Introduction This manual has been prepared as a supplement for the "Power Trim & Tilt" section described in the service manual of Tohatsu's 4 stroke gasoline outboard motors' 9.9/5/0C. Please utilize this manual together with the service manual of our outboard motors 9.9/5/0C. Contents.Outline Dimensions... Outboard Motor Dimensions... Transom Bracket Dimensions....Parts Layout... 4 Bracket (PTT)... 4 Power Tilt... 5.Operation of Power Tilt... 6 4.Operations of Hydraulic Circuit... 6 5.Removing PTT Unit... 6.Removing and Repairing Manual Release Valve... 7.Power Tilt Motor... 4 Removal, Inspection and Repair of Power Tilt Motor... 4 Continuity Test... 4 Inspection of Motor... 5 4 Replacement of Motor... 5 5 Assembling Power Tilt Motor... 5 8.Power Tilt Pump... 7 Disassembly of Power Tilt Pump... 7 Assembling Power Tilt Pump... 9 Air-Purging PTT Unit (Separated from Outboard Motor)... 4 Installation of Power Tilt Ass'y... 5 Inspection of PTT Relay... 4 6 Inspection of PTT Switch... 4 Wiring Diagram EFT EPT
PTT Unit. Outline Dimensions ) Outboard Motor Dimensions ITEM TRANSOM UNITS mm in A mm 75 4.76 S mm 690 7.7 B L mm 840.07 UL mm 967 8.07 S mm 4 6.6 C L mm 56. UL mm 689 7. D mm 70 4.57 E mm 655 5.79 F mm 05 4. G mm 445 7.5 H mm 540.6 I mm 05.0 S J K mm mm 0-70.8-.76 455 7.9 S mm 755 9.7 L L mm 895 5.4 UL mm 00 9.77 M F mm 65 4.7 P mm 45.59 N mm 5.80 N O P mm mm 0 8.7 480 8.90 Q deg 0 R deg H I G S T U Y deg deg mm mm 5 7 40 5.5 5 0.59 Q TRIM ANGLE (POSITION) deg 4-6 (5) M A E D F B C T R J U Y L K 4st 9.9/5/0 009
) Transom Bracket Dimensions CENTER LINE 76.6mm (.00in) 76.6mm (.00in) TOP OF TRANSOM 87.7mm (7.7in) 6mm (.4in) 8mm (0.7in) 8mm (0.7in) 8mm (0.7in) 75mm (0.80in) 8mm (0.7in) 5mm (.00in) 6.8mm (.5in) 97.5mm (.8in) 97.5mm (.8in) DIAMETER 6 (.4in) DIAMETER 0 (0.9in) 94.mm (.70in) 94.mm (.70in) 97mm (.8in) 97mm (.8in) DIAMETER 0 (0.9in) 0mm (0.9in) 4st 9.9/5/0 009
PTT Unit. Parts Layout Bracket (PTT) 4 N m (7 lb ft) [.4 kgf m] P/L Fig. 0 N m (9.4 lb ft) [. kgf m] GREASE OBM OBM N m (9.4 lb ft) [. kgf m] GREASE OBM OBM Ref. No. Description Q'ty 9.9 5 0 Remarks Ref. No. Description 9.9 5 0 Q'ty Remarks 4 4st 9.9/5/0 009
Power Tilt P/L Fig. 5 N m (. lb ft) [.5 kgf m] 5. N m (4 lb ft) [0.55 kgf m] Ref. No. Description Q'ty 9.9 5 0 Remarks Ref. No. Description Q'ty 9.9 5 0 Remarks Do not reuse. Do not reuse. Do not reuse. Do not reuse. Do not reuse. Do not reuse. Do not reuse. Do not reuse. 4st 9.9/5/0 009 5
PTT Unit. Operation of Power Tilt The power tilt system has an electric motor built in the system that drives the hydraulic pump to feed pressurized oil into the tilt cylinder. The power trim switch located on the tiller handle or remote control box is used to tilt-up or down the outboard motor. The switch is also used for trim operation of the outboard motor during driving at low speed. 4. Operations of Hydraulic Circuit Tilt rod : Tilt up : Tilt down Cylinder upper chamber Piston Cylinder lower chamber Manual valve Oil reservoir Manual Tilt Operation Turning the manual operation valve counterclockwise or times opens the manual operation circuit. The outboard motor can be tilted up or down easily by hand. When the manual circuit is closed completely by turning the manual valve clockwise before the outboard motor reaches completely tilted up or down position, the outboard motor holds the position at the time. 6 4st 9.9/5/0 009
Tilt rod Cylinder upper chamber Up-pressure main check valve Spool valve Piston Cylinder lower chamber Down-pressure main check valve Check valve A Gear pump Oil passage a Up relief valve Down relief valve Oil reservoir PTT motor Tilt up Operation Pressing "UP" side of PTT switch causes the PTT motor (gear of gear pump) to rotate clockwise. Check valve A opens to cause oil to flow from reservoir toward gear pump and spool valve. This oil flow shifts spool valve downward to open down-pressure main check valve. Oil in the cylinder upper chamber is returned to gear pump, hydraulic pressure of oil passage a is increased to open up-pressure main check valve, and the oil flows into cylinder lower chamber. As a result of the above operations, piston rod is pushed up to tilt up the outboard motor. The oil in the cylinder upper chamber returns to gear pump through down pressure main check valve. Because of difference of capacity difference between cylinder upper chamber and lower chamber (piston rod at upper chamber side), oil flows into the pump through check valve A to compensate for the lack of the oil. When the motor stops, down/up pressure main check valve closes, and spool valve moves to the center. As a result, piston rod is held at a position at the time. When tilt rod fully extends, up relief valve opens to prevent increase of hydraulic pressure of cylinder lower chamber by relieving the pressure to protect PTT unit. 4st 9.9/5/0 009 7
PTT Unit Tilt rod PTT cylinder Cylinder upper chamber Up-pressure main check valve Spool valve Piston Cylinder lower chamber Oil passage b Down-pressure main check valve Check valve B Gear pump Up relief valve Down relief valve Filter Oil reservoir PTT motor Tilt down/trim in Pressing "DOWN" side of PTT switch causes the PTT motor (gear pump) to rotate counterclockwise. Check valve B opens to cause oil to flow from reservoir toward gear pump and spool valve. This oil flow shifts spool valve upward to open up-pressure main check valve. Oil in the cylinder lower chamber is returned to gear pump, hydraulic pressure of oil passage b is increased to open down-pressure main check valve, and the oil flows into cylinder upper chamber. As a result of the above operations, piston rod is pushed down to tilt down the outboard motor. The oil in the cylinder lower chamber returns to gear pump through up-pressure main check valve. Because of difference of capacity difference between cylinder upper chamber and lower chamber, oil of amount exceeding upper chamber requirement returns to gear pump. When piston rod is drawn-in completely, all of oil discharged from the pump returns from down relief valve to the reservoir. 8 4st 9.9/5/0 009
Tilt rod Cylinder upper chamber Piston Shock absorber valve (Open to 9 69kgf/cm.6 6.6Mpa 85 404psi Cylinder lower chamber Shock Absorber Valve The PTT unit is provided with a shock absorber that protects the drive unit from an impact in case it hits underwater obstacle during cruising. In case drive unit hits an underwater obstacle, the hydraulic pressure in the cylinder upper chamber is increased suddenly. The high pressure opens shock valve of piston. When shock valve opens, oil in the cylinder upper chamber flows into the lower cylinder chamber to extend tilt rod upward to absorb the shock. 4st 9.9/5/0 009 9
PTT Unit Tilt rod Piston Cylinder lower chamber Thermal valve Thermal Valve Thermal valve protects drive unit from excessive force that attempts to push down tilt rod when the outboard motor is at full tilt up position. The piston rod to which excessive force is applied is pressed into the cylinder, resulting in increasing hydraulic pressure in the lower cylinder chamber over a rated value. The increased hydraulic pressure reaches the thermal valve, resulting in opening the valve to dissipate itself. 0 4st 9.9/5/0 009
5. Removing PTT Unit. Fully tilt up outboard motor and lock with tilt stopper. WARNING Be sure to lock outboard motor with tilt stopper after tilting up. Leaving outboard motor up without locking may lead to accidental descent due to reduction of PTT hydraulic pressure. IF PTT unit will not operate, open manual valve and lift up outboard motor with hands. When manual valve is opened, be sure to tighten it with specified torque after tilting up outboard motor. Manual valve : N m.5 lb ft 0. kgf m. Remove bolt and washer 4 located on the starboard side of the outboard motor, and then upper cylinder pin 5. Upper cylinder pin can be removed easily when tilt rod is retracted a little by performing tilt down operation. 4 5. Disconnect PTT cable 6 from PTT solenoid, and earth code 7 from power tilt unit. Disconnect negative battery cable first and then positive cable. 6 4st 9.9/5/0 009
PTT Unit 7 4. Remove bolt 8 and washer 9, and use a proper punch 0 to remove lower cylinder pin. Be careful not to drop PTT assembly. 89 0 6. Removing and Repairing Manual Release Valve. Loosen fill cap of power tilt unit slowly, and then remove it. Fully extend tilt rod when removing fill cap.. Drain power tilt fluid from filler cap outlet. 4st 9.9/5/0 009
. Remove manual valve C ring and turn manual valve counterclockwise to remove. 4. Remove O ring ( pcs) 4 from manual valve, check O ring for damages and deterioration, and replace with new part if necessary. 5. Remove seal washer 5, and replace with new part if necessary. Apply PTT fluid to new O ring before attaching it to power tilt assembly. 5 Manual valve 4 O ring 5 Seal washer 4 6. Attach O rings ( pcs) 4 to manual valve. 7. Attach manual valve to power tilt ass'y. 8. Attach C ring. 4st 9.9/5/0 009
PTT Unit 7.Power Tilt Motor Removal, Check and Repair of Power Tilt Motor. Remove inner hex bolts, and then remove motor ass'y from power tilt pump and cylinder ass'y. Before disassembling power tilt motor, drain power tilt fluid. <Refer to section 6.>. Remove screws 5, and then remove yoke ass'y 4 from motor bracket ass'y 6.. Remove armature ass'y 7 from yoke ass'y 4. 4 5 7 6 Yoke ass'y Screw Motor bracket 4Armature ass'y Continuity Test. Check electrical conductivity of armature. Replace armature ass'y if other than specification. Armature Conductivity : Commutator 4Armature shaft Non-conductive 4 Meter Armature Commutator 4Armature ass'y 4 4st 9.9/5/0 009
Inspection of Motor. Replace brush 5 if it is damaged or if gap between brush end in the groove of brush holder 4 and brush holder end is.6mm or less..6mm 4 Replacement of Motor. Remove screws, and remove brush 5 and circuit breaker 7 from motor bracket 8. 8 7 9. Remove circuit breaker 7.. Remove brush holder 4 and brush 5. 4 4 6 6 5 5 5 Assembling Power Tilt Motor. Attach circuit breaker 7 to motor bracket 8. Wire (blue) Wire (green) Screw 4Brush holder 5Brush 8 9 6Spring 7Circuit breaker 8Motor bracket 9O ring. Attach circuit breaker holder securely by using screws.. Attach blue wire to terminal post of circuit breaker 7. 4. Place green wire along bore of bracket. 5. Attach brush holder 4 by using screw. 7 4 6 4 6 6. Attach green wire and brush wire end to motor bracket 8 securely by using screw. 7. Attach springs 6 in the brush. 8. Attach circuit breaker 7 and brush 5 in the groove. Wire (blue) Wire (green) Screw 4Brush holder 5Brush 5 5 6Spring 7Circuit breaker 8 Motor bracket 9O ring 4st 9.9/5/0 009 5
PTT Unit 9. Attach armature while holding brush located in the groove during installation of armature to motor bracket. 0. Attach O ring 5 to motor bracket. 5 4 Armature Motor bracket Brush 4Brush 5O ring. Attach yoke ass'y by using screws. Yoke ass'y Screw () Motor bracket 6 4st 9.9/5/0 009
8.Power Tilt Pump Disassembly of Power Tilt Pump WARNING Contamination of hydraulic system can give damage to the components and circuits, possibly resulting in serious damage to the product. Before inspecting hydraulic circuit and parts, organize working space and tools. Do not use cloth for inspection and servicing of parts. Hydraulic circuit may be clogged. Remove oil feed plug before beginning the work. Keeps parts in the plastic bags during disassembly.. Remove power tilt ass'y from outboard motor.. Remove power tilt motor ass'y from power tilt ass'y. 4. Remove pump coupling 4. 4. Remove filter from power tilt ass'y. Filter 4Pump/motor coupling Relief valve ass'y is located in the power tilt pump. When removing pump, be careful not to lose its parts. 5. Remove screws, that secure power tilt pump and assembly. Power tilt pump Internal hex screw (5mm 0) Internal hex screw (5mm 5) 4st 9.9/5/0 009 7
PTT Unit 6. Remove UP side relief valve, DOWN relief orifice and O ring from power tilt housing. Up relief valve component Down relief orifice O ring 7. Check down side orifice screen and up side relief valve seat face. Replace parts if necessary. Up relief valve seat Down orifice screen 8 4st 9.9/5/0 009
Assembling Power Tilt Pump. Coat new O rings () q with oil, and attach it to power tilt housing.. Coat new O ring 9 with oil, and attach it to orifice 0.. Attach filter 8 and orifice 0. 4. Attach up side relief valve to power tilt pump housing. q 7 OIL Recommended PTT Fluid : ATF DEXRON II 4 5 6 7 8 9 0 Up relief valve ass'y O ring Valve seat 4Ball 5Spring guide 6Spring 7Down orifice ass'y 8Filter 9O ring 0orifice qo ring 5. Secure pump with screws,. Tighten screws to specified torque. Pump mounting screw : 5N m 4lb ft 0.5kg f m Power tilt pump Internal hex screw (5mm 0) Internal hex screw (5mm 5) 4st 9.9/5/0 009 9
PTT Unit 6. Attach cleaned screen. 7. Attach pump coupling to pump. 8. Install motor ass'y to power tilt pump and cylinder ass'y. 9. Attach wireharness mounting screws. Pump filter Pump/motor coupler 0. Install motor ass'y 4 to cylinder ass'y and power tilt pump by using screws 5, and tighten screws to specified torque. Motor ass'y installation screws: 5N m 4lb ft 0.5kg f m 4 5. Fill power trim system with power trim fluid. OIL Recommended PTT Fluid : ATF DEXRON II Extend trim rod and put PTT unit vertically. Pour fluid until it overflows from inlet.. Attach the cap 6. 6 0 4st 9.9/5/0 009
Air-Purging PTT Unit (Separated from Outboard Motor). Turn manual valve clockwise fully.. Put PTT unit on the work bench vertically, remove cap and check level of fluid in the reservoir. WARNING Check fluid level with tilt rod fully extended. Removing reserve tank cap with tilt rod at halfway position can cause blasting out of PTT fluid, which is dangerous, and also result in inaccurate fluid level reading.. Add recommended PTT fluid to specified level if it is lacking. OIL Recommended PTT Fluid : ATF DEXRON II 4. Put cap and tighten to specified torque. Reserve Tank Cap :.5N m.lb ft.5kgf m 5. Reconnect PTT motor lead wires to battery terminals to fully retract tilt rod. Tilt Rod PTT motor lead wires Battery Terminals DOWN Green (G) : Positive Terminal Blue (L) : Negative Terminal G L 6. Reconnect PTT motor lead wires to battery terminals to fully extend tilt rod. Tilt Rod PTT motor lead wires Battery Terminals UP Blue (L) Green (G) : Positive Terminal : Negative Terminal Repeat above steps several times to move up and down tilt rod (When reversing motor lead wire connection, keep the connection open for two or three seconds.). L G 7. Check fluid level with tilt rod fully stretched. Add recommended PTT fluid to specified level if it is lacking. OIL Recommended PTT Fluid : ATF DEXRON II 8. Repeat steps. to 7. until fluid reaches specified level. 9. Reattach cap. 4st 9.9/5/0 009
PTT Unit 4 Installation of Power Tilt Ass'y. Fully tilt up outboard motor and lock with tilt stopper.. Install bushing on the tilt cylinder rod. Power tilt cylinder Cylinder rod eye Bushing. Attach pivot bushings 5 () to clamp bracket. 4. Place power tilt ass'y 6 between clamp brackets. 4 5. Put tilt cylinder pivot pin (lower) in the hole of clamp bracket to secure power tilt ass'y 6. 5 5 4 6. Put washer and bolt 4 on the pin (lower) and tighten the bolt to specified torque. 6 Retaining screw 4 : N m 9.4lb ft.kgf m Clamp bracket Pivot pin Washer () 4Retaining screw 5Pivot bushings () 6Power tilt ass'y 4st 9.9/5/0 009
7. Secure earth cord by using screw. 8. Attach electrical cord of power tilt unit to power tilt relay, 4. 4 Positive terminal (red) Up relay terminal (blue) Negative terminal (black) 4Down relay terminal (green) 9. Attach bushings () to swivel bracket. 0. Extend power tilt cylinder rod to align tilt cylinder rod and swivel bracket.. Fit tilt cylinder rod by using cylinder pin (upper). Bushings () Swivel bracket Clamp bracket. Tighten tilt cylinder pin (upper) securing screw to specified torque. Tilt cylinder pin (upper) securing screw : N m 9.4lb ft.kgf m. Unlock tilt stopper, and repeat tilting up and down outboard motor to bleed air from hydraulic circuit. < Refer to ) Air-Purging PTT Unit > 4. Check power tilt fluid level, and replenish if necessary. 4st 9.9/5/0 009
PTT Unit 5 Inspection of PTT Relay This test can be made without removing parts. B L G a G (+)R. Disconnect positive and negative cables from battery.. Remove PTT lead wire socket a from coupler. - + 4 (-)B L. Check PTT relay wires in accordance with the following table. Replace if out of specification. B R Conductivity of PTT relay Blue (L) - Black (B) Coupler { Conductive Green (G) - Black (B) Terminal - Terminal 4 (-) Terminal - Terminal 4 (-) Terminal - Terminal (+) Terminal - Terminal (+) Conductive Non-conductive DW UP G L PT G L B Inspection of UP side relay 4. As shown in the figure, connect blue terminal (L) in the coupler to battery positive terminal and black terminal (B) to Up circuit B L G G (+)R negative terminal, and then, connect circuit tester leads to PTT relay terminals and. 5. Check electrical conductivity between terminals and. Replace relay if non-conductive. - + 4 (-)B L - + Inspection of DOWN side relay 6. As shown in the figure, connect green terminal (G) in the coupler to battery positive terminal and black terminal (B) to Down circuit B L G G (+)R negative terminal, and then, connect circuit tester leads to PTT relay terminals and. 7. Check electrical conductivity between terminals and. Replace relay if non-conductive. - + 4 (-)B - + L 6 Inspection of PTT Switch. Check electrical conductivity of PTT switch. Replace if out of specification. Lead Wires Switch Position Sky Blue (Sb) Red (R) Pink (P) UP (Tilt Up) Free DOWN (Tilt Down) R Sb P 4 4st 9.9/5/0 009
F 9.9C/5C/0C EFT MFS 9.9C/5C/0C EFT Connections decal TERMINAL No. CD UNIT CORD ASS'Y CONNECTOR PIN LAYOUT TERMINAL Name IGNITION GND IGNITION(+) EXCITER(H) EXCITER(L) TACHO LED POWER BLANK STOP SWITCH TERMINAL No. TERMINAL Name GND BLANK LED PULSEP(+) PULSEP(-) BLANK OIL PRESSURE SWITCH BLANK WIRE COLOR Black Blue Brown Green Orange Red White Yellow Light Green Pink Sky Blue Black / Red tracer Yellow / Red tracer Red / White tracer White / Red tracer Brown / White tracer CD UNIT IG COIL MAGNETO WARNING LANP OIL PRESSURE SWITCH REC. /REG. STARTER MOTOR SOLENOID STARTER MOTOR STOP SWITCH PTT SOLENOID OPTION MAIN SWITCH ASS'Y NEUTRAL SWITCH BATTERY OPTION TACHMETER 4st 9.9/5/0 008
F 9.9C/5C/0C EPT Connections decal TERMINAL No. CD UNIT CORD ASS'Y CONNECTOR PIN LAYOUT TERMINAL Name IGNITION GND IGNITION(+) EXCITER(H) EXCITER(L) TACHO LED POWER BLANK STOP SWITCH TERMINAL No. TERMINAL Name GND BLANK LED PULSEP(+) PULSEP(-) BLANK OIL PRESSURE SWITCH BLANK WIRE COLOR Black Blue Brown Green Orange Red White Yellow Light Green Pink Sky Blue Black / Red tracer Yellow / Red tracer Red / White tracer White / Red tracer Brown / White tracer OPTION HOURMETER OPTION VOLTMETER OPTION TACHMETER CD UNIT IG COIL MAGNETO METER LAMP SWITCH OPTION WARNING LANP REC. /REG. PTT Switch Circuite Sb R P DOWN UP OIL PRESSURE SWITCH STARTER MOTOR SOLENOID Main Switch Circuite Neutral Switch Circuite STARTER MOTOR STOP SWITCH CHOKE SOLENOID BATTERY MAIN SWITCH ASS'Y WARNING BUZZER PTT SOLENOID OPTION STOP SWITCH ASS'Y NUETRAL SWITCH BOTTOM COWL COLOR Blue Red Brown Green White Light Green Yellow Black CORD ASS'Y CONNECTOR PIN LAYOUT 4st 9.9/5/0 008 REMOTE CONTROL BOX