POWER TRIM. Table of Contents. Section 5A - Oildyne Trim Pump

Transcription

1 SERVICE MANUAL NUMBER 11 Tle of Contents POWER TRIM Setion 5A - Oildyne Trim Pump OILDYNE TRIM PUMP Trim Pump Speifitions A-2 Vlve Pressure Speifitions A-2 Eletril Speifition A-2 Torque Speifition A-2 Speil Tools A-2 Lurints/Adhesives/Selers A-2 Trim Pump Exploded View A-3 Oildyne Trim Pump A-3 Mintining Power Trim Pump Oil Level.. 5A-4 Air Bleeding Power Trim System A-5 Bleeding OUT/UP Trim Ciruit A-5 Bleeding IN/DOWN Trim Ciruit A-6 Testing Power Trim Pump A-7 Test Guge A-7 Internl Restrition Test A-8 OUT/UP Pressure Test A-8 IN/DOWN Pressure Test A-10 Trim Pump Hydruli System A-11 Trim Cylinder Internl Lek Test A-12 Trim Cylinder Shok Piston Test A-14 Motor nd Eletril Benh Tests A-15 Trim Pump Motor Test (In Bot) A-15 Trim Pump Motor Test (Out of Bot).. 5A-16 Solenoid Test (Pump In Bot) A-17 Solenoid Test (Pump Out of Bot).... 5A Amp Fuse Test (Pump in Bot).. 5A Amp Fuse Test (Pump Out of Bot) A Amp Fuse Test A-21 Trim Pump Removl A-22 Hydruli Repir A-23 Disssemly A-23 Filter Replement A-24 UP Pressure Relief Vlve Replement A-25 DOWN Pressure Relief Vlve Replement A-26 Therml Relief Vlve Replement... 5A-27 Pump Replement A-28 Adpter Replement A-29 Adpter Repir A-30 Pump Shft Oil Sel Replement... 5A-33 Motor Repir A-35 Disssemly A-35 Armture Tests A-38 Continuity Test A-38 Test for Shorts A-39 Clening Commuttor A-39 Field Tests A-39 Test for Open Ciruit A-39 Test for Short in Field A-40 Therml Swith Continuity Test A-41 Brush Replement A-42 Ressemly A-44 Trim Pump Instlltion A-50 Trim Pump Wiring Digrms A-51 Model With Three-Button Trim/Triler Pnel A-51 Model With Trim In Hndle nd Triler Swith Seprte A-52 5 A MARCH 1998 Pge 5A-1

2 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 11 Trim Pump Speifitions Vlve Pressure Speifitions Eletril Speifition Torque Speifition Speil Tools VALVE PSI PRESSURE kp Up Ciruit Down Ciruit PUMP AMPERAGE DRAW PSI PRESSURE kp 115 Amps t: DESCRIPTION TORQUE l. in. l. ft. N m Up Pressure Relief Vlve Down Pressure Relief Vlve Therml Relief Vlve Pump-to-Adptor Mounting Srews Motor-to-Adptor Mounting Srews Hex Plug Retiners UP Pressure Hydruli Hose (Blk) DOWN Pressure Hydruli Hose (Gry) DESCRIPTION PART NUMBER Trim Pump Test Guge Kit A6 Torque Wrenh (l. in.) Lurints/Adhesives/Selers DESCRIPTION PART NUMBER Quiksilver Power Trim nd Steering Fluid A1 Quiksilver 2-4-C Mrine Lurint with Teflon A12 Liquid Neoprene Pge 5A MARCH 1998

3 SERVICE MANUAL NUMBER 11 Trim Pump Exploded View Oildyne Trim Pump OILDYNE TRIM PUMP (Replement Vlve) Adptor 2 - Coupling 3 - Pump 4 - Filter 5 - O-ring-Motor End 6 - O-ring, Reservoir End 7 - Dipstik 8 - Reservoir 9 - Cp (With Vent Hole) 10- Srew (Inludes O-ring) 11- End Cp w/bering Srew 12- Srew 13- O-ring 14- Srew 15- Brush Holder Kit 16- Brush set 17- Armture 18- Thrust Wsher 19- Field nd Frme 20- Housing 21- Srew 22- Relief Vlve With: 23- Spring 24- Eyelet 25- Chek Bll Replement Relief Vlve Color Code: Down Pressure: Green Up Pressure: Blue Therml: Gold Torque Speifitions 75 l. in. (8 N m) 25 l. in. (2.8 N m) MARCH 1998 Pge 5A-3

4 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 11 Mintining Power Trim Pump Oil Level CAUTION Avoid pump dmge. Vent reservoir pressure y king out the vent srew two turns fter tightening ompletely. Units without vent srew hve vented fill p. Remove the fill nek sel on models without vent srew. IMPORTANT: Chek the oil level with the stern drive unit in the full down position. IMPORTANT: If quiksilver Power Trim nd steering fluid is not ville, SAE 10W-30 or 10W-40 engine oil n e used in the system. 1. Remove the fill p, the rise nd lower the drive unit 6 to 10 times to purge ir from the system. Chek the oil level visully. 2. If there is vent srew, it must e ked out 2 full turns. If there is no vent srew, remove the fill nek sel to vent the pump. 3. Mintin the oil level etween the Mx nd Min mrks on the side of the reservoir. Fill to the ottom lip on the fill nek. - Vent Srew - Bottom Lip on the Fill Nek - Vent Hole Pge 5A MARCH 1998

5 SERVICE MANUAL NUMBER 11 Air Bleeding Power Trim System OILDYNE TRIM PUMP 1. The Power Trim System will purge itself of smll mount of ir y rising nd lowering the drive unit severl times. However, if reuilt trim ylinder is eing instlled (whih hs not een filled with oil), the following leeding proedure should e used to remove the ir from the system. Bleeding OUT/UP Trim Ciruit 1. Fill the pump reservoir to the proper level s explined preeding. (The trim ylinder must e ompressed.) 2. Disonnet the OUT/UP hose from the front onnetion on the trim ylinder. If oth ylinders were reuilt, disonnet the hoses from oth ylinders. 3. Diret the end of the trim hoses(s) into ontiner. 4. Run the trim pump in the UP diretion until solid, ir-free strem of fluid is expelled from the hose(s). Reonnet the hose(s) nd tighten seurely. 5. Refill the trim pump to the proper level OUT/UP Trim Hose - Front Connetion On Trim Cylinder MARCH 1998 Pge 5A-5

6 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 11 Bleeding IN/DOWN Trim Ciruit 1. Ensure tht the pump reservoir is filled to the proper level. 2. Disonnet the IN/DOWN hose from the rer onnetion on the giml housing hydruli onnetor. If oth ylinders were reuilt, disonnet the hoses from oth sides of the hydruli onnetor. 3. Plug the holes in the hydruli onnetor, using plug ( ) or suitle devie. 4. Diret the end of the trim hose(s) into ontiner. 5. Run the trim pump in the Up diretion until the trim ylinders re fully extended. 6. Remove the plug(s) from the giml housing hydruli onnetor nd momentrily run the trim pump in the IN/DOWN diretion until solid, ir-free strem of fluid is expelled from the rer hole(s) in the hydruli onnetor. Reonnet the trim hose(s) nd tighten seurely. 7. Lower the drive unit to the full IN/DOWN position nd refill the trim pump to the proper level. Run the trim system IN/DOWN nd OUT/UP severl times nd rehek the fluid level. - In/ Down Trim Hose - Hydruli Connetor - Plug ( ) Pge 5A MARCH 1998

7 SERVICE MANUAL NUMBER 11 Testing Power Trim Pump OILDYNE TRIM PUMP Test Guge CAUTION Cross onneting trim hoses will dmge the stern drive housing. Appropritely mrk trim hoses nd hose onnetions to ensure proper ressemly. 1. Chek the trim pump oil level. Fill if neessry. 2. Ple the drive unit in the full IN/DOWN position. 3. Connet the test guge t the most onvenient lotion (t pump or hydruli onnetor). A B Guge Conneted to Pump - Hydruli Test Guge ( A6) A B d Guge Conneted to Hydruli Connetor - Hydruli Test Guge ( A6) - Giml Housing Hydruli Connetor - Cps (Supplied with Guge) d - Plugs (Supplied with Guge) 4. Open vlve A nd B nd run the pump UP nd DOWN severl times (to purge ir) MARCH 1998 Pge 5A-7

8 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 11 Internl Restrition Test OUT/UP Pressure Test 1. Open vlves A nd B. 2. Run pump OUT/UP nd IN/DOWN while oserving guge. 3. Reple dpter if pressure is in exess of 200 psi (1379 kp). NOTE: The numers in prenthesis, e.g. (3), refer to the trim pump hydruli system digrm on pge 5A Leve vlve A open nd lose vlve B. 2. Run pump OUT/UP while oserving the guge. The reding should e psi. ( kp). If Guge reding is within speifitions, proeed to step 3. If Guge reding is not within speifitions, perform the following: Reple UP Pressure Relese Vlve (3) nd Retest Reding OK Proeed to Step 3 Reding NOT OK Reple Therml Relief Vlve (4) nd Retest Reding OK Proeed to Step 3 Reding NOT OK Reple Adptor (2) Pge 5A MARCH 1998

9 SERVICE MANUAL NUMBER 11 OILDYNE TRIM PUMP 3. Run the pump OUT/UP until the guge reding rehes psi ( kp). Stop pumping OUT/UP The pressure should not fll elow 1900 psi (13104 kp). If Guge reding is 1900 psi (13104 kp) or ove, UP pressure test ompleted. If Guge reding is elow 1900 psi (13104 kp) perform the following: Chek for Externl Oil Leks, Corret nd Retest Reding OK Up Pressure Test Completed Reding NOT OK Reple Therml Relief Vlve (4) nd Retest Reding OK Up Pressure Test Completed Reding NOT OK Instll Trim Pump Reuild Kit nd Retest Reding OK Up Pressure Test Completed Reding NOT OK Reple Adptor (2) MARCH 1998 Pge 5A-9

10 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 11 IN/DOWN Pressure Test NOTE: The numers in prenthesis, e.g. (3), refer to the trim pump hydruli system digrm. 1. Close vlve A nd open vlve B. 2. Run the pump IN/DOWN while oserving the guge. The reding should e psi ( kp). If Guge reding is within speifitions, proeed to step 3. Guge reding is NOT within speifitions, perform the following. Reple DOWN Pressure Relese Vlve (6) nd Retest Reding OK Proeed to Step 3 Reding NOT OK Instll Trim Pump Reuild Kit Reding OK Proeed to Step 3 Reding NOT OK Reple Adptor (2) Pge 5A MARCH 1998

11 SERVICE MANUAL NUMBER 11 Trim Pump Hydruli System OILDYNE TRIM PUMP Shuttle 2 - Pump Adptor 3 - OUTUP/ Pressure Relief Vlve 4 - Therml Relief Vlve 5 - Fitting 6 - IN/DOWN Pressure Relief Vlve MARCH 1998 Pge 5A-11

12 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 11 Trim Cylinder Internl Lek Test IMPORTANT: Before performing the following test, ensure tht OUT/UP pressure meets speifitions designted in OUT/UP pressure test. 1. Reonnet the trim ylinder hoses (if removed in previous test) s follows:. Remove the plugs nd ps.. Instll the UP hose to the forwrd hole on the hydruli onnetor. Tighten seurely.. Instll the DOWN hose to the ft hole on the hydruli onnetor. Tighten seurely UP Hose - DOWN Hose - Hydruli Connetor 2. Connet the guge t the most onvenient lotion. e Guge Conneted to Pump - Hydruli Test Guge - Hose Conneted to UP (Left Hole) - Fittings - (Supplied with Guge) d - BLACK Hose (From Giml Housing) e - GREY Hose (From Giml Housing) d Pge 5A MARCH 1998

13 SERVICE MANUAL NUMBER 11 OILDYNE TRIM PUMP A B Guge Conneted to Hydruli Connetor - Test Guge - Coupling (Supplied with Guge) - Front Hydruli Connetor Port 3. Open vlves A nd B nd the run pump OUT/UP nd IN/DOWN severl times (to purge ir). 4. Run the pump OUT/UP until the trim ylinders re fully extended; then, oserve the guge while pumping. The pressure should e psi ( kp). 5. Stop pumping OUT/UP Pressure should not fll elow 1900 psi (13104 kp).. Reding elow 1900 psi (13105 kp) indites trim ylinder lek. Use the following steps to lote the fulty ylinder.. If the guge is onneted t the pump, reonnet the guge t the giml housing hydruli onnetor. Repet step 2: then run the pump in the OUT/UP diretion until the trim ylinder is fully extended.. Close the vlve on the test guge n repet Steps 3 nd 4. If Reding is now within speifition: The trim ylinder on the sme side tht test guge is onneted to is fulty. If Reding is still not within speifition: The trim ylinder on the opposite side from where the test guge is onneted is fulty MARCH 1998 Pge 5A-13

14 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 11 Trim Cylinder Shok Piston Test If ll previous trim system test results meet speifitions, ut drive unit will not trim In / Down, the prolem my e leky trim ylinder shok piston. Use the following test to hek for this ondition. No test guge required. 1. Run the pump in the OUT/UP diretion until the trim ylinders re fully extended. 2. Use suitle devise to keep trim ylinder piston rods from retrting. The Quiksilver Trilering Kit works well for this purpose. - Trilering Clip Disonnet the UP trim hose from trim ylinders. - UP Trim Hose - Front Connetion Run the pump in the IN/DOWN diretion. If oil flows from the UP port on the trim ylinder, the shok piston is leking nd must e repled. Pge 5A MARCH 1998

15 SERVICE MANUAL NUMBER 11 Motor nd Eletril Benh Tests OILDYNE TRIM PUMP Trim Pump Motor Test (In Bot) WARNING Mking eletril onnetions my use sprk. DO NOT perform this test ner flmmles (or explosives). WARNING Remin ler of the drive unit when performing power trim pump motor tests with pump in the ot nd hydruli hoses onneted. 1. OUT/UP Opertion.. Connet jumper wire etween the positive (+) solenoid terminl nd the lue-white motor led terminl.. The motor should run. d IN/DOWN Position - OUT/UP Solenoid - Positive Terminl (+) - BLUE-WHITE Motor Led Terminl d - Jumper Wire MARCH 1998 Pge 5A-15

16 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER IN/DOWN Opertion.. Connet jumper wire etween the positive (+) solenoid terminl nd the greenwhite motor led terminl.. The motor should run. d - IN/DOWN Solenoid - Positive Terminl (+) - GREEN-WHITE Motor Led Terminl d - Jumper Wire If the motor does not run, refer to Motor Repir. Trim Pump Motor Test (Out of Bot) WARNING Mking eletril onnetions my use sprk. DO NOT perform this test ner flmmles or explosives. 1. Remove the trim pump from the ot. Refer to Trim Pump Removl. 2. Remove the fluid from the trim pump reservoir. 3. OUT/UP Opertion. Connet 12 volt Positive (+) supply led to the lue-white motor led terminl.. Connet the negtive ( ) supply led to good ground on the pump.. The motor should run. - OUT/UP Solenoid - 12 Volt Positive (+) Supply Led - Negtive Supply Led Pge 5A MARCH 1998

17 SERVICE MANUAL NUMBER 11 OILDYNE TRIM PUMP 4. IN/DOWN Position.. Connet 12 volt Positive (+) supply led to the green-white motor led terminl.. Connet the negtive ( ) supply led to good ground on the pump.. The motor should run. - IN/DOWN Solenoid - 12 Volt Positive Supply (+) Led - GREEN-WHITE Motor Led d - Jumper Wire If the motor does not run, refer to Motor Repir. Solenoid Test (Pump In Bot) WARNING DO NOT perform this test ner flmmles (or explosives) s sprk my our when mking onnetions. CAUTION Remin ler of the drive unit when performing power trim pump motor tests with pump in the ot nd hydruli hoses onneted. 1. UP/OUT Solenoid.. Connet jumper wire etween the positive (+) solenoid terminl nd the lue-white hrness wire terminl.. The motor should run. d - OUT/UP Solenoid - Positive (+) Solenoid Terminl - BLUE-WHITE Hrness Wire Terminl d - Jumper Wire MARCH 1998 Pge 5A-17

18 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER IN/DOWN Solenoid.. Connet jumper etween the positive (+) solenoid terminl nd the green-white hrness wire terminl.. The motor should run. d - IN/DOWN Solenoid - Positive (+) Solenoid Terminl - GREEN-WHITE Hrness Wire Terminl d - Jumper Wire If the pump motor does not run in one diretion or nother, reple the pproprite solenoid. See the wiring digrm on pge 5A-51. Solenoid Test (Pump Out of Bot) WARNING DO NOT perform this test ner flmmles (or explosives) s sprk my our when mking onnetions. 1. Remove the trim pump from the ot. Refer to Trim Pump Removl. 2. Remove the fluid from the trim pump reservoir. 3. OUT/UP Solenoid.. Connet 12 volt Positive (+) supply led to lue-white hrness terminl wire.. Connet the negtive ( ) supply led to the solenoid ground terminl s shown. Pge 5A MARCH 1998

19 SERVICE MANUAL NUMBER 11. Connet the ohmmeter leds to the lrge terminls on the solenoid. OILDYNE TRIM PUMP f e d - OUT/UP Solenoid - 12 volt Positive (+) Supply Led - Negtive ( ) Supply Led d - Ohmmeter Leds e - BLUE-WHITE Hrness Wire Terminl f - Solenoid Ground Terminl Zero Ohms Reding (Full Continuity)-Solenoid is OK. High Ohms Reding (No Continuity)-Reple solenoid. 5. IN/DOWN Solenoid.. Connet 12 volt positive (+) supply led to the green-white hrness wire terminl.. Connet the negtive ( ) supply led to the solenoid ground terminl.. Connet the ohmmeter leds to the lrge terminls on the solenoid. d f e IN/DOWN Solenoid - 12 Volt Positive (+) Supply Led - Negtive ( ) Supply Led d - Ohmmeter Leds e - GREEN-WHITE Hrness Wire Terminl f - Solenoid Ground Terminl 6. Zero Ohms Reding (Full Continuity)-Solenoid is OK. High Ohms Reding (No Continuity)-Reple solenoid. See the wiring digrm on pge 5A MARCH 1998 Pge 5A-19

20 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER Amp Fuse Test (Pump in Bot) WARNING DO NOT perform this test ner flmmles (or explosives) s sprk my our when mking onnetions. 1. Chek for voltge t terminl d using volt meter. Voltge MUST BE indited efore proeeding with the next hek. d Volt Meter Negtive (-) Led - Volt Meter Positive (+) Led - Fuse (RED in Color) d - Chek for Voltge Here 2. Chek for voltge t terminl d using volt meter.. Voltge Indited: Fuse O.K.. Voltge Not Indited: Reple the fuse. d Volt Meter Negtive (-) Led - Volt Meter Positive (+) Led - Fuse (RED in Color) d - Chek for Voltge Here Pge 5A MARCH 1998

21 SERVICE MANUAL NUMBER Amp Fuse Test (Pump Out of Bot) 1. Connet the ohmmeter leds etween the terminls on the fuse. OILDYNE TRIM PUMP Amp Fuse (Red) - Ohmmeter Leds Amp Fuse Test Zero Ohms Reding (Full Continuity)-Fuse OK. High Ohms Reding (No Continuity)-Reple fuse. 1. Remove the fuse from the fuse holder. - Fuse Holder MARCH 1998 Pge 5A-21

22 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER Connet one ohmmeter led to eh end of the fuse Amp Fuse - Ohmmeter Leds Trim Pump Removl Zero Ohms Reding (Full Continuity)-Fuse OK. High Ohms Reding (No Continuity)-Reple fuse. 1. Disonnet the trim pump ttery leds from the ttery. Disonnet the negtive led first. 2. Disonnet the trim hrness onnetor (3 pronged onnetor) from the trim pump. 3. Remove the hydruli hoses from the trim pump. Cp the hose ends. 4. Remove the lg olts nd wshers. Then, lift the pump nd floor rket from the ot. f f d e Positive Bttery Led - Negtive Bttery Led - Hrness Connetor d - BLACK Hydruli Hose (UP Hose) e - GRAY Hydruli Hose (DOWN Hose) f - Lg Bolts nd Wshers Pge 5A MARCH 1998

23 SERVICE MANUAL NUMBER 11 Hydruli Repir OILDYNE TRIM PUMP Disssemly 1. Disonnet the trim motor wires. - BLUE/WHITE Motor Wire - GREEN/WHITE Motor Wire - BLACK Ground Wire Remove the mounting olts nd trim pump from the floor rket. - Trim Pump - Floor Brket - Mounting Bolts Remove the solenoids if replement is neessry. - UP Solenoid - DOWN Solenoid - Mounting Bolts (2 on Eh Solenoid) MARCH 1998 Pge 5A-23

24 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER Remove the pump reservoir Erlier style reservoir Lter style reservoir Pump Reservoir - Bolt nd O-ring - Sper Filter Replement 1. Remove the filter y twisting while pulling upwrd. - Filter 2. Instll new filter Filter - 5/8 in. Soket Pge 5A MARCH 1998

25 SERVICE MANUAL NUMBER 11 UP Pressure Relief Vlve Replement OILDYNE TRIM PUMP NOTE: The UP pressure relief vlve in the kit is olor oded lue for esy identifition. IMPORTANT: A differene exists etween the ftory instlled nd the replement pressure relief vlves. One the jm nut is loosened on ftory instlled relief vlve, the vlve is out of djustment. IMPORTANT: When instlling replement pressure relief vlve, DO NOT loosen or ttempt to remove the hex jm nut. This vlve is preset t the ftory for proper UP pressure relief. - Ftory Instlled UP Pressure Relief Vlve NOTE: Originl ftory instlled pressure relief vlves will e nturl steel finish - they will NOT e olor oded. 1. Reple the UP pressure relief vlve. Ensure tht the threded hole is free of dirt. Lurite the O-ring t the se of the new vlve with Power Trim nd Steering Fluid nd instll. Torque to 70 l. in. (7.9 N m). Current Replement Pressure Relief Vlve - Replement UP Pressure Relief Vlve - Color Coded Blue Are MARCH 1998 Pge 5A-25

26 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 11 d e f Originl Ftory Instlled Pressure Relief Vlve - Originl Ftory Instlled UP Pressure Relief Vlve - Jm Nut - Loosen Before Removing the Vlve - Be Sure to Remove the Pump Body Components (Spring, eyelet, Chek Bll) - Disrd d - Replement UP Pressure Relief Vlve (Blue) - Use the Bse of the vlve for tightening e - Jm Nut - DO NOT TURN or Attempt to Loosen f - O-ring DOWN Pressure Relief Vlve Replement NOTE: The DOWN pressure relief vlve in the kit is olor oded green for esy identifition. IMPORTANT: A differene exists etween the ftory instlled nd the replement pressure relief vlves. One the jm nut is loosened on ftory instlled relief vlve, the vlve is out of djustment. IMPORTANT: When instlling replement pressure relief vlve, DO NOT loosen or ttempt to remove the hex jm nut. This vlve is preset t the ftory for proper DOWN pressure relief Ftory Instlled DOWN Pressure Relief Vlve - Replement DOWN Pressure Relief Vlve - Color Coded Green Are Pge 5A MARCH 1998

27 SERVICE MANUAL NUMBER 11 OILDYNE TRIM PUMP 1. Reple the DOWN pressure relief vlve. Remove the pump ody omponents nd disrd. Ensure tht the threded hole is free of dirt. Lurite the O-ring t the se of the new vlve with Power Trim nd Steering Fluid nd instll. Torque to 70 l. in. (7.9 N m). Use the se of the vlve for tightening; DO NOT TURN or ttempt to loosen the jm nut. d e f Originl Ftory Instlled Pressure Relief Vlve - Originl Ftory Instlled DOWN Pressure Relief Vlve - Jm Nut - Loosen Before Removing the Vlve - Pump Body Components (Spring, Eyelet, Chek Bll) d - Replement DOWN Pressure Relief Vlve (GREEN) e - Jm Nut f - O-ring Therml Relief Vlve Replement NOTE: The Therml Relief Vlve in the kit is olor oded gold for esy identifition. IMPORTANT: The therml relief vlve is ftory preset. DO NOT loosen or ttempt to seprte the omponent prts. Do not use wrenh on the upper gold olored fitting. Use wrenh on the lower hex-fitting to tighten the relief vlve. 1. Reple the therml relief vlve. Remove the pump ody omponents nd disrd. Ensure tht the threded hole is free of dirt. Lurite the O-ring t the se of the new vlve with Power Trim nd Steering Fluid nd instll. Torque to 70 l. in. (7.9 N m). Use the se of the vlve for tightening; DO NOT TURN or ttempt to loosen the jm nut. d Therml Relief Vlve - Replement Therml Relief Vlve (Gold) - O-ring d - Pump Body Components (Spring, Eyelet, Chek Bll) MARCH 1998 Pge 5A-27

28 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 11 Pump Replement NOTE: The pump is nnot e re-uilt. If the pump is defetive, reple it s n ssemly. 1. Remove the pump tthing srews with hex loulr soket or stndrd 3/16 in. (188mm) soket nd the pump. Do NOT loosen the pump ssemly srews. - Srew - Pump Assemly Srews Remove the O-rings from the old pump nd instll them on the new pump. 3. Lurite the lip of the dpter sel with light weight oil. - O-rings - Adpter Sel Instll the pump nd torque the pump srews to 70 l. in. (7.9 N m) using hex loulr soket or stndrd 3/16 in. (188mm) soket. - Srews Pge 5A MARCH 1998

29 SERVICE MANUAL NUMBER 11 OILDYNE TRIM PUMP Adpter Replement 1. Remove the pump motor tthing srews nd remove the pump motor. - Pump Motor - Srews (2) 2. Remove nd disrd the dpter to reservoir O-ring Adpter - O-ring Remove nd disrd the motor to dpter O-ring. 4. If present, remove the vent srew (dipstik) from the old dpter. 5. If present, instll the vent srew (dipstik) nd new O-ring into the new dptor. 6. Ensure tht the oupling is instlled so tht the shllow slot is towrd the reservoir. Lurite the oupling with 2-4-C Mrine Lurint with Teflon. - Adpter - O-ring - Coupling - (Shllow Slot Towrd Reservoir) MARCH 1998 Pge 5A-29

30 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER Align the motor shft with the oupling nd instll the motor onto the dpter. Position the motor s shown nd seure with srews. Tighten seurely Adpter Repir - Motor Shft - Coupling - Srews (Opposite Corners) INTERNAL O-RING nd POPPET VALVE REPLACEMENT 1. Remove the hex plug retiners nd springs (one on eh side) Hex Plug Retiners (2) - Springs (2) Pge 5A MARCH 1998

31 SERVICE MANUAL NUMBER Remove nd disrd the poppet vlves. OILDYNE TRIM PUMP Poppet Vlve CAUTION Use re in removing hek vlve odies from dpter, so s not to dmge poppet vlve set surfe on vlve ody. 3. Remove the hek vlve odies nd spool Chek Vlve Body - Spool - Metl Rod 4. Remove nd disrd the O-rings on the hex plug retiners. 5. Disrd the hek vlve odies. 6. Clen the hex plug retiners nd spool. e f e d d O-rings - Hex Plug Retiners - Springs d - Poppet Vlves e - Chek Vlve Bodies f - Spool MARCH 1998 Pge 5A-31

32 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER Lurite the hek vlve ody O-rings with Power Trim nd Steering Fluid, or with 10W-30 or 10W-40 motor oil. CAUTION DO NOT fore hek vlve odies into dpter s dmge to O-rings my result. 8. Ple the spool nd hek vlve odies into the dpter. 9. Ple the poppet vlves into the hek vlve odies. d - Spool - Chek Vlve Body (2) - Poppet Vlve (2) d - Chek Vlve Body O-ring Lurite the hex plug retiner O-rings with Quiksilver Power Trim nd Steering Fluid, or 10W-30 or 10W-40 motor oil. 11. Ple the springs into the hex plug retiners. 12. Thred the hex plug retiners into the dpter y hnd until the retiner ontts the hek vlve ody. - Spring (2) - O-ring - Hex Plug Retiner (2) Hex plug retiners MUST BE turned into dpter extly s outlined or dmge to hek vlve ody O-rings my result. Pge 5A MARCH 1998

33 SERVICE MANUAL NUMBER Tighten the hex plug retiner seurely on eh side. OILDYNE TRIM PUMP - Hex Plug Retiner Pump Shft Oil Sel Replement 1. Remove the pump tthing srews with hex loulr soket or stndrd 3 / 16 in. (188mm) soket. Remove pump. DO NOT loosen or remove the pump ssemly srews. - Srew - Pump Assemly Srew Remove the oil sel y prying out with srewdriver Oil Sel MARCH 1998 Pge 5A-33

34 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER Remove nd reple the O-rings on the pump se if they re worn. 4. Instll new sel with the lips towrd the pump. The oil sel n e pressed in y hnd. 5. Lurite the lip of the sel with light weight oil. - Oil Sel - O-rings - Pump Instll the pump nd torque the tthing srews to 75 l. in. (8 N m) using hex loulr soket or stndrd 3/16 in. (188mm) soket. - Srews Instll the pump reservoir. - Pump Reservoir - Bolt nd O-ring - Sper Pge 5A MARCH 1998

35 SERVICE MANUAL NUMBER 11 Motor Repir OILDYNE TRIM PUMP Disssemly 1. Remove the trim motor from the dpter. - Trim Motor - Adpter - Srews 2. Remove the motor to dpter O-ring Adpter - O-ring Remove the motor end over nd wsher from the rmture shft ushing. - Cover - Srews (4) - Wsher MARCH 1998 Pge 5A-35

36 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER Loosen the rush hold down rms. - Brush Hold Down Arms - Srews IMPORTANT: Use re in removing rush holders so s not to lose springs. 5. Remove the rush holders nd springs. - Brush Holder - Spring 6. Remove the therml swith nd rush ssemly Therml Swith nd Brush - Srew Pge 5A MARCH 1998

37 SERVICE MANUAL NUMBER Remove the rush ssemly mounting rket. OILDYNE TRIM PUMP - Brush Assemly Brket - Srews Remove the rmture nd thrust wsher from the motor housing. - Armture - Thrust Wsher - Motor Housing 9. Remove the field ssemly from the motor housing Field Assemly - Motor Housing MARCH 1998 Pge 5A-37

38 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER Remove the motor housing O-ring. Armture Tests - O-ring - Motor Housing Continuity Test 1. Set the ohmmeter on the Rx1 sle. 2. Ple the lligtor lip meter led on the rmture shft. 3. Touh the meter led proe to eh ommuttor r one t time. Continuity Indited - Armture grounded (reple rmture). Continuity Not Indited - Armture not grounded Ohmmeter Set on Rx1 Sle - Meter Led Ple on Armture - Meter Led Ple on All Commuttor Brs (One t time) Pge 5A MARCH 1998

39 SERVICE MANUAL NUMBER 11 Test for Shorts Clening Commuttor OILDYNE TRIM PUMP 1. Chek the rmture on growler (follow the growler mnufturers instrutions). Reple the rmture if it hs short. 1. Clen the ommuttor with 00 grnet grit sndpper. DO NOT use emery pper. 2. Chek the gps etween the ommuttor rs for mteril. Remove mteril if present Commuttor - Gp Field Tests Test for Open Ciruit 1. Connet the ohmmeter etween the field rush led nd the lue-white led. Zero ohms indited (full ontinuity) - Field OK. Zero ohms not indited (no ontinuity) - Reple field ssemly. - Ohmmeter Led - Conneted to Brush Led - Ohmmeter Led - Conneted to Blue/White Led MARCH 1998 Pge 5A-39

40 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER Connet the ohmmeter etween the field rush led nd the green-white led. Zero ohms indited (full ontinuity) - Field OK. Zero ohms not indited (no ontinuity) - Reple field ssemly. - Ohmmeter Led - Conneted to Brush Led - Ohmmeter Led - Conneted to Green/White Led Test for Short in Field Connet the ohmmeter etween the field rush led nd the field frme. Zero ohms indited (full ontinuity) - Short indited (reple field ssemly). Zero ohms not indited (no ontinuity) - Field OK Field Frme - Field Brush Led Pge 5A MARCH 1998

41 SERVICE MANUAL NUMBER 11 Therml Swith Continuity Test 1. Connet the ohmmeter etween the spde onnetor nd the rush led. Zero ohms indited (full ontinuity) - Proeed to next step. Zero ohms not indited (no ontinuity) - Reple therml swith. OILDYNE TRIM PUMP - Therml Swith Spde Connetor - Brush Led Insert n insultor (piee of pper) etween the ontt points on the ohmmeter (etween spde onnetor nd rush led). Zero ohms indited (full ontinuity) -Reple therml swith. Zero ohms not indited (no ontinuity) - Therml swith OK. - Therml Swith Spde Connetor - Brush Led - Insultor (Piee of Pper) Remove the insultor from etween the ontt points on the therml swith. Cler ll mteril wy from the points MARCH 1998 Pge 5A-41

42 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 11 Brush Replement 1. Loosen the rush hold down rms Brush Hold Down Arms - Srews IMPORTANT: Use re in removing rush holders so s not to lose springs. 2. Remove the rush holders nd springs. - Brush Holder - Spring 3. Remove the therml swith nd rush ssemly Therml Swith nd Brush - Srew - Connetor Pge 5A MARCH 1998

43 SERVICE MANUAL NUMBER 11 OILDYNE TRIM PUMP IMPORTANT: When repling the rush tht is onneted to the field wires; ut the rush wire s lose to the rush s possile. 4. Cut the rush wire s lose to the rush s possile nd disrd the rush. - Brush Wire - Brush Connet the new rush wire to the field wire ut in the previous step. Seure y rimping oth wires together s shown. - Brush Wire - Field Wire (Old Brush Wire) - Crimp Connetor 6. Reinstll the spring nd rush in the rush holder Brush Holder - Spring - Brush MARCH 1998 Pge 5A-43

44 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER Position the rush hold down rms nd tighten them seurely. DO NOT OVERTIGH- TEN. - Brush Hold Down Arms - Srews Position the rush wire s shown efore ressemly. Ressemly - Brush Wire Instll the motor housing O-ring. - O-ring - Motor Housing Pge 5A MARCH 1998

45 SERVICE MANUAL NUMBER 11 OILDYNE TRIM PUMP IMPORTANT: The field ssemly wires must fe the front of the motor housing. Use the nothed re in the housing s referene in determining the front. - Motor Housing - Front - Nothed Are Instll the field ssemly into the motor housing Field Assemly - Motor Housing 3. Instll the thrust wsher on the rmture nd instll the rmture into the motor housing. - Armture - Thrust Wsher - Motor Housing MARCH 1998 Pge 5A-45

46 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER Instll the rush ssemly mounting. Tighten the srews seurely. - Brush Assemly Mounting Brket - Srews Instll the therml swith nd onnet the lk wire. DO NOT overtighten the srew. - Therml Swith - Srew - Blk Wire Connetor 6. Instll the springs nd rushes in the rush holders Brush Holders - Springs - Brushes Pge 5A MARCH 1998

47 SERVICE MANUAL NUMBER 11 OILDYNE TRIM PUMP 7. Position the rush holders nd seure them with the rush hold down rms. DO NOT overtighten the srews. - Brush Hold Down Arms - Srews Instll the motor end over. Apply Lotite to the srews nd tighten seurely. DO NOT overtighten. - Motor End Cover - Srews 9. Instll the motor to dpter O-ring Adpter - O-ring MARCH 1998 Pge 5A-47

48 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER Align the motor shft with the oupler nd instll the trim motor on the dpter. Torque the srews to 25 l. in. (2.8 N m). e d - Trim Motor - Adpter - Srews (2 in Opposite Corners) d - Coupler e - Motor Shft Instll the trim pump on the floor rket. Tighten seurely. - Trim Pump - Floor Brket - Srews nd Lok Wshers Pge 5A MARCH 1998

49 SERVICE MANUAL NUMBER Connet the trim motor wires to solenoids s shown. OILDYNE TRIM PUMP - Blue/White Motor Wire - Green/White Motor Wire - Blk Ground Wire CAUTION Solenoid terminl over srew is tthed to 12 volt positive soure. DO NOT GROUND the srew driver when instlling over. 13. Instll the solenoid terminl over. Tighten the srew seurely Solenoid Terminl Cover - Srew MARCH 1998 Pge 5A-49

50 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 11 Trim Pump Instlltion 1. Seure the pump nd mounting rket to the ot using lg olts nd wshers. 2. Reonnet the trim hoses to the pump; lk hose to the left onnetion, gry hose to the right onnetion. DO NOT ross-thred or overtighten the hose fittings. Torque the fittings to 110 l. in. (12 N m). 3. Reonnet the trim hrness onnetor to the trim pump. 4. Reonnet ttery leds to ttery. CAUTION Fill p is vented. Be sure to remove Cplug (fill nek sel) from fill nek on new replement pumps. Filure to do this n dmge pump, when operted. 5. Chek the fluid level nd fill if neessry. (Refer to Mintining Power Trim Pump Oil Level in this setion). g f f - Positive Bttery Led - Negtive Bttery Led - Hrness Connetor d - Blk Hydruli Hose (UP Hose) e - Gry Hydruli Hose (DOWN Hose) f - Lg Bolts nd Wshers g - Vent Plug (Erlier Models; Repled By Vented Fill Cp) h - Vent in the Vented Fill Cp d e Pge 5A MARCH 1998

51 SERVICE MANUAL NUMBER 11 Trim Pump Wiring Digrms OILDYNE TRIM PUMP d e f BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN ORN = ORANGE PNK = PINK PUR = PURPLE RED = RED TAN = TAN WHT = WHITE YEL = YELLOW LIT = LIGHT DRK = DARK Model With Three-Button Trim/Triler Pnel - 20 Amp Fuse - Ground Bolt (Floor Mount) - UP Solenoid d - DOWN Solenoid e - Trim Limit Swith f Amp Fuse MARCH 1998 Pge 5A-51

52 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 11 Model With Trim In Hndle nd Triler Swith Seprte i f e g h BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN ORN = ORANGE PNK = PINK PUR = PURPLE RED = RED TAN = TAN WHT = WHITE YEL = YELLOW LIT = LIGHT DRK = DARK - 20 Amp Fuse - Ground Bolt (Floor Mount) - UP Solenoid d Amp Fuse e - DOWN Solenoid f - Triler Swith g - Neutrl Swith to Instrument Wiring Hrness h - Trim Limit Swith i - Trim Buttons Pge 5A MARCH 1998