ULTRA QUIET DRIVE REBUILD INSTRUCTIONS

PRIOR  TO THE FOLLOWING SERVICE IT IS STRONGLY RECOMMENDED THAT YOU MAKE SURE THE DRIVE IS AT ITS CENTER POSITION AND THAT THE DRIVE PISTON IS PREVENTED FROM ROTATING AFTER REMOVAL

TO GAIN ACCESS TO THE INTERIOR OF THE DRIVE

Remove the rear cover.

1. Remove the 10-32 machine screw at the center of the cover.

2. Using a sharp tool cut the silicon seal where the rear cover joins the main drive body. ( use caution that the tool does not penetrate more than 1/4" as it can damage the internal cabling)

3. Pry off the cover.

MOTOR ACCESS

If access to the motor is required, the black aluminum canister must be removed. To do this use a strap wrench or oil filter wrench to rotate the cover. This will brake the seal and the cover may be pulled off. If the motor is being replaced it should be done prior to any work on the feed back. The motor is held in place with 4 bolts located inside the main gear housing.

TO REPLACE THE RUDDER FEED BACK POTENTIOMETER

1. Unsolder the three leads connected to the potentiometer.

2. Remove the two threaded fasteners holding the potentiometer bracket in position.

3. Remove the brass gear on the potentiometer.

4. Remove the potentiometer from the bracket

5. Install the new potentiometer ( note the small plastic nib must be inserted in the bracket hole, the lock washer must be installed and the nut must be sealed with removable lock-tite). NOTE: The drive must be extended to the center helm position through the next four steps.

6. Install the brass gear on the potentiometer shaft ( do not tighten the set screw ) 

7. Install the potentiometer bracket in the drive ( leave the mounting screws slightly loose )

8. Mate the gear teeth making sure they are well meshed, but not dead tight and bottoming in the threads. ( make sure the drive unit is still at it’s center position  and that the set screw on the brass gear is 180 degrees from the point of gear contact ) and secure the bracket using the hex bushing and philips head bolt.

9. Using a multi-meter ‘center‘ the potentiometer by rotating it's shaft in the brass gear ( the readings from S to CW and CCW will be equal and approximately 5 k ohms)

Use lock-tite secure the gear set screw to the shaft.

10. Re solder the three leads connected to the potentiometer.

Red is connected to the CCW terminal

White is connected to the CW terminal

Green is connected to the S terminal

11. Connect the drive to the controller and test per the owners manual. When the drive is fully retracted there should be 1 1/4" to 1 1/2" of stainless ram showing beyond the black bushing. Screw the ram in or out to achieve this measurement. Test the drive to make sure the feedback tracks the linear motion and that the ram does not over extend. When all is well reinstall the covers using silicon and the machine screw.( Test to insure that the belt is not dragging on the cover). Make sure the silicon is well cured prior to reinstallation as it could allow the cover to shift.

Drive repair.4-05