HYDRAULIC SYSTEMS –

POWER STEERING

5B

MC Transom Assys. and Hydraulic Systems (0606)

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Table of Contents
Power Steering Pump....................................................................................... 3
Power Steering Pump Pulley Removal ......................................................... 3
Removal Tool for Older (Steel) Pump Pulley ................................................ 3
Removal Tool for Newer (Composite or Steel) Pump Pulley ........................ 4
Power Steering Pump Pulley Installation Tool .............................................. 4
Power Steering Control Valve Installation ........................................................ 5
Earlier Model Control Valve .......................................................................... 5
Later Model (DHB) Control Valve.................................................................. 6
Power Steering System - 2004 ......................................................................... 7
DHB Power Steering System Operation........................................................... 9
Pump Description.......................................................................................... 9
Later Model (DHB) Power Steering System ................................................... 10
Neutral......................................................................................................... 10
NEUTRAL MODE DESCRIPTION .......................................................... 11
Right Turn ................................................................................................... 12
RIGHT TURN MODE DESCRIPTION ..................................................... 13
Left Turn...................................................................................................... 14
LEFT TURN MODE DESCRIPTION ....................................................... 15
Power Steering System Testing ..................................................................... 16

2 SECTION 5B HYDRAULIC SYSTEMS – POWER STEERING

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Power Steering Pump Notes:
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Power Steering Pump Pulley Removal ______________
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a) Pulley Removal Tool
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Removal Tool for Older (Steel) Pump Pulley
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KENT-MOORE SPECIAL TOOLS
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Can be ordered from:
Kent-Moore Tools, Inc.
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29784 Little Mack ______________
Roseville, MI 48066 ______________
Phone: 313-774-9500
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Power Steering Pump Kent-Moore Part
Pulley Remover No. J-25034
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HYDRAULIC SYSTEMS – POWER STEERING SECTION 5B 3

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Notes: Removal Tool for Newer (Composite or Steel) Pump
Pulley
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SNAP-ON SPECIAL TOOLS
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Pulley Remover
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P/N CJ124A
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______________ a) Typical Puller
______________ b) Serpentine Pulley
______________ Power Steering Pump Pulley Installation Tool
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______________ P/N 91-93656A1
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______________ a) Power Steering Pump Pulley
______________ b) Stud
______________ c) Bearing
d) Nut
______________ e) Tool Shaft
______________ NOTE: Current power steering pulley installation tool should fit either type of
______________ pulley.

4 SECTION 5B HYDRAULIC SYSTEMS – POWER STEERING

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Power Steering Control Valve Installation Notes:
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WARNING ______________
Steering cable outer casing MUST BE free to move back-and-forth for
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steering to function properly. DO NOT fasten any wires, cables or other ______________
items to steering cable, as this may prevent it from moving. ______________
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1. Apply a liberal amount of Special Lubricant 101 to end of steering cable
and install cable end in clevis. Secure with pin and cotter pin. ______________
2. Later model control valve: Using a suitable wrench, hold the flat ______________
surfaces on the cable guide tube in the vertical position.
3. Both models: Torque coupler nut to 35 lb. ft. (48 N·m). ______________
4. Earlier model control valve: Install and tighten locking plate on coupler ______________
nut. Secure with self locking bolt and washer.
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NOTE: Later model control valves do not have a locking plate on the coupler
nut. ______________
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Earlier Model Control Valve ______________
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a) Clevis Pin
b) Cotter Pin
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c) Locking Plate (If No Self Locking Coupler Nut) ______________
d) Coupler Nut ______________
e) Steering Cable
f) Bolt and Washer ______________
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HYDRAULIC SYSTEMS – POWER STEERING SECTION 5B 5
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Notes: Later Model (DHB) Control Valve
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______________ a) Clevis Pin
______________ b) Cotter Pin
c) Coupler Nut
______________ d) Steering Cable
______________ e) Flat (Hold Vertical)
f) Suitable Wrench
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6 SECTION 5B HYDRAULIC SYSTEMS – POWER STEERING

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Power Steering System - 2004

Older Design

Quick Connect Fittings

Power Steering hoses receive quick connect
Newer Design fittings. Cross threading eliminated. Reduced
installation time. Male/female connections to insure
correct connections.

Installation Clearance - .85”

Power Steering High Pressure

Hose

Power Steering Valve

Inlet Fitting

22-865414

Power Steering Valve

Power Steering Return Hose Outlet Fitting

22-865415

HYDRAULIC SYSTEMS – POWER STEERING SECTION 5B 7

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DHB Power Steering System Operation Notes:
The Power Steering system utilizes an engine-driven vane-type hydraulic ______________
pump that supplies fluid flow and pressure by means of hoses to a control ______________
valve that, in turn, controls fluid flow and pressure to-and-from a booster
cylinder. Three modes make up the basic function of the Power Steering ______________
system; 1) neutral, 2) left turn mode, and 3) right turn mode. The control valve, ______________
which is activated by the steering cable, controls the steering system mode.
______________
Pump Description ______________
Pump pulley rotation drives the pump shaft and rotor assembly. Rotor ______________
movement extends the pump vanes until contact is made with the outer cam ______________
ring surface. The vanes form adjustable chambers that move fluid through the
pump. ______________
The rotor is offset in relation to the cam ring surface and forms areas of ______________
increasing and decreasing volume in the pump. An increasing volume is ______________
created on the inlet side of the pump for fluid out of the reservoir to fill. The
vanes create chambers that trap fluid and move it to the outlet, where the ______________
decreasing volume forces it out. At the outlet, there is a decreasing volume ______________
formed between the rotor and the cam ring surface, forcing the vanes to
retract, and forcing the fluid out of the pump (outlet). ______________
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A pressure regulating valve is located inside the pump assembly. As pump ______________
outlet pressure rises fluid pressure forces the regulating valve back against
the regulating spring. As the pressure increases, the spring is collapsed.
______________
When sufficient pressure is achieved, the valve uncovers the fluid return ______________
passage, allowing fluid under pressure to enter the reservoir.
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HYDRAULIC SYSTEMS – POWER STEERING SECTION 5B 9
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Later Model (DHB) Power Steering System
Neutral
(VIEWING FROM INSIDE OF BOAT LOOKING AT TRANSOM)

10 SECTION 5B HYDRAULIC SYSTEMS – POWER STEERING

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NEUTRAL MODE DESCRIPTION
Notes:
In the neutral mode, pump outlet pressure is routed through hoses to the ______________
control valve. In the neutral mode, the control valve spool is forced into the
center position by the centering spring. The spools passages direct fluid ______________
through an interconnecting passage in the casting and back into the pump ______________
return line.
______________
The fluid in the hydraulic cylinder is locked in a static position by the surfaces
of the spool blocking the fluid passages. Thus not allowing the cylinder piston ______________
to move in either direction. ______________
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HYDRAULIC SYSTEMS – POWER STEERING SECTION 5B 11
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Right Turn
(VIEWING FROM INSIDE OF BOAT LOOKING AT TRANSOM)

12 SECTION 5B HYDRAULIC SYSTEMS – POWER STEERING

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RIGHT TURN MODE DESCRIPTION
Notes:
As the steering cable forces the drive into a right turn, resistance to the ______________
movement tries to force the cable housing in the opposite direction. The cable
housing is anchored to the control valve spool. The cable force collapses the ______________
centering spring and moves the spool inside the casting. ______________
The movement of the spool aligns the cylinder passages with passages in the ______________
spool. Fluid from the pump is directed through the spool and into the cylinder.
As cylinder internal pressure increases, the piston is moved inside the ______________
cylinder, forcing the ram to extend out of the cylinder. ______________
Fluid from the opposite side of the piston returns into the pump through the ______________
aligned spool passages and pump return line.
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HYDRAULIC SYSTEMS – POWER STEERING SECTION 5B 13
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Left Turn
(VIEWING FROM INSIDE OF BOAT LOOKING AT TRANSOM)

14 SECTION 5B HYDRAULIC SYSTEMS – POWER STEERING

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LEFT TURN MODE DESCRIPTION Notes:
As the steering cable forces the drive into a left turn, resistance to the ______________
movement tries to force the cable housing in the opposite direction. The cable ______________
housing is anchored to the control valve spool. The cable force collapses the
centering spring and moves the spool inside the casting. ______________
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HYDRAULIC SYSTEMS – POWER STEERING SECTION 5B 15

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Power Steering System Testing

Power Steering Test Gauge Kit – 91-38053A05

Adapter Kit for use with Later Model Power Steering Control Valves
(allows older kit to fit newer quick-connect fittings at the valve) – 91-
806908A02

a – Adapter fitting
b – O-ring
c – Adapter fitting
d – Adapter fitting
e – Adapter hose

16 SECTION 5B HYDRAULIC SYSTEMS – POWER STEERING

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Power Steering System Pressure Test
[Note:
This test for pressure is only for the Saginaw Banjo and Ham can style pumps.
The New Saginaw pump used on the 8.1 / 496 has higher pressure specs,
which will be sent out after testing is completed. The next pump coming out
will be a DHB power steering pump. These specs will also be sent out.]

Test Procedure:

CAUTION: Do not operate engine without cooling water being supplied

to water pickup inlet, or overheating damage to engine may result.

Power Steering Pressure Gauge Installation

a - Pump Pressure Hose

b - Test Gauge Assembly
c - Gauge to Control Valve Hose
d - Control Valve

Assemble and install test gauge assembly between control valve and pump
pressure hose. Tighten all fittings securely, but DO NOT OVERTIGHTEN.

Open valve on gauge completely.

Start engine and run at 1000-1500 RPM until engine reaches normal
operating temperature.

With engine at idle speed, test gauge reading should be between 483 and 862
kPa (70 and 125 psi). If not, proceed as follows.

• If lower than 483 kPa (70 psi), proceed to “Pump Pressure Test.”

• If higher than 862 kPa (125 psi), check for hose restrictions in the
system.

HYDRAULIC SYSTEMS – POWER STEERING SECTION 5B 17

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Push in and then pull steering cable momentarily. Gauge reading should
show an instant increase in pressure when block is pushed in both directions.

Push steering cable in until booster cylinder piston rod is fully retracted. With
piston rod in this position, momentarily push steering cable in until maximum
pressure reading is obtained.

• If pressure is above 6897 kPa (1000 psi), system pressure is good.

• If pressure is below 6897 kPa (1000 psi), conduct “Pump Pressure

Test.”

Pump Pressure Test:

CAUTION: In performing the following test, do not lug pump at maximum

pressure for more than 5 seconds or damage to power steering pump
may occur.

Start engine and run at 1000-1500 RPM until engine reaches normal
operating temperature (with cooling water being supplied to water pickup
inlet).

Close test gauge valve just long enough to obtain maximum pressure reading.

Close and open valve 3 times. Record highest pressure reading attained each
time.

a. If pressure readings are between 7932 and 8621 kPa (1150 and 1250
psi) and are within a range of 345 kPa (50 psi), the pump is within
specifications. If the pump tests OK, but system pressure was low (as
tested under “Power Steering System Pressure Test”), proceed to
“Booster Cylinder Test” (see service manual).

b. If pressure readings are between 7932-8621 kPa (1150 and 1250 psi),
but are not within a 345 kPa (50 psi) range, the Power Steering pump
flow control valve is sticking or pump hydraulic system is dirty.

c. If pressure readings are constant, but below 6897 kPa (1000 psi),
replace Power Steering pump.

18 SECTION 5B HYDRAULIC SYSTEMS – POWER STEERING

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