Merc Service Manual 6 5a

8/9/2019 Merc Service Manual 6 5a

1/36

A5

22163

POWER TRIM

OILDYNE POWER TRIM PUMP(WITH PLASTIC RESERVOIR)

Index


2/3690-12934--2 10975A-0 - OILDYNE POWER TRIM PUMP

Table of ContentsPage

Specifications 5A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .Valve Pressure Specifications 5A-1. . . . . . . . . . .Electrical Specification 5A-1. . . . . . . . . . . . . . . . .Torque Specification 5A-1. . . . . . . . . . . . . . . . . . .

Special Tools 5A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .Lubricants/Adhesives/Sealers 5A-1. . . . . . . . . . . . . .

Maintaining Power Trim Pump Oil Level 5A-1. . . . .Air Bleeding Power Trim System 5A-2. . . . . . . . . . .

Bleeding OUT/UP Trim Circuit 5A-2. . . . . . . . . . .Bleeding IN/DOWN Trim Circuit 5A-3. . . . . . . . .

Testing Power Trim Pump 5A-3. . . . . . . . . . . . . . . . .Connecting Test Gauge 5A-3. . . . . . . . . . . . . . . .Internal Restriction Test 5A-4. . . . . . . . . . . . . . . .OUT/UP Pressure Test 5A-4. . . . . . . . . . . . . . . . .IN/DOWN Pressure Test 5A-5. . . . . . . . . . . . . . . .Trim Pump Hydraulic System 5A-6. . . . . . . . . . . .

Trim Cylinder Internal Leak Test 5A-7. . . . . . . . . . . .Trim Cylinder Shock Piston Test 5A-8. . . . . . . . . . . .

Motor and Electrical Bench Tests 5A-9. . . . . . . . . . .Trim Pump Motor Test (In Boat) 5A-9. . . . . . . . .Trim Pump Motor Test (Out of Boat) 5A-9. . . . . .Solenoid Test (Pump in Boat) 5A-10. . . . . . . . . .Solenoid Test (Pump Out of Boat) 5A-11. . . . . . .110 Amp Fuse Test (Pump in Boat) 5A-12. . . . .110 Amp Fuse Test (Pump Out of Boat) 5A-13.20 Amp Fuse Test 5A-13. . . . . . . . . . . . . . . . . . . .

Trim Pump Removal 5A-13. . . . . . . . . . . . . . . . . . . . .Hydraulic Repair 5A-14. . . . . . . . . . . . . . . . . . . . . . . .

Disassembly 5A-14. . . . . . . . . . . . . . . . . . . . . . . . .Filter Replacement 5A-15. . . . . . . . . . . . . . . . . . . .UP Pressure Relief Valve Replacement 5A-15. .

Current Replacement PressureRelief Valve 5A-15. . . . . . . . . . . . . . . . . . . . . .

Original Factory Installed PressureRelief Valve 5A-16. . . . . . . . . . . . . . . . . . . . . .

Earlier Style Replacement PressureRelief Valve 5A-16. . . . . . . . . . . . . . . . . . . . . .

Page

DOWN Pressure Relief ValveReplacement 5A-16. . . . . . . . . . . . . . . . . . . . . . .

Current Replacement PressureRelief Valve 5A-16. . . . . . . . . . . . . . . . . . . . . .

Original Factory Installed PressureRelief Valve 5A-17. . . . . . . . . . . . . . . . . . . . . .

Earlier Style Replacement PressureRelief Valve 5A-17. . . . . . . . . . . . . . . . . . . . . .Thermal Relief Valve Replacement 5A-17. . . . . .Pump Replacement 5A-17. . . . . . . . . . . . . . . . . . .Adaptor Replacement 5A-18. . . . . . . . . . . . . . . . .Adaptor Repair 5A-19. . . . . . . . . . . . . . . . . . . . . . .

Internal O-ring And Poppet ValveReplacement 5A-19. . . . . . . . . . . . . . . . . . . . .

Pump Shaft Oil Seal Replacement 5A-21. . . . . .Motor Repair 5A-22. . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly 5A-22. . . . . . . . . . . . . . . . . . . . . . . . .Armature Tests 5A-25. . . . . . . . . . . . . . . . . . . . . . .

Continuity Test 5A-25. . . . . . . . . . . . . . . . . . . . .

Test For Shorts 5A-25. . . . . . . . . . . . . . . . . . . .Cleaning Commutator 5A-25. . . . . . . . . . . . . .

Field Tests 5A-26. . . . . . . . . . . . . . . . . . . . . . . . . . .Test For Open Circuit 5A-26. . . . . . . . . . . . . . .Test For Short In Field 5A-26. . . . . . . . . . . . . .

Thermal Switch Test 5A-26. . . . . . . . . . . . . . . . . .Continuity Test 5A-26. . . . . . . . . . . . . . . . . . . . .

Brush Replacement 5A-27. . . . . . . . . . . . . . . . . . .Reassembly 5A-29. . . . . . . . . . . . . . . . . . . . . . . . .

Trim Pump Installation 5A-33. . . . . . . . . . . . . . . . . . .Power Trim Wiring Diagram 5A-34. . . . . . . . .

Index


3/36OILDYNE POWER TRIM PUMP - 5A90-12934--2 1097

Specifications

Valve Pressure Specifications

Valve Pressure

Up Circuit2200-2600 psi

(15173-17932 kPa)

Down Circuit400-600 P.S.l.

(2759-4138 kPa)

Electrical Specification

Pump Amperage Draw115 Amps at

2200-2600 P.S.l.(15173-17932 kPa)

Torque Specification

TORQUE

lb. in. lb. ft. Nm

Up Pressure Relief Valve 70 7.9

Down Pressure ReliefValve

70 7.9

Thermal Relief Valve 70 7.9

Pump to Adaptor Mount-ing Screws

70 7.9

Motor to Adaptor Mount-ing Screws

25 2.8

Reservoir Screw 10-15 1.2-1.6

Hex Plug Retainers 38-50 51-67

Up Pressure HydraulicHose (Black)

70-150 7.9-16.9

Down Pressure HydraulicHose (Gray)

70-150 7.9-16.9

Special Tools

Description Part No.

Test Gauge Kit 91-52915A6

Multi-Meter 91-99750

Torque Wrench (lb. in.) 91-66274

Hex Lobular Socket(Torx Socket)

Obtain Locally

Jumper Wire Obtain Locally

Lubricants/Adhesives/Sealers

Description Part No.

Power Trim and Steer-ing Fluid

92-90100A12

2-4-C Marine Lubricant 92-825407A2

Liquid Neoprene 92-25711-2

Maintaining Power TrimPump Oil Level

! CAUTION

Vent screw, if equipped, MUST BE backed otwo (2) full turns (after bottoming out) to vepump reservoir. FAILURE TO BACK SCREW OUCOULD RESULT IN DAMAGE TO PUMP. Uniwithout vent screw: fill cap is vented. Check thCaplug (fill neck seal) is removed.

IMPORTANT: Check oil level with sterndrive unin the full down position.

IMPORTANT: SAE 10W-30 or 10W-40 engine ocan be used in system, if Quicksilver Power Triand steering fluid is not available.

Index



1. Remove fill cap, then raise and lower drive unit 6to 10 times to purge air from system. Check oillevel visually (b).

22031

a - If There Is A Vent Screw, It Must Be Backed Out 2 FullTurns; If There Is No Vent Screw, The Fill Cap Is Vented IfCaplug (Fill Neck Seal) Is Removed

b - Oil Level Should Be Maintained Between The Max. AndMin. Marks On The Side Of The Reservoir. When AddingOil, Fill To Bottom Lip On The Fill Neck, As Shown

c - Vent Hole

Air Bleeding Power Trim

SystemThe Power Trim System will purge itself of a smallamount of air by raising and lowering the drive unitseveral times. However, if a rebuilt trim cylinder isbeing installed (which has not been filled with oil), thefollowing bleeding procedure should be used toremove the air from the system.

Bleeding OUT/UP Trim Circuit

1. Fill pump reservoir to proper level as explainedpreceding. (Trim cylinder must be compressed.)

2. Disconnect OUT/UP hose from front connectionon trim cylinder. If both cylinders were rebuilt, dis-connect hoses from both cylinders.

3. Direct end of trim hose(s) into a container.

4. Run trim pump in the UP direction until a solid, air-free stream of fluid is expelled from hose(s). Re-connect hose(s) and tighten securely.

5. Refill trim pump to proper level.

50389

a - OUT/UP Trim Hose

b - Front Connection On Trim Cylinder

Index



Bleeding IN/DOWN Trim Circuit

1. Ensure pump reservoir is filled to proper level.

2. Disconnect IN/DOWN hose from rear connectionon gimbal housing hydraulic connector. If bothcylinders were rebuilt, disconnect hoses fromboth sides of hydraulic connector.

3. Plug holes in hydraulic connector, using plug

(22-38609) or suitable device.4. Direct end of trim hose(s) into container.

5. Run trim pump in the UP direction until trimcylinders are fully extended.

6. Remove plug(s) from gimbal housing hydraulicconnector and momentarily run trim pump in theIN/DOWN direction until a solid, air-free streamof fluid is expelled from rear hole(s) in hydraulicconnector. Reconnect trim hose(s) and tightensecurely.

7. Lower drive unit to the full IN/DOWN position andrefill trim pump to proper level. Run trim systemIN/DOWN and OUT/UP several times and re-check fluid level.

50389

a - IN/DOWN Trim Hoseb - Hydraulic Connector

c - Plug (22-38609)

Testing Power Trim Pump

Connecting Test Gauge

1. Check trim pump oil level. Fill if necessary.

2. Place drive unit in the full IN/DOWN position.

3. Connect test gauge at the most convenielocation (at pump or hydraulic connector):

2212

Gauge Connected to Pump

a - Hydraulic Test Gauge (91-52915A6)

Index



50390

a - Hydraulic Test Gauge (91-52915A6)

b - Gimbal Housing Hydraulic Connector

50391c - Caps

d - PlugsSupplied with Gauge

Gauge Connect to Hydraulic Connector4. Open Valve A and B and run pump UP and

DOWN several times (to purge air).

Internal Restriction Test

1. Open valve A and B.

2. Run pump OUT/UP and IN/DOWN whileobserving gauge.

3. Replace adaptor, if pressure is in excess of 200psi (1379 kPa).

OUT/UP Pressure Test

1. Leave Valve A open and close Valve B.

2. Run pump OUT/UP while observing gauge.Reading should be 2200-2600 psi (15173-17932kPa).

Gauge reading within specifications, pro-

ceed to step 3.

Gauge reading not within specifications,

perform the following:

Replace UP Pressure Re-lease Valve and Retest(3)*

ReadingOK

Reading NOT OK

Replace Thermal ReliefValve and Retest (4)*

Replace Adaptor (2)*

Reading NOT OK

Proceedto Step3

Proceedto Step3

ReadingOK

3. Run pump OUT/UP until gauge reading reaches2200-2600 psi (15173-17932 kPa). Stop pump-ing UP. Pressure should not fall below 1900 psi(13104 kPa).

Gauge reading NOT below 1900 psi

(13104 kPa). UP Pressure Test completed.

Gauge reading below 1900 psi (13104 kPa),

perform the following:

Check for External OilLeaks; Correct, Retest (5)*

ReadingOK

Reading NOT OK

Install Trim Pump RebuildKit and Retest (1)*

Reading NOT OK

Up PressureTestCompleted


Replace Thermal ReliefValve and Retest (4)*

ReadingOK

Up PressureTestCompleted

ReadingOK

Up Pres-sure TestCompleted

Reading NOT OK

* The callout numbers refer to the Trim Pump Hydraulic Systemdrawing on p. 5A-5.

Index



IN/DOWN Pressure Test

1. Close Valve A and open Valve B.

2. Run pump IN/DOWN while observing gauge.Reading should be 400-600 psi (2759-4138kPa).

Gauge reading within specifications, proceed

to step 3.

Gauge reading NOT within specifications,

perform the following.

Replace Down PressureRelief Valve and Retest (6)*

ReadingOK

Reading NOT OK

Install Trim Pump Rebuild

Kit (1)*


Reading NOT OK

Proceedto Step 3

Proceed

to Step 3

ReadingOK

3. Run pump IN/DOWN until gauge reading reaces 400-600 psi (2759-4138 kPa). Stop pumpinIN/DOWN. Pressure should not fall below 350 p(2414 kPa).

Gauge reading above 350 psi (2414 kPa

DOWN Pressure Test completed.

Gauge reading below 350 psi (2414 kPa), pe

form the following:

Check for External Oil Leaks;Correct and Retest (5)*

ReadingOK

Reading NOT OK

Install Pump Rebuild Kit andRetest (1)*

Reading NOT OK

DownPressureTestCompleted


ReadingOK

DownPressureTestCompleted

* The callout numbers refer to the Trim Pump Hydraulic Systedrawing on p. 5A-5.

Index



Trim Pump Hydraulic System

73552

1 - Shuttle

2 - Pump Adaptor

3 - UP/OUT Pressure Relief Valve

4 - Thermal Relief Valve

5 - Fitting

6 - IN/DOWNPressureRelief Valve

Index



Trim Cylinder InternalLeak TestIMPORTANT: The following test assumes thatpump OUT/UP pressure is within specificationsas determined by performing Power Trim PumpTest.

1. Reconnect trim cylinder hoses (if removed in pre-

vious test) as follows:

a. Remove plugs and caps.

b. Install UP hose to forward hole on hydraulicconnector. Tighten securely.

c. Install DOWN hose to aft hole on hydraulicconnector. Tighten securely.

50391

a - UP Hoseb - DOWN Hose

c - Hydraulic Connector

2. Connect gauge at most convenient location.

2212

a - Hydraulic Test Gauge

b - Hose Connected To UP (Left Hole)c - Fittings-(Supplied With Gauge)

d - Black Hose (From Gimbal Housing)

e - Grey Hose (From Gimbal Housing)

Index



50390

Gauge Connected to Hydraulic Connector

a - Test Gauge

b - Coupling (Supplied With Gauge)

c - Front Hydraulic Connector Port

3. Open Valve A and B and run pump OUT/UPand IN/DOWN several times (to purge air).

4. Run pump OUT/UP until trim cylinders are fullyextended; then, observe gauge while pumping.Pressure should be 2200-2600 psi(15173-17932 kPa).

5. Stop pumping OUT/UP. Pressure should not fallbelow 1900 psi (13104 kPa).

If readings are not within specifications, aninternal trim cylinder leak is indicated. Use thefollowing procedure to locate faulty cylinder.

a. If gauge is connected at pump, reconnectgauge at gimbal housing hydraulic connec-tor. Repeat Step 2; then, run pump in OUT/

UP direction until trim cylinder is fully ex-tended.

b. Close Valve B on test gauge and repeatSteps 3 and 4.

If readings are now within specifications:Trim cylinder on the same side that test gauge isconnected is faulty.

If readings are still not within specifications:Trim cylinder on the opposite side from where thetest gauge is connected is faulty.

Trim Cylinder Shock PistonTestIf trim system checks out good, but drive unit will nottrim IN/DOWN, problem may be due to a leaky trimcylinder shock piston. Use the following test to checkfor this condition. Test gauge is not required.

1. Run pump in OUT/UP direction until trim

cylinders are fully extended.

2. Prevent trim cylinder piston rods from retracting,using a suitable device. Quicksilver Trailering Kitworks well for this purpose.

22562

a - Trailering Clip

3. Disconnect UP trim hose from trim cylinders.

50389

a - UP Trim Hose

b - Front Connection

4. Run pump in IN/DOWN direction. If oil flows fromUP port on trim cylinder, shock piston is leakingand must be replaced.

Index



Motor and Electrical BenchTests

Trim Pump Motor Test (In Boat)

! WARNING

DO NOT perform this test near flammables (or ex-

plosives), as a spark may occur when makingconnections.

! WARNING

Remain clear of drive unit when performing pow-er trim pump motor tests with pump in the boatand hydraulic hoses connected.

1. OUT/UP Operation.

a. Connect a jumper wire between positive (+)solenoid terminal and BLUE/WHITE motor

lead terminal.b. Motor should run.

22494

a - OUT/UP Solenoid

b - Positive Terminal (+)

c - BLUE/WHITE Motor Lead Terminal

d - Jumper Wire

2. IN/DOWN Operation.

a. Connect a jumper wire between positive (solenoid terminal and GREEN/WHITE motlead terminal.

b. Motor should run.

2249

a - IN/DOWN Solenoid

b - Positive Terminal (+)

c - GREEN/WHITE Motor Lead Terminal

d - Jumper Wire

3. If motor does not run, refer to Motor Repair. SeTable of Contents.

Trim Pump Motor Test (Out of Boat)

! WARNING

DO NOT perform this test near flammables (oexplosives), as a spark may occur when makinconnections.

1. Remove trim pump from boat. Refer to Tr

Pump Removal. See Table of Contents.2. Remove fluid from trim pump reservoir.

Index



3. OUT/UP Operation.

a. Connect a 12 volt positive (+) supply lead toBLUE/WHITE motor lead terminal.

b. Connect the negative (-) supply lead to agood ground on pump.

22495

c. Motor should run.

a - OUT/UP Solenoid

b - 12 Volt Positive (+) Supply Lead

c - Negative (-) Supply Lead

4. IN/DOWN Operation.

a. Connect a 12 volt positive (+) supply lead toGREEN/WHITE motor lead terminal.

b. Connect the negative (-) supply lead to agood ground on pump.

22494

c. Motor should run.




5. If motor does not run, refer to Motor Repair. SeeTable of Contents.

Solenoid Test (Pump in Boat)

! WARNING

DO NOT perform this test near flammables (or ex-plosives), as a spark may occur when makingconnections.

! CAUTION

Remain clear of drive unit when performing pow-er trim pump motor tests with pump in boat andhydraulic hose connected.

1. UP/OUT Solenoid.

a. Connect jumper wire between positive (+) so-lenoid terminal and BLUE/WHITE harnesswire terminal.


22495

a - OUT/UP Solenoid

b - Positive (+) Solenoid Terminal

c - BLUE/WHITE Harness Wire Terminal

d - Jumper Wire

Index


13/36OILDYNE POWER TRIM PUMP - 5A-90-12934--2 1097

2. IN/DOWN Solenoid.

a. Connect a jumper wire between positive (+)solenoid terminal and GREEN/WHITE har-ness wire terminal.


22494


b - Positive (+) Solenoid Terminal

c - GREEN/WHITE Harness Wire Terminald - Jumper Wire

3. If motor does not run in one direction or another,replace appropriate solenoid. (See Wiring Dia-gram at end of this section for wire connectionpoints).

Solenoid Test (Pump Out of Boat)

! WARNING

DO NOT perform this test near flammables (oexplosives), as a spark may occur when makinconnections.

1. Remove trim pump from boat. Refer to TrPump Removal. See Table of Contents.

2. Remove fluid from trim pump reservoir.

3. OUT/UP Solenoid.

a. Connect 12 volt positive (+) supply lead BLUE/WHITE harness wire terminal.

b. Connect negative (-) supply lead to solenoground terminal.

c. Connect ohmmeter leads to large terminaon solenoid.

2249

a - OUT/UP Solenoid



d - Ohmmeter Leads

4. Zero Ohms Reading (Full Continuity)-Solenois ok.

High Ohms Reading (No Continuity)-Replacsolenoid.

Index



5. IN/DOWN Solenoid.

a. Connect 12 volt positive (+) supply lead toGREEN/WHITE harness wire terminal.

b. Connect negative (-) supply lead to solenoidground terminal.

c. Connect ohmmeter leads to large terminalson solenoid.

22494




d - Ohmmeter Leads

6. Zero Ohms Reading (Full Continuity)-Solenoidis OK.

High Ohms Reading (No Continuity)-Replacesolenoid.

See Wiring Diagram at the end of this section for wir-ing connection points.

110 Amp Fuse Test (Pump in Boat)

! WARNING

DO NOT perform this test near flammables (orexplosives), as a spark may occur when makingconnections.

1. Check for voltage at terminal 1 using a voltmeter. Voltage MUST BE indicated beforeproceeding with next check.

2. Check for voltage at terminal 2, using voltmeter.

Voltage Indicated: Fuse OK

Voltage Not Indicated: Replace fuse

22495

22493

a - Volt Meter Negative (-) Lead

b - Volt Meter Positive (+) Lead

c - FuseIndex



110 Amp Fuse Test (Pump Out ofBoat)

1. Connect ohmmeter leads between terminals onfuse.

Zero Ohms Reading (Full Continuity)-Fuse OK

High Ohms Reading (No Continuity)-Replace fuse

22493

a - 110 Amp Fuse

b - Ohmmeter Leads

20 Amp Fuse Test

1. Remove fuse from fuse holder.

22496

a - Fuse Holder

2. Connect ohmmeter; one lead to each end of fus

Zero Ohms Reading (Full Continuity)-Fuse OK

High Ohms Reading (No Continuity)-Replace fus

2249

a - 20 Amp Fuse

b - Ohmmeter Leads

Trim Pump Removal1. Disconnect trim pump battery leads from batte

(negative lead first).

2. Disconnect trim harness connector (3 prongefrom trim pump.

3. Remove hydraulic hoses from trim pump. Caend of hoses.

4. Remove lag bolts and washers. Lift pump anfloor bracket from boat.

2254

a - Positive Battery Lead

b - Negative Battery Lead

c - Harness Connector

d - Black Hydraulic Hose (UP Hose)

e - Gray Hydraulic Hose (DOWN Hose)

f - Lag Bolts and Washers

Index



Hydraulic Repair

Disassembly

1. Disconnect trim motor wires.

22497

a - Blue/White Motor Wire

b - Green/White Motor Wire

c - Black Ground Wire

2. Remove mounting bolts and remove trim pumpfrom floor bracket.

22548

a - Trim Pump

b - Floor Bracket

c - Mounting Bolts

3. Remove solenoids (if replacement is necessary).

22496

a - UP Solenoidb - DOWN Solenoid

c - Mounting Bolts (2 On Each Solenoid)

4. Remove pump reservoir.

22547

a - Pump Reservoirb - Bolt And O-ring-Spacer

Index



Filter Replacement

1. Remove filter by twisting while pulling upward.

22547

a - Filter

2. Install new filter.

22547

a - Filter

b - 5/8 in. Socket

UP Pressure Relief ValveReplacement

NOTE:UP pressure relief valve in kit is color codeblue for easy identification.

IMPORTANT: A difference exists between thfactory installed and the replacement pressurelief valves. Once the jam nut is loosened on

factory installed relief valve, the valve is out adjustment.

IMPORTANT: When installing a replacemepressure relief valve, DO NOT loosen nor attemto remove hex jam nut. This valve is preset the factory for proper UP pressure relief.

503770892

a - Factory Installed UP Pressure Relief Valve

b - Earlier Style Replacement Pressure Relief Valve

NOTE: Original factory installed pressure relivalves will be a natural steel finish-they will NOT bcolor coded.

CURRENT REPLACEMENT PRESSURE RELIEVALVE

5039

a - Replacement UP Pressure Relief Valve

b - Color Coded Blue

Index



1. Replace UP pressure relief valve. Loosen jamnut on original pressure valve. Do NOT loosen

jam nut on replacement valves. Remove spring,eyelet and check ball and discard. Ensure thatthreaded hole is free of dirt. Lubricate O-ring atbase of new valves with Power Trim and SteeringFluid and install. Use base of replacement valveto tighten. Torque to 70 lb. in. (7.9 Nm).

ORIGINAL FACTORY INSTALLED PRESSURERELIEF VALVE

50396

70872

50396

a - Original Factory Installed UP Pressure Relief Valve

b - Jam Nut (a)

c - Pump Body Components (Spring, Eyelet, Check Ball)

d - Replacement UP Pressure Relief Valve (Blue)

e - Jam Nut

f - O-ring

EARLIER STYLE REPLACEMENT PRESSURERELIEF VALVE

50396

50376

a - UP Pressure Relief Valve

b - Jam Nut

c - Replacement UP Pressure Relief Valve (Blue)

d - O-ring

DOWN Pressure Relief ValveReplacement

NOTE: DOWN pressure relief valve in kit is colorcoded green for easy identification.

IMPORTANT: A difference exists between the fac-tory installed and the replacement pressure reliefvalves. Once the jam nut is loosened on a factory

installed relief valve, the valve is out of adjust-ment.

IMPORTANT: When installing a replacementpressure relief valve, DO NOT loosen nor attemptto remove hex jam nut. This valve is preset atthe factory for proper DOWN pressure relief.

NOTE: Original factory installed pressure reliefvalves will be a natural steel finish-they will NOT becolor coded.

5037770892

a - Factory Installed DOWN Pressure Relief Valve

b - Earlier Style Pressure Relief Valve

CURRENT REPLACEMENT PRESSURE RELIEFVALVE

50396

a - Replacement DOWN Pressure Relief Valve

b - Color Coded Green

Index



1. Replace DOWN pressure relief valve. Loosenjam nut on original pressure valve. Do NOT loos-en jam nut on replacement valves. Removespring, eyelet and check ball and discard. Ensurethat threaded hole is free of dirt. Lubricate O-ringat base of new valve with Power Trim and Steer-ing Fluid and install. Use base of replacementvalve to tighten. Torque to 70 lb. in. (7.9 Nm).

ORIGINAL FACTORY INSTALLED PRESSURERELIEF VALVE

50396

70872

50396

a - Original Factory Installed DOWN Pressure Relief Valve

b - Jam Nut

c - Pump Body Components (Spring, Eyelet, Check Ball)

d - Replacement DOWN Pressure Relief Valve (Green)

e - Jam Nut

f - O-ring

EARLIER STYLE REPLACEMENT PRESSURERELIEF VALVE

50376

50396

a - DOWN Pressure Relief Valve

b - Jam Nut-DO NOT TURN Or Attempt To Loosen

c - Replacement Valve (Green)-Use Base Of Valve To Tighten

d - O-ring

Thermal Relief Valve Replacement

NOTE:Thermal Relief Valve in kit is color coded gofor easy identification.

IMPORTANT: Thermal relief valve is factory prset. DO NOT loosen or attempt to separate component parts. Do not use wrench on upper gocolored fitting; tightening with wrench must bon the lower hex-fitting of the replacement valv

1. Replace thermal relief valve. Remove and dicard spring, eyelet and check ball on earlier styvalves. Ensure that threaded hole is free of diLubricate O-ring at base of new valve with PowTrim and Steering Fluid and install. Torque to 7lb. in. (7.9 Nm).

70836

a - Thermal Relief Valve

b - Replacement Thermal Relief Valve (Gold)

c - O-ring

d - Spring, Eyelet And Check Ball On Earlier Style Valves

Pump Replacement

NOTE:The pump is not rebuildable. If pump is defetive, replace as an assembly.

1. Remove pump attaching screws with a hex loblar socket or standard 3/16 in. socket. Do NOloosen pinion assembly screws. Remove pum

70870

a - Screws

b - Pinion Assembly Screws

Index



2. Remove O-rings from old pump and install onnew pump.

3. Lubricate lip of adaptor seal with light weight oil.

22545

a - O-rings

b - Adaptor Seal

4. Install pump and torque screws to 70 lb. in.(7.9 Nm).

70870

a - Screws

Adaptor Replacement

1. Remove pump motor attaching screws andremove motor from adaptor.

22548

a - Pump Motor

b - Screws (2)

2. Remove and discard (adaptor to reservoir)O-ring.

70869

a - Adaptor

b - O-ring

Index



3. Remove and discard (motor to adaptor) O-ring.

4. Remove vent screw (dipstick) from old adaptor.

5. Install vent screw (dipstick) and new motor toadaptor O-ring.

6. Ensure coupling is installed so that shallow slotis toward reservoir. Lubricate coupling with 2-4-CMarine Lubricant.

22498

a - Adaptor

b - Vent Screw (Dipstick)

c - O-ring

d - Coupling-(Shallow Slot Toward Reservoir)

7. Align motor shaft with coupling and install motoronto adaptor. Position as shown and secure withscrews. Tighten securely.

22496

22548

a - Motor Shaft

b - Coupling

c - Screws (Opposite Corners)

8. Install adaptor and O-ring.

Adaptor Repair

INTERNAL O-RING AND POPPET VALVEREPLACEMENT

1. Remove hex plug retainers and springs (one oeach side).

2254

a - Hex Plug Retainers (2)

b - Springs (2)

2. Remove and discard poppet valves.

2254

a - Poppet Valves

Index



! CAUTION

Use care in removing check valve bodies fromadaptor, so as not to damage poppet valve seatsurface on valve body.

3. Remove check valve bodies and spool.

70868

a - Check Valve Body (2)

b - Spoolc - 1/8 in. Diameter Rod (Provided With Trim Pump Rebuild

Kit)

4. Remove and discard O-rings on hex plugretainers.

5. Discard check valve bodies.

6. Clean hex plug retainers and spool.

70867

a - O-rings

b - Hex Plug Retainers

c - Springs

d - Poppet Valves

e - Check Valve Bodies

f - Spool

7. Lubricate check valve body O-rings with powertrim and steering fluid, or with 10W-30 or 10W-40motor oil.

! CAUTION

DO NOT force check valve bodies into adaptor asdamage to O-rings may result.

8. Place spool and check valve bodies into adaptor.

9. Place poppet valves into check valve bodies.

70874

70875

a - Spool

b - Check Valve Body (2)

c - Poppet Valve (2)

d - Check Valve Body O-ring (2)

10. Lubricate hex plug retainer O-rings withQuicksilver Power Trim and Steering Fluid, or10W-30, or 10W-40 motor oil.

11. Place spring into hex plug retainers.

Index



12. Thread hex plug retainers into adaptor by handuntil retainer contacts check valve body.

70871

a - Spring (2)

b - O-ring (2)

c - Hex Plug Retainer (2)

! CAUTION

Hex plug retainers MUST BE turned into adaptorexactly as outlined or damage to check valvebody O-rings may result.

13. Tighten hex plug retainer 1/4 turn, then back off1/8 turn. Repeat until hex plug is tightenedsecurely.

70866

a - Hex Plug Retainer (2)

Pump Shaft Oil Seal Replacement

1. Remove reservoir.

2. Remove pump attaching screws and pump. DNOT remove pump assembly screws.

7087

a - Screws

b - Pump Assembly Screws

3. Remove oil seal by prying out with a screwdrive

5037

a - Oil Seal

4. Remove and replace O-rings on pump base.

5. Install new seal with lips toward pump. Oil secan be pressed in by hand.

Index



6. Lubricate lip of seal with light weight oil. ReplaceO-rings if necessary.

22545

a - Oil Seal-Lip Toward Pump

b - O-rings

7. Install pump and torque screws to 75 lb. in. (8Nm) using a hex lobular socket or a standard3/16 inch socket.

70870

a - Screws

8. Install a new pump to reservoir O-ring.

70869

a - O-ring

b - Adaptor

9. Install reservoir.

Motor Repair

Disassembly

1. Remove trim motor from adaptor.

22546

a - Trim Motor

b - Adaptor

c - Screws

Index



2. Remove (motor-to-adaptor) O-ring.

22498

a - Adaptor

b - O-ring

3. Remove motor end cover and washer from

armature shaft bushing.

22639

22640

a - Cover

b - Screws (4)

c - Washer

4. Loosen brush hold down arms.

2264

a - Brush Hold Down Arms

b - Screws

IMPORTANT: Use care in removing brush holdeso as not to lose springs.

5. Remove brush holders and springs.

2263

a - Brush Holder

b - Spring

Index



6. Remove thermal switch and brush assembly.

22637

a - Thermal Switch And Brush

b - Screw

7. Remove brush assembly mounting bracket.

22636

a - Brush Assembly Mounting Bracket

b - Screws

8. Remove armature and thrust washer from motorhousing.

22499

a - Armature

b - Thrust Washer

c - Motor Housing

Index



9. Remove field assembly from motor housing.

22501

a - Field Assembly

b - Motor Housing

10. Remove motor housing O-ring.

22645

a - O-ring

b - Motor Housing

Armature Tests

CONTINUITY TEST

1. Check armature for continuity. Set ohmmeter oRx1 scale. Place one lead on armature shaft anthen place the other on each commutator bar.

Continuity Indicated-Armature is grounded (rplace armature).

Continuity Not Indicated-Armature is ngrounded.

2264

a - Ohmmeter

b - Meter Lead-Place On Armature Shaft

c - Meter Lead-Place On All Commutator Bars (One At ATime)

TEST FOR SHORTS

1. Check armature on a growler (follow growlmanufacturers instructions). Indication of a shorequires replacement.

CLEANING COMMUTATOR

NOTE: If commutator is worn it can be turned dowon a lathe or an armature conditioner tool.

1. Clean commutator with OO garnet grit sandpper. DO NOT use emery paper.

2. Check gaps between commutator bars fmaterial. Remove material if present.

2264

a - Commutator

b - Gap

Index



Field Tests

TEST FOR OPEN CIRCUIT

1. Connect ohmmeter between field brush lead andBLUE/WHITE lead.

Zero Ohms Indicated (full continuity)-Field OK.

Zero Ohms Not Indicated (no continuity)-Replacefield assembly.

22644

a - Ohmmeter Lead-Connected To Brush Lead

b - Ohmmeter Lead-Connected To BLUE/WHITE Lead

2. Connect ohmmeter between field brush lead andGREEN/WHITE lead.

Zero Ohms Indicated (full continuity)-Field OK.

Zero Ohms Not Indicated (no continuity)-Replacefield assembly.

22642

a - Ohmmeter Lead-Connected To Brush Lead

b - Ohmmeter Lead-Connected To GREEN/WHITE Lead

TEST FOR SHORT IN FIELD

1. Connect ohmmeter between field brush lead andfield frame.

Zero Ohms Indicated (full continuity)-Shortindicated (replace field assembly)

Zero Ohms Indicated (no continuity) - field OK.

22643

a - Field Frame

b - Field Brush Lead

Thermal Switch Test

CONTINUITY TEST

1. Connect ohmmeter between spade connectorand brush lead.

Zero Ohms Indicated (full continuity)-Proceed to

Step 2.

Zero Ohms Not Indicated (no continuity)-Replacethermal switch.

22631

a - Thermal Switch Spade Connector

b - Brush Lead

Index



2. Insert an insulator (piece of paper) betweencontact points on ohmmeter between spadeconnector and brush lead.

Zero Ohms Indicated (full continuity)-Replace ther-mal switch.

Zero Ohms Not Indicated (no continuity)-Thermalswitch OK.

22649

a - Thermal Switch Spade Connector

b - Brush Lead

c - Insulator (Piece Of Paper)

3. Remove insulator from between contact pointson thermal switch. Ensure all material is clearfrom points.

Brush Replacement

1. Loosen brush hold down arms.

2264

a - Brush Hold Down Arm

b - Screws

IMPORTANT: Use care in removing brush holdeso as not to lose springs.

2. Remove brush holders and springs.

2263

a - Brush Holders

b - Springs

Index



3. Remove and replace thermal switch and brushassembly.

22637

a - Thermal Switch And Brush

b - Screw

c - Connector

IMPORTANT: When replacing the brush that isconnected to the field wires; be sure to cut thebrush wire as close to the brush as possible.

4. Cut brush wire at location shown and discardbrush. (As close to brush as possible.)

22632

a - Brush Wire

b - Brush

5. Connect new brush wire to field wire just cut inprevious step. Secure by crimping both wirestogether as shown.

22635

a - Brush Wire

b - Field Wire (Old Brush Wire)

c - Crimp Connector

6. Reinstall spring and brush in brush holder.

22638

a - Brush Holder

b - Spring

c - Brush

Index



7. Position and tighten brush hold down arms andtighten securely. DO NOT OVERTIGHTEN.

22648


b - Screws

8. Position brush wire as shown before reassembly.

22634

a - Brush Wire

Reassembly

1. Install motor housing O-ring.

2264a - O-ring

b - Motor Housing

IMPORTANT: Field assembly wires must bfacing toward the front of motor housing. Use thnotched out area in housing as a reference determining the front.

2263

a - Motor Housing

b - Frontc - Notched Out Area

Index



2. Install field assembly into motor housing.

22501

a - Field Assembly

b - Motor Housing

3. Install thrust washer on armature and install intomotor housing.

22499

a - Armature

b - Thrust Washer

c - Motor Housing

4. Install brush assembly mounting bracket. Tight-en screws securely.

22636

a - Brush Assembly Mounting Bracket

b - Screw

5. Install thermal switch and connect black wire. DONOT overtighten screw.

22637

a - Thermal Switch

b - Screw

c - Black Wire Connector

Index



6. Install springs and brushes into brush holders.

22638

a - Brush Holders

b - Springs

c - Brushes

7. Position brush holders and secure with brushhold down arms. DO NOT overtighten screws.

22648


b - Screws

8. Install thrust washer and motor end cover. AppLoctite to screws and tighten securely. DO NOovertighten.

2263

a - Motor End Cover

b - Screws

9. Install (motor-to-adaptor) O-ring.

2249

a - Adaptor

b - O-ring

Index



10. Align motor shaft with coupler and install trimmotor on adaptor. Torque screws to 25 lb. in. (2.8Nm).

22496

22548

a - Trim Motor

b - Adaptor

c - Screws (2) (Opposite Corners)

d - Coupler

e - Motor Shaft

11. Install trim pump on floor bracket. Tightensecurely.

22548

a - Trim Pump

b - Floor Bracket

c - Screws And Lock Washers

12. Connect trim motor wires to solenoids as shown.

22497

a - BLUE/WHITE Motor Wire

b - GREEN/WHITE Motor Wire

c - BLACK Ground Wire

! CAUTION

Solenoid terminal cover screw is attached to 12volt positive source. DO NOT GROUND screw-driver when installing cover.

13. Install solenoid terminal cover. Tighten screwsecurely.

22549

a - Solenoid Terminal Cover

b - Screw

Index



Trim Pump Installation

1. Secure pump and mounting bracket to boat usinglag bolts and washers.

2. Reconnect trim hoses to pump. Black hose to leftconnection; gray hose to right connection. DONOT cross-thread or overtighten hose fittings.Torque to 70-150 lb. in. (7.9-16.9 Nm).

3. Reconnect trim harness connector to trim pump.

4. Reconnect battery leads to battery.

! CAUTION

Fill cap is vented. Be sure to remove Caplug (fillneck seal) from fill neck on new replacementpumps. Failure to do this can damage pump,when operated.

5. Check fluid level and fill if necessary. (Refer Maintaining Power Trim Pump Oil Level in thsection).

2254

a - Positive Battery Lead

b - Negative Battery Lead

c - Harness Connector

d - Black Hydraulic Hose (UP Hose)

e - Gray Hydraulic Hose (DOWN Hose)

f - Lag Bolts and Washers

g - Vent Plug-Earlier Models; Replaced By Vented Fill Cap

h - Vent In Fill Cap

Index


36/36

POWER TRIM WIRING DIAGRAM

22252

BLK D BLackBLU D BLUEBRN D BROWNGRY D GRAYGRN D GREENORN D ORANGEPNK D PINKPUR D PURPLERED D REDTAN D TAN

WHT D WHITEYEL D YELLOWLIT D LIGHT

DRK D DARK

Documents

Merc Service Manual 6 5a