Trim Cylinders - Boating With TR!
Contents
1. 22131 a Floating piston b Trim cylinder c O ring Page 5B 12 90 863160 1 JUNE 2003 SERVICE MANUAL NUMBER 28 TRIM CYLINDERS 7 Disassemble shock piston assembly Ensure that check balls are not lost a Bolt b Flat washer c Spring guide d Spring 8 Remove and disassemble end cap a End cap b Piston rod c Large O ring d Small O ring 2 90 863160 1 JUNE 2003 22132 e Spring guide washer f Check balls 3 g Shock piston assembly h O ring 22133 e Continuity spring f Rod scraper g Plain washer h Retaining ring Page 5B 13 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 9 Remove small O ring from end of piston rod lt lt 10 Clean all parts in solvent Ensure all parts are dry before reassembly a a Small O ring b Piston rod Reassembly Ensure that work area and all components are clean before reassembling trim cylinders Power trim components can become damaged if dirt gets into system 1 Install small O ring into end of piston rod 22132 a Small O ring b End of piston rod Page 5B 14 90 863160 1 JUNE 2003 SERVICE MANUAL NUMBER 28 TRIM CYLINDERS 2 3 4 5 90 863160 1 JUNE 2003 Install small O rings and continuity spring into end cap Install rod scraper plain washer and retaining ring into end cap Install large O ring onto outside diameter of end cap Install end cap onto piston rod 221332. 76902 a Trim cylinder b Trim cylinder anode c Screw 2 d Washer 2 90 863160 1 JUNE 2003 Page 5B 19 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 15 Position trim cylinder rear connecting ends as shown 78880 a Port trim cylinder b Starboard trim cylinder c Connecting ends angled as shown 16 Install IN DOWN trim hose and torque 22130 a Down trim hose b Clamping plate c Screws Description dC Tin 17 Check painted areas of trim cylinders for scratches that expose metal and paint if necessary Page 5B 20 90 863160 1 JUNE 2003 SERVICE MANUAL NUMBER 28 TRIM CYLINDERS Installation NOTE Refer to Special Information at the front of this section before reinstalling trim cylinders 1 Install trim cylinder forward mounting hardware as shown 2 Lubricate anchor pin threads to prevent threads from galling 3 Hand thread locknuts onto pin Do not tighten at this time 71489 Washers small ID 2 ocknut 2 Plastic cap 2 Anchor pin threads a Anchor pin 1 b Slots 2 c Flat washer large ID 2 d Snap rings 2 e Bushings 4 2 4 C with Teflon Anchor pin threads 92 802859A1 IMPORTANT On Bravo One Two and Three Models the Trim In Limit Insert must be properly positioned before installing the trim cylinder anchor pin in the following steps f g h i NOTE Ensure that the Trim In Limit Insert is reinstalled in the same position th
3. 22132 a Small O rings e Plain washer b Continuity spring f Retaining ring c Endcap g Large O ring d Rod scraper Page 5B 15 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 Install large O ring on shock piston Install shock piston three check balls check ball eyelet spring guide washer spring spring guide spring guide washer and bolt onto piston rod 8 Apply sealant to threads of piston rod bolt and torque 22132 a Large O ring g Bolt b Shock piston h Check balls c Check ball i Spring guide washer d Check ball eyelet j Spring e Spring k Spring guide f Spring pin Spring guide washer Loctite 271 Threadlocker Threads of piston rod bolt 92 809819 Description SCN ns TO Piston rod bol ee a Page 5B 16 90 863160 1 JUNE 2003 SERVICE MANUAL NUMBER 28 TRIM CYLINDERS NOTE Before reassembly lubricate all internal parts with Power Trim and Steering Fluid or SAE 10W 30 or 10W 40 motor oll 9 Apply lubricant to parts 10 Install O ring onto floating piston and insert floating piston into cylinder 22132 a O ring b Floating piston c Cylinder Where Used Part Number Power Trim and Steering Fluid All internal parts 92 802880A1 IMPORTANT Some boat configurations may require tilt limit inserts to limit the total upward travel of the sterndrive unit Be sure to install the same number of inserts that were originally removed There must be an equal number in e
4. Washer 20 Nut 21 Cap 22 Connector trim pump 23 Retainer 24 Screw 25 Continuity washer 26 Trim cylinder anode 90 863160 1 JUNE 2003 SERVICE MANUAL NUMBER 28 Power Trim Hydraulic Schematic oRhQN 90 863160 1 JUNE 2003 LAAR OOO Xs Shuttle Pump adaptor OUT UP pressure relief valve Thermal relief valve Trim cylinder TRIM CYLINDERS 73552 IN DOWN pressure relief valve OUT UP hose IN DOWN hose Poppet valves Page 5B 5 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 Special Information Bravo Three Notice Trim In Limit Insert Some boats predominantly deep Vee heavy boats 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 sterndrive 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 sterndrive unit trim In Under these extreme stern lift oow 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
5. anchor pin shoulder 9 Install plastic caps 10 Reconnect OUT UP trim hose to the trim cylinder and torque Trim cylinder hoses 100 11 Reconnect trim hoses to the connector after air bleeding power trim cylinders and hoses following procedures outlined in Section 5A Trim cylinder hoses P41 100 90 863160 1 JUNE 2003
6. 1 821709T 0 235 in 5 97 mm 91 811908 Medium pin set 0 180 in 4 57 mm 91 811909 Small pin set 0 150 in 3 81 mm Tools Description Part Number Inverted Flare Plug 22 38609 Page 5B 2 90 863160 1 JUNE 2003 SERVICE MANUAL NUMBER 28 TRIM CYLINDERS Exploded Views Bravo Trim Cylinders NOTE Prior to reassembly of trim cylinders lubricate all internal parts with Power Trim and Steering Fluid or if not available 10W 30 or 10W 40 motor oil 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 90 863160 1 JUNE 2003 76676 14 Tilt limit spacer 15 Small O ring 16 Continuity spring 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 Page 5B 3 TRIM CYLINDERS Bravo Trim System Components Page 5B 4 1 IN DOWN hose to trim pump gray 2 OUT UPhose to trim pump black 3 OUT UP hose to trim cylinder 4 Starboard trim cylinder 5 Port trim cylinder 6 IN DOWN starboard trim cylinder hose 7 IN DOWN port trim cylinder hose 8 Plate 9 Screw 10 Front pin 11 Washer 12 Bushing 13 Washer SERVICE MANUAL NUMBER 28 73554 14 Nut 15 Cap 16 Rear pin 17 Washer 18 Bushing 19
7. 75157 Bravo One and Two positioned Bravo Three positioned aft forward a Trim in limit insert IMPORTANT The position of the Trim In Limit Insert on the Bravo Three sterndrive unit should only be changed after the boat has been properly tested Contact the boat manufacturer if you are not sure of the original position for a particular boat application Trim Cylinder Internal Leak Test Refer to Section 5A Power Trim Pump Trim Cylinder Shock Piston Test Refer to Section 5A Power Trim Pump 90 863160 1 JUNE 2003 Page 5B 7 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 Trim Cylinder Repair Removal Disconnect OUT UP trim hose from front hole on trim cylinder Disconnect IN DOWN trim hose from hydraulic connector on gimbal housing Plug holes with inverted flare or suitable plug e we MM Cap hoses 50389 a OUT UP hose b Front hole on trim cylinder c IN DOWN hose d Hydraulic connector Part Number Inverted Flare Plug 22 38609 Page 5B 8 90 863160 1 JUNE 2003 SERVICE MANUAL NUMBER 28 TRIM CYLINDERS 5 Remove front and rear power trim cylinder mounting hardware 2 mie BS ops 71489 Front a Anchor pin 1 b Slots 2 c Flat washer large ID 2 d Snap rings 2 Bushings 4 Flat washer small ID 2 Locknut 2 Plastic cap 2 Q O Rear a Rear anchor pin b Large ID washers port and starboard c Bushings 2 port a
8. SERVICE MANUAL NUMBER 28 Table of Contents Specifications 0ce eee ees 5B 2 Special Information Torque Specifications 5B 2 Bravo Three Notice Lubricants Sealants Adhesives 5B 2 Trim In Limit Insert Special Tools ccceeeeeeeuaeee 5B 2 Trim Cylinder Internal Leak Test TOOIS 0 0 cece cece ee eee en eens 5B 2 Trim Cylinder Shock Piston Test Exploded Views Bravo Trim Cylinders 5B 3 Removal Bravo Trim System Components 5B 4 Disassembly Power Trim Hydraulic Schematic 5B 5 Reassembly Installation 90 863160 1 JUNE 2003 POWER TRIM Section 5B Trim Cylinders PORES 5B 3 Trim Cylinder Repair TRIM CYLINDERS Page 5B 1 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 Torque Specifications Description Piston rod bolt End cap Trim cylinder hoses Lubricants Sealants Adhesives NOTE Prior to reassembly of trim cylinders lubricate all internal parts with Power Trim and Steering Fluid or if not available 10W 30 or 10W 40 motor oil Loctite 271 Threadlocker Threads of piston rod bolt 92 809819 Power Trim and Steering Fluid All internal parts 92 802880A1 End cap threads 2 4 C with Teflon 92 802859A1 Anchor pin threads Special Tools Spanner Wrench Removes trim cylinder end cap on all Mercury MerCruiser trim cylinders Uses interchangeable pin sets 91 811907 Large pin set 9
9. ach cylinder 11 If required install tilt limit inserts 71679 a Tilt limit inserts 90 863160 1 JUNE 2003 Page 5B 17 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 Ensure that work area and all components are clean before reassembling trim cylinders Power trim components can become damaged if dirt gets into system 1 Do not clamp center section of trim cylinder during reassembly If clamping of cylinder is necessary clamp cylinder on front mounting flange Use only 2 4 C with Teflon on end cap threads Other substances may act as an insulator and cause poor electrical continuity between cap and cylinder which could cause a corrosion problem NOTE Before reassembly lubricate all internal parts with Power Trim and Steering Fluid or SAE 10W 30 or 10W 40 motor oil 12 Apply lubricant to end cap threads and install piston rod assembly into cylinder 22133 a End cap b Piston rod c Cylinder 2 4 C with Teflon End cap threads 92 802859A1 Page 5B 18 90 863160 1 JUNE 2003 SERVICE MANUAL NUMBER 28 TRIM CYLINDERS 13 Using Spanner Wrench torque end cap 71677 a Spanner Wrench Spanner Wrench Removes trim cylinder end cap on all Mercury MerCruiser trim cylinders Uses interchangeable pin sets 91 811907 Large pin set 91 821709T 0 235 in 5 97 mm 91 811908 Medium pin set 0 180 in 4 57 mm 91 811909 Small pin set 0 150 in 3 81 mm 14 Install trim cylinder anodes
10. at it was in prior to removal of the sterndrive unit If you are not sure of the original position contact the boat manufacturer for their recommendation Refer to Special Information at the front of this section before reinstalling the Trim In Limit Insert 4 Ensure that the Trim In Limit Insert is positioned as shown for the appropriate Bravo model 75157 Bravo One and Two positioned Bravo Three positioned aft forward a Trim in limit insert 90 863160 1 JUNE 2003 Page 5B 21 TRIM CYLINDERS Page 5B 22 SERVICE MANUAL NUMBER 28 IMPORTANT The position of the Trim In Limit Insert on the Bravo Three sterndrive unit should only be changed after the boat has been properly tested Contact the boat manufacturer if you are not sure of the original position for a particular boat application 5 Install trim cylinder aft mounting hardware as shown 6 Lubricate anchor pin threads to prevent threads from galling 7 Hand thread locknuts onto anchor pin a Rear anchor pin b Large ID washers port and starboard c Bushings 2 port and starboard d Small ID washers port and starboard e Locknuts port and starboard f Plastic caps port and starboard Where Used Part Number 2 4 C with Teflon Anchor pin threads 92 802859A1 8 Tighten the anchor pin locknuts until nuts and washers contact
11. nd starboard d Small ID washers port and starboard e Locknuts port and starboard f Plastic caps port and starboard 90 863160 1 JUNE 2003 Page 5B 9 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 Disassembly Ensure work area is clean before disassembling power trim cylinders Cylinder parts can be damaged by dirt entering into power trim system Do not clamp center section of power trim cylinder during assembly or disassembly Clamp cylinder on front mounting flange 1 Remove IN DOWN trim hose from cylinder 22134 a IN DOWN trim hose b Clamping plate c Screws 2 Remove trim cylinder anodes 76902 a Trim cylinder b Trim cylinder anode c Screw 2 d Washer 2 Page 5B 10 90 863160 1 JUNE 2003 SERVICE MANUAL NUMBER 28 3 Use Spanner Wrench to remove trim cylinder end caps 90 863160 1 JUNE 2003 Spanner Wrench a Tilt limit insert TRIM CYLINDERS Removes trim cylinder end cap on all Mercury MerCruiser trim cylinders Uses interchangeable pin sets 91 811907 Large pin set 91 821709T 0 235 in 5 97 mm 91 811908 Medium pin set 0 180 in 4 57 mm 91 811909 Small pin set 0 150 in 3 81 mm Page 5B 11 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 5 Remove piston rod assembly from cylinder 22133 a End cap b Cylinder c Piston rod assembly 6 Remove floating piston from cylinder and remove O ring by tapping cylinder on block of wood
12. or starboard may worsen the condition The Trim In Limit devices reduce stern lift by preventing the sterndrive 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 the Trim In Limit Insert and the effectiveness of them can only be determined through boat testing and is ultimately the responsibility of the boat manufacturer It is recommended that only qualified personnel adjust the Trim in Limit Insert Boat must be water tested after 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 sterndrive unit is trimmed IN at higher speeds Increased trim IN range may cause handling problems on some boats which could result in personal injury IMPORTANT On Bravo One Two and Three Models the Trim In Limit Insert must be properly positioned before installing the trim cylinder anchor pin in the following steps NOTE When removing the sterndrive unit make a note of the position of the insert for reference when reinstalling the sterndrive unit Page 5B 6 90 863160 1 JUNE 2003 SERVICE MANUAL NUMBER 28 TRIM CYLINDERS 1 If equipped ensure that the Trim In Limit Insert is positioned as shown for the appropriate Bravo model 75158
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