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Seastar Solutions Hynautic 04 Series Installation Instructions And Owner's Manual

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INSTALLATION INSTRUCTIONS
AND OWNER'S MANUAL
80
E IGHTY
ISO 9001
Hydraulic Engine Controls – 04 Series

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Summary of Contents for Seastar Solutions Hynautic 04 Series

  • Page 1 INSTALLATION INSTRUCTIONS AND OWNER'S MANUAL E IGHTY ISO 9001 Hydraulic Engine Controls – 04 Series...
  • Page 2 Notice to Boat Manufacturer or Installer Observe Them Carefully! 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 COULD result in COULD result in proper installation or or death.
  • Page 3 Index Installation Instructions & Owner's Manual...
  • Page 4 This system does NOT use oil or Steering Fluid. Use HA5455 Hynautic shift and throttle control fluid ONLY. DO NOT use stop-leak type anti-freeze. SeaStar Solutions Engine Control System — Why it Works Hynautic Hydraulic Engine Controls – 04 Series...

  • Page 5: Preparation For Installation

    PREPARATION FOR INSTALLATION CAUTION Dirt and foreign matter in the hydraulic system cause damage and malfunction. It is extremely important to keep tubing and fittings clean when installing and connecting components. Cut tube cleanly and tape the open end while running tubing. COMPONENT INSTALLATION Sender Installation NOTICE...
  • Page 6 HYNAUTIC CONTROLS COMPONENT INSTALLATION NOTICE If the area under the control panel is too confined to allow the tubing to be connected with moderate ease, do not secure the sender at this time. Proceed with the installation of the remaining senders per Steps 1 through 5.
  • Page 7 HYNAUTIC CONTROLS COMPONENT INSTALLATION Throttle Slave Installation NOTICE The standard SeaStar Solutions System, MC-04, uses the ST-06 Integrated Throttle Slave. You may have chosen to order a non- standard system which includes the ST-04 Throttle Slave and STV-10 Lock-out Valve. Depending...
  • Page 8 HYNAUTIC CONTROLS COMPONENT INSTALLATION ST-06 System ONLY NOTICE This built-in valve will lock the slave arm in place allowing it to be moved only by the sender. NOTICE Tube connectors are installed on the tubing per instructions under “Tubing Installation” and “Connection” on page 10. Dirt and foreign matter in the hydraulic system cause damage and CAUTION malfunction.
  • Page 9 HYNAUTIC CONTROLS COMPONENT INSTALLATION TO CONTROL STATIONS NYLON TUBING 5/16" O.D. N-2 HYNAUTIC TUBE FITTING ASSEMBLY NUT (530015) ADAPTER 1/4" PIPE X 5/16 TUBE LOCK RING (530025) (530175) INSERT (530045) BLEEDER ASSEMBLY O-RING (002222) (690010) 1/4" PIPE NIPPLE 1/4" PIPE TEE (690551) (690441) 78˚...
  • Page 10 HYNAUTIC CONTROLS COMPONENT INSTALLATION Clutch Slave Installation SLAVE ARM LOCK NUT BALL JOINT LOCK NUT (670010) BALL JOINT (670010) 90˚ 90˚ 1/4-20 THREADED CLUTCH ARM Figure 7. Proper Clutch Slave to Throttle Arm Installation. NOTICE The clutch slave’s arm may be set to any desired position by loosening the tightening screw (using a 3/16"...
  • Page 11 HYNAUTIC CONTROLS COMPONENT INSTALLATION DETENT RING CONTROL ARM LOCK-SCREW DETENT RING LOCK-SCREW 240357 Figure 8. Detent Ring Location. NOTICE HYNAUTIC TUBE FITTING The tube fitting and ASSEMBLY bleeder valve may be ADAPTER 1/4" NUT (530015) BLEEDER reversed on the pipe PIPE 5/16"...

  • Page 12: Reservoir Installation

    NOTICE If your installation includes two reservoirs (one for each engine), or is a single-engine installation, special plumbing will required which is not covered in this manual. Contact SeaStar Solutions for this information. R-13 Reservoir Installation NOTICE The charging valve is located on the bottom of the reservoir.
  • Page 13 HYNAUTIC CONTROLS COMPONENT INSTALLATION NOTICE There are two ports located on the bottom of the reservoir. One is plugged and can be used as a drain port. The other has a filter assembly and is used for connecting to the system. See Figure 11.
  • Page 14 TUBING INSTALLATION AND CONNECTION CAUTION Cut tube cleanly and tape the open end while running tubing. Rules for Routing Tubing NOTICE The instructions and illustrations in this section apply to nylon tubing ONLY. Information on use of Copper Tubing may be found on page 12.
  • Page 15 HYNAUTIC CONTROLS TUBING INSTALLATION CAUTION TUBING Extreme care MUST be taken to 530015 avoid any contamination from entering the tubing. Failure to do LOCK so may lead to system failure. 530025 O-RING 002222 INSERT 530045 1/32" Figure 13. Assembling Tubing Connectors. Install Tubing Between Senders and Slaves (See page 33 to page 38 for...
  • Page 16 HYNAUTIC CONTROLS TUBING INSTALLATION Copper Tubing COPPER TUBING 5/16" O.D. ADAPTER-FILTER (690080) FILTER/ DRAIN PLUG (380574) TUBE NUT (690621) Figure 14. Charging Valve on Bottom of R-13 Integrated Reservoir. Hynautic Hydraulic Engine Controls – 04 Series...
  • Page 17 HYNAUTIC CONTROLS TUBING INSTALLATION TO CONTROL STATIONS COPPER TUBING 5/16" O.D. TUBE NUT (690621) 5/16", 45˚ FLARE UNION (691601) 5/16" FLEXIBLE HOSE WITH 45˚ FEMALE FLARE SWIVELS NOTE: MUST USE A MIN. OF 12" OF FLEX HOSE ADAPTER-FILTER (691601) ADAPTER 1/4" PIPE 5/16" TUBE (530175) ADAPTER 1/4"...
  • Page 18 HYNAUTIC CONTROLS TUBING INSTALLATION COPPER TUBING 5/16" O.D. ADAPTER- FILTER (690080) RESERVOIR FILTER PLUG ASSEMBLY ADAPTER (380070) (530175) TUBE NUT (690621) COPPER TUBING DRAIN PLUG TUBE NUT MOUNTING 5/16" O.D. (690010) (690621) HOLES Figure 17. Ports on Bottom of R-04 Reservoir. Figure 18.

  • Page 19: Filling And Bleeding The System

    FILLING AND BLEEDING THE SYSTEM Filling the System NOTICE See section on “System Fluid” for fluid specifications on page 17. Bleeding the System at Slave NOTICE Verify that linkage is disconnected, and sender’s handles are free to move. While bleeding, move the slave arm and verify that the piston has bottomed.
  • Page 20 HYNAUTIC CONTROLS FILLING AND BLEEDING Bleeding the System at Senders NOTICE Place a rag over the bleeder hole on the sender, to prevent fluid from spilling on the console. GASKET BLEEDER SCREW Figure 20. Bleeder Screw. Hynautic Hydraulic Engine Controls – 04 Series...
  • Page 21 SYSTEM FLUID NEVER USE STOP LEAK TYPE ANTI-FREEZE. MAKING THE SYSTEM OPERATIONAL Synchronizing the Controls NOTICE This synchronization can be performed at any of the control stations. Connecting Engine Controls NOTICE For any operational problems at this point, consult the trouble- shooting section.

  • Page 22: Operation And Maintenance

    OPERATION & MAINTENANCE Throttle Senders WARNING When working on engine and operating the engine throttle arm by hand, disconnect throttle linkage from the control slave. If linkage is not disconnected the pilot check valve will not allow a throttle retardation unless a sender arm is actuated to decrease the throttle. NOTICE Prior to starting engines, both throttles and clutches should be synchronized.

  • Page 23: Parts List

    PARTS LIST Nylon Tubing SINGLE ENGINE TWIN ENGINE COMPONENT DESCRIPTION R-13 Reservoir & Charging Valve MCVF-04 Charging Valve Fittings MCVF-05 Charging Valve Fittings CL-B4 or Control-Left (Ball Handle) or CL-T4 Control-Left ("T" Handle) CR-B4 or Control-Right (Ball Handle) or CR-T4 Control-Right ("T"...
  • Page 24 HYNAUTIC CONTROLS PARTS LIST Copper Tubing SINGLE ENGINE TWIN ENGINE COMPONENT DESCRIPTION R-13 Reservoir & Charging Valve MCVF-10 Charging Valve Fittings MCVF-11 Charging Valve Fittings CL-B4 or Control-Left (Ball Handle) or CL-T4 Control-Left ("T" Handle) CR-B4 or Control-Right (Ball Handle) or CR-T4 Control-Right ("T"...
  • Page 25 HYNAUTIC CONTROLS PARTS LIST Sender Assembly CR-B4 CR-T4 CL-B4 CL-T4 † OPTIONAL HANDLE Red Knob, Kit Part # CK-01 Black Knob, Kit Part # CK-02 NOTE: Ball is not available as a separate part. † † *INCLUDED IN SEAL KIT ECS-05: 2 x Valves 160011 1 x O-Ring...
  • Page 26 HYNAUTIC CONTROLS PARTS LIST Ball & Tee Handle Installation CAUTION When Installing Ball Handle DO NOT torque screw to more than 10 ft-lbs. CAUTION When installing Tee Handle DO NOT torque screw to more than 14 ft-lbs. NOTICE Standard hand-tightening with 1/4” short arm hex key wrench will not over-torque screw.
  • Page 27 HYNAUTIC CONTROLS PARTS LIST ST-06 Throttle Slave Assembly *INCLUDED IN SEAL KIT ECS-06: 2 x Dill Valve 160061 2 x O-Ring 002222 1 x O-Ring 223729 1 x O-Ring 345926 1 x O-Ring 211027 † 2 x O-Ring 211028 (1 extra) 1 x O-Ring 924022 1 x O-Ring...
  • Page 28 HYNAUTIC CONTROLS PARTS LIST SS-04 Transmission Slave Assembly † INCUDED IN SHIFT SLAVE REPAIR KIT# 68352K: 1 x Lever Arm 610024 1 x Screw 790323 1 x Cam Detent 730014 1 x Set Screw 240357 † 1 x Spring 430296 1 x Washer 740018 1 x End Gland...

  • Page 29: Installation

    OPTIONAL NEUTRAL SAFETY SWITCH KIT SSH-01 Installation SWITCH PLATE (520524) SWITCH COVER (870220) SCREW (240857) FLAT WASHER (260147) HEX NUT (270177) LOCK WASHER (260107) MICRO SWITCH (870240) SCREW (240201) ARM (SHOWN IN “UP” POSITION LOCK WASHER (260052) CAM FOLLOWER WHEEL DETENT Figure 25.
  • Page 30 HYNAUTIC CONTROLS SWITCH KIT SSH-1 GEAR RACK DILL DILL VALVE PILOT VALVE CHECK VALVE Figure 26. Clutch Slave. Figure 27. Throttle Slave. DILL VALVE PRESSURE (160031) GAUGE FILL PLUG ASSY O-RING (160052) (360020) (211910) PLUG (380574) GROMMET LABEL 4 REQ’D (180079) FILTER ELEMENT (140029)
  • Page 31 HYNAUTIC CONTROLS SWITCH KIT SSH-1 SPRING (4) MCV-04 CHARGING VALVE 430546* PLUG (4) 380514* O-RING (4) 014624* POPPET ASSEMBLY(4) 450040* BODY 900664 FILL PLUG *INCLUDED IN FITTING KIT MCVF-08: 4 x O-Ring 014624 PRESSURE 4 x Plug 380514 GAUGE AIR FILLER 4 x Spring 430546 VALVE...
  • Page 32 Hynautic Hydraulic Engine Controls – 04 Series...
  • Page 33 TEMPLATES LINE INDICATES OUTER EDGE OFCONTROL SENDER DRILL 7/16" DIA. HOLES DRILL 7/16" DIA. HOLES 2 PLACES 4 PLACES REMOVE THIS AREA REMOVE THIS AREA REMOVE THIS AREA REMOVE THIS AREA FROM THE PANEL FROM THE PANEL FROM THE PANEL FROM THE PANEL SINGLE HEAD SIDE-BY-SIDE MOUNTING...
  • Page 34 This page intentionally blank to allow removal/use of template. Hynautic Hydraulic Engine Controls – 04 Series...
  • Page 35 CDF-04 MOUNTING PLATE 1/8" THICK PLATE Installation Instructions & Owner's Manual...
  • Page 36 This page intentionally blank to allow removal/use of template. Hynautic Hydraulic Engine Controls – 04 Series...
  • Page 37 TUBING CIRCUITS Plan I – Twin Engine, One Station FORWARD Figure 31. Installation Instructions & Owner's Manual...
  • Page 38 HYNAUTIC CONTROLS TUBING CIRCUITS Plan II – Twin Engine, Two Station FORWARD Figure 32. Hynautic Hydraulic Engine Controls – 04 Series...
  • Page 39 HYNAUTIC CONTROLS TUBING CIRCUITS Plan III – Twin Engine, Three Station FORWARD Figure 33. Installation Instructions & Owner's Manual...
  • Page 40 HYNAUTIC CONTROLS TUBING CIRCUITS Plan IV – Twin Engine, Four Station FORWARD Figure 34. Hynautic Hydraulic Engine Controls – 04 Series...
  • Page 41 SUPPLEMENTAL THROTTLE CONTROL CIRCUITS Plan I-S Plan II-S FORWARD FORWARD Figure 35. Figure 36. Installation Instructions & Owner's Manual...
  • Page 42 HYNAUTIC CONTROLS SUPPLEMENTAL THROTTLE Plan III-S Plan IV-S FORWARD FORWARD Figure 37. Figure 38. Hynautic Hydraulic Engine Controls – 04 Series...

  • Page 43: Troubleshooting Guide

    Hydraulic Shift and Throttle, such work must only be carried out by a qualified marine hydraulic mechanic. SeaStar Solutions offers the following as a guide only and is not responsible for any consequences resulting from incorrect dismantling repairs.

  • Page 44: Troubleshooting

    HYNAUTIC CONTROLS TROUBLESHOOTING FAULT CAUSE SOLUTION 6 Engine Throttle tends to creep toward idle. 7 Full Throttle on sender gives idle on engine. 8 After a long running period the Throttle tends to go out of synchronization. NOTE: excessive tension in either throttle extremes will cause synchronization problems.
  • Page 45 HYNAUTIC CONTROLS TROUBLESHOOTING FAULT CAUSE SOLUTION 10 Loss of pressure and fluid on system. 11 Sender arm moved at one station resuIts in the wrong arm movement at the other station(s). 12 Sender arm moved at one station resuits in another arm moving at the same station.

  • Page 46: Technical Information

    45.0 (61.01) 37.0 (50.17) 3/4”-16 124.0 (168.12) 102.0 (138.29) 9/16”-12 57.0 (77.28) 47.0 (63.72) 7/8”-9 194.0 (236.03) 159.0 (215.58) 9/16”-18 63.0 (85.42) 51.0 (69.15) 7/8”-14 193.0 (261.67) 158.0 (214.22) SeaStar Solutions Technical Support Contacts: Hynautic Hydraulic Engine Controls – 04 Series...

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