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HYDRAULIC SYSTEMS

MC Transom Assys. and Hydraulic Systems (0606)

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Table of Contents

Hydraulic Systems – Power Trim.............................5A

Hydraulic Systems – Power Steering.......................5B

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HYDRAULIC SYSTEMS – POWER TRIM

MC Transom Assys. and Hydraulic Systems (0606)

5A

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SECTION 5A HYDRAULIC SYSTEMS – POWER TRIM 2

Table of Contents Oildyne Power Trim System .............................................................................5

Trim Cylinders ...............................................................................................5 Power Trim Cylinder Maximum Extension Dimension for Trim Limit Adjustment ....................................................................................................6

Maintaining Power Trim Pump Oil Level...........................................................8 Current Replacement Pressure Relief Valve ................................................8 Series V Oildyne Power Trim Pump Adaptors ..............................................9

Series I/II/III Power Trim Pump Identification (High Pressure/Low Flow) .......10 Series I/II – Prestolite Trim Pump ...............................................................10 Series III – Prestolite Trim Pump (Without Control Valve) 93247A4...........10 Service Replacement Trim Pump For Series I/II/III Trim Systems..............11 Oildyne High Pressure, Low Flow Power Trim Pump Kits ..........................11

Series IV Power Trim Pump Identification ......................................................12 Prestolite Low Pressure/High Flow (Plastic Reservoir Without Control Valve)....................................................................................................................12 Oildyne (with Eaton Motor)..........................................................................12

Series V Power Trim Pump Identification .......................................................13 Oildyne (with Eaton Motor)..........................................................................13 Oildyne (with Later Motor)...........................................................................13

Power Trim Pump - 2004 Changes ................................................................14 New Fuse Assembly ...................................................................................14 New Trim Pump Harness ............................................................................14 Control Harness to Trim Pump Adapter Harnesses....................................14 Power Trim Quick Connects .......................................................................15 Trim Pump Reservoir Cap...........................................................................15

93247A7 Low Flow/High Pressure Trim Pump Replacement Kit ...................16 Hydraulic Trim Pump Removal ...................................................................16 Hydraulic Trim Pump Installation ................................................................18 Final Check .................................................................................................21

Oildyne Power Trim – Series IV 1983–1985...................................................22 Special Information.........................................................................................23

Trail-Out Valve Removal .............................................................................23 Power Trim Cylinders .....................................................................................24

Alpha One Generation II Power Trim Cylinder (0D341151 and Above)......24 Bravo Trim Cylinder (Series V) ...................................................................26

Oildyne Power Trim Electrical System Series V 1986 and up ........................28 With 3-Button Trim/Trailer Panel.................................................................29 With Trim In Handle and Trailer Switch Separate .......................................30

Power Trim Systems / Oildyne Series V “UP” Circuit (1986 and Up) .............32 Oildyne Hydraulic “Up-Circuit”.....................................................................33

Oildyne Series V “DOWN” Circuit (1986 and Up) ...........................................34 Oildyne Hydraulic “Down-Circuit” ................................................................35

Oildyne Series V “Shock Absorber” System (1986 and Up) ...........................36 Oildyne Shock Absorber System ................................................................37

Bravo Three Drive Unit Trim “In” Limit Devices ..............................................38 Trim “In” Limit Blocks ..................................................................................39 Trim “In” Limit Spacers (Internal - Trim Ram) .............................................39 Trim “In” Limit Pin/Spacer (Drive Shaft Housing Mounted) .........................40

Bravo Drive Shaft Housing Replacement .......................................................41 Bravo Drive Shaft Housings Affected..........................................................41 Description ..................................................................................................41 Bravo One and Two ....................................................................................41 Bravo Three ................................................................................................42

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HYDRAULIC SYSTEMS – POWER TRIM SECTION 5A 3

Air Bleeding Power Trim System ....................................................................43 Bleeding OUT/UP Trim Circuit.....................................................................43 Bleeding IN/DOWN Trim Circuit ..................................................................44

Testing Power Trim Pump ..............................................................................45 Test Gauge..................................................................................................45 Internal Restriction Test...............................................................................46 OUT/UP Pressure Test ...............................................................................46 IN/DOWN Pressure Test .............................................................................48

Trim Pump Hydraulic System..........................................................................49 Trim Cylinder Internal Leak Test .....................................................................50 Trim Cylinder Shock Piston Test.....................................................................51 Motor and Electrical Bench Tests ...................................................................52

110 Amp Fuse Test (Pump in Boat) ............................................................52 110 Amp Fuse Test (Pump Out of Boat) .....................................................54 20 Amp Fuse Test .......................................................................................55 Trim Pump Motor Test (In Boat) ..................................................................56 Trim Pump Motor Test (Out of Boat) ...........................................................58 Solenoid Test (Pump In Boat) .....................................................................60 Solenoid Test (Pump Out of Boat)...............................................................62

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Oildyne Power Trim System Trim Cylinders Four Different Versions - DO NOT Intermix Original On M/C I and Bravo Drive 98703 or 98704 casting number on trim cylinder Machined outer tube for an additional 3_ tuck-in 98703--1 or 98704--1 casting number on trim cylinder. Outer tube 3/4” longer to achieve 6_additional tilt 14034--1 or 14035--1 casting number on trim cylinder. Trim cylinder used on the Alpha One, Gen II drive 815935-1 or 815954-1 casting number on the trim cylinder.

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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Power Trim Cylinder Maximum Extension Dimension for Trim Limit Adjustment a) 21-3/4 in. Max. (554mm) Earlier R/MR/Alpha One Models b) 20-3/4 in. Max. (520mm) Alpha One Generation II Models c) c - 21-3/4 in. Max. (554mm) Bravo Models

NOTE: There is a spacer available for the trim cylinders that will limit the upward travel of the drive unit to keep it from hitting the swim platform.

Blackhawk trim cylinders use 2 trim limit spacers.

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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Spanner Wrench Tool Part No. 91-821709 a) Special Tool 91-821709 b) Trim Cylinder c) Trim Cylinder End Cap

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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Maintaining Power Trim Pump Oil Level a) Vent Screw b) Bottom Lip on the Fill Neck c) Vent Hole

Avoid pump damage - vent reservoir pressure.

Check the oil level with the stern drive unit in the full down position.

If Quicksilver Power Trim and Steering fluid is not available, SAE 10W-30 or 10W-40 engine oil can be used in the system.

Remove the fill cap, the raise and lower the drive unit 6 to 10 times to purge air from the system. Check the oil level visually.

If there is a vent screw, it must be backed out 2 full turns. If there is no vent screw, remove the fill neck seal to vent the pump.

Maintain the oil level between the “Max” and “Min” marks on the side of the reservoir. Fill to the bottom lip on the fill neck.

Current Replacement Pressure Relief Valve a) Replacement Pressure Relief Valve b) Color Coded Area

UP Pressure Relief Valve - BLUE Colored

DOWN Pressure Relief Valve - GREEN Colored

THERMAL Relief Valve - GOLD Colored

NOTE: Original factory installed pressure relief valves will be a natural steel finish - they will NOT be color coded.

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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IMPORTANT: A difference exists between the factory installed and the replacement pressure relief valves. Once the jam nut is loosened on a factory installed relief valve, the valve is out of adjustment.

When installing a replacement pressure relief valve, DO NOT loosen or attempt to remove the hex “jam” nut. This valve is preset at the factory for proper pressure relief.

Do not use a wrench on the upper colored fitting. Use a wrench on the lower hex-fitting to tighten the relief valve.

Series V Oildyne Power Trim Pump Adaptors a) Down Pressure Relief Valve b) Up Pressure Relief Valve c) Thermal Relief Valve d) Adaptor Fitting - Used with Old Adaptor

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Series I/II/III Power Trim Pump Identification (High Pressure/Low Flow) Series I/II – Prestolite Trim Pump a) Metal or Plastic Reservoir b) Control Valve

Series III – Prestolite Trim Pump (Without Control Valve) 93247A4

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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Service Replacement Trim Pump For Series I/II/III Trim Systems a) The Oildyne Pump is Identified with the Production Part Number 93247A6

and Low Flow Branded on the Plastic Housing

The Prestolite trim pump has become no longer available (NLA) and is being replaced with an Oildyne floor mounted trim pump. This pump has the same pressures as the Prestolite style pump which was a high pressure low flow type pump. Refer to Service Bulletin 91-14 for additional information.

The Oildyne trim pump has internal valving that eliminates the need for an external reverse lock. However, the reverse lock may be required for shift cable attachment.

Oildyne High Pressure, Low Flow Power Trim Pump Kits

Mercury Part Number

Description

854285 Down Pressure Relief Valve

854286 Up Pressure Relief Valve

854287 Thermal Relief Valve

854288 Pump Adapter

Notes: ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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Series IV Power Trim Pump Identification Prestolite Low Pressure/High Flow (Plastic Reservoir Without Control Valve) a) Manual Release Valve b) Vent c) Fill Plug

Oildyne (with Eaton Motor) Older Production with Manual Release Valve a) Square Eaton Motor b) Manual Release Valve c) Adaptor

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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Series V Power Trim Pump Identification Oildyne (with Eaton Motor) Newer Production without Manual Release valve a) Manual Release Valve Has Been Removed from This Location b) Square Eaton Motor c) Adapter

Oildyne (with Later Motor)

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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Power Trim Pump - 2004 Changes

New Fuse Assembly Glass fuse assembly replaced with a "flat blade" style fuse.

New Trim Pump Harness

Control Harness to Trim Pump Adapter Harnesses

Current Three-Blade Round Connector New Three-Pin Packard Connector

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Power Trim Quick Connects

Trim Pump Reservoir Cap Current reservoir cap vents (left photo) are large enough to allow sloshing oil to pass from the reservoir to the exterior. New design cap (right photo) has a baffle which allows air to vent but reduces the ability for oil to migrate out. A rubber seal gasket is also installed.

Old Design

New Design

Trim Hose UP Pressure and Quick Connect Fitting

Trim Pump UP PressureFitting at the Adapter

22-865410 22-865412 22-865411 22-865413

Trim Hose DOWN Pressure

Trim Pump DOWN Pressure Fitting at the Adapter

Quick Connect Fitting

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93247A7 Low Flow/High Pressure Trim Pump Replacement Kit NOTE: The following information is contained in the instruction sheet that comes with 93247A7 Kit. The appearance and format is different with this manual.

For MerCruiser 120/140/165/888/225S/225/255TR/255TRS THIS REPLACEMENT PUMP CONTAINS THE REVERSE LOCK VALVE WITHIN THE PUMP BODY. THE EXISTING REVERSE LOCK VALVE ON ENGINE SHIFT BRACKET MUST BE RETAINED FOR SHIFT CABLE ATTACHMENT POINT.

NOTE: This kit can be installed on models equipped with Hydraulic Sender Indicator Assembly by removing Hydraulic Sender Unit as sender will not be usable with this kit.

Hydraulic Trim Pump Removal 1. Disconnect low pressure line between reverse lock valve and hydraulic

pump and discard. If Trim Sender Indicator Assembly is present, discard line attached to valve and line attached to hydraulic pump.

2. Disconnect Trim Sender Assembly and any remaining attaching hardware as it will not be usable with new hydraulic pump. Disconnect gray hydraulic hose (down) from valve.

IMPORTANT: Reverse Lock valve must be reattached to the shift bracket to allow shift cables to operate properly.

3. Remove reverse lock switch on reverse lock valve if installed and discard, reattach hardware to valve.

a) Reverse Lock Valve b) Reverse Lock Switch (Discard) c) Low Pressure Line d) Gray Hydraulic Hose (Down)

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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4. Remove control harness from pump and lay aside.

WARNING

Disconnect engine positive (+) (red) and negative (-) (black) battery cables from battery terminals before performing the following steps.

5. Disconnect black (-) negative ground cable to hydraulic pump and lay

aside.

6. Disconnect red (+) positive cable to hydraulic pump and lay aside. a) Negative Battery Lead (-) b) Positive Battery Lead (+)

7. Disconnect all hydraulic lines from old hydraulic pump. Remove opposite ends of lines from gimbal housing hydraulic manifold and discard lines.

a) Hydraulic Lines

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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Hydraulic Trim Pump Installation IMPORTANT: Both hoses in this kit are black. It will be necessary to mark the down hose with a piece of tape or equivalent after it is installed and in the proper position. 1. Assure that all attaching connections are within reach of pump. Secure

pump and mounting bracket to boat using lag bolts and washers.

2. Install the longer end of one of the hoses into the left connection on pump. This hose will be the “Up” hose. DO NOT cross-thread or overtighten fitting. Torque to 70-150 lb. in. (7.9-16.9 N·m).

3. Install the remaining hose with the shorter end connected to the right connection pump. DO NOT cross-thread or overtighten fitting. Torque to 70-150 lb. in. (7.9-16.9 N·). Mark both ends of this hose with a piece of tape to show that this is the down side hose.

a) “Up” Hydraulic Hose b) “Down” Hydraulic Hose - Marked with Tape

4. Run the “Up” hose through the transom and install into the hydraulic manifold using hole nearest to transom. DO NOT overtighten or cross-thread fitting. Torque to 70-150 lb. in. (7.9-16.9 N·m).

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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5. Run the “Down” hose (marked with tape) through the transom, and install into the remaining hole in the hydraulic manifold. DO NOT overtighten or cross-thread fitting. Torque to 70-150 lb. in. (7.9-16.9 N·m).

a) “Down” Hydraulic Hose - Marked with Tape b) “Up” Hydraulic Hose c) Hydraulic Manifold

6. Reconnect trim harness connector to the pump. a) Trim Limit Switch Wire (with Purple Sleeve) - to Purple/White Harness

Wire b) Trim Limit Switch Wire (with Blue Sleeve) - to Blue/White Harness Wire c) Wire Retainer and Sta-Strap

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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7. Connect trim wiring harness to pump. a) Trim Wiring Harness Connection

IMPORTANT: Engine electrical system is negative (-) ground.

8. Connect red positive (+) cable and black negative (-) cable to trim pump connections as shown.

a) Negative Battery Lead (-) b) Positive Battery Lead (+)

9. Reconnect red positive (+) cable to battery positive terminal and black negative (-) cable to negative battery terminal.

10. Make sure that all battery terminal connections are tight; then, spray terminals with a battery connection sealant to help retard corrosion.

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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Final Check

CAUTION

Fill cap on pump is vented. Be sure to remove the “Caplug” (fill neck seal) from fill neck on new replacement pump. Failure to do this can damage pump during operation.

IMPORTANT: Check oil level with stern drive unit in the full down position.

IMPORTANT: Use Quicksilver Power Trim and Steering Fluid, or SAE 10W-30 or 10W-40 engine oil in trim system.

1. Unscrew fill cap and remove and discard caplug from fill neck. Replace fill cap.

a) Caplug (Discard) b) Fill Cap 2. Raise and lower drive unit (to the full position) 6 to 10 times to purge air

from the system. Check oil level visually, (with drive unit in the full down position). Oil Level should be maintained at the bottom lip of the fill neck.

a) Fill Neck

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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Oildyne Power Trim – Series IV 1983–1985 1) Manual Relief Valve 2) Reverse Lock and Trail Out Valve

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Special Information Trail-Out Valve Removal Early production Oildyne pumps were equipped with a trailout valve. This valve was eliminated on later pumps. If this valve should fail on one of the early production pumps, the valve can be removed and replaced with a 7/16 – 20 pipe plug. a) Trail-Out Valve - Replaced with a 7/16–20 pipe plug

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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Power Trim Cylinders Alpha One Generation II Power Trim Cylinder (0D341151 and Above)

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1) Piston Rod 2) 2Retaining Ring 3) Plain Washer 4) Rod Scraper 5) End Cap 6) Large O-ring 7) Small O-ring (2) 8) Continuity Spring 9) O-ring (Shock Piston) 10) Small O-ring 11) Shock Piston 12) Check Balls (3) 13) Spring Pins (3) 14) Springs (3) 15) Washer 16) Spacer 17) Bolt 18) O-ring (Floating Piston) 19) Floating Piston 20) Cylinder Tube 21) Screws (2) 22) Plate 23) Spray Deflector 24) Connecting End 25) Anchor Pin 26) Bushing 27) Flat Washer 28) E-ring 29) Plastic Cap

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Bravo Trim Cylinder (Series V) NOTE: Except for diameter, Series III, IV and V trim cylinders are similar.

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1) Screws 2) Clamping Plate 3) Trim Cylinder 4) O-Ring 5) Floating Piston 6) Bolt 7) Washer 8) Spring Guide 9) Spring 10) Spring Guide Washer 11) Check Balls 12) Shock Piston 13) O-Ring 14) Small O-Ring 15) Continuity Spring 16) Small O-Ring 17) Large O-Ring 18) End Cap 19) Rod Scraper 20) Washer 21) Retaining Ring 22) Small O-Ring 23) Piston Rod 24) Anode 25) Star Washer 26) Screw 27) Trim-In Limit Spacers (1/4 in.) [P/N 23-806445A 3] 28) Trim-In Limit Spacers (3/4 in.) [P/N 23-806445A 1] 29) Trim-In Limit Spacers (1-1/4 in.) [P/N 23-806445A 2]

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Oildyne Power Trim Electrical System Series V 1986 and up The “Oildyne” pump is fitted with two solenoids as standard equipment. Without the use of solenoids, the smaller gauge wire in the control handle or the additional length of wire harness, would cause too great a voltage drop for the pump motor to operate properly.

Current is supplied to the control (panel or handle) from the battery via the red lead and is protected by a 110 amp fuse located on the solenoid and then on thru the red-purple lead to a 20 amp circuit breaker (on older pumps) or a 20 amp fuse (on new pumps), which serves to protect the trim control and harness from an overload. Pushing the “up/out button” (in the control panel) or the trim switch in the control handle upward, connects the red-purple jumper lead and the purple-white lead which routes current to the trim limit switch (which is normally a closed circuit). The blue-white lead then carries the current to the “up” solenoid where it activates the solenoid to supply current via the large blue-white lead to operate the trim motor in an up direction. The “up/out button” in the control panel, or the trim switch in the control handle, allows approximately 17_ of trim (from full “down” position), after which point the trim limit switch opens and current can no longer be supplied to the pump motor. By pressing the “up/out” and “up” button simultaneously or the trailer button on the control handle, this will connect the purple-white jumper lead to the blue-white lead which bypasses the trim limit switch. Current then proceeds to the “up” solenoid and allows the drive unit to travel to a full “up” position.

Pushing the “in” button (in the control panel), or the trim switch in the control handle downward, connects the red-purple jumper lead and the green-white lead. The green-white lead then carries the current to the “down” solenoid where it activates the solenoid to supply current via the large green-white lead to operate the trim motor in a “down” direction.

The pump motor is protected from overheating by an internal circuit breaker (in the field winding), which interrupts the ground circuit to the solenoids if an overheating condition is sensed.

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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With 3-Button Trim/Trailer Panel

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With Trim In Handle and Trailer Switch Separate

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Power Trim Systems / Oildyne Series V “UP” Circuit (1986 and Up)

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Oildyne Hydraulic “Up-Circuit” When you depress the up button, the power trim pump is activated in the up position, the motor shaft and gears “8” rotate and draw some oil from the pump reservoir “18” thru the up circuit oil pick-up “9” and past check ball “7”.

Oil pressure moves the shuttle valve “3” to the right and opens the down circuit pilot check valve “5” allowing oil to return from the down side cavity of the trim cylinders, which supplies most of the oil to operate the “up circuit”.

Oil under pressure moves the up circuit pilot check valve “2” to the left, which allows oil to exit through the up pressure port “1”. Both pilot check valves open at (20 psi). The oil then continues on through the up pressure hose “21” to connector block “11” and on into the trim cylinders, pushing the piston rod out and up.

If you continue to hold the up button in, after the piston comes to the end of its travel, the oil will unseat the up pressure regulator and relief valve “19”, which opens at (2200 to 2600 psi), allowing oil to return to the oil reservoir.

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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Oildyne Series V “DOWN” Circuit (1986 and Up)

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Oildyne Hydraulic “Down-Circuit” When you depress the down button, the power trim pump is activated in reverse for the down position, the motor shaft and gears “8” rotate, oil pressure then moves the shuttle valve “3” to the left and opens the up circuit pilot check valve “2” and draws returning oil form the up circuit trim cylinder cavity to supply oil to the trim pump for the down circuit.

At this same time, oil pressure opens the down circuit pilot check valve “5” allowing oil to exit through the down pressure port “4”. The oil then continues on through the down pressure hose “10” to connector block “11” and on into the trim cylinders, pushing the piston rod in and down.

If you continue to hold the down button in, after the piston has been fully retracted, the oil will unseat the down pressure regulator and relief valve “6” which opens at (400 to 600 psi) allowing oil to return to the oil reservoir. To supply oil to the pump “8” at this time, a small amount of oil will be drawn up through the down circuit oil pick up check ball.

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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Oildyne Series V “Shock Absorber” System (1986 and Up)


Oildyne Shock Absorber System When a submerged object is hit with great force, oil will build up sufficient pressure in the trim cylinder down side cavity to open the shock piston relief valve “15” (1100 to 1300 psi). Oil in the cavity of the up side of the cylinder cavity is locked in by the up circuit pilot check valve “2”, and the thermal relief “20” (2800 to 3200 psi). Therefore, the shock piston relief valve “15” allows the oil from the down side cavity of the trim cylinder to pass thru the shock piston “13”, into the vacuum area between the ram piston and the floating piston “16”. Syphon valve “14” (50 to 150 psi) allows the oil to return thru the piston as the drive unit returns to normal running position. Propeller thrust and weight of the drive unit provides the return motion of the drive unit. The thermal relief valve “20”, also allows for oil expansion from heat, to return the oil to the reservoir “18”.

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


Bravo Three Drive Unit Trim “In” Limit Devices NOTE: Some earlier Bravo Three models will be equipped with Trim-In Limit Blocks, later model Bravo One, Two, and Three will have a Trim-In Limit Spacer installed inside the trim rams. Current models use a crescent shaped pin, inserted in an elongated aft power trim cylinder anchor pin hole.

It has been brought to our attention that some boats (predominantly deep-Vee heavy boats), equipped with a Bravo Three drive unit, will roll up on their side under certain, specific, operating conditions. The roll can be either to port or starboard and may be experienced while moving straight ahead, or while making a turn. The roll occurs most frequently at or near maximum speed, with the drive unit trimmed at or near full “In”. While the boat will not roll completely over, the roll may be sufficient to unseat the operator or passengers, and thereby create an unsafe situation.

The roll is caused by “stern lift.” “Stern lift” can be created by excessive drive unit trim “In.” Under these extreme “stern lift”/“bow down” conditions instability can be created which may cause the boat to roll. Weight distribution to the stern can reduce “stern lift” and, in some circumstances, eliminate the condition. Weight distribution in the bow, port or starboard, may worsen the condition.

The Trim “In” limit devices reduce “stern lift” by preventing the drive unit from reaching the last few degrees of full trim under. While this device should reduce the rolling tendency, they may not eliminate the tendency entirely. The need for these trim “In” limit devices, and the effectiveness of them, can only be determined through boat testing and is ultimately the responsibility of the boat manufacturer.

WARNING

It is recommended that only qualified personnel remove or adjust the Trim “In” Limit devices. Boat must be water tested after removing or adjusting the device to ensure that the modified trim “In” range does not cause the boat to exhibit an undesirable boat handling characteristic if the drive unit is trimmed “In” at higher speeds. Increased trim “In” range may cause handling problems on some boats which could result in personal injury.

Early Bravo drive units that have the Trim “In” Limit Blocks should have them removed. These early drive units (with “round” aft power trim ram anchor pin holes) should have Trim “In” Limit Spacers installed internally, in the trim rams.

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


Trim “In” Limit Blocks

Trim “In” Limit Spacers (Internal - Trim Ram) 1) Bolt 2) Flat Washer 3) Spring Guide 4) Spring 5) Spring Guide Washer 6) Check Balls (3) 7) Shock Piston Assembly 8) O-ring 9) Spacer Bolt (3/4”, 1”)(19 - 25.4 mm) 10) Spacer Bushing (1/4”)(6.3 mm) 11) End Cap 12) O-ring

Kit Number Travel Reduction

23-806445A1 ¾”-1” (19-25.4 mm)

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


Trim “In” Limit Pin/Spacer (Drive Shaft Housing Mounted) 1997 1/2 Model Year starting with serial number 0K184626 the Bravo Drive Shaft Housing changed in the AFT ANCHOR PIN HOLE, location to accommodate for the new TRIM IN LIMIT SPACER PIN, this change replaced the (A - B) blocks that were on the Gimbal Housing on the front anchor pin.

IMPORTANT: On Bravo One, Two, and Three Models, the “Trim-In Limit Pin” (If equipped), must be properly positioned before installing the trim cylinder anchor pin in the following steps.

NOTE: When removing the stern drive unit, make a note of the position of the pin for reference when reinstalling the drive unit.

If equipped, ensure that the Trim-In Limit Pin is positioned as shown for the appropriate Bravo model. Bravo One and Two (Positioned Forward) Bravo Three (Positioned Aft) a) Trim-In Limit Pin Bravo Trim-In Limit Pin (808006)

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


Bravo Drive Shaft Housing Replacement (Information from MerCruiser Service Bulletin 98-16)

NOTICE Revised January, 1999. This bulletin information supersedes all of the following bulletins 94-1, 94-16, 96-1 and 97-7.

Bravo Drive Shaft Housings Affected 1589-8868A25 or 1589-8868A55

Description The 1589-8868A25 and 1589-8868A55 drive shaft housings will supersede to the 1589-8868G21 drive shaft housing. The anchor pin hole changes from the round aft anchor pin hole to the elongated (slotted) aft anchor pin hole. The elongated (slotted) aft anchor pin hole requires the use of a crescent shaped insert (808006). This insert is included with the housing to position the pin placement for Bravo One/Two/Three.

Bravo One and Two For the Bravo One and Two, the insert is placed in the FORWARD most position in the aft anchor pin hole. This placement will give the normal minus 5 degrees of trim under. The insert may be placed in the AFT most position of the slotted hole to limit the amount of trim under for boat hulls requiring less trim under. a) Bravo One / Two Standard Insert Location b) Bravo One / Two Optional Insert Location

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


Bravo Three For the Bravo Three drive unit, the insert MUST BE placed in the AFT most position in the slotted hole to limit the Trim Under. a) Trim-In Limit Spacer Location

When the 1589-8868G21 housing is used on a Bravo Three drive unit, the Trim-In Limit Blocks (806692A2) will no longer be required. DO NOT reinstall them on the drive unit. If the blocks are already installed, they MUST BE REMOVED. After placing the insert in the AFT most position of the slotted hole, install a Tilt Limit Spacer Kit (15768A3). Use 1 spacer per cylinder as shown below to prevent the bell housing and drive shaft housing from contacting the gimbal ring U-Bolt. Port Trim Cylinder Starboard Trim Cylinder

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


Air Bleeding Power Trim System 1. The Power Trim System will purge itself of a small amount of air by raising

and lowering the drive unit several times. However, if a rebuilt trim cylinder is being installed (which has not been filled with oil), the following bleeding procedure should be used to remove the air from the system.

Bleeding OUT/UP Trim Circuit 1. Fill the pump reservoir to the proper level as explained preceding. (The

trim cylinder must be compressed.)

2. Disconnect the OUT/UP hose from the front connection on the trim cylinder. If both cylinders were rebuilt, disconnect the hoses from both cylinders.

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

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

5. Refill the trim pump to the proper level. a) OUT/UP Trim Hose b) Front Connection On Trim Cylinder

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


Bleeding IN/DOWN Trim Circuit 1. Ensure that the pump reservoir is filled to the proper level.

2. Disconnect the IN/DOWN hose from the rear connection on the gimbal housing hydraulic connector. If both cylinders were rebuilt, disconnect the hoses from both sides of the hydraulic connector.

3. Plug the holes in the hydraulic connector, using a plug (22-38609) or suitable device.

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

5. Run the trim pump in the Up direction until the trim cylinders are fully extended.

6. Remove the plug(s) from the gimbal housing hydraulic connector and momentarily run the trim pump in the IN/DOWN direction until a solid, air-free stream of fluid is expelled from the rear hole(s) in the hydraulic connector. Reconnect the trim hose(s) and tighten securely.

7. Lower the drive unit to the full IN/DOWN position and refill the trim pump to the proper level. Run the trim system IN/DOWN and OUT/UP several times and recheck the fluid level.

a) In/Down Trim Hose b) Hydraulic Connector c) Plug (22-38609)

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


Testing Power Trim Pump

CAUTION

Cross connecting trim hoses will damage the stern drive housing. Appropriately mark trim hoses and hose connections to ensure proper reassembly.

Test Gauge 1. Check the trim pump oil level. Fill if necessary.

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

3. Connect the test gauge at the most convenient location (at pump or hydraulic connector).

Gauge Connected to Pump a) Hydraulic Test Gauge (91-52915A6) Gauge Connected to Hydraulic Connector a) Hydraulic Test Gauge (91-52915A6) b) Gimbal Housing Hydraulic Connector c) Caps (Supplied with Gauge) d) Plugs (Supplied with Gauge) 4. Open valve “A” and “B” and operate the pump UP and DOWN for several

seconds to purge air.


Internal Restriction Test 1. Open valves “A” and “B”.

2. Operate pump OUT/UP and IN/DOWN while observing gauge.

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

OUT/UP Pressure Test

NOTE: The numbers in parenthesis, e.g. (3), refer to the trim pump hydraulic system diagram.

1. Leave valve “A” open and close valve “B.”

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

If Gauge reading is within specifications, proceed to step 3.

If Gauge reading is not within specifications, perform the following:


3. Run the pump OUT/UP until the gauge reading reaches 2200-2600 psi (15173-17932 kPa). Stop pumping OUT/UP The pressure should not fall below 1900 psi (13104 kPa). If Gauge reading is 1900 psi (13104 kPa) or above, UP pressure test completed. If Gauge reading is below 1900 psi (13104 kPa) perform the following:

NOTE: A small leak will cause a pressure drop to be seen.


IN/DOWN Pressure Test

NOTE: The numbers in parenthesis, e.g. (3), refer to the trim pump hydraulic system diagram.

1. Close valve “A” and open valve “B.”

2. Run the pump IN/DOWN while observing the gauge. The reading should be 400-600 psi (2759-4138 kPa). If Gauge reading is within specifications, proceed to step 3. Gauge reading is NOT within specifications, perform the following.

3. Run pump IN/DOWN until gauge reading reaches 400 - 600 psi (2759 -

4138 kPa). Stop pumping IN/DOWN. Pressure should not fall below 350 psi (2414 kPa).

NOTE: A small leak will cause a pressure drop to be seen.

Gauge reading above 350 psi (2414 kPa), DOWN Pressure Test completed.

Gauge reading below 350 psi (2414 kPa), perform the following:


Trim Pump Hydraulic System 1) Shuttle 2) Pump Adaptor 3) OUT/UP Pressure Relief Valve 4) Thermal Relief Valve 5) Fitting 6) IN/DOWN Pressure Relief Valve


Trim Cylinder Internal Leak Test IMPORTANT: Before performing the following test, ensure that OUT/UP pressure meets specifications designated in OUT/UP pressure test.

1. Reconnect the trim cylinder hoses (if removed in a previous test) as follows: a) Remove the plugs and caps. b) Install the UP hose to the forward hole on the hydraulic connector.

Tighten securely. c) Install the DOWN hose to the aft hole on the hydraulic connector.

Tighten securely. a) UP Hose b) DOWN Hose c) Hydraulic Connector

2. Connect the gauge at the most convenient location, at the pump or at the hydraulic connector.

3. Open valves “A” and “B” and the run pump OUT/UP and IN/DOWN several times (to purge air).

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

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

a) Reading below 1900 psi (13105 kPa) indicates a trim cylinder leak. Use the following steps to locate the faulty cylinder.

b) If the gauge is connected at the pump, reconnect the gauge at the gimbal housing hydraulic connector. Repeat step 2: then run the pump in the OUT/UP direction until the trim cylinder is fully extended.

c) Close the valve on the test gauge an repeat Steps 3 and 4. If Reading is now within specification: The trim cylinder on the same side that test gauge is connected to is faulty.

If Reading is still not within specification: The trim cylinder on the opposite side from where the test gauge is connected is faulty.

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


Trim Cylinder Shock Piston Test If all previous trim system test results meet specifications, but drive unit will not trim IN/DOWN, the problem may be a leaky trim cylinder shock piston. Use the following test to check for this condition. No test gauge required. 1. Run the pump in the OUT/UP direction until the trim cylinders are fully

extended.

2. Use a suitable devise to keep trim cylinder piston rods from retracting. The Quicksilver Trailering Kit works well for this purpose.

a) Trailering Clip 3. Disconnect the UP trim hose from a trim cylinder. a) UP Trim Hose b) Front Connection

4. Run the pump in the IN/DOWN direction. If oil flows from the UP port on the trim cylinder, the shock piston is leaking and must be replaced.

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


Motor and Electrical Bench Tests 110 Amp Fuse Test (Pump in Boat)

WARNING

DO NOT perform this test near flammables (or explosives) as a spark may occur when making connections.

1. Check for voltage at terminal “d” using a volt meter. Voltage MUST BE

indicated before proceeding with the next check. a) Volt Meter Negative (-) Lead b) Volt Meter Positive (+) Lead c) Fuse (RED in Color) d) Check for Voltage Here

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


2. Check for voltage at terminal “d” using a volt meter. a) Voltage Indicated: Fuse O.K. b) Voltage Not Indicated: Replace the fuse.

a) Volt Meter Negative (-) Lead b) Volt Meter Positive (+) Lead c) Fuse (RED in Color) d) Check for Voltage Here

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


110 Amp Fuse Test (Pump Out of Boat) 1. Connect the ohmmeter leads between the terminals on the fuse. a) 110 Amp Fuse (Red) b) Ohmmeter Leads

Zero Ohms Reading (Full Continuity)-Fuse OK.

High Ohms Reading (No Continuity)-Replace fuse.

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


20 Amp Fuse Test 1. Remove the fuse from the fuse holder. a) Fuse Holder (Older Style-Glass Fuse Assembly, Newer Style-Flat Blade)

Older Style Fuse Newer Style Fuse

2. Connect one ohmmeter lead to each end (terminal) of the fuse. a) 20 Amp Fuse b) Ohmmeter Leads Zero Ohms Reading (Full Continuity)-Fuse OK.

High Ohms Reading (No Continuity)-Replace fuse.

a

ab


Trim Pump Motor Test (In Boat)

WARNING

Making electrical connections may cause a spark. DO NOT perform this test near flammables (or explosives).

WARNING

Remain clear of the drive unit when performing power trim pump motor tests with pump in the boat and hydraulic hoses connected.

1. OUT/UP Operation.

a) Connect a 12 gauge jumper wire between the positive (+) solenoid terminal and the blue-white motor lead terminal.

b) The motor should run. a) OUT/UP Solenoid b) Positive Terminal (+) c) BLUE-WHITE Motor Lead Terminal d) Jumper Wire

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


2. IN/DOWN Operation. a) Connect a 12 gauge jumper wire between the positive (+) solenoid

terminal and the green-white motor lead terminal. b) The motor should run.

a) IN/DOWN Solenoid b) Positive Terminal (+) c) GREEN-WHITE Motor Lead Terminal d) Jumper Wire

3. If the motor does not run, refer to “Motor Repair.”

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


Trim Pump Motor Test (Out of Boat)

WARNING

Making electrical connections may cause a spark. DO NOT perform this test near flammables or explosives.

1. Remove the trim pump from the boat. Refer to “Trim Pump Removal”.

2. Remove the fluid from the trim pump reservoir.

3. OUT/UP Operation a. Connect a 12 volt Positive (+) supply lead to the blue-white motor

lead terminal. b. Connect the negative (–) supply lead to a good ground on the

pump. c. The motor should run.

a) OUT/UP Solenoid b) 12 Volt Positive (+) Supply Lead c) Negative Supply Lead

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


4. IN/DOWN Position. a. Connect a 12 volt Positive (+) supply lead to the green-white motor

lead terminal. b. Connect the negative (–) supply lead to a good ground on the pump. c. The motor should run.

a) IN/DOWN Solenoid b) 12 Volt Positive Supply (+) Lead c) Negative Supply Lead 5. If the motor does not run, refer to “Motor Repair.”

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


Solenoid Test (Pump In Boat)

WARNING


CAUTION

Remain clear of the drive unit when performing power trim pump motor tests with pump in the boat and hydraulic hoses connected.

1. UP/OUT Solenoid.

a) Connect a 12 gauge jumper wire between the positive (+) solenoid terminal and the blue-white harness wire terminal.

b) The motor should run. a) OUT/UP Solenoid b) Positive (+) Solenoid Terminal c) BLUE-WHITE Harness Wire Terminal d) Jumper Wire

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


2. IN/DOWN Solenoid. a) Connect a 12 gauge jumper between the positive (+) solenoid

terminal and the green-white harness wire terminal. b) The motor should run.

a) IN/DOWN Solenoid b) Positive (+) Solenoid Terminal c) GREEN-WHITE Harness Wire Terminal d) Jumper Wire

3. If the pump motor does not run in one direction or another, replace the appropriate solenoid.

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


Solenoid Test (Pump Out of Boat)

WARNING


1. Remove the trim pump from the boat. Refer to “Trim Pump Removal”.

2. Remove the fluid from the trim pump reservoir.

3. OUT/UP Solenoid. a) Connect a 12 volt Positive (+) supply lead to blue-white

harness terminal wire. b) Connect the negative (–) supply lead to the solenoid ground

terminal as shown. c) Connect the ohmmeter leads to the large terminals on the

solenoid. a) OUT/UP Solenoid b) 12 volt Positive (+) Supply Lead c) Negative (–) Supply Lead d) Ohmmeter Leads e) BLUE-WHITE Harness Wire Terminal f) Solenoid Ground Terminal

Zero Ohms Reading (Full Continuity)-Solenoid is OK.

High Ohms Reading (No Continuity)-Replace solenoid.

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


4. IN/DOWN Solenoid. a) Connect a 12 volt positive (+) supply lead to the green-white

harness wire terminal. b) Connect the negative (–) supply lead to the solenoid ground

terminal. c) Connect the ohmmeter leads to the large terminals on the

solenoid. a) IN/DOWN Solenoid b) 12 Volt Positive (+) Supply Lead c) Negative (–) Supply Lead d) Ohmmeter Leads e) GREEN-WHITE Harness Wire Terminal f) Solenoid Ground Terminal

Zero Ohms Reading (Full Continuity)-Solenoid is OK.

High Ohms Reading (No Continuity)-Replace solenoid.

5. See the wiring diagram.

Notes: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

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