Mercury Mercruiser Marine Engine 6 SternDrives RMR Alpha Service Manual – PDF DOWNLOAD
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Mercury Mercruiser Marine Engine 6 SternDrives RMR Alpha Service Manual – PDF DOWNLOAD
Language : English
Pages : 566
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TABLE OF CONTENTS:
Mercury Mercruiser Marine Engine 6 SternDrives RMR Alpha Service Manual – PDF DOWNLOAD
6covr3 1
Models Covered in This Manual 3
Transom Assemblies 3
Sterndrive Units 3
Sea Ray Sterndrive Units and Transom Assembly (Oyster White) 4
Notice 5
Notice To Users of This Manual 5
Replacement Parts 6
Service Manual Outline 7
6A1R3 8
Table of Contents 9
How To Use This Manual Directional References 10
Page Numbering 10
Introduction 10
Special Product Information 10
Propeller Rotation 10
Serial Number Locations 11
Sterndrive Unit 10-Hour Break-In Period (New or with Replacement Gears) 11
Decal Application 11
Decal Removal 11
Hi-Performance Boating 11
Decal Application 11
Painting Procedures 12
Cleaning & Painting Aluminum Propellers & Gear Housings 12
6A2R3 14
Table of Contents 15
Specifications 16
Torque Specifications 16
Lubricants/Sealers/ Adhesives 16
Special Installation Tools 16
Special Information 16
Transom Specifications 16
Checking Transom Thickness 17
Sterndrive Unit Removal 17
Transom Assembly Removal 18
Transom Assembly Installation 22
Sterndrive Unit Installation 30
Shift Cable Adjustment 33
Installing Shift Cables 34
Propeller Installation 39
6A3R3 40
Table of Contents 41
Specifications 42
Torque Specifications 42
Upper Drive Shaft Bearing Preload 42
Gear Shimming Specifications 42
Lubricants/Sealers/ Adhesives 42
Special Tools 42
Overall Gear Ratios with 17/28 Lower Gears 43
R/MR Models 43
Overall Gear Ratios When Serviced with 13/21 Lower Gears 44
R/MR Models 44
Overall Gear Ratio with 17/28 Lower Gears 45
Alpha One / Alpha One SS Models 45
Overall Gear Ratio When Serviced with 13/21 Lower Gears 46
Alpha One / Alpha One SS Models 46
Special Information 47
C-Ring Kit To Eliminate U-Joint Knocking 47
Remarking Mercruiser IR-IMR Sterndrive Units After Gear Ratio Conversion 47
Torquing U-joint Bearing Retainer 48
Use Of Older Model Sterndrive Units On Mercruiser IR-IMR Models 49
Drive Unit Gear Ratio Identification 49
Drive Shaft Housing Exploded View 52
Drive Shaft Housing and Gear Housing Separation 52
Drive Shaft Housing Disassembly 53
U-joint Assembly Servicing 56
Pre-Disassembly Inspection 56
Disassembly 57
Cleaning 58
Reassembly 59
Upper Drive Shaft and Driven Gear Assembly Servicing 61
Disassembly 61
Cleaning 63
Reassembly 63
Water Pocket Cover Servicing 64
Disassembly 64
Cleaning and Inspection 64
Reassembly 64
Drive Shaft Housing Reassembly and Shimming 65
Gear Housing Installation 73
6A4R3 76
Table of Contents 77
Specifications 78
Torque Specifications 78
Lubricants/Sealers/ Adhesives 78
Special Tools 78
Special Information 78
Trim Limit Switch 78
New Trim Position Sender 79
Shift Cable 79
Trim Position Sender (Earlier Style) 81
Trim Position Sender and Trim Limit Switch Replacement 82
Bell Housing Installation 84
Trim Position Sender Installation 87
Trim Position Sender Adjustment (Early and Later Styles) 87
Trim Limit Switch Installation 88
Trim Limit Switch Adjustment 88
Gimbal Bearing 89
Shift Cable 91
Exhaust Bellows 97
Exhaust Tube (If Equipped) 99
6A5R3 102
Table of Contents 103
Specifications 104
Valve Pressure Specifications 104
Electrical Specification 104
Torque Specification 104
Special Tools 104
Lubricants/Adhesives/ Sealers 104
Maintaining Power Trim Pump Oil Level 104
Air Bleeding Power Trim System 105
Bleeding OUT/UP Trim Circuit 105
Bleeding IN/DOWN Trim Circuit 106
Testing Power Trim Pump 106
Connecting Test Gauge 106
Internal Restriction Test 107
OUT/UP Pressure Test 107
IN/DOWN Pressure Test 108
Trim Pump Hydraulic System 109
Trim Cylinder Internal Leak Test 110
Trim Cylinder Shock Piston Test 111
Motor and Electrical Bench Tests 112
Trim Pump Motor Test (In Boat) 112
Trim Pump Motor Test (Out of Boat) 112
Solenoid Test (Pump in Boat) 113
Solenoid Test (Pump Out of Boat) 114
Amp Fuse Test (Pump in Boat) 115
Amp Fuse Test (Pump Out of Boat) 116
Trim Pump Removal 116
Amp Fuse Test 116
Hydraulic Repair 117
Disassembly 117
Filter Replacement UP Pressure Relief Valve Replacement 118
DOWN Pressure Relief Valve Replacement 119
Thermal Relief Valve Replacement 120
Pump Replacement 120
Adaptor Replacement 121
Adaptor Repair 122
Pump Shaft Oil Seal Replacement 124
Motor Repair 125
Disassembly 125
Armature Tests 128
Field Tests 129
Thermal Switch Test 129
Brush Replacement 130
Reassembly 132
Trim Pump Installation 136
6A6R3 138
Table of Contents 139
Specifications 140
Torque Specification 140
Special Tools 140
Lubricants/Sealers/ Adhesives 140
Description 140
Power Steering System 141
Power Steering System 142
Power Steering System 143
Steering Helm and Cable 144
Power Steering Models 144
Filling and Air Bleeding Power Steering System 145
Balancing Power Steering Control Valve 146
Power Steering Drive Belt Inspection 148
Steering Cable Selection, Removal and Installation 148
Selection 148
Removal 149
Installation 149
Testing Power Steering System 150
Test Gauge Assembly 150
Power Steering Pump Lugging Test 150
Power Steering System Pressure Test 151
Pump Pressure Test 153
Booster Cylinder Test CAUTION 154
Power Steering Component Repair 155
Power Steering Unit 155
Cable Guide Tube 157
Control Valve 159
Booster Cylinder 165
Power Steering Pump 168
Determining Tie Bar Length 175
Selection 175
Installation 176
6A7R3 178
Table of Contents 179
Continuity Circuit 180
Anodic Block 182
Replacement 182
Anodic Trim Tab 184
Replacement 184
Integral MerCathode System 185
Removing Electrode Assembly 185
Installing Electrode Assembly 185
Connect Electrical Leads to Controller Assembly 186
Quicksilver Isolator 190
Corrosion Protection Testing and Troubleshooting 190
Low Reading 193
High Reading 194
Normal Reading But Corrosion Is Evident 195
6B1R3 196
Table of Contents 197
Maintenance Schedules 198
Maintenance Intervals 198
Scheduled Maintenance That Can Be Performed By Owner/Operator 198
Scheduled Maintenance That Can Be Performed by Dealer 199
Scheduled Maintenance That Can Be Performed by Dealer (Continued) 200
Lubricating Shift Cable Pivot Points 201
Lubricating Propeller Shaft 201
Lubricating Steering System 202
Power Steering Models 202
Manual Steering Models 202
Lubricating Tie Bar Pivot Points 202
Lubricating Tie Bar Pivot Points 203
Lubricating Transom Gimbal Housing Assembly Swivel Shaft, Swivel Pin, Hinge Pins and Gimbal Bearing 203
Checking and Adding Sterndrive Oil 204
Units Without Gear Lube Monitor 204
Models With Gear Lube Monitor 205
Checking Lubricant for Water 205
Models Without Gear Lube Monitor 205
Models With Gear Lube Monitor 206
Changing Sterndrive Oil 206
Models Without Gear Lube Monitor 206
Units With Gear Lube Monitor 207
General Maintenance 209
Maintaining Power Package Exterior Surfaces 209
Steering Head and Remote Control Maintenance 209
Checking Quicksilver MerCathode System 209
Maintaining Alloy Trim Tab and Anodic Heads 209
Maintaining Continuity Circuit 210
Checking Optional Quicksilver Anti-Corrosion Anode Kit 210
Boat Bottom Care 210
Power Package Layup (Out of Season Storage) 211
Engine 211
Sterndrive 211
Power Package Recommissioning 212
Engine 212
Sterndrive 212
6B3R3 214
Table of Contents 215
Identification 216
Specifications 216
Torque Specifications 216
Shimming Specifications 216
Lubricants/Sealers/ Adhesives 216
Special Tools 216
Special Tools (continued) 217
Special Information 217
Shift Spool Assembly 217
Forward Gear Bearing Bore 218
MR/Alpha One Gear Housing 223
Pre-Disassembly Inspection 227
Separate Drive Shaft Housing From Gear Housing 227
Gear Housing Disassembly 229
Component Servicing 234
Gear Housing Reassembly And Shimming 248
Gear Housing Installation 268
6B4R3 270
Table of Contents 271
Specifications 272
Torque Specifications 272
Lubricants/Sealers/ Adhesives 272
Special Tools 272
Special Information 272
Trim Limit Switch 272
New Trim Position Sender 273
Shift Cable 273
Gimbal Housing Water Tube 275
Replacement Bell Housing 275
Drive Screws Removal 275
Upper Swivel Shaft 276
Gimbal Housing Access Plug Kit 276
Increased Drive Unit Trim Range 276
Exhaust Tube Use on V-8 Drive Shaft Extension Models 277
Component Disassembly 278
Bell Housing Removal 278
Access Plug Kit Installation 281
Gimbal Ring, Swivel Shaft and Steering Lever Removal 283
Component Servicing 285
Bell Housing 285
Gimbal Ring 291
Gimbal Housing 293
Component Reassembly 297
Gimbal Ring, Swivel Shaft and Steering Lever Installation 297
Bell Housing Installation 302
6B5R3 310
Table of Contents 311
Identification 312
Specifications 312
Valve Pressure Specifications 312
Torque Specification 312
Electrical Specification 312
Lubricants/Sealers/ Adhesives 312
Special Tools 312
Description 313
Special Information 313
Trail-Out Valve Removal 313
Manual Release Valve Removal 313
New Adaptor And Reservoir 314
Thermal Circuit Breaker 314
Manual Release Valve (If Equipped) Operation 314
Maintaining Power Trim Pump Oil Level 315
Air Bleeding Power Trim System 315
Bleeding OUT/UP Trim Circuit 315
Bleeding IN/DOWN Trim Circuit 316
Testing Power Trim Pump 316
Connecting Test Gauge 316
Internal Restriction Test 317
OUT/UP Pressure Test 317
IN/DOWN Pressure Test 318
Trim Pump Hydraulic System 319
Trim Cylinder Internal Leak Test 320
Trim Cylinder Shock Piston Test 321
Motor and Electrical Bench Tests 321
Trim Pump Motor Test (In Boat) 321
Trim Pump Motor Test (Out of Boat) 322
Solenoid Test (Pump in Boat) 323
Solenoid Test (Pump Out of Boat) 324
Amp Fuse Test (Pump in Boat) 325
110 Amp Fuse Test (Pump Out Of Boat) 325
20 Amp Fuse Test (If Equipped) 325
Trim Pump Removal 326
20 Amp Circuit Breaker Test – (If Equipped) 326
Hydraulic Repair 327
Disassembly 327
Manual Release Valve Replacement (If Equipped) 328
Filter Replacement 328
UP Pressure Relief Valve Replacement 329
DOWN Pressure Relief Valve Replacement 329
Thermal Relief Valve Replacement 330
Replacement Plug – Trail-Out Valve 331
Pump Replacement 331
Adaptor Replacement 331
Adaptor Repair 333
Pump Shaft Oil Seal Replacement 335
Motor Repair 336
Disassembly 336
Armature Tests 337
Field Test 338
Thermal Switch Test 339
Brush Replacement 340
Reassembly 341
Trim Pump Installation 343
Wiring Diagram 344
6B6R3 346
Table of Contents 347
Specifications 348
Torque Specifications 348
Lubricants/Sealers/ Adhesives 348
Steering Cable Selection, Removal, and Installation 349
Selection 349
Removal 350
Installation 350
Manual Steering Swivel Ring Component Repair 351
Removal 351
Disassembly 351
Reassembly 352
Installation 352
6C1R3 354
Table of Contents 355
Troubleshooting 356
Sterndrive Unit Troubleshooting 356
Sterndrive Unit Will Not Slide Into Bell Housing 356
Drive Unit Does Not Shift Into Gear; Remote Control Shift Handle Moves 356
Drive Unit Does Not Shift Into Gear; Remote Control Shift Handle Does Not Move 357
Drive Unit Shifts Hard 357
Drive Unit In Gear, Will Not Shift Out Of Gear 358
Drive Unit Jumps Out Of Gear 358
Gear Housing Noise 358
Drive Shaft Housing Noise 359
Drive Shaft Housing Noise (continued) 360
Drive Shaft Housing Noise (continued) 361
Performance Troubleshooting 362
Low Full-Throttle Engine RPM 362
High Full-Throttle Engine RPM 362
Propeller Ventilating/Cavitating 362
Poor Boat Performance And/Or Poor Maneuverability-Bow Too Low 363
Poor Boat Performance And/Or Poor Maneuverability-Bow Too High 363
Steering System Troubleshooting 364
Hard Steering – Ride Guide Steering System 364
Hard Steering (Engine Running) Power Steering System 364
Power Steering System External Fluid Leaks 365
Power Trim Electrical System 366
Power Trim Pump Motor Will Not Run In The Out/Up Or In/Down Direction (Solenoids Do Not Click) 366
Power Trim Pump Motor Will Not Run In The Out/Up Or In/Down Direction (Both Solenoids Click) 367
Power Trim Motor Runs In The Out/Up Direction, But Not In The In/Down Direction (In/Down Solenoid Does Not Click) 367
Power Trim Motor Runs In The In/Down Direction, But Not In The Out/Up Direction – Both Trim And Trailer Switches Inoperative-(Out/Up Solenoid Does Not Click) 368
Power Trim Pump Motor Runs In The Out/Up But Not In The In/Down Direction – In/Down Solenoid Clicks 368
Power Trim Pump Motor Runs In The In/Down Direction, But Not In The Out/Up Direction – Both Trim And Trailer Switches Inoperative – (Out/Up Solenoid Clicks) 368
Trim Control Out/Up Switch Inoperative (Trailer Switch Operates) 369
Trim Control Trailer Switch Inoperative (Trim Out/Up Switch Functions) 369
Trim System Functions While Unattended 369
Power Trim 370
Auto Trim Electrical System 373
Pump Motor Will Not Run Up Or Down In Either Manual Or Auto Mode (Solenoids Click) 373
Pump Motor Will Not Run Up Or Down In Either Manual Or Auto Mode (Solenoids Do Not Click) 374
Pump Motor Will Run Up, But Not Down In Both Manual And Auto Modes (Down Solenoid Does Not Click) 374
Pump Motor Will Run Up, But Not Down In Both Manual And Auto Modes (Down Solenoid Clicks) 375
Pump Motor Runs Down, But Not Up In Both The Manual And Auto Modes (Up Solenoid Clicks) 375
Pump Motor Runs Down, But Not Up In Both the Manual and Auto Mode – (Up Solenoid Does Not Click) 375
Pump Motor Will Not Stop Running Down In Auto Mode (Trim Out/Up Switch And Trailer Switch Inoperative In Manual Mode) 376
Pump Motor Will Not Run Up Or Down In Auto Mode (Manual Mode Functions Properly) 376
Pump Motor Will Run Down, But Not Up In Auto Mode(Manual Mode Functions Properly) 377
Pump Motor Will Run Up, But Not Down In Auto Mode (Manual Mode Functions Properly) 377
Trim System Completely Inoperative In Manual Mode(Auto Mode Functions Properly) 377
Trim In/Down Switch Inoperative In Manual Trim Control – Trim Out/Up Switch and Trailer Switch Function (Auto Mode Functions Properly) 378
Trim Out/Up Switch And Trailer Switch Inoperative In Manual Trim Control – Trim In/Down Switch Operates (Auto Mode Functions Properly) 378
Trim Out/Up Switch Inoperative In Manual Trim Control – Trailer Switch Operates Properly (Auto Mode Functions Correctly) 378
Trailer Switch Inoperative In Manual Trim Control – Trim Out/Up Switch Functions 379
Boat Is On Plane Well Before Drive Unit Begins To Trim Out 379
Boat Is Not On Plane Before Drive Unit Begins To Plane Out 379
Auto Trim II System Wiring Diagram 380
Power Trim System Troubleshooting – Hydraulic System on Oildyne Trim Pump 381
Drive Unit Cannot Be Trimmed Out/Up, Trims Slowly Or Trims With Jerky Movements 381
Drive Unit Cannot Be Lowered From Up Position Or Lowers With Jerky Movements 382
Drive Unit Will Not Stay In Full Up Position For Extended Periods 383
Drive Will Not Stay In The Trimmed Out/Up Position When Underway 383
Drive Unit Trails Out/Up On Deceleration Or When Shifting Into Reverse (Unit Thumps When Shifting) 383
Oil Foams Out Of Pump Fill/Vent Screw 384
The Trim Pump Motor Runs But Does Not Pump Oil 384
Power Trim Hydraulic Schematic 385
Power Trim System Troubleshooting – Hydraulic System on Prestolite Trim Pump 386
Drive Unit Cannot Be Trimmed OUT/UP Or Trims Slowly Or with Jerky Movements 386
Drive Unit Cannot Be Lowered From OUT/UP Position or Lowers with Jerky Movements 386
Drive Unit Will Not Stay In Full OUT/UP Position For Extended Periods 387
Drive Unit Will Not Stay In Trimmed OUT/UP Position When Underway 387
Drive Unit Trails OUT/UP on Deceleration or When Shifting into Reverse (Unit Thumps When Shifting) 387
Oil Foams Out of Pump ïVent Screw 387
Prestolite Trim System Diagram 388
Corrosion Protection 389
Corrosion Of Underwater Parts, Without Mercathode Or Current Protection 389
Corrosion On Underwater Parts, With Mercathode Or Current Protection (Drive Corroding) 389
Corrosion On Underwater Parts, With Mercathode Or Impressed Current Protection (Drive Corroding) (Continued) 390
Corrosion On Underwater Parts, With Mercathode Or Impressed Current Protection (Drive Overprotected) 391
Corrosion Troubleshooting Procedures 392
Shift System Troubleshooting 393
Checking for Excessive Play 393
Boat Out of Water (Engine Off) 393
Boat In Water (Engine Running) 395
Isolating Excessive Play 396
Checking Remote Control Shift Cable Output 397
Checking Cutout Switch Timing 399
Checking Operation 400
6C3R3 402
Table of Contents 403
Identification 404
Specifications 404
Torque Specifications 404
Shimming Specifications 404
Special Tools 404
Lubricants/Sealers/ Adhesives 405
Special Information 405
Shift Spool Assembly 405
Forward Gear Bearing Bore 405
Pre-Disassembly Inspection 413
Separate Drive Shaft Housing From Gear Housing 413
Gear Housing Disassembly 415
Component Servicing 419
Gear Housing Reassembly And Shimming 433
Gear Housing Installation 445
6C5R3 449
6D3R3 475
Table of Contents 476
Identification 477
Specifications 477
Torque Specifications 477
Shimming Specifications 477
Lubricants/Sealers/ Adhesives 477
Special Tools 477
Special Information 478
Shift Spool Assembly 478
Forward Gear Bearing Bore 478
Exploded View – Alpha One Counter Rotating Gear Case 482
Separate Drive Shaft Housing From Gear Housing 486
Gear Housing Disassembly 487
Component Servicing 497
Water Pump Inspection 497
Water Pump Reassembly 499
Drive Shaft and Pinion Bearing Inspection and Cleaning 500
Drive Shaft Disassembly 500
Pinion Bearing Removal 500
Pinion Bearing Installation 501
Drive Shaft Reassembly 501
Bearing Carrier and Retainer Inspection 501
Bearing Carrier Disassembly 502
Bearing Carrier Reassembly 503
Forward Gear Inspection 503
Forward Gear Bearing Adaptor Disassembly and Inspection 504
Forward Gear Bearing Adaptor Reassembly 504
Propeller Shaft, Reverse Gear and Shift Spool Disassembly 505
Propeller Shaft, Reverse Gear and Bearing and Shift Spool Assembly Inspection and Cleaning 505
Propeller Shaft, Reverse Gear and Shift Spool Reassembly 508
Shift Shaft Disassembly 509
Shift Shaft Inspection and Cleaning 509
Shift Shaft Reassembly 509
Reverse Gear Bearing Adaptor Roller Bearing Replacement 510
Gear Housing Cleaning and Inspection 510
Gear Housing Shimming 510
Shift Shaft Installation 510
Reverse Gear Bearing Adaptor Installation 511
Drive Shaft and Pinion Gear Installation (Without Propeller Shaft in Place) 512
Checking Forward Gear Backlash 516
Checking Reverse Gear Backlash 522
Gear Housing Reassembly 528
Gear Housing Installation 538
6D5R3 540
Table of Contents 541
Specifications 542
Torque Specifications 542
Lubricants/Sealers/ Adhesives 542
Special Tools 542
Trim Cylinder Internal Leak Test 542
Trim Cylinder Shock Piston Test 542
Trim Cylinder Repair 542
Removal 542
Reassembly 546
Installation 549
6E5R3 550
Table of Contents 551
Important information 552
Testing Dual Power Trim System 552
Relay Test 552
Diode Module Test 552
Trailer Switch Test 553
Starboard Trim Switch Test 553
Port Trim Switch Test 553
Dual Power Trim System Component Repair 553
Important Information 553
Relay Replacement 553
Diode Module Replacement 554
Trim Control Panel Switch(es) Replacement 555
6F5R3 558
Table of Contents 559
Auto Trim System 560
Description 560
Auto Trim Operation 561
Electrical System Overload Protection 563
Auto Trim Limit Adjustment 563
Control Module Adjustment (Auto Trim Il Only) 565
Trim Position Indicator Adjustment 565
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