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17HYDRAULIC POWER ASSIST FOR SEASTAR
STEERING SYSTEMS
OPERATING INSTRUCTIONS
AND OWNERS MANUAL
w w w . s e a s t a r s t e e r i n g . c o m
SEVENTEENI S O 9 0 0 1
MANUFACTURED BYTELEFLEX CANADA LIMITED
PARTNERSHIP
Including:
Dedicated to our friend and mentor Jack Hoster.
Through the years you have always helped to steer usin the right direction, you are a true friend and mentor,
you will be missed, but not forgotten.
December 2003
your friends from SeaStar
Power Assist for SeaStar Systems i
Throughout this publication, Warnings and Cautions (accompanied by theInternational Hazard Symbol ) are used to alert the manufacturer orinstaller to special instructions concerning a particular service oroperation 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 performingthe installation and maintenance plus “common sense” operation aremajor accident prevention measures.
Notice to Boat Manufactureror Installer
Hazards or unsafepractices whichCOULD result inminor injury orproduct or propertydamage.
CAUTIONHazards or unsafepractices whichCOULD result insevere personalinjury or death.
WARNINGImmediate hazardswhich WILL result insevere personalinjury or death.
DANGERInformation which isimportant to properinstallation ormaintenance, but isnot hazard-related.
NOTICE
Cleaning fluids containing ammonia, acids or any other corrosiveingredients MUST NOT be used for cleaning any part of thisHydraulic Steering System. Failure to comply will cause seriousdamage to the steering system, resulting in possible loss ofsteering, causing property damage, personal injury and/or death.
WARNING
Help protect your boating environment by ensuring that all used oilis disposed of properly.
NOTICE
Don't compromise performance... use genuineSeaStar parts only!• SeaStar helms • SeaStar Cylinders• SeaStar hoses • SeaStar Oil
Substituting non SeaStar parts in any part of the SeaStar hydraulicsteering system, may seriously compromise system performance.
ii SEASTAR Hydraulics ii
INTRODUCTION
IndexTools/Specifications .................................................................. 2How the System works .............................................................. 3Before Starting ......................................................................... 4System Set-up/Quick Reference Guide ....................................... 5
Specific InstallationOutboard Front Mount & HC5332............................................... 6Side Mount & Splashwell Mount cylinders................................... 7Inboard & Sterndrive ................................................................. 8Autopilot Connection.................................................................. 9Electrical Installation ............................................................... 10Filling and Purging ................................................................... 12Trouble Shooting ..................................................................... 20Accessories ............................................................................ 22Warranty ................................................................................. 23
Before proceeding with the installation, read these instructionsthoroughly. Teleflex cannot accept responsibility for installationswhere instructions have not been followed, where substituteparts have been used, or modifications have been made toour products. Warranty may be void if products other thanTeleflex products are used with this system.
Due to a small amount of internal hydraulic slip, a "master spoke:or "centered" steering wheel cannot be maintained with a HydraulicSteering System. For best results, use an equal distance spokesteering wheel.
DO NOT use a wire coil type trim switch with a hydraulic steeringsystem. Wire coil can wind up tight around the steering wheelshaft and prevent further steering!PRO Trim offers fingertip trim or jackplate control with a column-mounted switch, enabling you to keep both hands on the steeringwheel and concentrate on your driving. PRO Trim PT1000 controlstrim or jackplate only. PRO Trim Dual PT2000 controls both functions.
NOTICE
WARNING
This installation manual coversthe entire, SeaStar and SeaStarPRO PA Series. Notes are made,when required, to cover anydifferences between the partnumbers.
NOTICE
SeaStar PRO Power Assist units are to be used with SeaStar PROSteering ONLY!
WARNING
Power Assist for SeaStar Systems 1
Ensure that the following check list is carried out
1 With the P/A unit "OFF" (ignition off) perform a system pressuretest by turning the helm all the way to hard over and then forcingthe helm another one quarter to one half turn past the stop point.
Inspect the following areas for leaks.- Inspect helm fittings- Inspect P/A fittings- Inspect cylinder fittings
Look for evidence of a leak. This test is to be done in BOTHdirections. Any leak that is noticed will need to be repairedbefore operating the boat.
2 Confirm that extruded nylon tubing has NOT beensubstituted for SeaStar/SeaStar PRO Hydraulic Steering hose.
3 Confirm that there is no interference between the steeringcylinder and the transom, splashwell or jackplate or anycombination of these parts by performing these simple steps:
• If installed on an outboard engine, with the engine fully titled,turn steering from hard over to hard over and confirm that NOinterference occurs. If you are using a hydraulic jack plate thisalso must be performed at the top and bottom position of thejack plate. (If interference is present, it MUST be eliminatedwith trim limiting switches and/or jack plate restrictors. ContactJack plate manufacturer for advice if required.)
• Confirm that the steering cylinder can be stroked fully in bothdirections as well as full tilt and trim without stretching and/orkinking the hydraulic hoses.
• Confirm that the hydraulic hoses are not subjected to chafingor rubbing.
BEFORE OPERATINGYOUR BOAT
Failure to comply with above may result in loss of steering,causing property damage and/or personal injury.
WARNING
The SeaStar P/A unit has beendesigned and tested for use withMarine Hydraulic Steering ONLY.It is not recommended for anyother use. Not complying withthis warning may result inproperty damage and/orpersonal injury or death.
WARNING
Stretched, kinked or chafed hose will fail over a period of time.WARNING
When working in an area were fumes from fuel are present, allowthe fumes to disperse completely BEFORE doing any electricalconnection to the battery. Failure to do so may result in anexplosion and or fire.
WARNING
The SeaStar P/A has a 40 amp fuse and electronic current limiterto protect eh electronics from overheating. If either of thesedevices is triggered, the steering will revert back to manualsteering, requiring substantially more force to turn the wheel.
CAUTION
2 SEASTAR Hydraulics
HYDRAULIC POWER ASSIST
SEASTAR
You will need the following tools to complete your installation.• 1/2", 5/8", and 3/4" open end wrench• Electrical cut and crimp pliers.• All other tools noted with your Helm Pump and Steering Cylinder
Installation Instructions.
SeaStar P/A Compatibility Chart
Tools
The P/A is designed for use in recreational marine applications inconjunction with SeaStar Hydraulic Steering. Optimal performance willbe obtained when used with SeaStar 1.4, 1.7 and 2.0 cu in (1000psi)helm pumps, or, 2.0 cu in (1500 psi) SeaStar P/A PRO Hydraulic Steering.
Specifications
4 x 0.25"
4.50"
6.65"
10.5"
8"
SeaStar nylon tube may ONLY be usedfor the compensating line. DO NOT useSeaStar Nylon tube to plumb any otherportion of the steering system.
NOTICE
SeaStar P/A PRO is NOT to be used with SeaStar Hydraulic Steering,performance will be compromised. ONLY use P/A PRO with a SeaStarPRO Hydraulic steering system and ensure that SeaStar PRO (1500psi) hose is used to plumb the entire system. (Nylon tubing may beused for the compensating/return line ONLY.
Use ONLY Teleflex products withthe P/A unit as with ALL Teleflexsystems. Failure to do so may void your warranty.
NOTICE
Display buttons UP, DOWN and SET are preset at the factory. DONOT attempt to adjust the setting of the P/A unit.
CAUTION
DO NOT exceed peak operatingpressure. 1000psi – Standard, 1500psi – Pro.
WARNING SEASTAR P/A 12VOLT, SEASTAR PRO P/A, 12 VOLT• 12 Volts• 1000 psi MAX System peak pressure (500 psi working load)
SeaStar Standard• 1500 psi MAX System peak pressure (500 psi working load)
SeaStar Pro• MAX Current Draw (at 1000psi) 55 amps• Purple ignition wire MAX. current draw = 1 amp• Typical current draw:
Single outboard ~ 3 amps, averageTwin Rudder inboard ~ 8 amps, average
SEASTAR P/A 24 VOLT. (SEASTAR PRO P/A IS NOT AVAILABLE IN 24 VOLT POWER).• 24 Volts• 1000 psi MAX., System peak pressure
(500psi working load)• MAX Current Draw (at 1000psi)
25 amps• Purple ignition wire MAX.
current draw = 1 amp• Typical current draw:
Single outboard ~ 1.5 amps, averageTwin Rudder inboard ~ 4 amps, average
GREEN 'ON' LED INDICATES
P/A UNIT IS ON
FACTORYPROGRAMPRESETS
Power Assist for SeaStar Systems 3
HOW THE SYSTEM WORKS SeaStar P/A (Power Assist) steering uses an electronically controlledhydraulic pump to provide "Power" for your SeaStar HydraulicSteering system.The SeaStar P/A system is comprised of two circuits: a handoperated manual system, which is the control element, and ahydraulic power pump, which is the working element.The manual system consists of a helm pump with internal relief andcheck valves, as well as a built in reservoir. Two steering lines and acompensating line which provide a routing for fluid to transmit throughthe system, and a steering cylinder which moves the steering deviceon the boat from side to side.The power system, is an electronically controlled hydraulic pump thatboosts the fluid being sent from the helm pump to the steering cylinder(this will result in much easier effort at the wheel—even when underheavy loads). A compensating line connects the P/A unit to the helmpump, allowing the P/A unit to share fluid with the helm reservoir.The SeaStar P/A is compatible with multiple steering stations, andwith the use of an autopilot. In the event of a P/A power loss orfailure the hydraulic system will automatically revert to a manualhydraulic system.
H1 H2
C1 C2
H1 H2
C1 C2
HELM PUMP
STEERING LINES
COMPENSATING LINE
POWER ASSIST UNIT
POWER ASSIST UNIT
HELM PUMP
STEERING LINES
COMPENSATING LINE
SEASTAR OUTBOARD CYLINDER
TILLER ARM SEASTAR INBOARD CYLINDER
Typical installations shown (please refer to you cylinder installation manual for proper hoseinstallation diagrams).
4 SEASTAR Hydraulics
THINGS YOU NEED TO KNOW
BEFORE STARTINGStudy this manual and the other manuals provided with yourSeaStar Steering system carefully, and thoroughly to familiarizeyourself with all of the components and their intended or requiredmounting locations. Ensure there is adequate space available forinstallation of all components, hydraulic lines, and easy access forservice. It is good practice to mount all components first, beforerunning hoses. This allows port to port connection with lesschance of an error. If you must run hoses first, a system ofmarking the various lines must be used. ALL hose ends must beclosed with tape or similar material to prevent contamination.Contamination is the most common cause of system failure.
Read ALL bold print text, notes and cautions. Reading them nowwill help prevent unexpected surprises during the installation.
SeaStar/SeaStar PRO Steering hoses CANNOT be cut. Cuttingthese hoses will render them useless. Failing to comply may resultin possible loss of steering causing property damage, personalinjury and/or death.
Due to various mounting configurations, mounting hardware is notsupplied with the SeaStar P/A, make sure you collect the appropriatemounting screws before getting started (refer to Specifications onpage 2 for mounting hole size). A mounting bracket part# HA1202,(refer to page 22 for details) can be purchased as an accessoryfrom Teleflex
WARNING
If it is necessary to replace the fuse for the P/A unit, the P/A unitMUST have the power turned OFF.
WARNING
DO NOT use SeaStar Nylon tube with P/A unit, other than to plumbthe compensating line. Use of SeaStar or SeaStar PRO steeringhose is the ONLY hose recommended for use with the P/A unit.
CAUTION
Confirm that all components needed to complete the installationare purchased, including: helm pump, steering cylinder, hoses,fluid, fittings and pipe sealant such as Loctite PST, NEVER USETEFLON TAPE.
CAUTION
Take EXTREME care not to allow any foreign material or contaminationto enter the hydraulic system. Contamination is the main causefor a hydraulic system to wear and or fail. Keep protective capson hose ends until ready to install onto the fitting.
CAUTION
NOTICE
These instructions have been made as complete aspossible, but as brief as practical. If you have any questions,contact your Distributor or Teleflex Canada.
Filling and Purging Procedure• Refer to steps 1 through 5, located on page 12 of this manual.
DO NOT run the P/A unit until the SeaStarSteering System has been bled free of air. Failure to do somay result in non-repairable damage to the P/A unit.
Electrical Installation• Refer to page 10 of this manual for electrical connection.
Power Assist for SeaStar Systems 5
SYSTEM INSTALLATIONOVERVIEWSystem Installation• Install SeaStar Helm pump onto the dash using installation
instructions provided with your helm pump.• Install Steering Cylinder into boat using the installation
instructions provided with your steering cylinder.• The P/A unit will make a noise similar to that of an autopilot.
Install the P/A unit in a vertical position (see diagram) as closeto the steering cylinder as possible.DO NOT mount the P/A unit in a horizontal position.
The P/A motor may be HOT to the touch, DO NOTmount P/A in an area where fabrics and/or any other flammablematerial may come in contact with the P/A motor.
• Install steering hoses using diagrams noted on page 6 throughpage 8, using your specific application.
The SeaStar PRO system must use SeaStar PROsteering hose.
Due to the different cylinders options availablewith SeaStar Steering, be sure that you choose the correctinstallation diagram noted in this book.
NOTICE
CAUTION
WARNING
WARNING
CYLINDER
P/A UNIT
HELM
10° 10°
STEP 1
Final Purge and System Check• Turn ignition ON and continue with the filling and purging
instructions step 6 on page 16 of this manual
STEP 4
STEP 2
STEP 3
6 SEASTAR Hydraulics
SYSTEM INSTALLATION
SEASTAR POWER ASSIST
Hose connection is as follows.
• Helm to P/A = S (helm) to H1 (P/A), P (helm) to H2 (P/A), lower Rport (helm) to R (P/A).
• P/A to cylinder = C2 (P/A) to starboard side (cylinder), C1 (P/A) toport side (cylinder).
SeaStar Outboard Front MountCylinders and I/O Cylinder
H1 H2
C1 C2
H1 H2
C1 C2
Outboard Front MountCylinders: HC5345HC5347HC5345HC5348HC5358
I/O Cylinder:HC5332
C2C1
R
H1H2
PORT STARBOARD
Power Assist for SeaStar Systems 7
Hose connection is as follows.
• Helm to P/A = S (helm) to H1 (P/A), P (helm) to H2 (P/A), lower Rport (helm) to R (P/A).
• P/A to cylinder = C1 (P/A) to starboard side (cylinder). C2 (P/A) toport side (cylinder).
SeaStar Outboard Side Mount andSplashwell Mount Cylinders
H1 H2
C1 C2
Side Mount Cylinder:HC5370
Splashwell Cylinder:HC5380
C2C1
SYSTEM INSTALLATION
SEASTAR POWER ASSIST
PORT STARBOARD
R
H1H2
DO NOT use SeaStar PRO systemswith HC5370 side mount and/orHC5380 Splashwell mountcylinders as SeaStar PRO systemsare not compatible with anyunbalanced cylinder.
WARNING
8 SEASTAR Hydraulics
H1 H2
C1 C2
SYSTEM INSTALLATION
SEASTAR POWER ASSIST
Hose connection is as follows.
• Helm pump to P/A = S (helm) to H1 (P/A), P (helm) to H2 (P/A),lower R port (helm) to R (P/A).
• P/A to cylinder = C1 (P/A) to starboard side (cylinder), C2 (P/A)to port side (cylinder).
SeaStar Inboard and SterndriveCylinders ALL
All Inboard & SterndriveExcept: HC5332
C2C1
R
H1H2
PORT STARBOARD
Power Assist for SeaStar Systems 9
Hose connection is as follows.
• Autopilot pump MUST be connected to the steering lines AFTERthe P/A (see diagram below). The return R line MUST be tee'dinto the system in front of the P/A unit (see diagram below).
• Refer to page 6 through page 8 for you cylinder application.
• Be sure to run the autopilot in both directions during the purgeprocedure, refer to page 15 for details.
Autopilot Connection Detail
COMPENSATING LINE
P/A UNIT
HELM PUMP
AUTOPILOT
CYLINDER
SYSTEM INSTALLATION
SEASTAR POWER ASSIST
PORT STARBOARD
P/A UNITBATTERY
+
+-
-FUSE
ACCESS
BLACK
PURPLE
RED
TO BATTERY(FUSED)
IGNITION
ON/OFF SWITCH(OPTIONAL SEE NOTICE)
10 SEASTAR Hydraulics
SYSTEM INSTALLATION
SEASTAR POWER ASSIST
Electrical Installation
DO NOT run the wires or hosesin areas where the may comein contact with battery acid orexcessive heat, i.e. engineexhaust, manifolds or anyother area that may damagethe wires or hoses.
WARNING
NOTICEIt is recommended that a twoposition switch is purchased toallow the P/A unit to be turnedoff to help conserve batterypower in a situation wherebattery power is limited. In orderto prevent accidental P/A shutdown, Teleflex recommends theuse of a 12-Volt, 15 amp, ON/OFF,rocker style or push button styleswitch. ON/OFF switches arenot available from Teleflex.
NOTICEFor multiple engine applicationsit is advisable to install the DualIgnition Control Switch. This kitwill enable the Power Assist towork in the event an engine maynot be running. Please refer topage 11 for wiring details.
The SeaStar P/A electrical connection is recommendedto be made using an on/off rocker, or push button switch. Use afuse protected switch ONLY.
• Refer to wiring diagram on this page.• Connect the RED (+ positive) wire to the Positive (+) terminal
of your battery.• Connect the Black wire (- Negative) to the Negative (-) terminal
of your battery.• Connect purple wire (power) to the ignition of the boat. Use of
a two-position toggle switch recommended. Refer to the wiringdiagram below for details.
DO NOT cut or lengthen any of the wires providedwithout first consulting Teleflex Canada, or your Distributor.
CAUTIONReduce fire risks by only usingwires of good quality. ANY wireshowing ANY sign of damageMUST be replaced.
Wiring Diagram
NOTICE
WARNING
Power Assist for SeaStar Systems 11
SYSTEM INSTALLATION
SEASTAR POWER ASSIST
P/A UNIT
BATTERY
+
+-
-FUSE
ACCESS
BLACK
PURPLE
RED
P/A UNIT ENGINE B
ENGINE A
IGNITION
IGNITION
ON/OFF SWITCH(OPTIONAL)
1P/A UNIT
ENGINE C
ENGINE A
ENGINE B1 1
ITEM PART # QTY DESCRIPTION
1 799100 1 Dual Ignition Control Switch
Three engine configuration (Requires [2]HA1201 Kits)
Installation of the power assist unit on two or more engineapplications you may want to install the Dual Ignition Control Kit sothat the power assist will be on if one of the motors is running.
• Connect "purple" ignition wire from the P/A unit to the P/Alocation on the switch.
• Connect ENG. A to the one ignition switch.• Connect ENG. B to the other ignition switch.• Mount Dual ignition control switch to the underside of the dash
and away from the elements.
Installation Procedure:
Dual Ignition Control KitPart# HA1201
If your boat is equipped with tripleengines, you will need to purchasetwo (2) of the HA1201 Ignition Switches.Refer to figure inset.
NOTICE
12 SEASTAR Hydraulics
FILLING AND PURGINGTHE SYSTEM
Read First
Hydraulic Oil Requirements
NOTICE
NOTICE
NOTICE
These instructions show how to fill and purge a SeaStar SteeringSystem with the P/A unit installed. The same steps apply to ALLcylinders with the exception of which bleed fitting to open and closeand the direction the cylinder rod moves. These variations areshown in inset diagrams at each step. For multiple steeringstations, start with the lowest station while going through steps #1through #7, repeat at each higher station until complete.
DO NOT turn ON P/A unit until manual portion is completed.This procedure requires two people. One person may not be ableto 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 fillertube. DO NOT allow oil level to disappear into the helm pump, asthis may introduce air into the system and increase your filling time.
2 bottles (2 quarts or liters) for single station and single cylindersystems. One additional bottle for each cylinder, helm, and orautopilot added to the system.
Oil can be re-used if filtered through a fine mesh screen such asthat used for gasoline. If unable to filter oil, an additional bottleof fluid is required.
"Bleeder" refers to cylinder or P/A unit fitted with bleed fittings.Bleed fittings can be opened by unscrewing bleed nipple nut two turns.
Protect your boating environment by ensuring that all used oil isdisposed of properly.
CAUTION
Power Assist for SeaStar Systems 13
FILLING AND PURGING
Step 1
Single Station One Cylinder
Manually Fill & Purge
If using the SeaStar Power purge JR/Sr. please refer to page18.
BEFORE bleeding the main steering system (helm, hoses andcylinders), the RETURN line will need to be purged.
Removing air from Return line• Using the clear tube and the spring clamps provided, connect one
end of the tube to the H1 (P/A) and the R (P/A) bleed fitting(refer to figure below)
• Open both the H1 (P/A) and the R (P/A) bleed fittings 1-1/2 turn,
• Install the fill tube and a FULL bottle of fluid into the helm pump(see figure below)
• Fill helm with fluid, then turn steering wheel to the starboard(clockwise direction) 40 revolutions.
• Close H1 (P/A) bleed fitting and continue with steps 2 through 5.
Filling the helm full of oil can be done faster if oil is poured into thehelm prior to connecting the filler tube and oil bottle to the helm.
SEASTAR POWER ASSIST
NOTICE
NOTICE
NOTICE
BLEED FITTING
BLEED FITTINGBLEED FITTING
CLEAR TUBE
R
H1H2
FILLER PLUG(REMOVED)
PUSH PIN
FILLER KIT
HELM FILL PORT
DO NOT LET OIL LEVEL FALL BELOWTHIS POINT
14 SEASTAR Hydraulics
FILLING AND PURGING
SEASTAR POWER ASSIST
Step 2
OPEN RIGHT SIDEBLEEDER
TURN CLOCKWISE
OPEN LEFT SIDEBLEEDER
TURNCLOCKWISE
• Turn the steering wheel clockwise until the cylinder rod is fullyextended on the right side of the cylinder.
• Open bleed fitting as per your installation.
Outboard Front Mount & HC5332 Cylinder Side Mount / Splashwell Mount Cylinder All Balanced Cylinder. Inboard & Sterndrive Cylinders
OPEN LEFT SIDEBLEEDER
TURN CLOCKWISE
Step 3
TURN COUNTER-CLOCKWISE
CLOSE RIGHTSIDE BLEEDER
CLOSE LEFT SIDEBLEEDER
TURN COUNTER-CLOCKWISE
•Holding the cylinder body (Front Mount cylinder) or rod (Side Mountcylinder) to prevent the body/rod from moving, turn the steeringwheel counter-clockwise until a steady stream of air free oil comesout of the bleeder. (Drain approx. 1/2 bottle of oil or as required).Do not use anything other than your hands to restrain the cylinderbody/rod.
•While continuing to turn the wheel read close the bleed fitting for yourapplication and let go of the cylinder body/rod.
Outboard Front Mount & HC5332 Cylinder Side Mount / Splashwell Mount Cylinder All Balanced Cylinder. Inboard & Sterndrive Cylinders
TURN COUNTER-CLOCKWISE
CLOSE LEFT SIDEBLEEDER
Power Assist for SeaStar Systems 15
Step 4
TURN COUNTER-CLOCKWISE
OPEN LEFTSIDE BLEEDER
OPEN RIGHT SIDE BLEEDER
TURN COUNTER-CLOCKWISE
• Continue turning the steering wheel counter-clockwise until the cylinderrod is fully extended to the left. (Steering wheel will come to a stop).
• Open bleed fitting as per your installation.
FILLING AND PURGING
SEASTAR POWER ASSIST
Outboard Front Mount & HC5332 Cylinder Side Mount / Splashwell Mount Cylinder All Balanced Cylinder. Inboard & Sterndrive Cylinders
TURN COUNTER-CLOCKWISE
OPEN RIGHTSIDE BLEEDER
Step 5
TURN CLOCKWISE
CLOSE LEFT SIDE BLEEDER
TURN CLOCKWISE
CAUTION Prior to operating system, perform Oil Level System Check, refer topage 19.
• Holding the cylinder body (Front Mount cylinder) or rod (Side Mountcylinder) to prevent the body/rod from moving, turn the steering wheelclockwise until a steady stream of air free oil comes out of the bleeder.
• While continuing to turn the wheel read close the bleed fitting for yourapplication and let go of the cylinder body/rod.
CLOSE RIGHT SIDEBLEEDER
Outboard Front Mount & HC5332 Cylinder Side Mount / Splashwell Mount Cylinder All Balanced Cylinder. Inboard & Sterndrive Cylinders
TURN CLOCKWISE
CLOSE RIGHT SIDEBLEEDER
16 SEASTAR Hydraulics
R
H1H2
R
H1H2
FILLING AND PURGING
SEASTAR POWER ASSIST
Step 7 WITH P/A OFF.• Turn wheel counter-clockwise until
cylinder rod is fully extended.• Open P/A H2 bleed fitting.• Continue turning counter-clockwise
until steady stream of fluid comes from the P/A unit.
• Close P/A H2 Bleed fitting.• Note – Only a few air bubbles (if
any) will come out of the fitting.
Step 6 • Complete electrical connection and installation as per Step 3 onpage 5 of this manual.
• Repeat steps 2 – 5 of purging instructions with P/A unit "ON".• Continue with Steps 7 and 8.
Step 8 WITH P/A OFF.• Turn wheel clockwise until
cylinder rod is fully extended.• Open P/A H1 bleed fitting.• Continue to turn clockwise until
a steady stream of fluid comesfrom the P/A unit.
• Close P/A H1 Bleed fitting.• Note – Only a few air bubbles (if
any) will come out of the fitting.
Autopilot. If you have an autopilot installed, ensure autopilot pump isrun for 10 seconds in both directions during Step 3 and Step 5.
NOTICE
Power Assist for SeaStar Systems 17
FILLING AND PURGING
SEASTAR POWER ASSIST
Perform steps 1 through 8 atstation no. 1. Then repeat steps1–8 at station no. 2.
Twin Station Single Cylinder STATION NO.2
STATION NO.1
CYLINDER
P/A UNIT
Follow same procedure asinstructed for single station-twincylinders, beginning at station no.1, and repeat entire procedure at station no. 2.
Twin Station Twin Cylinder
CYLINDER NO.2 CYLINDER NO.1
STATION NO.2
STATION NO.1
Note: Refer to Oil Level & SystemCheck on page 19.
Note: Refer to Oil Level & SystemCheck on page 19.
CYLINDER NO.2 CYLINDER NO.1
When performing steps 2 through8, perform instructions in eachstep first on cylinder no. 1 andthen on cylinder no. 2, beforeproceeding to the next step. ie:Perform instructions referring toright side of cylinder first on cylinderno. 1 and then on cylinder no. 2.
Single Station Twin Cylinder
Note: Refer to Oil Level & SystemCheck on page 19.
P/A UNIT
P/A UNIT
18 SEASTAR Hydraulics
Step 3
P/A Unit OFF during this step.
WARNING
Step 1
Step 2
Fill & Purge using Power Purge"BEFORE bleeding the main steering system (helm, hoses andcylinders), the RETURN line will need to be purged
Removing air from Return line• Install the helm adapter into the helm pump and attach the helm
hose from the power purge unit.• Connect one of the two fluid return hoses (cylinder purge hoses)
from the Power Purge unit to the R (P/A) bleed fitting.• Open the R (P/A) port bleed fitting 1/2—1 turn.• Turn ON Power Purge unit and let run until NO air is visible
leaving the P/A unit.• Turn OFF the Power purge unit.• Close the R (P/A) bleed fitting and continue on with the following steps
• Connect helm adapter to the helm pump, hand tighten.• Remove and connect the blue purge hoses to the helm adapter.
Be sure that the quick connect fittings are completely connected.• Remove the clear hose from the power purge unit and connect to
the bleed fittings on the steering cylinder. Be sure that the quickconnect fittings are completely connected.
• Open ALL bleed fittings 1/2—1 turn• Turn Power purge unit ON.• Oil should flow into and out of the helm. 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)SLOWLY continue to turn the wheel to hold the cylinder in thisposition for approximately 30 seconds. Ensure there are NO airbubbles escaping through the cylinder hoses.
• Quickly turn the steering wheel counter-clockwise until the cylinderrod is fully extended (you may have to manually push the cylinder)SLOWLY continue to turn the wheel to hold the cylinder in thisposition for approximately 30 seconds. Ensure there are NO airbubbles escaping through the cylinder hoses.
• Turn off Power purge unit.• Tighten ALL bleed fittings on the steering cylinder(s)
• Connect ends of the clear cylinder hose to both the H1 (P/A) andthe H2 (P/A) bleed fittings.
• Open both bleed fittings 1/2—1 turn.• Turn ON Power purge unit.• Turn steering wheel clockwise for 20 seconds.• Turn steering wheel counter-clockwise for 20 seconds.• Turn OFF power purge unit • Tighten both H1 (P/A) and H2 (P/A) bleed fittings
NOTICE
CAUTIONRefer to your Power Purgeinstallation manual for importantWarnings and Notices whileusing the Power Purge Units
FILLING AND PURGING
SEASTAR POWER ASSIST
Power Assist for SeaStar Systems 19
FILLING AND PURGING
SEASTAR POWER ASSIST
At this time the steering system must be checked for properconnections hose and fittings, possible leaks, and air removal.Please complete the following steps with the P/A Unit OFF.• Turn steering wheel to hard over, then force the wheel another
one quarter to one half turn past the stop point. Check thefollowing areas for evidence of a leak.- Helm fitting connections.- P/A fitting connections- Cylinder fitting connections
• 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 as the wheel is being turned thereis still air in the system. Complete bleeding instructions againuntil no obvious fluid level change is noticed.
Oil Level and System Check
Helms mounted on a 20 degree angle or with the wheel shaft verticalMUST have the fluid level within 1/2" of the filler hole, refer todiagram below.
NOTICE
Helms mounted with the wheel shaft completely horizontal must befilled to the bottom of the filler hole at all times. DO NOT allow thefluid level to drop more than one-quarter inch below the filler hole.
NOTICE
1/2" (12.5mm)
VERTICAL
20°
20 SEASTAR Hydraulics
TROUBLE SHOOTING GUIDE
FAULT CAUSE SOLUTION
1. P/A unit does not turn on.
Blown Fuse (A green light willcome on but the P/A unit willnot provide power assist.)
Wrong electrical connections
Replace with 40amp ATO automatic fuse.If it is necessary to replace
the fuse for the P/A unit, the P/A unitMUST have the power turned OFF.Refer to wiring diagram and location offuse on page 10.
2. Turns the wrong way Lines reversed Review the plumbing diagrams for your systemnoted on page 6 through page 8, confirmthat your hoses are hooked up correctly.
3. Wheel is bumpy Air in system Re-Bleed. Concentrate on remaining air inthe P/A unit.Autopilot has not been bled as per instructions.
4. Helm locks up in bothdirections
Hoses installed in the wrongports.
Kinked or collapsed line
Review the plumbing diagrams for your systemnoted on page 6 through page 8, confirmthat your hoses are hooked up correctly.Check ALL lines for sign of a collapsed orkinked line.
5. Helm only turns in onedirection and freewheels in the other
Port or Starboard line isconnected to the reservoir Rport on the P/A unit.
Review the plumbing diagrams for your systemnoted on page 6 through page 8, confirmthat your hoses are hooked up correctly.
6. Steering is very hard(stiff)
P/A unit is not turned on.Partially kinked or collapsedline.H1, H2 or R port screenfilters are plugged withcontamination.
See fault #1Check ALL lines for a sign of a collapsedor kinked lineRemove H1, H2 and R hose and fittings.Clean screens located in the adapter fittings.
7. Error code on the P/Aunit read E1?
Low Battery voltage Refer to Battery maintenance.24 Volt SPA on 12V Boat.
8. Steering is good at firstbut then becomesspongy?
R line from the helm pumptot he P/A unit is notproperly purged.
See #3.
9. SPA unit displays error code “E2”
High battery voltage Refer to battery maintenance.12 Volt SPA on 24V Boat.
WARNING
Power Assist for SeaStar Systems 21
10. SPA unit displays errorcode “EO”
Not Calibrated Return to Teleflex Canada
11. After hitting hard overand/or running at highloads with the SeaStarPRO Power Assist, theeffort at the wheelincreasing dramatically.
Helm is super charging Super charging is a normal occurrencewith ALL PRO systems, while running athigher loads and/or hitting the hard overpoint. This should not be taken as a faultin the system.
12. The power assist unit isreally hot to the touch.
Motor operating This is a normal occurrence with the PowerAssist unit; mount the P/A in an areawhere it can not easily be handled andaway from flammable materials.
Whenever a solution calls for the removal from vessel and/ordismantling of steering system components, such work mustONLY be carried out by a qualified marine hydraulic mechanic.Teleflex offers this information as a guide ONLY and is notresponsible for any consequences resulting from incorrectrepairs. When in doubt, contact your parts distributor or Teleflexfor assistance.
WARNING
FAULT CAUSE SOLUTION
22 SEASTAR Hydraulics
ACCESSORIES
The P/A Mounting Bracket isdesigned to provide a flatmounting surface for the P/AUnit when mounting to the flooror when an alternate mountingsurface is required.
The Dual Ignition Control Kit is designed to connect the P/A unit'signition wire to two engines allowing one engine to be turned offand retain power assist control.
SeaStar P/A MountingBracketPart# HA1202
SeaStar P/A Dual IgnitionControl KitPart# HA1201
SeaStar®/BayStar™ Power PurgeJr. is the quickest way to bleeda SeaStar®/ BayStar™ system inthe field and assure a rock-solidsteering feel every time!
SeaStar Power Purge JR.Part# HA5445
• Steering feel is solid every time• Complete Fill & Purge in 10
minutes or less• Fast and efficient• Easy to operate• Screens contaminants from oil• Quick connect fittings
• Convenient portable size• Convenient electrical hook-up
utilizing 12 volt boat battery• Optional Dual Cylinder Purging
Kit HA5461 available• Optional 50’ Hose Extension
Kit HA5462, for longer runs
Advantages:
Power Assist for SeaStar Systems 23
Statement of Limited Warranty
Return Goods Procedure
We warrant to the original retail purchaser that Teleflex CanadaLimited Partnership products have been manufactured free fromdefects in materials and workmanship. This warranty is effectivefor two years from date of purchase, excepting that where TeleflexCanada Limited Partnership products are used commercially or inany rental or income producing activity, then this warranty islimited to one year from the date of purchase.
We will provide replacement product without charge, for any TeleflexCanada Limited Partnership product meeting this warranty, which isreturned (freight prepaid) within the warranty period to the dealerfrom whom such product were purchased, or to us at theappropriate address. In such a case Teleflex Canada LimitedPartnership products found to be defective and covered by thiswarranty, will be replaced at Teleflex’s option, and returned to thecustomer.
The above quoted statement is an extract from the completeTeleflex Canada Limited Partnership products warranty statement.A complete warranty policy is available in our Teleflex CanadaLimited Partnership products catalogue.
Prior to returning product to Teleflex Canada Limited Partnershipunder 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, andb) the return goods authorization number (claim number)
Please address the returned goods as follows:
From U.S.A.RGA # ?Teleflex Canada c/o Panalpina#8 – 14th StreetBlaine, WA 98230
From CanadaRGA # ?Teleflex Canada 3831 No.6 RoadRichmond, B.C.Canada V6V 1P6
TELEFLEX CANADA3831 NO.6 ROADRICHMOND, B.C.CANADA V6V 1P6
FAX 604-270-7172
www.seastarsteering.com
© 2004 TELEFLEX CANADA LIMITED PARTNERSHIP
PRINTED IN CANADA
FORM NO. 298303 400-04/06 Rev G
ISO 10592
HYDRAULIC