Summary of Contents for Dometic HC4645H
- Page 1 HYDRAULIC STEERING SYSTEMS Dometic Hydraulic Steering Systems Troubleshooting Guide WARNING Cancer and Reproductive Harm [REVISION C] Form No. SL61501 | ©2020 Dometic Corporation www.P65Warnings.ca.gov...
- Page 2 ©2020 Dometic All Rights Reserved. This document, subject matter and all information herein is the sole, exclusive and confidential property of Dometic and shall not be disclosed, copied, reproduced or used in whole or in part for any purpose other than as specifically authorized in writing by Dometic.
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Page 3: Table Of Contents
Table of contents 1 Important safety information ..........1 1.1 Explanation of symbols ............. 2 1.2 Safety considerations and safe operation ......3 2 How to use this manual ............5 3 Common terms and definitions ..........5 4 Manual troubleshooting ............6 4.1 Loss of fluid/fluid level not visible in helm pump .... - Page 4 This page left intentionally blank.
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Page 5: Important Safety Information
A failure to read and follow the instructions and warnings set forth herein may result in an injury to yourself and others, damage to your product or damage to other property in the vicinity. Dometic accepts no liability for any loss, damage or injury incurred, directly or indirectly, from the installation, use or maintenance of the product not in compliance with the instructions and warnings in the product manual. -
Page 6: Explanation Of Symbols
1.1 Explanation of symbols The symbols below are used throughout this publication to alert you to potential hazards involved with the operation and installation of this product. Observe these warnings and notices carefully. The safety alerts alone cannot eliminate hazards; strict compliance with any special instructions during installation, operation, and maintenance, along with common sense operation, are important measures to prevent hazardous situations. -
Page 7: Safety Considerations And Safe Operation
It is critical that you read and understand all the points noted. If you have any questions regarding any of these warnings, contact Dometic. Before installation The safe operation of the steering system is dependent upon proper installation &... - Page 8 6. Outboard Systems: Confirm that extruded nylon tubing has not been substituted for SeaStar steering hose. 7. Do not use a wire coil type trim switch with a hydraulic steering system as the wire can wind up tight around the steering wheel shaft and prevent further steering.
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Page 9: How To Use This Manual
2 How to use this manual Each fault will be labeled as a “Symptom” at the top of the page, followed by possible “Causes”, and then followed by possible “Solutions”. • Symptom = Problem reported • Causes = Most likely cause that can lead to the symptom •... -
Page 10: Manual Troubleshooting
4 Manual troubleshooting 4.1 Loss of fluid/fluid level not visible in helm pump Causes A. Leak in steering system. B. Air remaining in system/system not properly bled originally/fluid level set too low. Solutions WARNING! Repair all leaks prior to use. A. -
Page 11: Helm Locks Up Completely
4.2 Helm locks up completely Causes A. PRO helm used with “unbalanced” steering cylinder. B. Mechanical interference. C. Restriction in hose/helm. Solutions A. A SeaStar PRO helm cannot be used with any unbalanced cylinder, this will result in the steering wheel locking up completely. B. -
Page 12: Difficulty Purging The Air From The System
D. Steering cylinder MUST hit hard-over. E. Remove power pump from power purge unit. Clean screen filters located on pump pick up tubes (inside the reservoir). Dometic recommends the use of Power Purge service kit part # HP6125 for this procedure. Root Causes A. -
Page 13: Steering Wheel(S) Are Hard To Turn At Dock
4.4 Steering wheel(s) are hard to turn at dock Causes A. Mechanical interference. B. Cylinder Adjusting nut over-tightened. C. Restriction in steering hoses. D. Wrong fluid being used to fill system. E. Cylinder not installed correctly, or, incorrect cylinder used for the application. -
Page 14: Steering Wheel(S) Are Hard To Turn While Underway (Easy At Dock)
4.5 Steering wheel(s) are hard to turn while underway (easy at dock) NOTICE! All outboard engines create propeller torque that want to turn the engine, making it easy to turn the wheel 1-direction (typically starboard), and hard to turn the other (typically port). Each engine/boat combination will have different effort. -
Page 15: Steering Wheel(S) Freewheel(S) To One/Both Direction(S)
A system that is not responding must be diagnosed and corrected prior to use. WARNING! Dometic does not recommend the disassembly of any helm pump. Contact an Authorized Service Center, or, replace helm pump. NOTICE! On multiple helm applications, there is a possibility to enter a slow freewheel situation if 1–helm is turned 1–direction and then the opposite... -
Page 16: Steering Wheel(S) Are Bumpy When Turning Either Direction
NOTE: A timing issue within a helm pump is very rare. Most timing related problems are felt immediately after installation and purging. WARNING! Dometic does not recommend the disassembly of any helm pump. Contact an authorized service center, or, replace helm pump. -
Page 17: Boat Drifts To One Side Or The Other While Underway
A system that is not responding must be diagnosed and corrected prior to use. WARNING! Dometic does not recommend the disassembly of any helm pump. Contact an Authorized Service Center, or, replace helm pump. NOTICE! On multiple helm applications, there is a possibility to enter a slow freewheel situation if 1–helm is turned 1–direction and then the opposite... -
Page 18: Power Assist System Troubleshooting
5 Power Assist system troubleshooting 5.1 Steering wheel(s) “lock up” to one or both directions Causes A. Mechanical interference. B. Pro helm used with “unbalanced” cylinder. C. Blockage or restriction in steering hoses between helm pump and power assist pump. D. -
Page 19: Power Assist Motor Runs But No Power Assist
5.2 Power Assist motor runs but NO Power Assist Causes A. Air in system. B. Faulty/damaged coupler. Solutions A. Bleed system as outlined in the power assist installation and operating manual. B. Inspect coupler for wear and/or damage (see inspection details below). Inspection •... -
Page 20: Bumpy Feeling At Steering Wheel(S) With Power Assist Turned On
5.3 Bumpy feeling at steering wheel(s) with Power Assist turned ON Causes A. Air in system. Hoses between power assist and helm pump too short. Solutions A. Confirm that return line from power assist has been bled free of air. Refer to power assist installation and operating manual for proper filling and purging details. -
Page 21: System Checks
1/4” or less cylinder body movement, contact technical support at 604-248-3858 for further testing. Good Optimal BayStar Helm Disp. (In /Rev) Outboard cylinders Disp. (in HC4645H/47H/48H/58H and -3 models Inboard cylinders Disp. (in BA125-6.25 BA100-6 3.53 Table 6-1. -
Page 22: System Pressure Test
Good Optimal SeaStar Helm Disp. (In /Rev) Front Mount, Outboard Pivot cylinders Disp. (in Single Dual 16.6 11.9 Triple 24.9 17.8 14.6 12.5 10.4 Quad 33.3 23.7 19.5 16.6 13.8 11.1 Table 6-2. Good Optimal SeaStar Helm Disp. (In /Rev) Front Mount, Outboard Pivot cylinders Disp. -
Page 23: Cylinder/Helm Pump Check
6.3 Cylinder/helm pump check • Center engine • Trim engine UP • Turn steering wheel 1 turn to the starboard side • Let go of wheel • Let engine fall over to the side • While the engine is falling, watch the steering wheel (place a piece of tape on the wheel) •... -
Page 24: Helm/Cylinder & Power Assist Checks
3. Bleed steering system • Consult with your power assist owner’s manual for bleeding details. 4. Torque end glands • Using a torque wrench, and the pin wrench available from Dometic, torque ALL end glands to 50 ft-lb. 5. Check cylinders for leaks •... - Page 25 Stray current corrosion is the leading contributor to pitting of the steering cylinder shafts. Part # HA5477 contains one ground strap for non -3 cylinders. For -3 cylinders contact Dometic technical services.
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Page 26: Routine Maintenance
3. Check for mechanical play or slop throughout steering system, correct as required. 4. Check for signs of corrosion. If corrosion is present contact your dealer or Dometic. After every 200 hours or 12 months (whichever comes first): 1. All points noted above. - Page 27 Item Description Grease Support ROD, tilt tube and support bracket HOLE Figure 7-1.
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Page 28: Specifications And Replacement Parts
8 Specifications and replacement parts 8.1 BayStar Front mount pivot cylinders NOTICE! H and -3 models (i.e. HC4645H and HC4645-3) Covers part numbers: HC4645H, HC4647H, HC4648H and HC4658H SPECIFICATIONS Figure 8-1. Outboard use only (150HP max) Item Description Volume: 7.24 cu.in. -
Page 29: Seastar
8.2 SeaStar Front mount pivot cylinders NOTICE! Covers part numbers: HC5345, HC5347, HC5348, HC5375 and HC5358 (includes -3 models). Any difference in part numbers will be noted in replacement parts list. SPECIFICATIONS Figure 8-2. Outboard use only Item Description Volume: 8.3 cu.in. Design: Balanced cylinder Seal kits: P/N HS5157 (includes wrench, does NOT include center/internal seal) -
Page 30: Fitting Identification
8.3 Fitting identification Typical NPT fittings NOTICE! Liquid thread sealant is used on the NPT side of these fittings only. Straight Fitting Elbow Fitting 45° Fitting 3/8” 1/4” NPT 1/4” TUBE 1/4” NPT 3/8” TUBE 3/8” TUBE Figure 8-3. Typical ORB fittings NOTICE! No sealant is used on either side of ORB fittings. -
Page 31: Advisory Notice
9 Advisory notice 9.1 Power Assist pumps We at Dometic have become aware of a few isolated cases where the SeaStar power assist causes the steering wheel to stick when coming out of a full (hard over) turn. This has been traced to a batch of rubber seals in 2012. -
Page 32: How To Disable The Power Assist
604-248-3858 9.4 How to obtain a service kit End User: Contact dealer for service kit. Dealer: Contact Dometic. Dometic will provide a service kit (HA1220) and a predetermined cost of labour to service the unit. -
Page 33: How To Test The Seastar Power Assist
7. Turn the wheel quickly and note the maximum voltage. This reading should be comparable with that recorded at point (B). 8. If there is low or no voltage at this point contact Dometic technical support at 604-248-3858. TEST FOR VOLTAGE AT THESE POINTS Figure 10-1. - Page 34 _______________________________________________ Notes _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________...
- Page 35 YOUR LOCAL YOUR LOCAL YOUR LOCAL DEALER SUPPORT SALES OFFICE dometic.com/dealer dometic.com/contact dometic.com/sales-offices A complete list of Dometic companies, which comprise the Dometic Group, can be found in the public filings of: DOMETIC GROUP AB Hemvärnsgatan 15 SE-17154 Solna Sweden...
- Page 36 Mobile living made easy. DOMETIC VANCOUVER 3831 NO.6 ROAD RICHMOND, B.C. CANADA V6V 1P6 TECHNICAL SUPPORT Tel.: 604-248-3858 www.dometic.com © 2020 DOMETIC PRINTED IN CANADA 12/20 ISO 25197:2012 Please scan FORM NO. SL6151 REV. C this QR code and watch our latest Boating Safety video.