.3 Engine Compartment

The gearbox control system can be mounted anywhere on the boat provided that there is sufficient cable length (within approximately 3-4 meters from the alternator). However, it is intended that the control unit will be located on the rear transom board, which is strengthened and suitable for screwing the controller to. This is also ideal for the connections to both the gearbox(s) and the alternator. The StepDrive control box will need to be firmly attached to the structure (via 2 screws, pilot hole 2.8mm), and although it is protected against water ingress, it should be kept dry, i.e. a safe distance from (and not directly below) fluid reservoirs, exhaust pipes water jackets etc. The StepDrive unit receives an electrical signal (12v in reduction, 0v in direct drive) from the control box to actuate the gear change. This will require drilling a 16mm hole (using a hole saw to limit damage to the gel coat) in the back of the boat, above the water line and to the right of the drive (viewed from astern) for the electrical cable (see section 2.6.4). The cable itself is then fed through the gland supplied and routed to the control box. It is worth noting that the drive leg is likely to be removed when servicing, so the StepDrive signal cable will need to be unplugged, and fed back through the hole; the cable routing should therefore be simple and easy to remove. The illustration below shows the recommended installation for a twin-engine boat with the helm on the starboard side:

Figure 17 – Installation guide

Engine 2

Engine 1

Alternator Feed Switch Panel

Control Box


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NOTE: Always ensure that the battery has been disconnected before starting any of the electrical work.

The diagram below shows the electrical feed, signal and earth terminals from the alternator. With this configuration the system will only be ‘On’ when the corresponding engine isolator is on, and hence if only one engine is to be used on a twin installation then the correct isolator must also be on to achieve the reduction gear. Note, this engine does not need to be running to achieve the reduction gear, but the StepDrive will not change gear automatically if the engine the control is connected to is not running.

Figure 18 – Alternator wiring (diesel engines)

Notes: Common installation fault: If the yellow signal wire is not connected to the ‘W’ terminal, the gearbox will not change gear (out of reduction). Do not attach to the ‘D’ terminal adjacent to it. Spanner sizes for reference: Positive = 10mm spanner & 10mm socket Negative = 10mm spanner & 8mm socket (deep) Signal = 10mm spanner & 7mm socket (deep)

Red = StepDrive Feed Black = Common earth Blue = Common earth Yellow = Signal feed


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2.6.4 Outside the boat

It is essential that the cable has sufficient length between the gearbox and gland to enable full steering lock to be achieved, and that the cable does not get trapped when trimming the leg to its extremities. The gland is attached using the screws supplied; drill a 2. 8mm pilot hole to a depth of approx 10mm and a 3mm hole through the gel coat to avoid the screw from splitting the outer surface. The cable should be ‘P’ clipped to the hull as illustrated below, using a sealing agent around the screws:

Note: Vertical tube is Speedo

Figure 19 – Example of cable run, ‘P’ clips and gland mounting.


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3 Testing

3.1 Post assembly testing

As with all PRM gearboxes, StepDrive is tested after manufacture to the specification listed in section 1.3 of this manual. For this reason the extent of post-build testing is limited to proving the successful installation of StepDrive to the 290DP sterndrive. As highlighted in the Volvo Penta’s ‘Drive’ workshop manual, the complete assembly should be pressure and vacuum tested prior to being filled with oil to ensure that no water can enter the drive during use. This should be done using Volvo Penta Part numbers 3810152 and 3858578, and following their guidelines, however, the procedure has been summarised below: 1) Pressure Test:

? With no oil in unit pressurise the assembly to 21-35KPa (3-5psi), turn the input and output shafts and observe any pressure loss. If passed:

? Increased the pressure to 110-124KPa (16-18psi). No more than 7KPa (1psi) must be lost over a 3-minute test.

If the test fails, use a soapy water solution or dip the drive in water to find the leak point. Do the necessary repairs and repeat the test. 2) Vacuum Test

? Evacuate the drive through the drain hole to 10-17KPa (1.5-2.5psi), turn the input and output shafts and observe vacuum loss. If passed:

? Increased vacuum to 47-54KPa (7-8psi) and monitor decay, no more than 3.4KPa (0.5psi) must be lost over a 3-minute test.

On completion of the above tests the StepDrive may be filled with oil (approximately 4 litres, GL-5 synthetic oil). It is important that the oil level is to the top of the dipstick mark, and as such should only be filled in the vertical position to avoid creating air locks within the StepDrive. For this reason do not fill with oil at an angle as described in the Volvo manual for the standard leg.

NOTE: The following testing should be completed with the Propellers removed. This work should never be completed alone.

When attached to the transom shield, the drive should be tested up to a speed of approximately 1500rpm in forward gear (by using the tap water muffs for cooling). The gearbox may take a second or two to prime for the first time, but if the output fails to rotate increase the engine speed to 2500prm. Under no circumstances should the output shaft be touched during this process. Repeat in reverse and leave running for approximately 1 minute at 1500rpm. Once the gearbox has been ‘spun up’ and the hydraulics primed, the drive should be left for approximately 2 minutes to allow the oil to settle. Then re-check the oil level and top up as required (to the top of the dipstick mark). For reference: 3800rpm is 886Hz (Approximate gear change point from reduction to direct drive) 1500rpm is 350Hz (Approximate gear change point back to reduction)


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4 Warranty

The product you have purchased comes with a limited warranty from Newage Transmissions Ltd; the terms of are which are listed below. The warranty statement contains a description of what is covered, what is not covered, the duration of coverage, how best to obtain warranty coverage, important disclaimers and limitations of damages, and other related information. The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage. Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in material and manufacture. Installation errors, normal wear and a variety of other causes that affect the product are not covered. Warranty is limited to defects in material or manufacture, but only when the customer purchases from a distributor authorised by us, or otherwise agreed in writing by Newage. Should you have any questions concerning warranty coverage contact your authorised distributor.

4.1 Validity Period

Newage’s Conditions of Sale set out Newage’s standard warranty. You will note that the standard warranty period is two years from the date of commission or 1000hrs operation for pleasure use only. We may vary the standard warranty by notice to you in writing.

4.2 StepDrive Product

Where the Step Drive does not comply with its warranty then Newage will, at its option, either replace the defective product or take such steps as it deems necessary to render the product free from such defects, provided that: a) The units have been stored, installed, used and maintained properly and carefully, and in accordance with the instruction issued by Newage; and the warranty registration form has been completed & returned to Newage. b) The problem is related to parts supplied by Newage as part of a Step Drive gearbox. Problems arising from oil leaks at the interface of the Step Drive and the Volvo drive leg are not covered by this agreement. c) Newage has received notice in writing of the alleged defect within fourteen days of its discovery. d) Newage is given a reasonable opportunity to inspect the product which, if required by Newage, will be returned to Newage's works at Coventry, England, for inspection. e) The owner/operator makes no further use of the product that is alleged to be defective after the defect is discovered or ought to have been discovered.


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4.3 Limitation of Liability

Your attention is drawn to the various exclusions and limitations of liability of Newage set out in Newage’s Conditions of Sale.

4.4 Items not supplied by Newage

For the avoidance of doubt, parts or components not supplied by Newage as an integral part of, or for use with its products, do not have the benefit of a warranty from Newage.

4.5 Advice

All recommendations and advice given by or on behalf of Newage as to the methods of installing or using the products or the purposes to which the products may be applied are given without liability on the part of Newage, its servants or agents. Newage does not include any liability for death or personal injury arising from Newage’s negligence.

4.6 Illustration of Warranty Cover

By way of illustration only, the following non-exhaustive list of services and expenses are not covered by Warranty:

a) Damage or loss related to shipping and handling.

b) Lift out and launch fees, towing charges, dockage, storage fee telephone calls, fuels, loss of revenue, transportation charges, overtime pay, loss of or damage to personal property, cost of oils and lubricants, medical expenses.

c) Costs of preparatory work related to warranty work, such as costs of moving furniture and

removing carpet or other installations or fittings.

d) Failure caused by use of improper lubricant.

e) Failure caused by inadequate cooling.

f) Failure caused by non-observance of recommended operation and maintenance procedures detailed in Newage's owner’s handbook or workshop manual.

g) Cost of repairs caused by misuse, accident, neglect or racing.

h) Cost of repairs made necessary by installations that do not meet the minimum standards

set out in Newage's workshop manual, including failures due to misalignment, ingress of foreign matter etc.

i) Repeat failures when the distributor performs repair.

j) Warranty will not be allowed on any unit that fails after being used in any application

outside the ratings and classification approved by the factory.

k) Newage Transmissions Limited will provide all possible information and assistance to help find solutions to torsional problems, but it is the ultimate responsibility of the person assembling the drive and driven equipment to ensure that they are torsionally compatible.

These items, together with non -reimbursable materials and labour supplied by a distributor are exclusively the responsibility of the distributor who performs such work.


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4.7 Transferable Warranty

The product warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited warranty. This will not apply for commercial applications. The second owner can be registered as the new owner and retain the unused portion of the limited warranty by sending a copy of the bill of sale to Newage Transmissions Ltd. to show proof of ownership.

4.8 Stolen StepDrive Unit

If your StepDrive is stolen, immediately advise the local authorities and Newage Transmissions Ltd of the serial number(s) and to whom the recovery is to be reported. The “Stolen StepDrive” information is placed into a file at Newage Transmissions Ltd to aid authorities and distributors in recovery of stolen units Claims for replacement of parts under warranty must always be submitted with the gearbox serial number to the distributor who supplied the gearbox; if this is not possible, application may be made to Newage Transmissions Ltd, who must be advised of the supplier's name and address. REMEMBER TO RETURN YOUR WARRANTY REGISTRATION – This is supplied loose, and an example of which is shown below. Failure to do so may invalidate warranty

Figure 20 – Copy of Warranty Registration Form - send to Newage


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5 Servicing

Yearly, or every 200 hours:

? Suction strainer cleaned and refitted (use existing ‘O’ ring) ? Replace pressure filter kit – MT0516-KIT (tighten to 55Nm) ? Replace the Oil (approx 4 litres of synthetic GL-5). Note the hydraulics will need to be

primed, and the oil level check after testing. ? Grease linkages ? Anti foul as required

Drive unit oil capacity - approx 4.0 litres, SAE 75W/90, GL-5 synthetic transmission oil

Volvo Penta Part Number: 1141634 – 1 litre Plastic Bottle 1141635 – 5 litre Plastic Bottle 1141636 – 20 litre Metal Drum

If the StepDrive is split to gain access to the Volvo top box, or is removed from the Volvo lower section, the Loctite 518 flange sealant will need to be scraped off using a flat scraper without damaging the joint face. To reassemble the gearbox, repeat the relevant instructions from above and fit with new ‘O’ rings (Part number MT0519-KIT). The gearbox should also be pressure tested before commissioning. Other service parts available: MT9058: Loctite 518 flange sealant (50ml). To be used on all joint faces (except pump face). MT9059: Loctite Super Lube (85g). To be used in MT9004 potting box. MT9060: Pressure gauge adaptor To use with MT4733 pump pressure gauge

(taken from the top manifold by removing the pressure plug; item 10 in section 6.5).

For all serviceable parts and consumables please contact your StepDrive dealer, or

StepDrive Sales Newage Transmissions Ltd Barlow Rd Coventry CV2 2LD England


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6 Parts List

6.1 StepDrive General Assembly – Main Gearbox

Note: 518 Sealant used on joint face


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ITEM NO. QTY. NEWAGE PART No. DESCRIPTION

1 1 MT9002 Manifold

2 2 092065SA Lee Plug3 1 MT9009SA Suction Strainer

4 1 04302025V 'O' Ring

5 1 MT9033 Oil Return Tube

6 2 09303AV Zero Leak -3 Plug

7 1 MT9015SA MainShaft Assembly

8 1 MT9016SA Layshaft Assembly

9 1 MT9001 Maincase

10 1 MT9034 Oil Collection Tube

11 n/a MT1075/02 Layshaft Shim (0.002")

12 n/a MT1075/10 Layshaft Shim (0.010")

13 n/a MT9053/02 Mainshaft Shim (0.002")

14 n/a MT9053/10 Mainshaft Shim (0.010")

15 2 0210815 Dowel

16 1 04908080S Stud M8 x 80

17 1 0191006S M8 Washer (plain)

18 1 0050801S M8 Nut (std)

19 4 0081435ZP M8 Cap Screw (Zinc & Clear)

20 1 0081320S M6 Cap Screw

21 4 0430072V 'O' Ring - Solenoid Ports

22 1 0430623V 'O' Ring - Layshaft Brg

23 1 002-0320V 'O' Ring - Mainshaft brg

24 3 002-0340V 'O' Ring - Lub ports25 1 04308030V 'O' Ring - Volvo bottom joint face

26 2 04302530V 'O' Ring - Volvo lub joint faces

27 1 04309930V 'O' Ring - Volvo top joint face

O' r

ings

MT

0519

-KIT

Par

ts n

ot s

how

n:08

9062

0 -

Hel

icoi

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12 (

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9081

5 -

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12 (

12 o

ff)09

0032

0 -

Hel

icoi

l 3/8

" U

NC

x3/4

" (4

off)

0930

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- Z

ero

Leak

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(1

off)

Par

ts n

ot s

how

n:Ite

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7 (S

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.2)

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ifold

Ass

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Par

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6.2 StepDrive General Assembly – Top Manifold

From section 5.1


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* Items supplied loose as parts required for assembly.


1 1 MT9038 StepDrive Cover2 1 MT9041 Fwd/Rev Crank *

3 1 MT9043 Linkage Assy *

4 1 MT9044 Clevis Assy *

5 1 Mt9042 Morse Bracket

6 1 MT9045 Control System (Not shown)

7 1 MT9061 Signal Cable Assy

8 2 0771312 3/8 UNC Cap Screw *

9 2 W102 3/8 UNC Washer *

10 2 0060656 3/8 UNC Nut (Nyloc, Type 'T') *

11 1 0050801S M8 Nut (std)

12 1 0191006S M8 Washer (plain)

13 5 0081465S M8 Cap Screw (65 long)

14 2 0081485S M8 Cap Screw (85 long)

15 2 0083310S M6 Button Screw *

16 1 0081435S M8 Cap Screw (35 long) *

17 1 0050806S M8 Nut (Nyloc, Type 'T') *

18 2 0060555S 5/16 UNC Nut (Nyloc) *

19 2 0191006S M8 Washer (plain) *

20 2 04805125S 5/16 UNC Stud x 38 long *

Fas

tene

rsG

ener

al P

arts


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6.3 Mainshaft Assembly


1 1 MT9019 Clutch Gear Insert

2 1 MT9015 Mainshaft Clutch Gear

3 2 MT9024 Piston Ring

4 1 MT9022 Mainshaft Clutch Feeder

5 2 04307415V O' Ring (Viton)

6 2 0540455 Tapper Roller Bearing

7 1 04307030V O' Ring (Viton)

8 1 04303530V O' Ring (Viton)9 1 MT9025 Clutch Piston

10 1 MT9026 Crest-To-Crest Spring

11 1 MT9048-MC Thrust Washer

12 1 0603001 Thrust Bearing

13 1 0593001 Thrust Washer

14 7 MT9014 Clutch Mating Plate

15 7 MT9013 Sintered Clutch Plate

16 1 MT9012 Reaction Plate

17 1 0250800 Circlip

18 1 0270500 Brg Retaining Ring

19 1 0535041 Cylindrical Roller Bearing

20 1 MT9017 Mainshaft Pinion Short (C, D & E)


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1 1 MT9020 Layshaft 2 1 MT9016 Layshaft Clutch Gear

3 2 MT9024 Piston Ring

4 1 MT9023 Layshaft Clutch Feeder

5 2 04306215V O' Ring (Viton)

6 2 0540251 Tappered Roller Bearing

7 1 04307030V O' Ring (Viton)

8 1 04303530V O' Ring (Viton)

9 1 MT9025 Clutch Piston

10 1 MT9026 Crest-To-Crest Spring

11 1 MT9048-MC Thrust Washer

12 1 0603001 Thrust Bearing

13 7 MT9014 Clutch Mating Plate

14 7 MT9013 Sintered Clutch Plate

15 1 MT9012 Reaction Plate

16 1 0250770 Circlip

17 2 0300250 External Spring Ring

18 2 0562504 Needle Roller Bearing

19 2 MT1600 Spacer

20 1 MT9018 Layshaft Pinion Gear21 1 0602801 Thrust Bearing

22 1 0592501 Thrust Washer (REF AS2542)

6.4 Layshaft Assembly


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6.5 Solenoid Housing Assembly

ITEM NO. QTY. PART NO. DESCRIPTION

1 1 MT9003 Solenoid Housing Manifold

2 1 MT9004SA Potting Box Assy

3 4 MT9006SA NRV Sub Assy

4 2 MT9008 NRV Plug5 1 MT9027 Solenoid Spool Valve

6 1 MT9028 Solenoid Coil (12v)

7 1 MT9051 M4 Cheese Head (70 long)

8 1 092065A Lee Plug

9 1 MT9054SA Relief Valve Assy

10 1 09303SA Pressure plug (-3)

Note: Hydraulic sealant (Loctite 542) to be used on M24 threads (items 4 and 9)


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6.6 Pump Manifold Assembly


1 1 MT9005 Pump Manifold

2 2 MT323 Pump Gear

3 1 MT1496 Secondary Pump Spindle

4 1 MT9032 Pump Drive Spindle5 1 MT9037SA Filter Bowl Assy

6 1 0430712V O' Ring (Viton)

7 3 0560801 Needle Roller Brg

8 1 0560901 Needle Roller Brg

9 2 022D304 Dowel (3/16" x 1/2")

10 3 0081320S M6 Cap Screw (Stainless)

11 4 0081416S M8 Cap Screw (Stainless)

Note: Pump faces and filter bowl thread to be smeared with grease when assembled.


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1 1 MT9006 NRV Cassette

2 1 066M140 NRV Steel Ball3 1 0311055 NRV Ball Spring

4 1 MT9007 NRV Spring Seat

5 1 0250180 NRV Circlip

6 1 04301915V O' Ring (Viton)


1 1 MT9004 Solenoid Cover

2 1 MT9040 Grease Nipple

3 1 MT9046 Grommet

4 1 0050601S M6 Nut (SS)

6.7 Non-Return Valve Sub-Assembly

6.8 Solenoid Cover Assembly

Note: NRV Steel Ball to be seated into NRV Cassette when assembled.

Note: Potting box to be filled with Loctite Super Lube (available through spares MT9059)


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6.9 Relief Valve Assembly

6.10 Filter Kit (MT0516-KIT)


1 1 MT9055 Piston Housing

2 1 MT9054 Piston3 1 MT9057 Spring (550psi)

4 2 04301915V O' Ring (Viton)

5 1 MT9056 Spring Housing

Note: Piston to be seated into the piston hsg when assembled, and should be free moving within the bore. Shims available from Newage Spares for pressure setting.


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6.11 Inside the box

1) StepDrive Gearbox, including signal lead & top cover 2) Gland 3) Electrical Control Box (MT9045). 4) ‘O’ ring kit, see above (MT0519-KIT). 5) Loctite 518 sealant (MT9058) 6) Switch panel, optional (MT9062). 7) Assembly Parts shown over page.

NOTE: The StepDrive gearbox has been supplied with 4 rubber bungs to limit the oil (used for testing at the factory) from leaking. These should be removed and returned to Newage Transmission Ltd.

518

FLA

NG

E S

EA

LAN

T50

ml

Control Box (MT9045)

Loctite 518 Sealant (MT9058)

Gland

Switch Box (MT9062)


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Assembly Parts

MT9041

MT9043

MT9044

0771312

0083310S

MT9052

0081435S

0050806S

0060555S

0191006S

04805125S

0060656

W102

MT9065

Upper leg mounting Lower leg mounting

Pivot Bolt & Nut

0050601S

Morse Cable Lock


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04309930V

04308030V

0430623V

002-0320V

0430072V

04302530V

002-0340V

‘O’ Rings (MT0519-KIT)

x1

x1

x1

x3

x2

x1

x4


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6.12 StepDrive Fault Finding Chart

Symptom Reason Cause Remedy

No Drive ahead or astern No internal oil pressure

Not in gear - Broken/incorrect cable installation

Check morse cable operation

No input rotation - Damaged Volvo cone clutch g/box

Check yoke joint etc, repair as required

Low oil level Top up as required (drive vertical)

StepDrive not priming through NRV's

Follow procedure in manual

Damaged pump Contact Newage PRM

Low oil pressure Low oil level Top up as required (drive vertical)

Blocked oil strainer and/or filter Remove, clean strainer/replace filter

Jammed PRV Contact Newage PRMDamaged/worn pump Contact Newage PRM

Slipping clutch Worn clutch feeder ring Contact Newage PRMDamaged joint face 'O' ring Use 'O' ring kit and repairNRV's not seating Remove, clean and re-seatWorn Clutch plates Contact Newage PRM

Slipping clutch Worn clutch feeder ring Contact Newage PRMDamaged 'O' ring Use 'O' ring kit and repairNRV's not seating Remove, clean and re-seatWorn Clutch plates Contact Newage PRMLow oil pressure See above

Excessive oil temperature

Internal damage Over load through hitting forign bodies

Contact Newage PRM

Too much oil Over filled Fill to correct levelClutch slip Low oil pressure See above

Blocked oil way Contact Newage PRM

Drive will not start in reduction

Electrical fault No power to alternator Check relevant engine isolator

No power to control box Check alternator terminalsNo power to solenoid Damaged electrical cableSolenoid coil/valve inoperative Contact Newage PRM

Drive will not change to direct drive

No input signal to control box

Failed alternator Check tacho is operative

Low boat battery voltage Check charging circuit voltage

Incorrect cable instalation Check yellow lead is 'W' terminal

Damged signal cable from alternator Check yellow cable for damage

Prop speed does not increase with engine speed ahead or astern

Prop does not increase with engine speed in reduction

Prop does not increase with engine speed in direct drive


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Approved Installation Centres

Berkshire DB International Ltd Cookham Bridge Cookham-on-Thames SL6 9SN Tel: 01628 526 032 Fax: 01628 520 564

E-mail: [email protected]

Cornwall Marine Engineering Looe The Quay East Looe PL13 1AL Tel: 01503 262 887 Fax: 01503 264 722


Essex VOLSPEC LTD Woodrolfe Road Tollesbury Maldon CM9 8SE Tel: 01621 869756 Fax: 01621 868859


Hampshire RK MARINE LTD Hamble River Boatyard Bridge Road Swanwick Southampton SO3 7EB Tel: 01489 583572 & 583585 Fax: 01489 583172


Sussex BA Peter Plc Peters Shipyard Chichester Marina Chichester PO20 7EJ Tel: 01243 512 831 Fax: 01243 511 447 E-mail: [email protected]

Wales Abersoch Land & Sea Royal Garage Abersoch Pwhelli Tel: 01758 713 434 Fax: 01758 713 150 E-mail: [email protected]

Documents

Manual, Stepdrive for 290