FILLING AND PURGING THE SYSTEM - Seatech Marine
FILLING AND PURGINGTHE SYSTEMRead FirstNOTICEIf system is fitted with SeaStarPower Assist, please refer toyour Power Assist InstallationManual for bleeding instructions.NOTICEThese instructions show how to fill and purge a Single Station Front MountCylinder System. For twin station and/or twin cylinder filling and purginginstructions refer to instructions on page 39 first and then proceed withinstructions on this page.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 filler tube.DO NOT allow the oil level to disappear into the helm pump, as this mayintroduce air into the system and increase your filling time.If using a Liquid Tie bar Valve, part # HA5471-2, please refer to thebleeding instructions included with the liquid tie bar valve.Hydraulic Oil Requirements2 bottles (2 quarts or liters) for single station and single cylinder systems.1 additional bottle for each additional helm, cylinder, or auto pilot.NOTICEOil can be re-used if filtered through a fine mesh screen such as usedfor gasoline. If unable to filter oil, an additional bottle of oil is required.NOTICE“Bleeder” may refer to cylinders fitted with bleed tee fittings or bleedscrews. If fitted with bleed tee fitting, open bleeder by unscrewing bleednipple nut two turns.NOTICEFilling the helm full of oil can bedone faster if oil is poured into thehelm prior to connecting filler tubeand oil bottle to the helm. Part #HA5438.PUSH PINFILLER PLUG(REMOVED)FILLER KITDO NOT LETOIL LEVELFALL BELOWTHIS POINTHELM FILLPORTFigure 36. Optional Filler Kit Part # HA5438NOTICEOutboard Powered VesselsIn the following pages you are instructed to hold cylinder body with yourhand, if the cylinder is mounted to an engine, use the engine to hold thebody in position.35
HYDRAULIC STEERINGFILLING AND PURGINGHydraulic FluidWARNINGANY NON-APPROVED FLUID MAYCAUSE SERIOUS DAMAGE TO THESTEERING SYSTEM RESULTINGIN POSSIBLE LOSS OF STEERING,CAUSING PROPERTY DAMAGE,PERSONAL INJURY AND/OR DEATH.Due to recent upgrades in our steering system components, SeaStar Solutionsrecommends use of SeaStar Steering Fluid ONLY in our hydraulic steeringsystems. SeaStar Steering Systems have been engineered and validatedusing our proprietary SeaStar Hydraulic Steering Fluid. SeaStar Steeringfluid is engineered with special additive package that contains anti-foamingand anti-rusting agents, anti-oxidants, viscosity stabilizers, corrosion inhibitors,wear additives as well as water emulsification additives. It is highly recommendthat SeaStar Steering Fluid be used to ensure optimum system performanceand safety.Use of any non-approved fluid may result in the following; higher steering effort, particularly at ambient or lower temperatures and/orover 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 orelevated wear rates seal degradation – incompatibility with various proprietary sealcompounds used in our products.In an emergency, SeaStar EPS Fluid, any MD-3/4 rated ATF or MIL-PRF-5606Hequivalent fluid that is filtered through a fine mesh screen can be used.The system MUST be thoroughly flushed as soon as possible with genuineSeaStar Steering Fluid after using an emergency fluid.In an EXTREME emergency, any non-toxic, non-flammable fluid that is filteredthrough a fine mesh screen may provide temporary steering.Use of non-standard fluids will require an immediate and complete systemflush using approved fluids, by an approved steering technician.WARNINGNEVER FILL OR MIX BRAKE FLUIDS, TRIGYCERIDES OR POLYALKYLENEGLYCOLS WITHIN A HYDRAUILIC STEERING SYSTEM.NOTICESeaStar Hydraulic Steering Fluid can be used in Hynautic, BayStar andBayStar Plus steering systems.NOTICEHelp protect your boating environment by ensuring that all used oil isdisposed of properly.Fill Plugs for SeaStarHelmsVENT PLUG - Part No. HP6126NON-VENT PLUG - Part No. HP6000SUPPLIED WITH SEASTAR HELM PUMP MUST BE USED ON ALL HELM PUMPS OTHER THANUPPER MOST HELM PUMP ON MULTI STEERINGSTATION SYSTEMS. THIS NON-VENT PLUG IS SUPPLIED WITH ADDITIONALSTATION FITTING KIT NO. HF5501 AND HF5502. MUST BE USED WITH HELM PUMP ON ALL SINGLESTEERING STATION SYSTEMS. MUST BE USED ON UPPERMOST HELM PUMP ONMULTI STEERING STATION SYSTEMS.Figure 37.36SEASTAR Hydraulics
Single Station One CylinderStep 1FRONT MOUNTCYLINDERHELMOIL BOTTLEFILLER TUBESTEERINGWHEELFRONT MOUNTCYLINDERStep 2 Screw the threaded end of thefiller tube into the helm filler port. Remove the cap from the oil bottleand holding upright screw into thefiller tube bottle cap. Poke holein the bottom of the bottle. Fill the helm pump full of hydraulicoil so that it is visible in the fillertube. Oil should always be visiblein the filler tube. Use the nextbottle of fluid at any time duringthe procedure in order to maintainthe oil level. DO NOT proceedwith step two until helm is full. Turn the steering wheel clockwiseuntil the cylinder rod is fullyextended on the right side of thecylinder.FRONT MOUNTCYLINDERTURN CLOCKWISE Open right side bleeder.OPEN RIGHT SIDEBLEEDERStep 3 Holding the cylinder body (FrontMount cylinder) or rod (Side Mountcylinder) to prevent the body/rodfrom moving, turn the steeringwheel counter-clockwise until asteady stream of air free oil comesout of the bleeder. (Drain approx.1/2 bottle of oil or as required).FRONT MOUNTCYLINDERTURN COUNTERCLOCKWISECLOSE RIGHTSIDE BLEEDEROutboard Powered VesselsDO NOT use anything other thanyour hands to restrain the cylinderbody/rod. While continuing to turn the wheelclose the right side bleeder and letgo of the cylinder body/rod.37
HYDRAULIC STEERINGFILLING AND PURGINGStep 4 Continue turning the steeringwheel counter-clockwise untilthe cylinder rod is fully extendedto the left. (Steering wheel willcome to a stop).FRONT MOUNTCYLINDERTURN COUNTER-CLOCKWISE Open the left bleeder.OPEN LEFTSIDE BLEEDERStep 5FRONT MOUNTCYLINDERTURN CLOCKWISE Holding the cylinder body (FrontMount cylinder) or rod (Side Mountcylinder) to prevent the body/rodfrom moving, turn the steeringwheel clockwise until a steadystream of air free oil comes out ofthe bleeder. While continuing to turn the wheelclose the left side bleeder and letgo of the cylinder body/rod.CLOSE LEFT SIDEBLEEDERCAUTIONPrior to operating system, performOil Level System Check, refer topage 40.Number of SteeringWheel TurnsWhen steering system has been properly bled, steering wheel turns fromhard over to hard over will be as shown in the chart.HelmDisplacement38SingleCylinderTwin Cylinder withMechanical TiebarTwin Cylinder withLiquid 52.43.456.903.453.02.765.502.76SEASTAR Hydraulics
Twin Station Single CylinderPerform steps 1 through 5 atstation no. 1. Then repeat steps1-5 at station no. 2.STATION NO.2Oil requirements 4-5 bottles.Note: Refer to Oil Level andSystem Check page 40.STATION NO.1When properly bled, steering wheelturns will be as shown in the chart.Single Station Twin CylinderWhen performing steps 1 through 5,perform instructions in each stepfirst on cylinder no. 1 and then oncylinder no. 2, before proceedingto the next step. ie: Performinstructions referring to right side ofcylinder first on cylinder no. 1 andthen on cylinder no. 2.Oil requirements 4-5 bottles.Note: Refer to Oil Level and SystemCheck on page 40. Steeringwheel turns will be as shown in thechart.CYLINDER NO.2CYLINDER NO.1Twin Station Twin CylinderFollow same procedure asinstructed for single station-twincylinders, beginning at station no.1, and repeat entireprocedure at station no. 2.STATION NO.2STATION NO.1Note: When properly bled, steeringwheel turns will be as shown in thechart.CYLINDER NO.2Outboard Powered VesselsCYLINDER NO.139
HYDRAULIC STEERINGFILLING AND PURGINGStep 1 – Oil level SettingOil Level and System CheckWARNING The oil level MUST be checked and maintained BEFOREEACH use to ensure safe steering operation. Failure to adhere to thiswarning may lead to loss of steering control resulting in persons beingejected from vessel or collision with an obstacle, leading to propertydamage, personal injury and/or death. For helms mounted with the wheel shaft completely horizontal MUST befilled to the bottom of filler hole AT ALL TIMES. DO NOT allow oil levelto drop more than 1/4” below filler threads. For helms mounted on a 20 degree angle, or, with wheel shaft in thevertical position, oil level should be within 1/2” from the bottom of thefiller hole.NOTICEStep 2 – System CheckIf the helm is overfilled fluid WILL leak out of the vent cap.WARNING The system check MUST be completed after installation.Doing so will ensure the safe operation of your steering system and willany fault/leak will show at this time. Failure to adhere to this warning/check may result in the loss of steering control leading to ejection fromthe vessel, or, collision with an obstacle resulting in property damage,personal injury and/or death. Turn steering wheel hard over to hard over to confirm unrestrictedmovement of the steering system and hoses. Repeat this procedure inALL trim/tilt positions of the engine(s). If interference occurs, or, hosesare being stretched this MUST be removed prior to operating your boat. Confirm that engine(s) are deflecting to the proper direction whensteering wheel is turned. If no interference is noticed, or, any interference is corrected, go tonext step. Take steering wheel hard over to starboard (any helm can be used ona multi-station boat). Once the wheel reaches its stop point (cylinder isfully stroked out), continue to force the wheel one (1) full turn past stop.Leave wheel in this position while you check all PORT side connections,fittings, seals and hoses for leaks.NOTICEThis step will NOT harm the system and any noise madeduring this step should not be considered a fault in the steering system. If leaks are noticed they MUST be repaired prior to operating boat.After repair repeat bleeding procedures as outlined in this manual Repeat to the Port direction and inspect ALL starboard sideconnections, fittings, seals and hoses for leaks.NOTICEThis step will NOT harm the system and any noise madeduring this step should not be considered a fault in the steering system. If leaks are noticed they MUST be repaired prior to operating boat.After repair repeat bleeding procedures as outlined in this manual.WARNING40Failure to complete the above noted step or, failure to correct a problemmay result in loss of steering control leading to ejection from the vesselor collision with an obstacle resulting in property damage, personalinjury and/or death.SEASTAR Hydraulics
MANUAL FILLING ANDPURGINGNOTICEPower Purge Users. Please refer to the instructions included withyour power purge unit.Power Assist Users. You MUST refer to the bleeding instructionsincluded with your SeaStar Power Assist Unit.Liquid Tiebar Users (Catamarans). You MUST refer to the bleedinginstructions included with your Liquid Alignment/Tiebar Valve.Read FirstSteps 1 – 5 noted on page 25 refer to a single station, single cylinderinstallation. For twin station and/or twin cylinder installations youMUST perform steps 1 – 5 first, then, see page 26 and page 27 tocomplete the removal of air from the system.This procedure requires two people. One person may not be able toremove 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 the oil level to disappear into the helm pump, as thismay introduce air into the system and increase your filling time.NOTICEHydraulic FluidWARNINGEmergency Use FluidsWARNINGSeaStar Solutions recommends the use of SeaStar Steering Fluid ONLY.SeaStar Steering Systems have been engineered and validatedusing our proprietary SeaStar Hydraulic Fluid.Any non-approved fluid may cause serious damage to the steeringsystem resulting in possible loss of steering, causing propertydamage, personal injury and/or death.In an emergency, SeaStar EPS Fluid, any MD-3/4 rated ATF or MIL-PRF5606H equivalent fluid that is filtered through a fine mesh screen canbe used. The system MUST be thoroughly flushed as soon as possiblewith genuine SeaStar Steering Fluid after using an emergency fluid. Inan EXTREME emergency, any non-toxic, non-flammable fluid that isfiltered through a fine mesh screen may provide temporary steering.Never fill or mix brake fluids, trigycerides or polyalkylene glycolswithin a hydraulic steering system.Vent Plug Must be used with helm pump on allsingle steering station systems.Part # HP6126 (5 per kit) Must be used on upper-most helm pumponly on multi-steering station systems. Vent hole: actual size as shown. Colour: threads, silver – cap, black.Figure 26.Inboard & Sterndrive Powered Vessels23
HYDRAULIC STEERINGFILLING AND PURGINGNon-Vent Plug Must be used on all helm pumps otherthan upper-most helm pump on multisteering station systems. This non-vent plug is supplied withadditional station fitting kit no. HF6007and HF6010. Actual size shown. Colour: black.Part # HP6000 (5 per kit)CAUTIONFailure to install a non-vent plugin ALL lower helms of multi-helmsystems will result in fluidleaking out of the vent cap.Hydraulic Oil RequirementsFigure 27.2 bottles (2 quarts or litres) for single station and single cylindersystems.1 additional bottle for each additional helm, cylinder, or auto pilot.NOTICEThese instructions will result in hydraulic oil flushed in and out of thesystem. Oil can be re-used if filtered through a fine mesh screen suchas used for gasoline. If unable to filter oil, an additional bottle of oilis required.NOTICE“Bleeder” refers to cylinders fitted with bleed tee fittings. If fitted withbleed tee fitting, open bleeder by unscrewing bleed nipple nut two turns.CAUTIONUnbalanced Cylinders.The oil level in the helm must be set with the cylinder rod fullyretracted. Failing to observe this caution will result in an oil spillat the helm.NOTICEPUSH PINFilling the helm full of oil can bedone faster if oil is poured intothe helm prior to connecting fillertube and oil bottle to the helm.FILLER PLUG(REMOVED)FILLER KITDO NOT LETOIL LEVELFALL BELOWTHIS POINTHELM FILLPORTFigure 28.24SEASTAR Hydraulics
HYDRAULIC STEERINGSingle Station One CylinderFigure 29.Step 1 Screw the threaded end of thefiller tube into the helm filler hole. Remove the cap from the oilbottle and holding upright,screw into the filler tube bottlecap. Poke hole in the bottomof the bottle. Fill the helm pump full of oil (Oilshould always be visible in thefiller tube). Use the next bottle atany time throughout the procedurewhen the oil level drops in thefiller tube. Do not proceed withstep two until helm is full of oil.Figure 30.Step 2TURNCLOCKWISE Turn the steering wheel clockwise until the cylinder rod isfully extended on the Port sideof the cylinder. Open Port side bleeder.OPEN PORT SIDEBLEEDERFigure 31.Step 3 Holding the cylinder rod (toprevent it from moving back intothe cylinder) turn the steeringwheel counter-clockwise until asteady stream of air free oilcomes out of the bleeder.(Drain out approx. 1/2 bottleof oil or as required.) While continuing to turn thewheel, close the Port sidebleeder and let go of thecylinder rod.CLOSE PORT SIDEBLEEDERTURN COUNTERCLOCKWISE Continue turning the steeringwheel counter-clockwise untilthe cylinder rod is fully extendedto Starboard. (Steering wheelwill come to a stop.) Open the Starboard bleeder.OPENSTARBOARDSIDEBLEEDERFigure 33.Step 5Inboard & Sterndrive Powered VesselsTURN COUNTERCLOCKWISEFigure 32.Step 4 Holding the cylinder rod (toprevent it from moving backinto the cylinder) turn thesteering wheel clockwise untila steady stream of air free oilcomes out of bleeder.FILLING AND PURGING While continuing to turn thewheel, close the Starboardside bleeder and let go of thecylinder rod.TURNCLOCKWISECLOSESTARBOARDSIDE BLEEDERFill and purge is now complete.25
HYDRAULIC STEERINGFILLING AND PURGINGOil Level Set Proper oil level set can beobtained by opening Starboardbleeder and turning steeringwheel to Starboard until fluidlevel reaches top of plasticfiller fitting and then turningwheel one more full turn.CAUTIONFor unbalanced cylinders theoil level in the helm must beset with the cylinder rod fullyretracted. Failing to observethis caution will result in anoil spill at the helm.FILLERASSEMBLYOIL INTUBEPLASTICFITTINGONE WHEEL ROTATIONON HELM WILL DROPFLUID THIS MUCH TOSET FLUID LEVELTOP OFHELM PUMPFigure 34.Twin StationSingle CylinderRefer to OilLevel and System ProofCheck on page 28.NOTICE Perform steps 1 through 5 atstation no.1. Then repeatsteps 1 – 5 at station no.2.STATION NO.2STATION NO.1 Oil requirements 4 – 5 bottles.Figure 35.Single StationTwin CylinderNOTICERefer to OilLevel and System ProofCheck on page 28. When performing steps 1through 5, perform instructionsin each step first on cylinderno.1 and then on cylinder no.2,before proceeding to the nextstep. ie: Perform instructionsreferring to Starboard side ofcylinder first on cylinder no.1and then on cylinder no.2. Oil requirements 4 – 5 bottles.CYLINDER NO.2CYLINDER NO.1Figure 36 .26SEASTAR Hydraulics
HYDRAULIC STEERINGFILLING AND PURGINGTwin StationTwin CylinderSTATION NO.2 Follow same procedure asinstructed for single-station/twin-cylinders, beginning atstation no.1, and repeat entireprocedure at station no.2.STATION NO.1CYLINDER NO.2CYLINDER NO.1Figure 37.Inboard & Sterndrive Powered Vessels27
OIL LEVEL AND SYSTEMPROOF CHECKSTEP 1WARNINGCAUTIONWhen setting fluid level in asystem fitted with an unbalancedcylinder, the cylinder shaft MUSTbe fully retracted (IN). Failure tohave cylinder shaft retracted (IN)will lead to very stiff steering and/or oil spillage at the helm pump.STEP 2WARNINGOil Level SettingThe oil level MUST be checked and maintained BEFORE each useto ensure the safe operation of your steering system. Failure toadhere to this warning may lead to loss of steering control. Lossof steering control may result in unpredictable boat behavior,collision with an obstacle and/or ejection from vessel, leading toproperty damage personal injury and/or death. Helms mounted with the wheel shaft completely horizontal MUSTbe filled to the bottom of the filler hole AT ALL TIMES.DO NOT allow oil level to drop more than 1/4" below the fillerport threads. For helms mounted on a 20 angle, or, with wheel shaft in thevertical position the oil level must be no lower than 1/2" below fillerport threads and no higher than 1/8" below filler port threads.System Proof CheckThe System Proof Check MUST be completed after installation.Doing so will ensure the safe operation of your steering system.Any fault (leaks or malfunction) will present itself during this check.Failure to adhere to this check may result in loss of steering control.Loss of steering control may lead to unpredictable boat behavior,leading to a collision with an obstacle and/or ejection from theboat, resulting in property damage personal injury and/or death. Turn steering wheel hard over to hard over to confirm unrestrictedmovement of steering components.NOTICEWARNING28If equipped with a tilting helm, repeat this step in "EVERY" tilt position. Confirm that rudder(s) and outdrive(s) are turning to the properdirection. If no interference is noticed and rudder(s) and/or outdrive(s) areturning to the proper direction, go to next point Take steering wheel hard over to starboard. Once the wheelreaches its stop point, force the wheel another 1/4 – 1/2 turnpast stop. Leave wheel in this position while you inspect ALLfittings, helms and hose/tubes for any signs of a leak. Repeat above step to the starboard side of each steering station Repeat above steps to the port side of each steering station. If ANY leaks are noticed they MUST be repaired BEFORE operatingyour boat.Failure to correct ANY problem that becomes present during the'System Proof Check' may lead to loss of steering control. Loss ofsteering control can lead to unpredictable boat behavior and/orcollision with obstacle and/or ejection from vessel resulting inproperty and/or personal injury or death.SEASTAR Hydraulics
CYLINDER Number of Steering Wheel Turns Step 5 TURN CLOCKWISE CLOSE LEFT SIDE BLEEDER FRONT MOUNT CYLINDER Helm Single Twin Cylinder with Twin Cylinder with Displacement Cylinder Mechanical Tiebar Liquid Tiebar 1.4 5.90 11.8 5.90 1.7 4.90 9.76 4.90
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