Arneson ASD 8 08301E Trim Cylinder, ASD 8 08302D-1 Steering Cylinder SERVICE MANUAL

SERVICE MANUAL
ASD 8
HYDRAULIC CYLINDER SERVICE
FOR STEERING AND TRIM CYLINDERS
ASSEMBLIES COVERED BY THIS MANUAL:
TRIM STEERING
08301E 083020-1
=
A
ARNESON 57:
1.0
Hydraulic System Servicing
1.1
1.2
General
A. Propeller steering and propeller trim are achieved
through the use of hydraulic cylinders located outside the
vessel as shown in Fig. 1. The cylinders are mounted on the
transom with articulating ball joints. The trim cylinder is
connected directly to the Drive at the top of the thrust
tube. The steering cylinder is connected to the Drive either
through the trim cylinder yoke when the steering cylinders
are mounted outboard or through the trim yoke pin when the
steering cylinders are mounted inboard.
B. Arneson Marine, Inc. recommends that the inboard
hydraulic components and outboard flex hoses be serviced on a
replacement basis only. Rebuilding of pumps, valves, hoses,
etc., is not recommended.
C. Hydraulic system cleanliness must be maintained at all
times. When assembling threaded fittings with sealant, avoid
using excess material that could contaminate system. Teflon
tape is not recommended.
D. Protect sealing surfaces of cylinders during all service
operations.
E. Section 1.13 lists the special tools required for
servicing the hydraulic system.
F. See Figs. 2 and 3 for a schematic of the hydraulic trim
and steering system and associated parts list.
Cylinder Removal from Drive and Transom
A. Support the thrust tube and prop shaft assembly before
removing hydraulic cylinders to prevent unit from rotating
downward and damaging the thrust ball and socket.
B. Disconnect hose swivel fittings at the hydraulic
cylinders (See Fig. 8). Plug or cap transom and cylinder
fittings to prevent leakage and contamination of system.
Plug hose ends to prevent contamination of hoses.
C. Remove steering cylinder clevis bolt, nut, and washers
(See Fig. 4). While supporting steering cylinder, remove the
four (4) transom bracket mounting bolts, nuts, and washers
(See Fig. 6). Remove steering cylinder.
1.3
D. For twin drive installations using a mechanical tie bar,
remove tie bar clevis bolts, nuts, and washers. Slide tie
bar away from trim yoke (See Fig. 5).
E. Remove trim cylinder yoke pin, washers, and cotter pin,
Remove the four (4) trim cylinder transom bracket bolts,
nuts, and washers (See Fig. 6). Remove trim cylinder.
Trim Cylinder Disassembly
See the attached Trim Cylinder Assembly Drawing (Fig. 2) and
the associated parts list for identification of the various
trim cylinder components,
A. Remove all hydraulic fittings from trim cylinder tube
prior to cylinder disassembly. Fittings must be removed to
prevent damage to the piston as it is removed from the
cylinder,
B. Drain oil from both ports by manually cycling cylinder.
С. Hold trim cylinder tube (Item 11) using a strap wrench or
suitable padded split blocks and loosen rod guide (Item 6)
using a wrench on the machined flats. Thread rod guide out
of tube and slide rod/piston assembly from the tube.
D. Clamp the rod (Item 5) between rubber pads in a vise,
remove piston set screw (Item 30) and remove piston (Item 7)
from rod using a strap wrench. Use care to avoid scratching
rod.
E. Slide rod guide (Item 6) off the rod. Remove guide
towards piston end of rod.
F. Inspect for evidence of leakage past center plug (Item 8)
or end plug (Item 13). If leakage is suspected or there is
contamination trapped between center plug and cylinder wall,
disassemble the remainder of trim tube assembly as follows.
If no leakage or trapped contamination is noted, proceed to
Item E under Section 1.4 (Trim Cylinder Rebuild).
1. Remove yoke/tube set screws (Item 29). Clamp yoke
(Item 12) in vise and loosen trim tube using a strap
wrench.
2. Slide center/end plug assembly out yoke end of
tube.
1.4
Trim Cylinder Rebuild
A. Remove and discard all O-rings, seals and rod wipers.
Pre-clean all parts to be reused with clean solvent and a
soft bristle brush. Air dry with compressed air.
В. Inspect cylinder rod (Item 5), rod guide (Item 6), piston
(Item 7), and cylinder bore (Item 11) for nicks, scratches,
burrs, or uneven wear. Shallow nicks or scratches can be
polished out from piston, rod guide and tube using fine
sandpaper (400 grit). Replace ball/rod assembly if rod is
scratched.
С. Final clean all parts using a clean solvent rinse and air
dry with compressed air.
D. Lightly Tube ball (Item 4), transom bracket (Item 1), and
ball lock nut (Item 3) with #1 or #2 grease. Install
ball/rod assembly through transom bracket. Install ball lock
nut (Item 3) and tighten firmly against ball. Torque to 50
ft-1bs (6.91 kgm). Install transom bracket set screw (Item
28) using a suitable thread locking compound (Loctite 271
"Red" is recommended).
E. Lightly lube the rod guide inner O-rings (Item 21), outer
O-ring (Item 22), and wiper seal (Item 20). Install wiper
with lip outward. Slide rod guide onto rod, taking care not
to nick seals and wiper. Lubricate the rod guide I.D. and
cylinder rod 0.D. to allow a smooth fit.
F. Lightly lube piston interior O-rings (Item 23) with ATF
and install inside piston (Item 7). Thread piston onto rod
and tighten with strap wrench against rod shoulder. Install
piston locking set screw (Item 30) using a suitable thread
locking compound (Locktite 242 "Blue" is recommended).
G. Lube piston external O-rings (Item 24) with ATF and
install on piston. |
H. If yoke and center plug are disassembled in Section
1.3-F, reassemble yoke/tube assembly as follows:
1. Lightly lube O-rings (Item 25, 26) with ATF. Install
O-ring on center plug (Item 8) and O-ring on end plug
(Item 13).
Slide center/end plug assembly into cylinder tube from
the yoke end.
1.5
1.6
2. Thread cylinder assembly into yoke and tighten using
a strap wrench. Install yoke set screw (Item 29) using
Loctite 271 thread locking compound.
1. Slide piston and rod assembly into cylinder tube and
thread rod guide into cylinder. Hold cylinder tube using a
strap wrench or suitable split blocks when tightening rod
guide.
J. Cap or plug cylinder ports to maintain cleanliness.
Steering Cylinder Disassembly
See the attached Steering Cylinder Assembly Drawing (Fig. 3)
and the associated parts list for identification of the
various steering cylinder components.
A. Drain oil from both ports by manually cycling cylinder
over container,
B. Hold cylinder tube using a strap wrench or suitable split
blocks. Loosen rod guide (Item 9) using a suitable wrench.
Thread rod guide out and slide entire rod/piston assembly
from tube.
C. Clamp rod (Item 7) between soft pads or split blocks and
remove piston retainer nut (Item 17). Slide piston (Item 6)
and rod guide (Item 9) off of rod.
D. Inspect for evidence of leakage past end cap (Item 4) and
port ring (Item 5). If leakage is suspected or if there is
excessive contamination in the end cap/port ring area,
disassemble as follows:
Hold cylinder tube as in Section 1.5-B and remove end
cap/port ring using a suitable wrench on the flats
machined into end cap. Turn end cap counterclockwise and
cap will thread off.
E. After cap is removed, inspect and replace seals/0-rings
as required. Inspect part for damages to threads, etc.
Steering Cylinder Rebuild
A. Remove and discard all O-rings, seals and rod wiper.
Pre-clean all parts to be reused with clean solvent and a
soft bristle brush. Air dry with compressed air.
B. Inspect cylinder rod (Item 7), rod guide (Item 9), piston
(Item 12), and cylinder bore (Item 8) for nicks, scratches,
burrs, or uneven wear. Shallow nicks or scratches can be
polished out from piston, rod guide, and tube using fine
sandpaper (400 grit). Replace rod/clevis assembly if damaged
or worn.
C. Inspect transom bracket ball joint for looseness. Loosen
set screw and tighten ball lock nut (Item 2) as required to
remove axial play. Torque to 50 ft-lbs (6.91 kgm). Ball
joint should still pivot with only moderate resistance.
Reinstall set screw (Item 22) using Loctite 271 thread
locking compound. _
D. Final clean all parts using a clean solvent rinse and
compress air dry.
E. Lightly lube O-rings (Items 14, 26) and wiper (Item 14)
with ATF and install on rod guide, taking care not to nick or
cut O-rings and wiper.
F. Lightly lube O-rings (Item 24) with ATF and install on
piston. Carefully slide piston onto rod and install flexloc
nut (Item 17). Carefully clamp rod assembly and torque nut
to 75 ft-1bs (10.37 kgm).
G. If cylinder is disassembled as in Section 1.5, reassemble
tube/end cap assembly as follows:
Lightly lube O-rings (Items 23, 24) with ATF and install
on end cap. Slide port ring (Item 5) over end cap and
thread end cap into cylinder tube. Orient port ring
in-line with ball slot and tighten end plug using a
wrench. Cylinder tube should be locked in suitable split
blocks (Ref. Step B, Section 1.5).
H. Slide port ring (Item 5) onto rod guide (Item 9) and
carefully slide piston/rod assembly into cylinder tube.
Using a strap wrench or suitable split blocks to hold tube,
tighten rod guide. NOTE: Outboard port ring should be
aligned with inboard port ring prior to tightening rod guide.
Make sure rod guide is tight and port ring does not spin.
I. Cap or plug cylinder ports to maintain cleanliness.
1.7
1.8
1.9
Cylinder Installation
A. Prior to installation, prime each cylinder with ATF.
Using gravity as an aid, bleed as much air from cylinder as
possible. Reinstall plugs or caps.
B. Install trim cylinder bracket using 1/2-inch diameter
stainless steel fasteners. Torque nuts to 50 ft-lbs (6.91
kgm). Attach trim yoke to thrust tube, taking care to use
the proper shims between yoke and thrust tube. Trim yoke
should have a small amount of side play when installed, not
to exceed .020" (.51 mm).
С. Install steering cylinder bracket using 1/2-inch diameter
stainless steel fasteners. Torque nuts to 50 ft-lbs (6.91
kgm). Attach steering cylinder clevices and tie bar clevises
(if applicable) per Section 1.5. Torque nuts to 50 ft-1bs
(6.91 kgm). |
D. Prime outboard flex hoses with ATF and connect to transom
and cylinder fittings. Avoid trapping air in the system.
Verify that hose installation will allow adequate flexing of
hoses when operating. Minimum hose bend radius is 3" for -4
hose and 4" for -6 hose. |
E. Bleed hydraulic system as described in Section 1.9.
Trim Pump Fluid Level
Check fluid level in the trim pump hydraulic reservoir at
the beginning of each day of operation. Required fluid is
Automatic Transmission Fluid (ATF). Fluid level should be
checked with Drive(s) in the fully "down" position, fluid
cold, and steering in the neutral position.
Bleeding Trim Hydraulic System
Should air enter the hydraulic system, the system must be
bled. Air in the system may be evidenced by:
a) Soft springy trim cylinder action.
b) Cyclic up and down motion of the trim cylinder
and associated unit vibration during operation.
NOTE: Prior to bleeding the system, the cause of air
entering the system (leaking hose or fittings, low reservoir
level, etc.) must be determined and the problem corrected.
A. In order to facilitate bleeding of the system each
component and section of hose must be primed with automatic
transmission fluid (ATF) prior to installation. Note: A
small hand or garden pump provides a useful means for priming
Tong sections of tubing.
В. The trim system is an unbalanced system. This means that
more fluid is required from the pump at the fully extended
position than at the fully retracted position. The cylinder
rod reduces the volume requirement at the retract position.
When the system is installed, it should be bled as follows:
1. Fill and maintain reservoir fluid level throughout
the bleeding procedure to prevent further air from
entering system.
2. Extend the trim cylinder to maximum position (down).
3. Fill reservoir on pump to minimum fluid level marked
on tank. Do not fill above the minimum mark as the area
over minimum is required when the cylinder is retracted,
since the volume requirements differ between the two
positions of contraction and extension. The additional
space will be required as “fill space" since the system
is an unbalanced system.
4, Fully compress the cylinder next. The level should
rise in the reservoir as the fluid is displaced. Fluid
level should not exceed the maximum level on tank.
5. Cycle cylinders in both directions to bleed air out
of system. It is important that the cylinders reach
maximum positions to purge air.
NOTE: Do not run trim pump for long periods of time as heat
generation by the pump can cause damage. Normally, cycling
time should not exceed 2 minutes actual running time.
Additional bleeding may be performed by loosening the
uppermost hydraulic fitting at the thru hull location to
purge trapped air. Perform this step only when hose is
pressurized, or additional air will invade system.
. 10
Steering System Bleeding Procedures (Fig. 9)
The power steering kit is considered to be a self-bleeding
system. Normal bleeding procedures are accomplished simply
by running the engine and cycling the cylinders using the
steering helm. Steering from port to starboard, lock-to-lock
positions and back again for a specified period of time
normally purges the system. However, certain precautions
must be observed to assure proper bleeding.
Follow these steps for normal steering system bleeding.
A. Always maintain adequate fluid in reservoir. Periodic
checking of level must be performed during the bleeding
process.
NOTE: Do not run engine(s) for extended periods of time
without an engine cooling source attached and power steering
cooling source available.
B. Assure all fittings, hose connections, etc. are
sufficiently tight to hold hydraulic pressure.
C. Run engine(s) at approximately 1000 RPM and cycle
cylinders with ‘a smooth even rhythm back and forth to remove
air. Always check and maintain fluid level in reservoir.
D. Under normal applications, routine cycling of cylinders
is all that is required to purge system of air.
To check for trapped air, a simple check can be performed as
outlined in the following procedure:
1) Shut engines off and remove key.
2) Position steer cylinders in the center position and at
the neutral running angle.
3) Let system "settle" for approximately 15 minutes.
4) At this point, push or pull side-to-side on the aft
portion of Drive unit, near the propeller shaft, to see
if cylinders are tight. There should be no spongy or
springing action in the steering system. If some
movement is noted, additional bleeding will be required
by repeating the process above.
Special or non-standard packages may require different
bleeding procedures. Special instructions are available as
supplemental technical bulletins and available by contacting
AMI.
1.11
Hydraulic Trim Pump (Fig. 10)
The hydraulic trim pump is a 12 volt DC electrically driven,
self-contained system. The hydraulic fluid is held in a
plastic or metal reservoir which is fastened to the bottom of
pump body. The capacity of the plastic and metal tank are as
follows:
A. Plastic Reservoir - 28 cubic inch (15.5 0z.) capacity
В. Metal Reservoir - 23 cubic inch (10.0 oz.) capacity
The hydraulic trim pump is designed to be a trouble free unit
with very little maintenance required. Routine checks for
the following areas must be performed at certain intervals as
specified.
Ref. Fig. 10 for pump details.
A. Fluid level - Maintain levels using Dextron II Automatic
Transmission Fluid (ATF). Check levels daily before
operation, ВЕ
В. Electrical connections - Check for good connections of
all terminals and absence of corrosion build-up in critical
areas.
C. Wiring - Maintain wiring condition.
D. Pump mounting location - Trim pump should be located away
from heat sources and excessive moisture areas. Failure to
locate pump in a suitable area voids the warranty.
1.12 Trouble Shooting Guide - Hydraulic Trim Pump
Prob lem
1. Pump will not activate.
2. Pump activates - cylinder
does not move
3. Pump activates
Cylinder operates in short
jerky movements
4. Pump runs for short time
Potential Solutions
Faulty wiring/check
Switch bad/check, replace
Fuse blown/replace
Wiring corroded/clean
Improper ground/correct
Solenoids blown/check, replace
Air in system/bleed
Fluid low/add
Dirt, debris in hose/clean
Dirt, debris in pump/clean, flush
P/U screens clogged/remove res.
and clean
Air in system/bleed
Fluid level low/add
*Pressure setting incorrect/adjust
Pump run too long, temp build-up
over thermal relief/let pump cool
try again
*Pump pressure settings are preset at AMI factory. Consult AMI for
procedures and recommendations prior to adjusting or attempting to adjust
pump pressures.
-10-
1.13 Special Tooling/Handling Requirements
1. Strap Wrench - with 12" mín. strap - fabric or nylon type
2. Bench mounted vise - jaw opening capacity of 5"
3. 2 strips re-enforced rubber pads - min. 1/4" thick - to line vise
jaws :
4. Loctite thread locking compound -
A. 271 "Вей" - to be used on all external set screws exposed to
outside environment
B. 242 "Blue" - used on all internal set screws not exposed to
outside environment
5. Clean pressurized air supply - to maintain cleanliness of components
(hydsys/manuall)
-11-
FIG.1
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STEERING CYLIN
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| |” И --—SPHERICAL BEARING
| Ого STEERING CYLINDER MOUNTING BRACKET
| “|
TOP VIEW
Fe
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TRANSOM —_ : j NN MOUNTING BRACKET
; “TRIM CYLINDER
INPUT
FLANGES _-—TRIM YOKE
= -
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THRUST BALL,
-12-
SIDE VIEW
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ARNESON SURFACE DRIVE PART'S LIST
ASSEMBLY #
MODEL #
DESCRIPTION
Oé-May-88
O8301E REV.C
ASD 8-1
TRIM CYLINDER ASSEMBLY
DESCRIPTION
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OESESD
c=C32
21119
0E362C
28008
c2019
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38010-2
023635-1
1010-3
OSOYEC-3
11505-2
23EC10-1
22035 .040
. CSO
. 050
.070
F1600000C
FO800000C
COBCREFOC
JOBCOOOOB
00504E5E-16
00501B-44
OOSOIB-46
OCSO1B-279
00501b-6
00501B-30
00501B-23
c2034
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BOSCOOBOC
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TRANSOM BRACKZ
BACKING PLATZ
RANECM BALL RETAINER
TRANSOM SOCKET BALL
ROD
RCD CUIDE
FISTON
PLUS
SPACIR ROD
SPACER TUBE
CYLINDZR TUBE
YOKE
PLUG
YOKE SIN
WASHER, YOKE (INNER)
WASHER, YOKE (INNER)
WASHER, YOKE (INNER)
WASHER, YOKE (INNER)
AN WASHER
AN WASHER
MOUNTING BOLT
NYLOCK NUT
WIFER
O-RINE
O-RING
O-RING
O-RING
O-RING
O-RING
BALL PIVOT SCREW
SET SCREW
SET SCREW
SET SCREW
COTTER PIN
FITTING
FITTING
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MATERIAL
VENDOR
PART NO.
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PART
NO. QTY. REF. DESCRIPTION
08366D - 1 1 TRANSOM BRACKET
21119 1 2 TRANSOM BALL RETAINER
08342C 1 3 BALL, TRANSOM SOCKET
28004 1 4 TUBE CAP
28010 2 5 PORT RING
OBI54BrxxA 1 6 PISTON
08357Bxxxx 1 7 “ROD, PISTON
08095B-Sxxxx 1 8 CYLINDER TUBE
28003 1 9 ROD GUIDE
22031 1 10 PIVOT, CLEVIS
41501 1 11 CLEVIS
C12C0540C 1 12 HEX HEAD BOLT
22033 1 13 BACKING PLATE
00504B-2 1 14 WIPER
COSCREFOC 4 15 MOUNTING BOLT
JOSCOO0O0B 4 16 NYLOCK NUT
112F000CA 1 17 FLEXNUT, CAD PLATED
F0800000C = 18 WASHER, AN
F1200000C 2 19 HASHER, АМ 3/4"IDx.060
JIPCO000C*xxx 1 20 NYLOCK NUT
yO6TOOSOC 1 21 SET SCREW
22034 1 22 SOCKET HEAD CAP SCREW
00S01B-24 4 23 O-RING, BUNA 70
00S01B-45 4 24 O-RING, BUNA 70
00501B-27 1 25 O-RING, BUNA 70
00504B-9 2 26 T-SEAL
F120000TE 6 27 WASHER, CLEVIS (INNER)
BOSCOOBOCkxXxx 1 28 SET SCREW
A05C0040C 1 29 SOCKET HEAD CAP SCREW
00FAQ202346B 1 30 FITTING, 45 DEGREE EL
00FAQ202446B 1 31 FITTING, 90 DEGREE EL
PART # 8: LISTED AS 08095B-3
PART # 20: LISTED AS J12C0000B
PART # 28: LISTED AS BOSC0100C
NEW PART NUMBERS ANNOTATED WITH ###æ (VERIFY W/ MATERIALS)
(.032)
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CDA 865
BRASS
31655
BRASS
BRASS
6061-76 ALUM.
17-4 PH H1150
C33000 BRASS
BRASS
31655
CDA 865
31655
6061-76 ALUN.
POLYURETHANE 90 DM.
316SS
BRASS
C-38 CARBON STEEL
316SS
3165S
BRASS
31655
3165S
BUNA 70 DUROMETER
BUNA 70 DUROMETER
BUNA 70 DUROMETER
BUNA 70 DM W/ NYLON
31655
31655
31655
BRASS
BRASS
940-9
x Ls
2-031
2-222
2-118
TR-014
STEERING CYLINDER INSTALLATION
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Not for Production
2.0.
a
PS
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LM
W.O
00:18 PM
»
.
3/ , 99 2
NOTES:
1) TWO PLUGS (P/N 1005250) USED ON FITTINGS (P/N 1005273) TO PROTECT THREADS.
2) ONE SWITCH (P/N 1008112) SHIPPED LOOSE.
3) TORQUE ALL SCREWS ACCORDING TO TWIN DISC S574C.
4) PUMP VENDOR: OILDYNE
4301 QUEBEC AVE. NORTH
MINNEAPOLIS, MN. 55428-4998
5)
|| PUVP ASSY. PUMP MODEL OILOYNE P/N |
| 1006176 10BAM10—-CL—~2VT
| 1006178 06179 1OBAM32—CL— 3VT 18 GAGE WIRE
UP (GREEN)
10 GAGE WIRE (BLACK)
TO BATTERY (-)
10 AMP,
AGC-10 FUSE
18 GAGE WIRE
DOWN (BLUE)
18 GAGE WIRE
(RED)
1005273 (2
10 GAGE WIRE (RED) FITTING
TO BATTERY (+
12 VOLT TRIM PUMP
T
NOT TO BE USED IN ANY MANNER
DETRIMENTAL TO THE INTERESTS OF
TWIN DISC, INCORPORATED
RACINE, Wi 33403 — USA
Hs NCE NOT INTENDE
GRANTED TO THE U.S. GOVERNMENT -
OR OTHERS BY CONTRACT.
PUMP ASS'Y
IiINCERPO
RACE,
GAM | SueET
D
ATEO
53463 — USA
1006178
oF
“ PO. — Not for Production
o
W.O
:00:12 PM
‘99 2
>
Aa
3/
}
NOTES:
1
2
TWO HOSES
TWO PLUGS
P/N 1006258) AND ONE SWITCH (P/N 1008112) SHIP SEPARATELY.
P/N 1005250) USED ON FITTINGS (P/N 1005273) TO PROTECT THREADS.
3) TORQUE ALL SCREWS ACCORDING TO TWIN DISC S574C.
1004862
SCREW
1004974
WASHER
10 GAGE WIRE
TO BATTERY (-)
(2)
(2) |
TO GROUND (-)
10 GAGE WIRE
TO BATTERY (+)
18 GAGE WIRE O
(RED)
18 GAGE WIRE
DOWN (BLUE)
10 AMP.
AGC-10 FUSE
18 GAGE WIRE
UP (GREEN)
TO TRIM SWITCH (DOWN)
TO TRIM SWITCH (UP)
CONNECT TO GROUND (--)
24 VOLT TRIM PUMP
NONCE! THIS PRINT CONTAINS
INF TION AND IS
ORMA
NOT ТО ВЕ USED IN ANY MANNER
DETRIMENTAL TO THE INTERESTS OF
TWIN DISC, INCORPORATED
RACINE, M 53403 — USA
THIS NOTICE IS NOT INTENDED
TO NULLIFY OR LIMIT RIGHTS
GRANTED TO THE US
OR OTHERS BY CONTRACT.
10 GAGE WIRE TO
BATTERY (-) (BLACK)
REF, 002659
THIRD ANGLE
PROJECTION
1010222
1010223
INCORPORATED
RACE, W 53403 — USA
1010960
PUMP ASS'Y Se