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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


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).


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.


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


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



• 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


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


H1 H2

C1 C2

SYSTEM INSTALLATION



• 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



• 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


PORT STARBOARD

P/A UNITBATTERY

+

+-

-FUSE

ACCESS

BLACK

PURPLE

RED

TO BATTERY(FUSED)

IGNITION

ON/OFF SWITCH(OPTIONAL SEE NOTICE)


SYSTEM INSTALLATION


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


SYSTEM INSTALLATION


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


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


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.


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


FILLING AND PURGING


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


•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.



CLOSE LEFT SIDEBLEEDER


Step 4


OPEN LEFTSIDE BLEEDER

OPEN RIGHT SIDE BLEEDER


• 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




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


TURN CLOCKWISE

CLOSE RIGHT SIDEBLEEDER


R

H1H2

R

H1H2

FILLING AND PURGING


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


FILLING AND PURGING


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.


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


P/A UNIT

P/A UNIT


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



FILLING AND PURGING


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°


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


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


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:


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

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