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Teleflex Marine BayStar Installation Manual

Steering cylinder for hydraulic inboard and sterndrive powered vessels
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INSTALLATION INSTRUCTIONS
2
AND OWNER'S MANUAL
w w w . s e a s t a r s t e e r i n g . c o m
. 1
I S O
9 0 0 1
Steering Cylinder Installation Manual
for Hydraulic Inboard and Sterndrive
Powered Vessels
ManufaCtured by
teleflex Canada lIMIted
PartnerSHIP

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  • Page 1 INSTALLATION INSTRUCTIONS AND OWNER’S MANUAL w w w . s e a s t a r s t e e r i n g . c o m I S O 9 0 0 1 Steering Cylinder Installation Manual for Hydraulic Inboard and Sterndrive Powered Vessels ManufaCtured by teleflex Canada lIMIted...
  • Page 2 Notice to Boat Manufacturer or Installer Throughout this publication, Warnings and Cautions (accompanied by the International Hazard Symbol ) are used to alert the 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. DANGER WARNING CAUTION NOTICE Immediate hazards Hazards or unsafe Hazards or unsafe Information which which WILL result in practices which practices which is important to severe personal injury...

  • Page 3: Table Of Contents

    INTRODUCTION Before proceeding with the installation, read THESE instructions and ALL other instructions included with the rest of your system (helm pumps, Power Assist etc). Teleflex Marine cannot accept responsibility for installations where instructions have not been followed, where substitute parts have been used, or modifications have been made to our products. Warranty may be void if products other than Teleflex products are used within the system. NOTICE Due to a small amount of internal slip, a “Master Spoke” or “centered” steering wheel cannot be maintained with a hydraulic steering system. For best results, us an equal distance spoke steering wheel.
  • Page 4 Typical Inboard Steering System FILL AND VENT SYSTEM HERE COMPENSATING LINE SEASTAR HOSE/TUBE ADDITIONAL STEERING AND/OR STATION 3/8" COPPER TUBING CAUTION THIS HELM MUST BE FITTED WITH A NON-VENT PLUG. FAILING TO DO SO WILL RESULT IN AN OIL LEAK. ROD END BALL JOINT IF COPPER TUBE IS USED FOR GENERAL INSTALLATION, USE...

  • Page 5: Tools

    TOOLS Standard Helm Mounts You will need the following tools to complete your installation. • 3" (77mm) diameter Hole Saw or Key Hole Saw. • 5⁄16" (8mm) dia. Drill. • 7⁄16", 9⁄16", 5⁄8" and 3⁄4" Open End type Wrench/Spanner. • 15⁄16" Socket. Optional Helm Mounts • Square Bezel Backmount, HA5418, 4-1 ⁄2" (115 mm) Hole Saw • Round Bezel Backmount, HA5478, 4-3⁄8" (112mm) Hole Saw • Rear mount Helm, HH5261, 1-1/6" (27mm) drill • Tilt Helms 4-1 ⁄2" (115mm) Hole Saw • 20° Wedge Kit HA5419 and HA5408 Additional Tools Needed 20° Mount Wedge • Key Hole or Sabre Saw • 5⁄16" (8mm) dia. Drill • 1 ⁄2" Wrench/Spanner, Box or Open End type • 7⁄16" Socket and Drive Cylinder, ATM and TM Models • 3⁄4" Wrench/Spanner, Box or Open End type, 2 required. Cylinder, Model HC5328-3 (125-8EM) • 1-5⁄16" Wrench/Spanner, Open or Adjustable type.

  • Page 6: Things You Need To Know

    THINGS YOU NEED TO KNOW WARNING DO NOT use SeaStar PRO helms with ANY unbalanced steering cylinder. Use of a PRO helm with an unbalanced cylinder will lead to a lock up of the steering wheel preventing further steering control, resulting in collision with an obstacle causing property damage, personal injury and/or death.

  • Page 7: System Installation Overview

    SYSTEM INSTALLATION OVERVIEW STEP 1 System Installation • Install your SeaStar helm pump(s) onto the dash using the installation instructions provided with your helm pump(s). HELM HOSE DO NOT use a SeaStar PRO helm with an WARNING unbalanced cylinder. • Install steering cylinder as per the instructions on the following pages. Ensure that you follow the installation instructions NOTICE for YOUR Steering Cylinder. CYLINDER • Install hose/tube as per the plumbing diagrams shown on page 15.

  • Page 8: Cylinder Mounting All Inboard Atm & Tm/Tmc Models

    CYLINDER MOUNTING All Inboard ATM & TM/TMC Models Proper cylinder mounting is CRITICAL to the successful operation of General your hydraulic steering system. An incorrectly installed cylinder WILL lead to rapid seal and bearing wear as well as non-repairable damage. Select the diagram and dimensional data that corresponds with your cylinder model. Note, not all possible cylinder mounting configurations are shown, however, all necessary dimensions are shown regardless of mounting configurations. CAUTION If installing rudder stops, ensure that the cylinder(s) reach hard- over BEFORE rudder stops are engaged. WARNING Where applicable, cylinders should be secured with thru bolts, NOT with lag screws.
  • Page 9 HYDRAULIC STEERING INBOARD (ATM) Inboard ATM Cylinder 1 Minimum side loading of cylinder rod and maximum cylinder Models: performance of ATM and TM Models can be achieved as illustrated below. HC5312-3 (BA125-7ATM) An imaginary line drawn through the tiller arm hole at both hard HC5313-3 (BA135-7ATM) over positions will create the cylinder centre line. With tiller arm HC5314-3 (BA150-7ATM) at hard over positions, angle X and Y should be the same. NOTICE To achieve MAXIMUM cylinder performance it is suggested that an imaginary line is drawn though the tiller arm hole at both hard over positions (see figure 2), this will create the “cylinder center line”.
  • Page 10 HYDRAULIC STEERING INBOARD (ATM) CAUTION There is NO adjustment for centering cylinder after installation. Correct mounting is critical at this time. Total cylinder travel is 7" (178mm). NOTICE For twin rudders, the cylinder may be mounted directly to the tiebar or to one of the tiller arms.
  • Page 11 HYDRAULIC STEERING INBOARD (TM & TMC) 2-1/4" HC6324-3 (BA150-3.5ATM) (57mm) 1/2" (13mm) HOLE 2-1/4" (57mm) RETRACTED = 12.485" (317mm) EXTENDED = 15.978" (406mm) MID-STROKE = 14.235" (362mm) Figure 5. Inboard, TM & TMC 1 To achieve MAXIMUM cylinder performance it is suggested that Cylinder Models: an imaginary line is drawn though the tiller arm hole at both hard over positions (see figure 6), this will create the “cylinder center HC5318 (BA150-7TM) line”. With the tiller arm at hard over positions, angle X and Y HC5319 (BA175-7TM) should be the same.
  • Page 12 HYDRAULIC STEERING INBOARD (TM & TMC) HC5318 (BA150-7TM) 3-1⁄2" (89mm) 1-9⁄16" (40mm) 4" (102mm) 6" 4-3⁄4" (152mm) 21" (533mm) (121mm) 8" (203mm) HC5319 (BA175-7TM) 3" (76mm) 4-1⁄4" 6" (108mm) (152mm) 21" (533mm) 29" (736mm) HC5369 (BA150-9TM) HC5373 (BA175-9TM) 9" (228mm) 7-3⁄4"...

  • Page 13: Cylinder Mounting: Sterndrive Engine Mount Cylinders

    HYDRAULIC STEERING STERNDRIVE Sterndrive Engine Mount Cylinders WARNING DO NOT use SeaStar PRO helm(s) with an unbalanced cylinder. Using a PRO helm with an unbalanced cylinder WILL lead to steering wheel “lock-up”. Lock-up may lead to collision with an obstacle resulting in property damage, personal injury and/or death.
  • Page 14 HYDRAULIC STEERING STERNDRIVE HC5331-3 (92VPS) Referring to Figure 9 please observe the following: • Rotate Cable Tube item 1 into threads of Item 2 until tight. • Torque setscrew (item 7) to 90 in-lbs and tube insert (item 8) until tight. • Item 3 must pass through items 4 and 5 before being secured by Item 6. • Always mount cylinder in lower mount position of item 2 and without spacer item 9, unless mechanical interference prevents you from doing so. CAUTION Cut Clevis Pin, (item 3 Figure 9) to a length of 2" when mounting cylinder in lower position. Figure 9. HC5331-3 (92-VPS), NOT for use with SeaStar PRO helm(s). NOTICE The Teleflex HC5331-3 steering cylinder is NOT compatible with some early model power steering rams.
  • Page 15 HYDRAULIC STEERING STERNDRIVE ALWAYS INSTALL CYLINDER NOTICE HC5331 IN THE OUTER HOLE HOERBIGER SHOWA (LATE MODEL) COMPATIBLE COMPATIBLE Figure 10. Figure 11. SHOWA TELEFLEX (EARLY MODEL PRE 1992) COMPATIBLE COMPATIBLE Figure 12. Figure 13. 1 Move the main steering ram to the fully retracted position. HC5339-3 (125-6.5EM) 2 Insert the long rod of the HC5339-3 cylinder into the clevis Installation Instructions bracket until the through hole in the rod is aligned with the hole Mercury Bravo I and II ONLY...
  • Page 16 HYDRAULIC STEERING STERNDRIVE WARNING If Mercruiser power steering fails, service unit immediately or complete loss of steering may result. HC5339-3 (125-6.5EM) CAP SCREW Figure 14. HC5339-3 (125-6.5EM) MOUNTING NUT WRENCH FLATS Figure 15. Sterndrive Engine mounted, A Support Tube Mount – Requires support/cable tube from engine manufacturer for installations.
  • Page 17 HYDRAULIC STEERING STERNDRIVE A Transom Bracket Mount – Mounts directly to the transom bracket HC5326-3 (BA150-7EM) and tiller arm. Transom Bracket Mount This cylinder is designed for use with 1984 to date Mercruiser, and OMC Cobra non power assisted steering sterndrives (OMC Cobra requires Teleflex part HA5424). Sterndrives equipped with optional power assist steering require Cylinder Model 125-8EM. NOTICE Quicksilver Clevis Adapter Kit, part No. B98735A1 is required to complete cylinder connection to Mercruiser sterndrives. This part is supplied with the Quicksilver Tie Bar Kit for twin sterndrives. CAUTION When connecting the cylinder to a Mercruiser the two washer spacers must be installed between the cylinder and mounting bracket.

  • Page 18: Hose And Tubing Installations

    HOSE AND TUBING INSTALLATIONS Proper steering hose/tube is required for the best performance and General safe operation of your steering system. Use of a hose/tube other than that recommended by Teleflex may drastically effect performance and the safe operation of your system. Teleflex Marine cannot be responsible for ANY consequences resulting from the use of a substitute tube or hose. WARNING Use of a substitute hose and/or tube may lead to hose breakage or rupture resulting in loss of steering control. Loss of steering control may lead to unpredictable boat behavior and/or a collision with an obstacle and/or ejection from boat, resulting in property damage, personal injury and/or death.
  • Page 19 HYDRAULIC STEERING HOSE & TUBE INSTALLATION WARNING Failure to properly tighten the locknut (item 1, figure 19) may lead to loss of steering control. Loss of steering control may result in unpredictable boat behavior, collision with an obstacle and/or ejection from vessel, leading to property damage, personal injury and/or death.
  • Page 20 HYDRAULIC STEERING HOSE & TUBE INSTALLATION VENTED PLUG COMPENSATING LINE NON-VENTED PLUG TILLER ARM CYLINDER Figure 21. Dual Station. TO PORT SIDE OF TO STARBOARD SIDE HELM PUMP OF HELM PUMP Figure 22. HC5332-3 Cylinders ONLY. Hoses are crossed when plumbing. 3 The following considerations MUST be taken into account when planning and routing steering hose/tubes.
  • Page 21 HYDRAULIC STEERING HOSE & TUBE INSTALLATION c) Hose/Tube must be routed so that it will not interfere with any other functional equipment; (such as, hatches, doorways or in a walking path where it may become a tripping hazard). d) Hose/Tube MUST be installed with a gradual rise from the steering cylinder to the helm pump(s). If hose/tube is not installed with a gradual rise, air removal from system will be difficult. e) Hose/tube should be secured at regular intervals using non- metallic type ties. f) Do not allow tubing to rest or chafe against any abrasive material. NOTICE Fiberglass although soft to the touch can be extremely abrasive. Care MUST be taken when securing hose/tubing. g) Ensure that hose/tube ends are covered prior to passing through bulkheads, cable tubes and any other blind area. Failure to do so may allow contamination to enter the steering system. WARNING If hose/tubing is kinked during and/or after installation it MUST be replaced prior to operation.

  • Page 22: Additional Stations, Autopilots & Seastar Power Assist Units

    ADDITIONAL STATIONS, AUTOPILOTS AND SEASTAR POWER ASSIST UNITS General ALL SeaStar helm pumps are fitted with internal check valves. These valves allow the installation of multiple steering stations and autopilots. ALWAYS check with autopilot manufacturers to confirm use with a SeaStar Steering System. Teleflex offers the following “add a station fitting kits” for easy installation. • HF5501 For use with SeaStar Outboard, flexible, hoses ONLY. NOTE: this kit comes with a 25’ cut to fit nylon tubing that is to be used for the return line ONLY. Another set of SeaStar Steering hoses, part # HO51xx will be required to complete this installation. • HF5502 For use with SeaStar Extruded Nylon tubing and/or copper tubing. Designed to splice into existing tubing. NOTICE The following points should be taken into consideration when installing additional steering stations and/or autopilots. Following these simple points before installation will allow for easier trouble shooting in the future if required • Shut-Off valves should be installed into each additional station.

  • Page 23: Manual Filling And Purging

    MANUAL FILLING AND PURGING NOTICE Power Purge Users. Please refer to the instructions included with your power purge unit. NOTICE Power Assist Users. You MUST refer to the bleeding instructions included with your SeaStar Power Assist Unit. Read First Steps 1 – 5 noted on page 21 refer to a single station, single cylinder installation. For twin station and/or twin cylinder installations you MUST perform steps 1 – 5 first, then, see page 22 and page 23 to complete the removal of air from the system.
  • Page 24 HYDRAULIC STEERING FILLING AND PURGING Hydraulic Oil Requirements 2 bottles (2 quarts or litres) for single station and single cylinder systems. 1 additional bottle for each additional helm, cylinder, or auto pilot. NOTICE These instructions will result in hydraulic oil flushed in and out of the system. Oil can be re-used if filtered through a fine mesh screen such as used for gasoline. If unable to filter oil, an additional bottle of oil is required.
  • Page 25 HYDRAULIC STEERING Single Station One Cylinder FILLING AND PURGING Figure 27. Step 1 • Screw the threaded end of the • Fill the helm pump full of oil (Oil filler tube into the helm filler hole. should always be visible in the filler tube). Use the next bottle at • Remove the cap from the oil any time throughout the procedure bottle and holding upright, when the oil level drops in the screw into the filler tube bottle filler tube. Do not proceed with cap. Poke hole in the bottom step two until helm is full of oil. of the bottle. Figure 28. Step 2 TURN CLOCKWISE • Turn the steering wheel clock- wise until the cylinder rod is fully extended on the left side of the cylinder. OPEN LEFT SIDE BLEEDER • Open left side bleeder.
  • Page 26 HYDRAULIC STEERING FILLING AND PURGING CAUTION FILLER Oil Level Set ASSEMBLY OIL IN For unbalanced cylinders the TUBE • Proper oil level set can be oil level in the helm must be obtained by opening right set with the cylinder rod fully bleeder and turning steering retracted. Failing to observe PLASTIC wheel to the right until fluid this caution will result in an FITTING...
  • Page 27 HYDRAULIC STEERING FILLING AND PURGING Twin Station STATION NO.2 Twin Cylinder • Follow same procedure as STATION NO.1 instructed for single-station/ twin-cylinders, beginning at station no.1, and repeat entire procedure at station no.2. CYLINDER NO.2 CYLINDER NO.1 Figure 35. Inboard & Sterndrive Powered Vessels...

  • Page 28: Oil Level & System Check

    OIL LEVEL & SYSTEM CHECK STEP 1 Oil Level Setting The oil level MUST be checked and maintained BEFORE each use WARNING to ensure the safe operation of your steering system. Failure to adhere to this warning may lead to loss of steering control. Loss of steering control may result in unpredictable boat behavior, collision with an obstacle and/or ejection from vessel, leading to property damage personal injury and/or death.

  • Page 29: Routine Maintenance

    ROUTINE MAINTENANCE Following the routine maintenance schedules below, in the time frame noted, will ensure years of great service from your SeaStar Steering System, as well as keep you and your passengers safe from the dangers that are present on the water. NOTICE Maintenance requirements will vary depending on usage and climate. Bi-Annual inspection by a qualified marine mechanic is required. 1 Every Trip, prior to engine start up or launch • Check Fluid level in uppermost helm pump . • Hose/Tube. Ensure hose/tubing are in good condition and free of wear, kinks or any other signs of fatigue or damage. *REPLACE IF DEEMED FAULTY.

  • Page 30: Troubleshooting Guide

    TROUBLESHOOTING GUIDE SeaStar hydraulic steering will provide years of safe reliable performance with a minimum of service if properly installed with correct cylinder. SeaStar steering systems have been designed with protection against over-pressure situations, by a pressure relief valve, to minimize the possibility of total loss of steering. Most faults occur when the installation instructions are not followed and usually show up immediately upon filling the system. Provided below, are the most common faults encountered and their likely cause and solution. The term “Rudder” also applies to stern drives, when applicable. Sometimes when returning the wheel from a hardover position, a slight resistance may be felt and a clicking noise may be heard. This should not be mistaken as a fault, as it is a completely normal situation caused by the releasing of the lockspool in the system. WARNING Whenever in the following text, a solution calls for removal from vessel and/or dismantling of steering system components, such work must only be carried out by a qualified marine hydraulic mechanic.
  • Page 31 HYDRAULIC STEERING TROUBLESHOOTING FAULT CAUSE SOLUTION 3 Steering is stiff and hard to • Rudder post glands are too • To test, disconnect cylinder(s) turn, even when the vessel is tight or rudder post is bent, from the tiller arm and turn not moving. causing mechanical binding. the steering wheel. If it turns The same applies to tiller easily, correct above mentioned arm and linkage on outdrives. problems. Please note that excessively loose connections to tiller arm or tie-bar can also cause mechanical binding. • Restrictions in hose, copper • Find restriction and correct. Note: Collapsing of copper tubing, piping or fittings.
  • Page 32 • Consult with boat builder ball and or mounting foot. and/or Naval architect for vibration cure. 9 Sterndrive system is hard to • Engine driven power steering • This is normal in a power turn with engine off. pump not operating. steering application. Teleflex Marine Technical Phone: 604-248-3858 Support Contacts: Web: www.teleflexmarine.com e-mail: info@teleflex.bc.ca Hours: 8am - 7pm EST SeaStar Hydraulics...

  • Page 33: Technical Information

    TECHNICAL INFORMATION Bolt Torque Specifications These are the recommended maximum torque values for reusable dry bolts. Bolts should be torqued to this value +0% -20%. For lubricated bolts, multiply the dry bolt torque values by .75. Values are stated in: in/lbs (N.m) Bolt Size 18-8SS Brass Bolt Size 18-8SS Brass Bolt Size 18-8SS Brass 2-56 2.5 (.282) 2.0 (.226) 6-32 9.6 (1.08) 4.9 (.554) 5/16”-18 132.0 (14.91) 107.0 (12.10) 2-64 3.0 (.338) 2.5 (.282)

  • Page 34: Parts List

    PARTS LIST HC5318 and HC5318CAT (BA150-7TM) NOTICE Teleflex does not sell internal parts. Contact Authorized repair center for repair and/or replace cylinder. WARNING When replacing any seals, make sure shaft is clear of any abrasions. Figure 36. ITEM PART # DESCRIPTION ITEM PART #...
  • Page 35 HYDRAULIC STEERING PARTS LIST HC5369 (BA150-9TM) NOTICE Teleflex does not sell internal parts. Contact Authorized repair center for repair and/or replace cylinder. WARNING When replacing any seals, make sure shaft is clear of any abrasions. Figure 37. ITEM PART # DESCRIPTION ITEM PART #...
  • Page 36 HYDRAULIC STEERING PARTS LIST HC5319 and HC5319CAT (BA175-7TM) NOTICE Teleflex does not sell internal parts. Contact Authorized repair center for repair and/or replace cylinder. WARNING When replacing any seals, make sure shaft is clear of any abrasions. Figure 38. ITEM PART # DESCRIPTION ITEM...
  • Page 37 HYDRAULIC STEERING PARTS LIST HC5373 (BA175-9TM) NOTICE Teleflex does not sell internal parts. Contact Authorized repair center for repair and/or replace cylinder. WARNING When replacing any seals, make sure shaft is clear of any abrasions. Figure 39. ITEM PART # DESCRIPTION ITEM PART #...
  • Page 38 HYDRAULIC STEERING PARTS LIST HC5303-3 and HC5312-3 NOTICE Teleflex does not sell internal parts. Contact Authorized repair center for repair and/or replace cylinder. WARNING When replacing any seals, make sure shaft is clear of any abrasions. Figure 40. ITEM PART # DESCRIPTION ITEM PART #...
  • Page 39 HYDRAULIC STEERING PARTS LIST HC5328-3, HC5329-3 and HC5330-3 NOTICE Teleflex does not sell internal parts. Contact Authorized repair center for repair and/or replace cylinder. WARNING When replacing any seals, make sure shaft is clear of any abrasions. Figure 41. ITEM PART # DESCRIPTION ITEM...
  • Page 40 HYDRAULIC STEERING PARTS LIST HC5326-3 NOTICE Teleflex does not sell internal parts. Contact Authorized repair center for repair and/or replace cylinder. WARNING When replacing any seals, make sure shaft is clear of any abrasions. Figure 42. ITEM PART # DESCRIPTION ITEM PART # DESCRIPTION...
  • Page 41 HYDRAULIC STEERING PARTS LIST HC5303-3, HC5313-3, HC5314-3 and HC5324-3 NOTICE Teleflex does not sell internal parts. Contact Authorized repair center for repair and/or replace cylinder. WARNING When replacing any seals, make sure shaft is clear of any abrasions. Figure 43. ITEM PART # DESCRIPTION...
  • Page 42 Hose/Bleed Fitting (2 per kit) 321446 Support Rod 343608 Barrel 963721 Clevis Block 343150 End Gland 343424 Piston Shaft * Replacement parts cannot be ordered by individual part number. Contact Teleflex Marine for kits that included these items. SeaStar Hydraulics...

  • Page 43: Statement Of Limited Warranty

    2 YEAR LIMITED WARRANTY We warrant to the original retail purchaser that Teleflex Canada Limited Partnership products have been manufactured free from defects in materials and workmanship. This warranty is effective for two years from the date of original retail purchase, excepting that where Teleflex Canada Limited Partnership products are used commercially or in any rental or other income producing activity, then this warranty is limited to 1 year from the date of original purchase. We will provide replacement product without charge, for any Teleflex Canada Limited Partnership product not meeting this warranty, which is returned (freight prepaid) within the warranty period to the dealer from whom such products were purchased, or to us at the appropriate address. In any such case Teleflex Canada Limited Partnership products found to be defective and covered by this warranty, will be replaced or repaired at Teleflex Canada Limited Partnership’s option, and returned to the customer. Teleflex Canada Limited Partnership’s sole responsibility under this warranty is limited to the repair or replacement of product which is, in Teleflex Canada Limited Partnership’s opinion, defective. Teleflex Canada Limited Partnership is not responsible for charges connected with the removal of such product or re-installation of replacement or repaired parts. We will have no obligations under this warranty for any product: • Which has been improperly installed. • Which has been used in an installation other than as recommended in our installation or operation instructions or specifications. • Which has failed or has been damaged due to an accident or abnormal operation including racing, misuse or alterations outside our factory. • Which has been repaired or modified by other than Teleflex Canada Limited Partnership. • Which has been used on an engine/boat combination where the engine horsepower exceeds the boat horsepower rating established by the boat manufacturer. • Which has been used with other products which, in Teleflex Canada Limited Partnership’s opinion, are incompatible with the Teleflex Canada Limited Partnership product.
  • Page 44 M A R I N E TELEFLEX CANADA 3831 NO.6 ROAD RICHMOND, B.C. CANADA V6V 1P6 FAX 604-270-7172 www.seastarsteering.com ISO 10592 © 2009 TELEFLEX CANADA LIMITED PARTNERSHIP PRINTED IN CANADA FORM NO. 343319 02/10 REV. D...

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