SERVICE MANUAL
Contents
1. SS q XX d OS N es Gi P SA sey P N SS ROI D EE PUSH PISTON THRU CYLINDER UNTIL FIRST GROVE IS EXPOSED INSTALL SEAL Ww BACKUP RING AND SLIDE PISTON INTO CYLINDER AS SHOWN GROVE FACING px THIS DIRECTION CH SS EE ESSE es bes RSSI Ge ELSK Ge d Get LSS ESSA Ka Ka o i gt xm DO SS FIGURE SIA 4 Guide Assembly Lightly grease and install the scarf cut wear ring item 16 into the rod guide item 3 as shown in figure ST 5 Install the rod seal item 14 and wiper seal item 15 into the rod guide Care should be taken not to damage any of the internal bores in the rod guide Install the o ring item 10 onto the guide Lightly lubricate the inside of the seals and gently rotate guide past the threaded portion of the rod Note Do not apply oil in the seal groove areas This may cause the seals to rotate in the bore when the guide is assembled over the cylinder rod Apply a small amount of removable Loctite thread locker number 242 to the thread on the guide Use all applicable solvents primers and activators to aid in applying the thread locker Lightly lubricate o ring and tighten to the cylinder tube Lock in place using the socket head cap screw item 19 with thread locker 242 FIGURE SST OS 5 End Cap Assembly Install o ring item 10 on to end cap item 4 and lightly lubricate the outside of the o ring Apply a small amount of removable Loctite thread lock2. 5 has machined flats and the cap item 4 has two spanner holes Remove both the carrier and cap from the spacer tube item 7 7B Refer to figure TR 4 Loosen the strain relief connector item 24 Remove the retaining ring item 13 and gently pull the transducer body from the carrier while feeding the transducer cable through the carrier 70 TRANSDUCER RETAINING RING 13 19 O RING KA CARRIER SS Se SI CH FIGURE TR 4 7C Remove the retaining ring item 12 which holds the sleeve core into the piston Remove the sleeve core and wave spring from the piston Piston rod replacemen 8 The piston is originally assembled to the rod with non removable Loctite Remove the seals item 15 from both ends of the piston Heating of the joint to 400 degrees F is required to age cure the loctite Disassemble by loosening the piston in a counter clockwise direction CLEAN AND INSPECTION ik ee Do not use any solvents on the transducer core or core sleeve Remove all seals o rings wiper rings and wear rings from the cylinder components Be extremely careful not to damage any internal machined surfaces while removing the seals Do not use sharp objects which may scratch the internal bores of the components A scratch on the rod or rod guide I D will cause the cylinder to leak Carefully clean all components to prepare for a pre assembly inspection Inspect the inside diameter of the stainless steel cylinder tub
3. sleeve Remove all seals o rings wiper rings and wear rings from the cylinder components Be extremely careful not to damage any internal machined surfaces while removing the seals Do not use sharp objects which may scratch the internal bores of the components A scratch on the rod or rod guide I D will cause the cylinder to leak Carefully clean all components to prepare for a pre assembly inspection Inspect the inside diameter of the bronze cylinder tube The internal tube should be highly polished and show no scratches or wear Deep scratches finger nail test will cause an internal leak path in the cylinder Inspect the rod piston rod guide etc for abnormal wear or wear zones Polish or buff minor imperfections Inspect all threads and remove any burrs or repair any damage which will create an assembly problem STEERING CYLINDER ASSEMBLY PROCEDURE OPTIONAL ASSEMBLY PROCEDURE 1 amp 2 1 Transducer Assembly Crimp the strain relief clamp item 23 onto the cable 1 5 inches from the body of the transducer as shown in Figure ST 3 Spiral wrap between the strain relief clamp and the body of the transducer Spiral wrap the cable from the strain relief clamp outward along the cable for approximately 6 inches Lightly oil the o ring and back up washer item 13 and install on to the transducer body Lead the wire cable through the cap item 4 Pull all the wire through until the transducer seats in the cap Secure the transducer i
4. IT RKX 11725 40 2 RING O s KIT 1006592 poi 2 SEA KIT 1008592 12 2 RING WEAR Ee A MO 1 SEA TA EA 16 1 RING WEAR 18 1 RING RETAINING Km 1006592 19 2 SCREW WICH 20 1 WRAPPING WIRE A 11725 J 2 1 SPRING A 11725 J 22 Lol LINE Y 223 1 CLAMP A SPL11725 A 24 1006652 1 TRANSDUCER Y 25 1007240 1 PLUG POBNOOOLC BRACKET BRONZE 08359C IR 27 1006126 1 JCLEVIS 440421 Y 28 1004803 2 SCREW A05CO040C 29 1006346 1 SCREW BOSCOOS0C 2 WASHER F160000T o 2 WASHER Fi600000C 32 1006509 1 NUT Y16CO000B 35 1004906 1 BOLT C16COB0OC 34 1006060 1 SCREW 22034 SCREW 80500120C Es ea UNE a el o Hs TRERI YLINDER The cylinder plumbing group includes the steering cylinder along with the hoses and fittings as shown in Figure ST 1 The hoses shoula be removed prior to servicing the cylinder Important Hose assembly item 11 is used to seal and protect the transducer cable The transducer cable connects the transducer inside the cylinder to the electronic module inside the vessel The transducer cable must be disconnected from the electronic module prior to removing the cylinder from the vessel Care should be taken to loosen the hose from the fittings on both ends and gently remove the hose over the cable Drain the oil through the two pipe ports by manu
5. SERVICE MANUAL OP ASD 14 STEERING AND TRIM CYLINDERS SPECIFICATION NUMBERS 1006614 amp 1006612 Twin Disc Incorporated Original Issue May 1993 1328 Racine Street Racine Wisconsin 53403 1758 U S A GENERAL INFORMATION GENERAL This publication provides the information necessary for the service and adjustment of the product specifie on the cover of this manual Specific engineering details can be obtained from the Product Service Department of Twin Disc Incorporated a SAFETY Safe operating practices must be employed by all people servicing this unit Twin Disc is not responsible for any personal injury resulting from unsafe and careless use of hand tools power tools lifting equipment or unsafe practices Because of the possible danger to people or property from accidents which may result from the use of manufactured products it is important that correct procedures be followed Products must be used in accordance with the information specified Proper installation procedures must be used Proper safety devices such as guards may be required as specified in applicable codes Safety devices are not provided by Twin Disc nor are they the responsibility of Twin Disc WARRANTY Equipment for which this manual was written has a limited warranty See Twin Disc for details SERVICE INFORMATION Each series of manuals issued by Twin Disc is current at the time of printing Changes are made to reflect advances in technol
6. SNUILVILIIIAS ISI NIMU EE Na ENEE what 12 IN SE CYLINDER 10009 9 E or Ja 1006638 1 ROD C 11735 A A 2 1008639 1 TUBE C 11735 B 3 1006644 CA GUIDE C 11735 y ee O 11735 D SES 5 1006646 1 CARRIER C 11735 E 6 1006647 1 PISTON B 11755 F 7 1006648 1 TUBE TRM SPACER B 11735 0 8 1006649 1 NUT LOCK B 11735 9 1006650 1 BALL BRACKET B 11735 J so we rena 10 TRANSDUCER ED a SEAL KIT RK 11735 212 1 RING RETAWING A SPL11735 KIT 1006591 13 1 RING RETAINING A SPL11735 KIT 1OOB591 IA E ta EM Rimas ME bb RO RD KIT 1006591 EE SEAL 18 1 WIPER 19 emo N STA 20 mm 1 RING WEAR KT 1006591 OM Poo 1 SPRING A SPLIN735 22 1 WRAPPING WIRE A SPL11735 Po 25 2 SCREW SET A SPL11735 24 1 CONNECTOR A SPL11735 25 1 a 26 Po 1 SCREW A SPLIN735 SCREW SET A SPL11735 WE 28 1006080 T si 29 1006609 1 BRACKET o o 30 1007550 2 PIN COTTER vo6006400 31 1006087 1 PN 27008 o o SPACER TRIM YOKE 24052 TI WASHER 24051 aca 1009874 1 YOKE _ ae i SE ee E D Ea TRIM CYLINDER The cylinder plumbing group includes the trim cylinder along with the hoses and fittings as shown in Figure TR 1 The hoses should be removed prior to servicing the cylinder Important Hose assembly item 7 is used to seal and protect the t
7. SSI SS 7 een keen GE SE SORA Tn A e EE E A EE A LL RE An HE SSS SE GER CURAR TO KEE V FIGURE TR 7 7 Feed the cable through the 90 degree fitting Apply the wire wrap item 22 over the cable and work through the entire fitting Leave approximately 6 inches of loose cable between the fitting and strain relief connector Rotate the cable 4 full turns in a counter clockwise direction Tighten the fitting in a clockwise direction The reverse winding of the cable prior to installation prevents the cable from being twisted in the final installed position 8 Install the transom ball item 9 onto the rod Coat the threads with a copper based anti seize compound prior to assembly O
8. ally extending and retracting the cylinder STEERING CYLINDER DISASSEMBLY PROCEDURE Refer to Figure ST 2 for part identification throughout the service procedure for the steering cylinder Prior to disassembly mark the end of the symmetrical cylinder tube item 2 with respect to the rod guide item 3 This should be done with a marker to prevent any damage to the plated tube surfaces This will ensure the guide and cylinder tube will be oriented properly when assembled Support the cylinder in a V block support or a means to prevent any damage to the cylinder components 1 Remove clevis item 27 set screw item 35 and pivot item 6 from the cylinder rod 2 Remove the two socket head cap screws item 19 which secures the guide item 3 and cap item 4 to the cylinder tube Before performing the following step study figure ST 3 and note the two piece transducer item 24 identified as the body and sleeve core The body of the transducer is retained in the guide the sleeved core is retained in the piston WIRE WRAP 17 RETAINING RING WAVE SPRING ASS 7 7 NA VE RR Es ESCHER Ml a Y BSS SS aN ay GE ill SY e ARZZZERZ RR RAR ZAR RRA RARA ER RARR RARA RRA RAR RARA RA AAA RRA RR RA RRA RA RR AAA RRAAARAAAAAAAAR NY EEES A NN NS ESA ES AB H E TRANSDUCER SLEEVED CORE 13 TRANSDUCER BODY O RING AND BACKUP WASHER ER EE SIS 3 Using the flats on the cylinder cap item 4 remove the cap from the cylinde
9. e The internal tube should be highly polished and show little or no scratches or wear Deep scratches finger nail test will cause an internal leak path in the cylinder Inspect the rod piston rod guide etc for abnormal wear or wear zones Polish or buff minor imperfections Inspect all threads and remove any burrs or repair any damage which will create an assembly problem TRIM CYLINDER ASSEMBLY PROCEDURE OPTIONAL ASSEMBLY PROCEDURE 1 2 1 Optional piston rod assembly The bronze piston is attached to the stainless steel rod using permanent Loctite thread locker number 271 Use all applicable solvents primers and activators to aid in applying the thread locker 2 Optional transducer assembly Lightly oil the o ring item 19 and install on to the transducer body Lead the wire cable through the carrier item 5 and pull all the wire through until the transducer seats in the cap see figure TR 4 Secure the transducer in place with the retainer ring item 13 Feed the cable through the strain relief connector and tighten snugly Insert wave spring item 21 into machined bore in the rod Insert the sleeve core into the rod and secure with retainer ring item 12 17 3 Piston rod seal assembly Install one of the seals and back up rings onto the bore end of the cylinder piston as shown in figure TR 5 Start the piston rod assembly and pull through the cylinder tube Care must be used to slide the seals past the two pipe
10. er number 242 to the thread Use all applicable solvents primers and activators to aid in applying the thread locker Be sure the transducer core aligns with the core sleeve freely and tighten cap to the cylinder tube Lock in place with the socket head cap screw item 19 with thread locker 242 6 Clevis and Bracket Be sure that no burrs or other damage exists on the threaded rod or the cylinder pivot item 6 Any burrs or other thread damage may cause the components to gall together prior to full thread engagement Coat threads liberally with a copper based anti seize compound Lock in place with set screw item 35 This Same procedure to be followed if the transom bracket assembly was disassembled lt J 0 Pc ee FS RITA K BR mg N meo N Bag Mi S vi Ki PS Fal ba No 7 CR a a E y d mato VT i d la qa y a UE SA dA SN E NE gt D LAY xo LL Amas ASOH Teen 8 Leit ESSES 1 699001 a ANS aSDH 1 9629001 e o ts o E REN NA EN RT RE PTT 2 co8 001 2 A TAWSSY SON Wal 1 6Ls9001 t NOILSISISIT LIV UN SAJVWHIS PA UN Lava O er UU UN IA NR elo 200 Na da NL TAO Ala 2 31 ISNDTA to 6 ES EEG EK ZEN CEO Ein GS Ni SINES iff SS A Ra LH att wi E E Hz RK SA SS ee gt gt ss A We a UR Se Oe ee EE Ee AR is gt ES B ES via dos SCH 8259001
11. n place with the retainer ring item 17 Apply Teflon tape or other good quality pipe sealer on the 45 fitting item 22 Route the cable through the 45 fitting and secure to the cylinder Note With the spiral wrap in place the 45 degree fitting may be loosened or tightened without damaging the cable To loosen or tighten the fitting grasp the cable while turning the fitting 2 Piston Rod Assembly The aluminum piston item 5 is attached to the stainless steel rod item 1 using permanent Loctite thread locker number 271 Use all applicable solvents primers and activators to aid in applying the thread locker 3 Piston rod seal assembly Lightly grease and install both scarf cut wear rings item 12 onto to the piston as shown in Figure ST 4 Install one rod end of the piston of the two seals with a back up ring item 11 to the piston Note the orientation of the seal as shown in step 1 Figure ST 4 Lightly oil the outside of the seal only and slide the assembly into the cylinder tube and push through until the forward groove on the piston extends beyond the tube as shown in figure ST 4 step 2 Install the second seal and once again oil the outside only and pull the assembly back into the cylinder tube STEP 1 INSTALL THE TWO WEAR RINGS AND ONE SEAL W BACKUP RING NOTE DIRECTION OF GROVE IN SEAL PUSH PISTON INTO CYLINDER AS SHOWN WEAR RING SEAL W BACKUP RING a ZA GROVE FACING THIS DIRECTION avs Ke
12. ogy and improvement in state of the art when required All revisions and design improvements are subject to change without notice Individual product service bulletins are issued to provide the field with immediate notice of new service information These service bulletins are distributed to all Twin Disc distributors through the United States and many foreign countries Contact your nearest Twin Disc distributor for the latest service information Laks alla N d IFANITAO ONISGIIS a eo Je JWGGW JINGYLIS 73 D Y A e SE Lavd SHSVANTA ND11d139S 20 vY199001 N d XJANITAI ONISIILS SES denota lt 2 ON M JUE GU Gi eppes y S o TT SS EN NN SS N Sy 7 AN NY NN SY a SS ST ee ss ss ss S US ES N I aes gt ARES SS N Juana d Y me ES lao LEN bat Ro O OAOD O Ore ODIO ODOR O a l VS EH bi vl 008 Mi i JEET e E SINES End aN y A AMA OTI ASI NX 2 1 2 3408 LU WAWIXYW ISd 00S2 3INSSIYA ONILVAIAO 8469001 DN TICON SNUILVILIIIIAS ISIA NIAL SESDUOL NZad NN TAS DNAs aS 10009 0 STEERING CYLINDER E mo on ROD B 11725 A E ae 2 1006654 1 TUBE C 11725 B 3 1006655 1 GUIDE C 11725 C A 1006656 Mt CAP C 11725 D o Sooo o o 5 1006657 1 PISTON C 11725 E O 6 1006075 1 Pwo 24050 BALL SOCKET 08562 IN 8 1006051 1 RETANER 21119 PS 9 1006592 1 SEAL K
13. r tube by loosening in a counter clockwise direction Before removing the cap completely from the cylinder tube be sure to support the cap to prevent damage to the transducer body or sleeve core Remove the cap with transducer body straight away from the cylinder tube 4 Using the flats on the rod guide item 3 remove the guide from the cylinder tube by loosening in a counter clockwise direction Once loose slide the guide up to the machined threads and gently rotate the guide past the threads on the rod 5 Remove the piston rod assembly items 1 amp 5 from the cylinder tube by pushing or pulling the assembly out of the cylinder tube OPTIONAL DISASSEMBLY Transducer lacement 6A Remove retainer item 17 from the transducer body as shown in figure ST 3 Gently pull the transducer body from the cap while feeding the transducer cable through the end cap 6B Remove the retainer item 18 which fastens the sleeved core into the piston Remove the sleeved core and wave spring item 21 from the piston Piston Rod Replacement 7 Remove the two seals item 11 and two wear rings item 12 from the piston The piston is assembled to the rod with non removable Loctite To aid in removal heat the threaded area between the piston and rod joint to 400 degrees F to age cure the Loctite Disassemble by loosening the piston in a counter clockwise direction CLEAN AND INSPECTION Do not use any solvents on the transducer core or core
14. ransducer cable The transducer cable connects the transducer inside the cylinder to the electronic module inside the vessel The transducer cable must be disconnected from the electronic module prior to removing the cylinder from the vessel Care should be used to loosen the hose from the fittings on both ends and gently remove the hose over the cable Drain oil from both hydraulic ports by manually cycling the cylinder TRIM CYLINDER DISASSEMBLY Refer to Figure TR for an assembly drawing with item numbers for part identification Support the cylinder in a V block support or a means to prevent any damage to the cylinder components 1 Remove the lock nut item 8 and the ball item 9 from the cylinder rod Both the lock nut and ball have a machined hex slot for removal 2 Loosen the 90 degree hydraulic fitting item 25 Leave the wire wrap item 22 in the fitting and feed the cable through the fitting into the stop tube cavity as shown in figure TR 3 step kb 3 Remove two set screws item 23 and remove the yoke item 34 from the tube by rotating in a counter clockwise direction Examine Figure TR 3 step 2 before proceeding with the next procedure Note the two piece transducer item 10 identified as the body and sleeve core The unit must be removed straight from the tube to prevent damage to the transducer 4 Remove the cap screw item 26 which retains the rod guide item 3 Using the flats on the rod guide remove
15. tapped ports in the cylinder barrel The seal must be guided past the ports with the aid of a dull instrument The piston rod assembly should be pulled out of the cylinder past the first seal groove as shown in figure TR 5 Again install the piston seal and back up ring item 15 onto the piston Lightly oil inside diameter of the seal and slide assembly into the cylinder STEP 1 INSTALL ONE SEAL NA RING NOTE ORIENTATION OF SEAL PUSH PISTON INTO CYLINDER AS SHOWN SEAL W BACKUP RING a Ya SEAL ORIENTATION ET S mel a S E e Z STEP 2 PUSH PISTON THRU CYLINDER UNTIL FIRST GROOVE IS EXPOSED INSTALL SEAL W BACKUP SING AND SLIDE PISTON INTO CYLINDER AS SHOWN Fa RITA ET A IT IE 0 DO OT MA O A SES FIGURE TR 5 18 4 Rod guide Install the seal item 17 and wiper item 18 into the rod guide as shown in figure TR 6 Note the orientation of both the seal and wiper Install the scarf cut wear ring item 20 into the rod guide A light film of grease may be used to retain the wear ring in the guide Lightly oil the inside diameter of the seal and wiper to ease installation over the threaded rod E O RING W 2 BACKUP RINGS SEAL ORIENTATION FLOUR ROO Install the o ring and backup ring item 14 onto the guide and lightly oil the outside diameter Apply a small amount of removable Loctite threadlocker number 242 to the thread on the guide Use all applicable solvents primers and activa
16. the guide 14 from the cylinder tube by loosening in a counter clockwise direction Once loose slide the guide up to the machined threads and gently rotate the guide past the threads on the rod STEFI REMOVE 90 FITTING TOGETHER WITH SPRIAL WRAP AND PUSH CABLE INTO BUDY AS SHOWN 90 Pid TING SPRIAL WRAP FIGURE 3A jaan CABLE RA STEP 2 REMOVE 2 SET SCREWS LOOSEN YOKE FIGURE 3B COUNTER CLOCKWISE AND UNSCREW YOKE SET SCREWS SCREW 3 8 x16 UNC EYELET INTO CAP AND DRAW ASSEMBLY OUT A OF CYLINDER AS SHOWN LLLLLLLALA DELL LLL LL VF ILIAD LI ELLA ISS n th amp SS Poo ti im GC KR 2 ISS ASA VILLI X 77 77 777777 EE ZE TRANSDUCER BODY SLEEVE CORE FIGURE TRES 5 Pull the stop tube assembly items 4 745 from the tube by inserting a 3 8 16 eye bolt into the center of the cap item 4 The eye bolt will be used to pull the assembly straight out of the tube The pull force required will be overcoming the resistance of the two o ring seals item 16 on the carrier item 5 and 1 o ring on the cap item 4 Remove the assembly with transducer body straight away from the cylinder tube 6 Remove the piston rod assembly from the cylinder tube by pulling the assembly through the tube OPTIONAL DISASSEMBLY Trans r Repl men nl 7A The stop tube assembly removed in operation 5 must be 15 disassembled to replace the transducer The carrier item
17. tors to aid in applying the threadlocker Rotate the guide over the threaded section of the rod and tighten onto the cylinder barrel Lock in place using the socket head cap screw item 26 with threadlocker 242 5 Stop Tube Assembly Complete the stop tube assembly by installing the cap item 4 Install the o ring item 16 Apply a small amount of removable Loctite threadlocker number 242 to the thread Use all applicable solvents primers and activators to aid in applying the threadlocker Tighten the stop tube ends with the use of the flats on the carrier and the spanner holes on the cap Install the two o rings item 21 onto the carrier Orient the stop tube assembly cable port with the 1 2 in pipe port on the cylinder 19 tube Lightly oil the outside of the EES and slide into the cylinder tube 6 Gently pull all the cable from the stop tube cavity A piece of 3 8 tube will be required to prevent the stop tube assembly from rotating in the cylinder bore Lead the cable though the tube and position as shown in figure TR 7 Apply a copper based anti seize compound onto the yoke threads item 34 and install onto the cylinder barrel Lock in place with the two set screws item 23 Apply a small amount of removable Loctite threadlocker number 242 to the thread Use all applicable solvents primers and activators to aid in applying the threadlocker sra LE Gries TUBE APRUX 6 LUNG TRANSDUCER CABLE EEE A ENS SI
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