OPERATING INSTRUCTIONS
AND OWNER’S MANUAL
www.seastarsolutions.com
4
0
FORTY
ISO 9001
Autopilot Pump
Before you do it your way,
please try it our way
Notice to Boat Manufacturer
or Installer
Throughout this publication, Warnings and Cautions (accompanied
by the International Hazard Symbol
manufacturer or installer to special
instructions concerning a particular service or operation that may
be hazardous if performed incorrectly or carelessly.
Observe Them Carefully!
These “safety alerts” alone, cannot eliminate the hazards that they
signal. Strict compliance to these special instructions when performing
the installation and maintenance plus “common sense” operation
are major accident prevention measures.
) are used to alert the
WARNING
NOTICE
NOTICE
DANGER
Immediate hazards
which WILL result
in severe personal
injury or death.
WARNING
Hazards or unsafe
practices which
COULD result in
severe personal
injury or death.
CAUTION
Hazards or unsafe
practices which
COULD result in
minor injury or
product or property
damage.
NOTICE
Information which
is important to
proper installation or
maintenance, but is
not hazard-related.
Cleaning fluids containing ammonia, acids or any other corrosive
ingredients MUST NOT be used for cleaning any part of this
Hydraulic Steering System. Failure to comply will cause serious
damage to the steering system, resulting in possible loss of
steering, causing property damage, personal injury and/or death.
Help protect your boating environment by ensuring that all used oil
is disposed of properly.
Marine Canada Acquisition Inc. DBA SEASTAR SOLUTIONS is referred to
as SeaStar Solutions throughout this publication.
Don’t compromise performance... use genuine
SeaStar parts only!
• SeaStar helms • SeaStar cylinders
• SeaStar hoses • SeaStar oil
Substituting non SeaStar parts in any part of the SeaStar hydraulic
steering system, may seriously compromise system performance.
SAFETY INFORMATION
WARNING
Before installation
The safety information provided below is intended to inform you of the
dangers that may be present before, during and after the installation.
It is critical that you read and understand ALL the points noted.
The safe operation of the steering system is dependant upon proper
installation and maintenance, common sense, safe judgment and the
knowledge/expertise of the operator. Every installer/user of the
steering system should know the following requirements ‘before’
installing/using the steering system.
If you have any questions regarding any of these warnings, contact
SeaStar Solutions.
To reduce risk of severe injury or death. Always wear a Coast Guard
Approved personal flotation device (PFD) and use an engine shut-off
cord (lanyard).
1. Read and understand the Installation and Owner’s Manuals
provided with your steering components.
2. Ensure that all components required to complete the installation
are on hand (including hoses, fittings, oil and the proper tools
required for the installation).
3. SeaStar components are highly engineered and safety tested to
ensure system integrity, DO NOT substitute any component with
non-SeaStar components as this may compromise system
performance/reliability.
Installation
CAUTION
-3 steering cylinders are fitted
ORB hose fittings. DO NOT
with
use NPT
damage to cylinder WILL occur.
fittings, irreparable
1. Install components as directed in all Installation Manuals
(including helm pumps, hoses and fitting kits).
2. DO NOT modify or substitute any component in any way without
written consent from SeaStar Solutions.
3. Comply with all system ratings/regulations (boat/engine, U.S.C.G.).
- Cylinder MUST be compatible with engine(s) installed.
- Cylinder MUST be rated for use on the engine(s) installed.
4.
Confirm that there is no interference between the steering cylinder(s),
tiebars and the transom, splashwell, outboard engine or jackplate
or any combination of these parts by performing the following steps;
a) With engine fully tilted DOWN, turn steering wheel from hard
over to hard over and confirm that no interference occurs.
- if using a hydraulic jack plate the above must also be performed
at all the positions of the jack plate.
b) Repeat step 4a) with engines tilted UP.
c) Perform step 4a) with each engine in DOWN/UP
positions confirming that independent TRIM/TILT can be done
without any interference.
5. Confirm that the steering cylinder can be fully stroked in both
directions as well as full tilt and trim without stretching, chafing,
rubbing and/or kinking of the hydraulic hoses.
6. Confirm that extruded nylon tubing has NOT been substituted for
SeaStar Steering Hose.
7. DO NOT use a wire coil type trim switch with a hydraulic steering
system as the wire can wind up tight around the steering wheel
shaft and prevent further steering.
8. Conduct System Check as outlined on page 20 of this manual.
Autopilot Pump
i
WARNING
The safety information provided below is intended to inform you of
the dangers that may be present before, during and after use. It is
critical that you read and understand ALL the points noted.
Prior to every use
During use
1. Check Fluid level in highest helm pump (see page 15 for proper
fluid level setting).
2. Verify immediate steering response when turning steering wheel(s).
(Ensure engine turns when steering wheel is turned.)
3. Visually inspect all steering hoses and fittings for wear, kinking
and/or leaks.
4. Check for binding, loose, worn or leaking steering components.
DO NOT OPERATE BOAT IF ANY COMPONENT IS NOT IN PROPER
WORKING CONDITION.
1.
WEAR A COAST GUARD-APPROVED PERSONAL FLOTATION DEVICE (PFD).
2. ATTACH ENGINE SHUT-OFF CORD (LANYARD) TO YOUR PFD.
3. Never allow anyone not familiar with the operation of the steering
system operate the boat at any time.
4. Know and adhere to the operator restrictions for your area including;
- Federal Laws/Regulations,
- State Laws/Regulations and
- Municipal Laws/Regulations.
DO NOT OPERATE BOAT IF ANY COMPONENT IS NOT IN PROPER
WORKING CONDITION.
After use
Maintenance
1. Rinse off steering system thoroughly using ‘fresh, clean water only’.
- Cleaning fluids containing ammonia, acids or any other corrosive
ingredients MUST NOT be used for cleaning any part of the
hydraulic steering system.
1. Maintain steering system at a minimum of twice per year.
- See Maintenance, on page 21 of this manual.
Keep our waters clean for all current and future users. Dispose of ALL
fluids in accordance with your local regulations.
ii
SEASTAR Hydraulics
INTRODUCTION
Before proceeding with the installation, read these instructions
thoroughly to familiarize yourself with the workings of the SeaStar
Autopilot pump. SeaStar Solutions cannot accept responsibility
for installations where instructions have not been followed, where
substitute parts have been used, or, where modifications have been
made to our products. Warranty may be void if products other than
SeaStar Solutions products are used with this system.
Index
Safety Information ..................................................................... i
Introduction ............................................................................. 1
Before Operating Your Boat ...................................................... 2
Things You Need To Know! ...................................................... 3
SeaStar Autopilot Pump Compatibility ...................................... 4
Specifications .......................................................................... 5
System Installation ................................................................. 6
Before Starting ....................................................................... 6
Tools ..................................................................................... 6
Overview ................................................................................ 7
Step 1 Mounting and Plumbing ............................................... 8
Step 2 Autopilot Electrical Connections ................................. 12
Step 3 Filling & Purging the System ....................................... 13
Step 3.1 Fill & Purge Manually ............................................ 15
Step 3.2 Fill & Purge Using Power Purge ............................. 18
Step 3.3 Additional Purge Instructions ................................. 19
Step 4 System Check ........................................................... 20
Maintenance .......................................................................... 21
Troubleshooting Guide ........................................................... 22
Statement of Limited Warranty .............................................. 23
Return Goods Procedure ......................................................... 23
Mounting Template ................................................................ 25
Autopilot Pump
1
BEFORE OPERATING
YOUR BOAT
Ensure that the following check list is carried out.
1. With the Autopilot pump turned OFF (ignition OFF) perform a
system pressure test by turning the wheel all the way to hard
over and then forcing the wheel another one quarter to one half
turn past the stop point.
Inspect the following areas:
• Inspect helm fittings
• Inspect Power Assist/Autopilot interface (if installed) and
Autopilot pump fittings
• Inspect cylinder and cylinder bleed fittings
• Inspect hoses
Look for evidence of a leak. This test is to be completed in BOTH
directions. ANY leak that is noticed MUST be corrected prior to
operation of the boat.
2.
Confirm that extruded nylon tubing has NOT been substituted
for SeaStar/SeaStar PRO Hydraulic Steering Hoses.
3. Confirm that there is no interference between the steering
cylinder and the transom, splashwell or jack plate or any
combination of these parts by performing these simple steps:
• If installed on an outboard engine, with the engine fully tilted,
turn steering from hard over to hard over and confirm that NO
interference occurs. If you are using a hydraulic jack plate this
step must also be performed at the top and bottom position of
the jack plate. If interference is present, it MUST be eliminated
with trim limiting switches and/or jack plate restrictors.
Contact jack plate manufacturer for advice if required.
• Confirm that the steering cylinder can be stroked fully in both
directions as well as full tilt and trim without stretching
and/or kinking the hydraulic hoses.
• Confirm that the hydraulic hoses are not subjected to chafing
or rubbing.
WARNING
2
Failure to comply with the above may result in loss of steering
causing property damage and/or personal injury or death.
SEASTAR Hydraulics
WARNING
CAUTION
WARNING
CAUTION
AUTOPILOT PUMP
Things You Need To Know!
SeaStar/SeaStar PRO Steering hoses CANNOT be cut. Cutting
these hoses will render them useless. Failing to comply may
result in possible loss of steering causing property damage,
personal injury and/or death.
DO NOT use SeaStar nylon tubing with the Autopilot pump, other
than for the compensating line. Use of SeaStar/ SeaStar PRO steering
hose is the ONLY hose recommended for use in these systems.
Stretched, kinked or chafed hose will fail over a period of time.
Check hoses frequently to avoid potential loss of steering causing
property damage and/or personal injury or death.
Take EXTREME care not to allow any foreign material or contaminant
to enter the hydraulic steering system. Contamination is the
main cause of hydraulic system wear and/or failure. Keep
protective caps on hose ends until ready to thread onto a fitting.
CAUTION
WARNING
NOTICE
WARNING
Confirm that ALL components needed to complete the installation
are purchased, including helm pump, steering cylinder, hoses,
fluid, fittings and pipe sealant such as Loctite
TEFLON TAPE, ONLY USE A LIQUID, TEFLON BASED PIPE SEALANT.
If installed in a system that does NOT have a SeaStar helm, an
external pressure relief valve set at 1000psi MAX, such as Part
# HA5822 or equivalent, MUST be installed.
If retrofitting onto an existing SPA installation a HA1205 retrofit kit will
be required.
When working in an area where fumes from fuel are present, allow
the fumes to disperse completely BEFORE doing any electrical
connections of any kind. Failure to do so may result in an
explosion or fire.
®
PST. NEVER USE
Autopilot Pump
3
AUTOPILOT PUMP
SeaStar Autopilot Pump Compatibility
The SeaStar Autopilot pump is designed for use in recreational marine
applications, in conjunction with SeaStar Hydraulic Steering Systems.
It is a fixed flow, reversible pump-set that uses a high efficiency gear
pump, producing very little vibration or noise. It is offered in 12
and 24 volt configurations, as well as two different pump outputs
(type 1 and type 2). It can be used as a standalone Autopilot pump
or can be mounted to a previously installed SeaStar Power Assist
unit avoiding the need to install additional hydraulic lines.
Optimal performance will be attained when used with SeaStar
helm pumps and other genuine SeaStar components, such as;
SeaStar Hoses and SeaStar Steering Cylinders.
Figure 1.
WARNING
4
SeaStar extruded nylon tubing may ONLY be used for the
compensating line. DO NOT use SeaStar extruded nylon tubing
ANYWHERE else within the system.
SEASTAR Hydraulics
SPECIFICATIONS
WARNING
DO NOT exceed peak operating
pressure. 1000psi.
12V SEASTAR
AUTOPILOT PUMP
• 12 Volts
• 1000psi MAX system
pressure
• Flow Rate (No-Load):
Type 1: 60in
Type 2: 100in
• Typical current draw
(up to 300 psi):
Type 1: 4–8A
Type 2: 5–11A
• Cylinder Capacity:
Type 1: 4.9–12.5in3
Type 2: 12.5–21in
3
/min
3
/min
3
24V SEASTAR
AUTOPILOT PUMP
• 24 Volts
• 1000psi MAX system
pressure
• Flow Rate (No-Load):
Type 1: 60in
Type 2: 100in
• Typical current draw
(up to 300 psi):
Type 1: 2–4A
Type 2: 3–6A
• Cylinder Capacity:
Type 1: 4.9–12.5in3
Type 2: 12.5–21in
3
/min
3
/min
3
Figure 2.
Autopilot Pump
4.15" (106mm)
4.78" (122mm)
NOTICE
6.63"
(168mm)
4.61" (117mm)
To assist with the installation, a mounting template is provided on
page 25.
5
SYSTEM INSTALLATION
Before Starting
Carefully study this manual and ALL other manuals provided with
your SeaStar Steering system to familiarize yourself with all of the
components and their intended, or required mounting locations.
Ensure that there is adequate space available for installation of all
components and easy access for service. It is good practice to
mount all components before installing hoses. This allows port to
port connection with less chance of an error. If you must run hoses
first, a system of marking the various lines must be used. ALL
hose ends must be closed with tape or similar material to prevent
contamination. CONTAMINATION IS THE MOST COMMON CAUSE OF
SYSTEM FAILURE.
Read ALL bold print text, notes, cautions and warnings. Reading them
now will help prevent unexpected surprises during the installation.
These instructions have been made as complete as possible, and
as brief as practical. If you have any questions, please contact your
Distributor or SeaStar Solutions for assistance.
WARNING
Failure to follow these and ALL other installation instructions may
cause loss of steering control leading to property damage,
personal injury and/or death.
Tools
You will require the following tools to complete your installation.
• 1/2”and 3/4” open-ended wrench.
• Wire cutters, crimpers, soldering iron.
• Screwdriver for attaching mounting plate.
• All other tools noted with your helm pump and steering cylinder
installation instructions.
6
SEASTAR Hydraulics
Overview
AUTOPILOT PUMP
HELM
CYLINDER
NOTICE
STEP 1
STEP 2
Mounting & Plumbing
• Install SeaStar helm pump(s) using installation instructions
provided with your helm pump.
• Install steering cylinder(s) into boat using the installation manual
instructions provided with your steering cylinder.
• Install Autopilot pump as per instructions on page 8.
• Install steering hoses as outlined on page 9 to page 11 of
this manual.
Due to the different cylinders options available with SeaStar
Steering, be sure that you choose the correct installation diagram
noted in this book.
Electrical Connections
• Refer to page 12 for electrical connections.
Autopilot Pump
STEP 3
STEP 4
Filling and Purging
• Refer to page 13 for filling and purging of the steering system.
System Check
• Refer to page 20 of this manual.
7
AUTOPILOT PUMP
Step 1 Mounting and Plumbing
1.1
1.2
1.3
NOTICE
To assist the installation, a
mounting template is provided
on page 25.
NOTICE
Autopilot pump must be mounted
at a lower height than the highest
helm pump in your system.
Install Helm Pump(s)
• Install SeaStar Helm pump(s) using the instructions provided
with your helm(s).
Install Steering Cylinder(s)
• Install SeaStar steering cylinder(s) using the instructions
provided with your cylinder(s).
Autopilot Pump Mounting
• Using the four (4) holes in the mounting bracket, mount the pump
using #10 fasteners in your desired location. Prior to drilling,
confirm that there is sufficient room to allow for hose connections
and tightening of these hoses.
• Mount the autopilot pump as close to the cylinder as possible, in
a cool and dry location, away from excessive heat sources such
as engine manifolds. Avoid any areas that seem to collect water.
• Install the Autopilot pump in a vertical position (refer to figure 3).
DO NOT mount the unit in a horizontal position.
10ϒ 10ϒ
NOTICE
The SeaStar Autopilot pump will
make a noise similar to common
Autopilot pumps; this should be
taken into consideration when
locating a mounting area for
the units.
WARNING
8
AUTOPILOT
MUST MOUNT
VERTICALLY
Figure 3.
The SeaStar Autopilot pump may be hot to the touch. DO NOT
mount the pump in an area where fabrics and/or any other
flammable materials may come in contact with the units.
SEASTAR Hydraulics
1.4 Plumbing the SeaStar Autopilot Pump
C1 C2
R
H1
H2
C1 C2
Outboard Front Mount
Cylinders:
HC5345-3, HC5347-3
HC5348-3, HC5358-3
AUTOPILOT PUMP
Hose connection is as follows.
• Helm to AP = S (helm) to H1 (AP), P (helm) to H2 (AP), lower R port
(helm) to R (AP).
• AP to cylinder = C2 (AP) to starboard side (cylinder), C1 (AP) to port
side (cylinder).
I/O Cylinder:
HC5332-2
CAUTION
All SeaStar hose connections
must be torqued to 15 ft-lbs.
PORTSTARBOARD
H1 H2
C1 C2
H1 H2
C1 C2
Autopilot Pump
Figure 4.
9
C1 C2
R
H1
H2
C1 C2
AUTOPILOT PUMP
Side Mount Cylinder:
HC5370
Splashwell Cylinder:
HC5380
CAUTION
All SeaStar hose connections
must be torqued to 15 ft-lbs.
Hose connection is as follows.
•
Helm to AP = S (helm) to H1 (AP), P (helm) to H2 (AP), lower R port
(helm) to R (AP).
•
AP to cylinder = C1 (AP) to starboard side (cylinder). C2 (AP) to port
side (cylinder).
PORTSTARBOARD
10
H1 H2
C1 C2
Figure 5.
SEASTAR Hydraulics
C1 C2
R
H1
H2
C1 C2
AUTOPILOT PUMP
All Inboard & Sterndrive
Except: HC5332-2
CAUTION
All SeaStar hose connections
must be torqued to 15 ft-lbs.
Hose connection is as follows.
• Helm pump to AP = S (helm) to H1 (AP), P (helm) to H2 (AP),
lower R port (helm) to R (AP).
• AP to cylinder = C1 (AP) to starboard side (cylinder), C2 (AP) to
port side (cylinder).
PORTSTARBOARD
H1 H2
C1 C2
Figure 6.
Autopilot Pump
11
AUTOPILOT PUMP
Step 2 Autopilot Electrical Connections
Connect the Red (+) and Black (-) wires of the Autopilot pump to
he controller as per the Autopilot manufacturers recommendations.
t
The polarity may need to be reversed on some controllers in order to
operate correctly.
When extending wire leads, marine best practices must be followed.
Solder and shrink wrap are highly recommended. Appropriately
sized and properly installed crimp connections with shrink wrap
protection are also acceptable. A MIN of 12AWG wiring should be
used for any extensions.
Lead wires should be kept as short as possible.
NOTICE
WARNING
WARNING
Refer to the Autopilot controller manufacturer for EMC wire guidelines,
installation manuals and ALL notices, cautions and warnings.
ONLY use approved electrical connectors or junction boxes with
the correct power rating.
If installing in an area where fumes from fuel are present, be sure to
completely vent this area prior to making ANY electrical connections.
Failure to do so may result in an explosion and/or fire causing
property damage, personal injury and/or death.
12
SEASTAR Hydraulics
AUTOPILOT PUMP
Step 3 Filling & Purging the System
Read First
CAUTION
Hydraulic Fluid
These instructions show how to fill and purge a SeaStar steering
system with the SeaStar Autopilot pump installed. The same steps
apply to ALL cylinders with the exception of which bleed fitting to
open and close and the direction the cylinder rod moves. These
variations are shown in inset diagrams at each step. For multiple
steering stations, start with the lowest station while going through
Steps 3.1.1 – 3.1.6, repeat at each higher station until complete.
The use of a Power Purge kit (HA5445 or equivalent) is highly
recommended and will improve the speed and quality of the purge
procedure.
This procedure requires two people. One person may not be able
to remove all the air from the system, which will result in spongy,
unresponsive steering.
During the entire filling procedure, oil MUST be visible in the filler
tube. DO NOT allow oil level to disappear into the helm pump, as
this may introduce air into the system and increase your filling time.
Due to recent upgrades in our steering system components,
SeaStar Solutions recommends use of SeaStar Steering Fluid ONLY
in our hydraulic steering systems. SeaStar Steering Systems have
been engineered and validated using our proprietary SeaStar
Hydraulic Steering Fluid. SeaStar Steering fluid is engineered with a
special additive package that contains anti-foaming and anti-rusting
agents, anti-oxidants, viscosity stabilizers, corrosion inhibitors, wear
additives as well as water emulsification additives. It is highly
recommended that SeaStar Steering Fluid be used to ensure
optimum system performance and safety.
Autopilot Pump
WARNING
Any non-approved fluid may cause serious damage to the steering
system resulting in possible loss of steering, causing property
damage, personal injury and/or death.
Use of any non-approved fluid may result in the following;
• higher steering effort, particularly at ambient or lower temperatures
and/or over time due to oil degradation and breakdown
• increased steering slip and/or drift resulting in lost motion
• foaming or air entrapment causing a bumpy feel during steering
• high rates of moisture absorption causing internal component
corrosion
• scratched steering cylinder bores and shafts due to contamination
or elevated wear rates
• seal degradation – incompatibility with various proprietary seal
compounds used in our products.
13
AUTOPILOT PUMP
In an emergency, SeaStar EPS Fluid, any MD-3/4 rated ATF or MILPRF-5606H equivalent fluid that is filtered through a fine mesh
screen can be used. The system MUST be thoroughly flushed as
soon as possible with genuine SeaStar Steering Fluid after using an
emergency fluid.
In an EXTREME emergency, any non-toxic, non-flammable fluid that is
filtered through a fine mesh screen may provide temporary steering.
Use of non-standard fluids will require an immediate and complete
system flush using approved fluids, by an approved steering technician.
WARNING
NOTICE
NOTICE
Fill Plugs for SeaStar
Helms
Never fill or mix brake fluids, trigycerides or polyalkylene glycols
within a hydrauilic steering system.
SeaStar Hydraulic Steering Fluid can be used in Hynautic, BayStar
and BayStar Plus
steering systems.
Help protect your boating environment by ensuring that all used oil
is disposed of properly.
VENT PLUG - Part No. HP6126
SUPPLIED WITH SEASTAR HELM PUMP
• MUST BE USED WITH HELM PUMP ON ALL SINGLE
STEERING STATION SYSTEMS.
• MUST BE USED ON UPPERMOST HELM PUMP ON
MULTI STEERING STATION SYSTEMS.
Figure 7.
NON-VENT PLUG - Part No. HP6000
• MUST BE USED ON ALL HELM PUMPS OTHER THAN
UPPER MOST HELM PUMP ON MULTI STEERING
STATION SYSTEMS.
• THIS NON-VENT PLUG IS SUPPLIED WITH ADDITIONAL
STATION FITTING KIT NO. HF5501 AND HF5502.
14
SEASTAR Hydraulics
Step 3.1 Fill & Purge Manually
AUTOPILOT PUMP
NOTICE
If using the SeaStar Power Purge
JR/SR please refer to page 18.
3.1.1
NOTICE
Filling the helm full of fluid prior to
connecting the filler tube and oil
bottle will decrease purge time.
The following procedure applies to a single helm and single cylinder
installation.
Other configurations will require this procedure plus the additional
steps outlined on page 19.
• Attach helm filler kit (HA5438) and fluid bottle to the helm. Refer
to figure 8.
PUSH PIN
FILLER PLUG
(REMOVED)
FILLER KIT
HELM FILL PORT
DO NOT LET
OIL LEVEL
FALL BELOW
THIS POINT
TURN
CLOCKWISE
OPEN RIGHT SIDE
BLEEDER
Outboard Front Mount & HC5332-2 Cylinder
3.1.2
Figure 8.
• Turn the steering wheel clockwise until the cylinder rod is fully
extended as shown below.
• Open bleed fitting as per your installation.
TURN
CLOCKWISE
OPEN LEFT SIDE
BLEEDER
Side Mount / Splashwell Mount Cylinder All Balanced Cylinder. Inboard & Sterndrive Cylinders
OPEN LEFT SIDE
BLEEDER
TURN
CLOCKWISE
Autopilot Pump
15
AUTOPILOT PUMP
3.1.3
TURN COUNTERCLOCKWISE
CLOSE RIGHT
SIDE BLEEDER
• Holding the cylinder body (Outboard Front Mount cylinder) or rod
(Side Mount cylinder) to prevent the body/rod from moving, turn
the steering wheel counter-clockwise until a steady stream of air
free oil comes out of the bleeder. (Drain approx. 1/2 bottle of oil
or as required).
Do not use anything other than your hands to restrain the
cylinder body/rod.
• Run SeaStar Autopilot pump continuously in the same direction
you have been turning for a minimum of 2 minutes.
• While continuing to turn the wheel close the bleed fitting for your
installation and let go of the cylinder body/rod.
TURN COUNTERCLOCKWISE
CLOSE LEFT SIDE
BLEEDER
TURN COUNTERCLOCKWISE
CLOSE LEFT SIDE
BLEEDER
Outboard Front Mount & HC5332-2 Cylinder
TURN COUNTERCLOCKWISE
OPEN LEFT
SIDE BLEEDER
Outboard Front Mount & HC5332-2 Cylinder
3.1.4
Side Mount / Splashwell Mount Cylinder All Balanced Cylinder. Inboard & Sterndrive Cylinders
• Continue turning the steering wheel counter-clockwise until the
cylinder rod is fully extended as shown below. Steering wheel will
come to a stop.
• Open bleed fitting as per your installation.
TURN COUNTERCLOCKWISE
OPEN
RIGHT
SIDE
BLEEDER
Side Mount / Splashwell Mount Cylinder All Balanced Cylinder. Inboard & Sterndrive Cylinders
TURN COUNTERCLOCKWISE
OPEN
RIGHT
SIDE
BLEEDER
16
SEASTAR Hydraulics
AUTOPILOT PUMP
TURN CLOCKWISE
CLOSE LEFT SIDE
BLEEDER
3.1.5
• Holding the cylinder body (Outboard Front Mount cylinder) or rod
(Side Mount
steering wheel
cylinder) to prevent the body/rod from moving, turn the
clockwise until a steady stream of air free oil comes out
of the bleeder.
• Run SeaStar Autopilot pump continuously in the same direction
you have been turning for a minimum of 2 minutes.
• While continuing to turn the wheel close the bleed fitting for your
application and let go of the cylinder body/rod.
• Torque all cylinder bleed fittings to 180 in-lbs.
TURN CLOCKWISE
CLOSE
RIGHT SIDE
BLEEDER
TURN CLOCKWISE
CLOSE
RIGHT SIDE
BLEEDER
Outboard Front Mount & HC5332-2 Cylinder
CAUTION
Prior to operating system,
perform Oil Level System
Check, refer to page 20.
3.1.6
Side Mount / Splashwell Mount Cylinder
All Balanced Cylinder. Inboard & Sterndrive Cylinders
• Open Autopilot pump reservoir bleed fitting. Refer to figure 9.
• Wait approximately 30 seconds while reservoir purges. Fluid may
or may not exit bleeder at this time depending on individual
configuration.
• Close reservoir bleed fitting and torque to 180 in-lbs.
Autopilot Pump
RESERVOIR BLEED FITTING
Figure 9.
17
AUTOPILOT PUMP
Step 3.2 Fill & Purge using Power Purge
NOTICE
CAUTION
3.2.1
3.2.2
BEFORE bleeding the main steering system (helm, hoses and
cylinders), the RETURN line will need to be purged.
• Install the helm adapter into the helm pump and attach the helm
hose from the power purge unit.
• Connect one of the fluid return hoses (cylinder lines) from the
Power Purge unit to the reservoir bleed fitting on the SeaStar
Autopilot pump (see figure 9 on page 17 for bleed fitting location).
• Open reservoir bleed fitting 1 turn.
Refer to your Power Purge installation manual for important
Warnings and Notices while using the Power Purge Units.
• Turn ON the Power Purge unit and continue to run until NO air is
visible leaving the SeaStar Autopilot pump.
• Turn OFF Power Purge unit.
• Close the reservoir bleed fitting and torque to 180 in-lbs.
• Remove the hose from the reservoir bleed fitting and connect to
the bleeder fittings on the steering cylinder. Be sure that the quick
connect is locked onto the fitting.
• Open ALL cylinder bleed fittings 1-1/2 turn.
• Turn Power Purge unit ON.
• Oil should flow into and out of the helm pump. Wait twenty
seconds for the helm to fill with oil.
• Quickly turn the steering wheel clockwise until the cylinder rod is
fully extended (you may have to manually push the cylinder rod).
SLOWLY continue to turn the wheel to hold the cylinder in this
position for approximately 30 seconds. Ensure there are NO air
bubbles escaping through the cylinder hoses.
• Quickly turn the steering wheel counter-clockwise until the cylinder
rod is fully extended (you may have to manually push the cylinder
rod). SLOWLY continue to turn the wheel to hold the cylinder in
this position for approximately 30 seconds. Ensure there are NO
air bubbles escaping through the cylinder hoses.
• Turn OFF Power Purge unit.
• Remove hoses and replace helm vent cap.
• Tighten ALL bleed fittings on the steering cylinder(s) and torque to
180 in-lbs.
18
3.2.3
Continue on with Oil Level and System Check on page 20.
SEASTAR Hydraulics
Step 3.3 Additional Purge Instructions
AUTOPILOT PUMP
3.3.1
Twin Station Single Cylinder
Perform Steps 3.1.1 – 3.1.6 at
station no. 1. Then repeat Steps
3.1.2 – 3.1.5 at station no. 2.
Note: Refer to Oil Level & System
Check on page 20.
3.3.2
Single Station Twin Cylinder
When performing Steps 3.1.1 –
3.1.6, perform instructions in
each step first on cylinder no. 1
and then on cylinder no. 2,
before proceeding to the next
step. ie: Perform instructions
referring to right side of
cylinder first on cylinder no. 1
and then on cylinder no. 2.
Note: Refer to Oil Level & System
Check on page 20.
STATION NO.2
STATION NO.1
AP UNIT
CYLINDER
AP UNIT
CYLINDER NO.2
CYLINDER NO.1
3.3.3
Twin Station Twin Cylinder
Follow same procedure as
instructed for single station-
twin cylinders, beginning at
station no. 1, and repeat entire
procedure at station no. 2.
Note: Refer to Oil Level & System
Check on page 20.
Autopilot Pump
STATION NO.2
STATION NO.1
AP UNIT
CYLINDER NO.2
CYLINDER NO.1
19
AUTOPILOT PUMP
Step 4 System Check
At this time the steering system must be checked for proper hose
and fitting connections, possible leaks, and air removal. Please
complete the following steps with the Autopilot pump OFF.
• Turn steering wheel to hard over, then force the wheel another
one quarter to one half turn past the stop point. Check the
following areas for evidence of a leak.
- Inspect helm fittings
- Inspect Power Assist/Autopilot interface (if installed) and
Autopilot pump fittings
- Inspect cylinder and cylinder bleed fittings
- Inspect hoses
• Repeat above steps to the other steering direction.
• Any sign of a leak MUST be repaired prior to operating the boat.
• While turning steering wheel observe fluid level in the helm pump.
If fluid level drops and rises significantly as the wheel is being
turned there is still air in the system. Complete bleeding
instructions again until no obvious fluid level change is noticed.
NOTICE
NOTICE
Helms mounted on a 20 degree
angle or with the wheel shaft
vertical MUST have the fluid level
within 1/2” of the filler hole,
refer to the diagram below.
WARNING
If a leak is noticed, it MUST be
corrected prior to using the boat.
Failure to do so may lead to
loss of steering causing
property damage, personal
injury or death.
Consult with autopilot controller manual for the remainder of the
autopilot check list.
Helms mounted with the wheel shaft completely horizontal must be
filled to the bottom of the filler hole at all times. Do NOT allow the
fluid level to drop more than one-quarter inch below the filler hole.
VERTICAL
1/2"
(12.5mm)
20°
20
Figure 10.
SEASTAR Hydraulics
MAINTENANCE
NOTICE
WARNING
Check the oil level of highest helm in your system routinely.
of fluid indicates a leak somewhere in the system which must be
repaired immediately before operating the vessel.
Hoses should also be routinely inspected. Replace any hose(s)
showing signs of wear and remove the cause or reroute the hose(s).
Check all fittings and seal locations for leaks/damage and services
as necessary.
Failure to comply with maintenance checks may result in loss of
steering, causing property damage and/or personal injury.
Maintenance requirements will vary depending on usage and climate.
Bi-annual inspection by a qualified marine mechanic is required.
Any loss
Autopilot Pump
21
TROUBLESHOOTING GUIDE
NOTICE
These troubleshooting notes have been gathered from several
cases throughout the years. Whenever a solution calls for removal
of parts, disassembly of parts etc. The work must ONLY be
performed by a ‘Qualified Marine Technician’.
FAULT CAUSE SOLUTION
1. Steering response is
slow and feels bumpy
2. Steering is very hard
(stiff)
3. Autopilot motor is really
hot to the touch
4. Autopilot pump steering
in wrong direction
Leak/Air in system Repeat system check inspecting system
for leaks.
Rebleed system.
Partially kinked or
collapsed line
Partially kinked or
collapsed line
Controller settings are
incorrect
Motor polarity reversed
Check all lines for signs of a collapsed or
kinked line
See step 2
Refer to autopilot controller manual
Reverse motor leads at Autopilot controller
5. Autopilot pump will not
turn on
6. Autopilot pump draws
too much current
7. Autopilot pump hunts/
overshoots
8. Helm locks up in both
directions
9. Helm only turns in
one direction and free
wheels in the other
Blown Fuse
Electrical connections
are wrong
Partially kinked or
collapsed line.
Controller not properly sized
Refer to autopilot controller
manual
Hoses installed in the wrong
ports.
Kinked or collapsed line
Port or Starboard line is
connected to the reservoir R
port on the Autopilot Pump.
Check for blown fuses and bad connections in
Autopilot wiring. Refer to page 12.
See step 2
Review pump Specifications
Refer to autopilot controller manual
Review the plumbing diagrams for your system
noted on page 9 through page 11, confirm
that your hoses are hooked up correctly.
Check ALL lines for sign of a collapsed or
kinked line.
Review the plumbing diagrams for your system
noted on page 9 through page 11, confirm
that your hoses are hooked up correctly.
22
SEASTAR Hydraulics
Statement of Limited Warranty
We warrant to the original retail purchaser that Marine Canada
Acquisition Inc. DBA SEASTAR SOLUTIONS (herein forward referred
to as SeaStar Solutions) products have been manufactured free
from defects in materials and workmanship. This warranty is effective
for two years from date of purchase, excepting that where SeaStar
Solutions
producing activity, then this warranty is limited to one year from the
date of purchase.
We will provide replacement product without charge, for any SeaStar
Solutions
prepaid) within the warranty period to the dealer from whom such
product were purchased, or to us at the appropriate address. In
such
covered by this warranty, will be replaced at SeaStar Solutions
option, and returned to the customer.
The above quoted statement is an extract from the complete SeaStar
Solutions
available in our SeaStar Solutions products catalogue.
products are used commercially or in any rental or income
product meeting this warranty, which is returned (freight
a case SeaStar Solutions products found to be defective and
products warranty statement. A complete warranty policy
is
Technical Support
Return Goods Procedure
Prior to returning product to SeaStar Solutions under warranty,
please obtain a Return Goods Authorization number (claim number).
Be sure to label the goods with:
a) the name and address of the sender, and
b) the return goods authorization number (claim number)
Please address the returned goods as follows:
From U.S.A.
RGA # ?
SeaStar Solutions
c/o UPS-SCS
19308 70th Ave S.
Kent, WA 98032
Phone:
email:
Hours: Monday - Friday 05:00 – 15:30 PST
Web: www.seastarsolutions.com
604-248-3858
seastar@seastarsolutions.com
From Canada
RGA # ?
SeaStar Solutions
3831 No.6 Road
Richmond, B.C.
Canada V6V 1P6
Autopilot Pump
23
This page left intentionally blank.
24
SEASTAR Hydraulics
2.50
MOUNTING TEMPLATE
4.20
"
"
Autopilot Pump
!
NOTICE
4 x Ø
.22
If this mounting template is
be checked using a measuring device prior to use.
photocopied, ALL measurements
must
25
This page left intentionally blank.
26
SEASTAR Hydraulics
FORM NO. 798320 REV. D
SEASTAR SOLUTIONS
3831 NO.6 ROAD
RICHMOND, B.C.
CANADA V6V 1P6
FAX 604-270-7172
www.seastarsolutions.com
ISO 10592
© 2007 MARINE CANADA ACQUISITION INC.
DBA SEASTAR SOLUTIONS
PRINTED IN CANADA
100–03/16
Loading...