Seastar Solutions DC1000 Assembly instructions

Before you do it your way,
please try it our way
30
OPERATING INSTRUCTIONS
AND OWNER'S MANUAL
www.seastarsolutions.com
T H I R T Y
ISO 9001
DC Power Steering Unit
Part # DC1000 & DC2000

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.
Not ce to Boat Manufacturer
or Installer
Hazards or unsafe
practices which
COULD result in
minor injury or
product or property
damage.
CAUTION
Hazards or unsafe
practices which
COULD result in
severe personal
injury or death.
WARNING
Immediate hazards
which WILL result in
severe personal
injury or death.
DANGER
Information which is
important to proper
installation or
maintenance, but is
not hazard-related.
NOTICE
Cleaning fluids containing ammonia, acids or any other corrosive
ingredients MUST NOT be used for cleaning any part of this
Hydraulic Steering System. Failure to comply will cause serious
damage to the steering system, resulting in possible loss of
steering, causing property damage, personal injury and/or death.
WARNING
Help protect your boating environment by ensuring that all used oil
is disposed of properly.
NOTICE
Don't compromise performance... use genuine
SeaStar parts only!
• SeaStar helms • SeaStar Cylinders
• SeaStar hoses • SeaStar Oil
Substituting non SeaStar parts in any part of the SeaStar hydraulic
steering system may seriously compromise system performance.

INTRODUCTION
Index
Introduction.............................................................................. 1
How the System Works............................................................. 2
SeaStar DC Power Unit Compatibility Chart ................................ 3
Tools ........................................................................................ 4
Specifications ........................................................................... 4
System Overview....................................................................... 5
System Installation................................................................... 7
Step 1 Mounting & Plumbing ..................................................... 7
1.1 DC Power Unit Mounting ........................................... 7
1.2 Relief Module Installation ......................................... 8
1.3 Plumbing the DC Power Unit .................................... 9
Step 2 Electrical Connections ................................................. 12
2.1 DC Power Unit Battery Connections......................... 12
2.2 Ignition Connection ................................................ 13
2.3 Autopilot Connections............................................. 13
Step 3 Filling and Purging ....................................................... 14
3.1 Purging Using Fast Purge Kit (HA2266).................... 14
3.2 Purging Using Supplied Bleed Tubing....................... 15
Step 4 Autopilot Tuning .......................................................... 17
Step 5 System Verification and Operation Check ...................... 18
Maintenance ......................................................................... 18
Troubleshooting Guide ........................................................... 19
Statement of Limited Warranty .............................................. 21
Return Goods Procedure ......................................................... 21
Before proceeding with the installation please read these instructions
thoroughly to familiarize yourself with the workings of this SeaStar DC
Power Steering System. SeaStar Solutions cannot accept responsibility
for installations where instructions have not been followed where
substitute parts have been used or where modifications have been
made to our products. Warranty may be void if products other than
SeaStar Solutions products are used with this system.
1
DC Power Steering System

2
The SeaStar DC Power Unit is a self contained steering system
designed to provide an alternative to existing power steering
systems. Unlike conventional power steering systems which require
engine/pulley driven pumps oil coolers oil reservoir filter and
relief control valves the DC Power Unit is an integrated power
steering solution requiring only the DC Power Unit a steering
cylinder and one or multiple helm pumps. The end result will be
less power consumption and very little heat generation. Installation
of the SeaStar DC Power Unit requires fewer parts less installation
time and easy troubleshooting making it an all around user friendly
system. With the built in semi-automated purge system the
SeaStar DC Power Unit will help the installer bleed ALL of the air
out of the steering system in minimal time.
The DC Power unit incorporates an autopilot pump as well for a
cleaner more reliable installation than using external pumps.
HOW THE SYSTEM WORKS
Fi ure 1.
SEASTAR Hydraulics
2

DC Power Steering System 3
SeaStar DC Power Unit Compatibility
DO NOT use extruded nylon tubing for plumbing this system. ONLY use
SeaStar Outboard type steering lines for all helm pump connection
and ONLY use Dash - , 2000psi hose for PRS/TNK connections.
3/ " Copper tubing is also acceptable as a substitution for SeaStar
lines, provided 4' SeaStar hose sections are used to connect the
copper to any fittings.
Failure to follow the above may lead to loss of steering control
causing property damage and/or personal injury or death.
WARNING
Never use Brake Fluid. Any non-approved fluid may cause irreparable
damage, loss of steering, and cancellation of warranty.
In cases of extreme emergency any non-toxic non-flammable fluid
may provide temporary steering.
CAUTION
The DC Power Unit is compatible with the following SeaStar
steering equipment:
All 1.4 and 1.7 SeaStar Non-Feedback helms. DC Power Unit is NOT
compatible with Hynautic Capilano or other manufacturers’ helms.
Helms
Recommended hydraulic fluids are:
Hydraulic Fluid
Cylinders 9" STROKE, 2" DIA. 11" STROKE, 2" DIA. 9" STROKE 2.5" DIA.
SINGLE YES YES YES
(HC5801 2) (HC5803 2) (HC5805)
TWIN YES (HC5801 2 YES (HC5804 NOT
& HC5802) & HC5803 2) Recommended
DC POWER STEERING UNIT
DC Power Unit is designed specifically for use with SeaStar NFB helms.
DO NOT use Hynautic, Capilano, or other manufacturers Helms.
NOTICE
• SeaStar Steering Fluid
• Fluids meeting MIL H5606
Specifications
• Automatic transmission fluid
Dextron II may be used in an
emergency

4SEASTAR Hydraulics
16-1/8" (410 mm)10-5/8" (270 mm)
15-3/4" (400 mm)
Fi ure 2.
DC POWER STEERING UNIT
You will need the following tools to complete your installation.
Tools
Specifications
• 5/32" and 1/4" Allen keys
• Phillips head screw driver
• Slotted/Flat head screw driver
• PST Liquid Teflon based pipe
sealant
• 3/4" and 7/8" open ended
wrenches
• Electrical cut and crimp pliers
• ALL other tools noted in your
helm pump and steering
cylinder owner’s manual
• Funnel
• Crescent wrench
DO NOT Use Teflon Tape.
WARNING
DC 1000
• Power unit = 24Volts
• Autopilot pump = 12Volts
0-60 in3/min
(fully adjustable)
• Peak current draw
@ 1250psi = 72A
• Idle current draw = 0.2 amps
• Average current draw = 10-15
amps
(depending on application)
• Weight = 55 lb (25kg) Dry
• Tank Capacity = 1.85 gal (7L)
DC 2000
• Power unit = 24Volts
• Autopilot pump = 24 Volts
0-60in3/min
(fully adjustable)
• Peak current draw @
1250psi = 72A
• Idle current draw = 0.2 amps
• Average current draw = 10-15
amps
(depending on application)
• Weight = 55 lb (25kg) Dr y
• Tank Capacity = 1.85 gal (7L)

DC Power Steering System 5
System Installation
• Install SeaStar helm pump(s) using installation instructions
provided with your helm.
• Install steering cylinder using the installation instructions
provided with your cylinder.
Install non-vent plug part # HA5432 into ALL helm pump stations
on board vessel. Failure to properly install non-vent plugs can
result in loss of steering causing property damage, personal injury
and/or death.
Included with your kit
Additional items required
for installation
WARNING
STEP 1
System Overview
DC POWER STEERING UNIT
• Power steering cylinder (See cylinder selection guide and
page 3 for DCPU compatibility).
• Hoses (See hose information on page 9).
• Liquid Teflon Sealant (DO NOT USE TEFLON TAPE).
• Helm (1.4 or 1.7 NFB models ONLY).
• Non-vent caps for helms.
• Wiring (see "Wiring Connections" section for details).
• 90A peak power supply on vessel.
• Autopilot controller (Optional).
• Fast Purge Kit (Optional).
• SeaStar Steering Fluid.
1.85 gal (7L) for Power Unit tank
0.13 gal (1/2L) for each steering cylinder
0.26 gal (1L) for each helm station
Additional 1–2 gal (4–8L) depending on hose length and type
• Misc. mounting hardware.
• Misc. crimp or solder connectors for making electrical
connections.
• One HF5529 fitting kit per additional helm station
SeaStar
DC Power
Unit x 1
Relief Valve
Module x 1
Bleeder Tube with Clamps x 1
Screws for Relief Valve x 3
Quad Ring
Seals x 2 90° Elbow
Fittings x 2

6SEASTAR Hydraulics
Making Electrical Connections
• Refer to page 12 of this manual for electrical connections.
Prior to making electrical connections of any type, be sure to vent
installation area of any fumes. Failure to do so may result in a
fire causing property damage and/or personal injury or death.
Filling and Purging Procedure
• Refer to page 14 of this manual for filling and purging of the
steering system.
Autopilot Tuning
• Refer to page 17 of this manual to adjust autopilot speed.
System Verification & Operation Check
• Refer to page 17 of this manual to verify system operation.
WARNING
STEP 2
STEP 3
STEP 4
STEP 5
TO AUTOPILOT
(RED/BLACK)
+IGNITION
+BATTERY
–BATTERY
Fi ure 3.
• Mount DC Power Unit. Refer to page 7 for mounting details.
• Install relief module on power steering cylinder. Refer to page 8
for installation details.
DO NOT mount the DC Power Unit in an area where pump noise
may disturb passengers.
• Install steering hoses using the figures and table shown on
page 9 and page 10.
The DC Power unit may be HOT to the touch. DO NOT mount the
DC Power Unit in an area where fabrics and/or any other
flammable material may come in contact with the unit.
WARNING
NOTICE
DC POWER STEERING UNIT

DC Power Steering System 7
MOUNTING
HOLES (4)
3/8" DIA.
15-1/8" (384 mm)
6-3/4" (172 mm)
Fi ure 4.
NOTICE For installations with minimal clearance behind unit, it is advised
that electrical connections are made prior to mounting the Unit.
NOTICE For installations in areas where pump noise may disturb passengers,
the use of rubber isolation mounts is recommended. SeaStar Solutions
part # HA2222.
1.3
1.1
1.2
Install Helm Pump(s)
• Install SeaStar Helm pump(s) using the instructions provided
with your helm(s).
Install Steering Cylinder(s)
• Install SeaStar steering cylinder(s) using the instructions
provided with your cylinder(s).
DC Power Unit Mounting
• Using the four mounting holes on the base of the unit mount
the DC Power Unit in the desired location. Confirm that there
will be sufficient room for filling/purging hose connections and
future access to the unit.
Mount the unit in a cool
location, away from any
sources of excessive heat,
such as engine manifolds, and
also free of any water splash.
CAUTION
Step 1 Mounting and Plumbing
SYSTEM INSTALLATION

8SEASTAR Hydraulics
1
2
2
3
TAPPED
HOLES (3)
ENSURE QUAD RING SEALS
SEAT PROPERLY IN COUNTER
BORES ON RELIEF MODULE
Fi ure 5.
DC POWER STEERING UNIT
1.4 Relief Module Installation
• Remove steering cylinder from its packaging and inspect servo
valve block. The cylinder MUST have three tapped holes on the
face of the servo valve block as shown in figure 5 below. If the
servo valve block does NOT have these tapped holes contact
SeaStar Solutions Technical Support.
• Remove fittings from the PRS and TNK ports on the steering
cylinder servo block if required.
• Inspect valve block face. It MUST be free of ALL contaminants
including thread sealant debris burrs gouges or large
scratches. Clean as required.
• Install both quad rings (items #2) into relief valve module as
shown in Figure 5.
• Insert three (3) socket head cap screws (items #1) into relief
valve module (item #3) and fasten to front face of cylinder servo
valve as shown in Figure 5. Torque mounting bolts to 40 in.lb.
• Clean threads and apply a Teflon based liquid pipe sealant to the
threads of the fittings that were removed in the second point
above. Install fittings into the ports on the relief module. DO NOT
USE TEFLON TAPE. Torque fittings to 200 in. lb.
WARNING
Ensure that the quad rings
remain seated in the relief
valve module and are not
pinched and/or rolled between
the module block and the
servo cylinder valve. Failure do
so will result in fluid leaks
causing property damage,
personal injury and/or death.
NOTICE
All cylinders manufactured
during or after January 2008
will have mounting provisions
for the relief module.

DC Power Steering System 9
Plumbing the DC Power Unit
DC POWER STEERING UNIT
1.5
ONLY use SeaStar or SeaStar
PRO steering lines for all lines
except PRS and TNK. 3/ "
Copper tubing is also acceptable
as a substitution for SeaStar
lines, provided 4' of SeaStar
hose is used to connect copper
to fittings. Failure to comply may
lead to loss of steering control
causing property damage and/
or personal injury or death.
CAUTION
DO NOT reverse PRS/TNK lines
or damage to unit may result.
CAUTION
All SeaStar hose connections
and bleeders must be torqued
to 15 ft-lb. SAE- fittings should
be torqued to 40 ft-lb. Failure to
correctly torque may lead to
loss of steering control
causing
property damage and/or
personal
injury or death.
CAUTION
Install non-vent plug part
# HA5432 into ALL helm pump
stations on board vessel. Failure
to properly install non-vent plugs
can result in loss of steering
causing property damage,
personal injury and/or death.
WARNING
Helm pump to DC Power Unit
• Connect P and S helm pump ports to H1 and H2 as outlined in
Table 1 Figure 8 and Figure 9.
• Connect hose from lower R port on the helm pump to the HB
port on the DC Power Unit. (Refer to Figures 6 and 7.)
• Connect hose from upper R port (or fill port) on helm to the HT
port on the DC Power Unit. (Refer to Figures 6 and 7.)
DC Power Unit to steering cylinder
•
Connect 1/2" Dash 8; 2000psi SAE 100R hose from the PRS port
on the DC Power Unit to the PRS port on the steering cylinder.
•
Connect 1/2" Dash 8; 2000psi SAE 100R hose from the TNK port
on the DC Power Unit to the TNK port on the steering cylinder.
• Connect C1 port on DC Power Unit to HS port on cylinder.
• Connect C2 port on DC Power Unit to HP port on cylinder.
TO POWER UNIT
'HT' PORT
TO POWER UNIT
'HT' PORT
NON VENT CAP
NON VENT CAP
NON VENT CAP
TO POWER UNIT
'HB' PORT
TO POWER UNIT
'HB' PORT
Fi ure 7. Standard helms. (Acceptable
confi uration; helms will need to be
burped durin pur e. Refer to pa e 14
to pa e 17)
TO POWER UNIT
'HT' PORT
TO POWER UNIT
'HB' PORT
TO POWER UNIT
'HT' PORT
TO POWER UNIT
'HB' PORT
Fi ure 6. Rear Mount Helms.
(Recommended wherever possible.)
NOTICE
For multiple helm installations,
helm reservoirs must be
DIRECTLY chained together by
connecting the upper reservoir
port of the lower helm to the
lower reservoir port of the next
highest helm. (Refer to Figures
6 and 7.)

10 SEASTAR Hydraulics
Aux P Aux S
HP
CONFIGURATION 'A'
CONFIGURATION 'A'
CONFIGURATION 'B'
CONFIGURATION 'B'
HS PRS TNK
AFT
FORE
Fi ure 9.
Table 1
Config. Hose Connection
AConnect ‘P’ on helm to ‘H2’ on power unit
Connect ‘S’ on helm to ‘H1’ on power unit
BConnect ‘P’ on helm to ‘H1’ on power unit
Connect ‘S’ on helm to ‘H2’ on power unit
C1
HB
HT
H2
H1
C2
TNK
PRS
Fi ure 8.
DC POWER STEERING UNIT

DC Power Steering System 11
DC POWER STEERING UNIT
POWER STEERING CYINDER
SEASTAR
HELM PUMP
P
R
R
S
AUTOPILOT
PUMP
HB
TNK
HP PRS
HS
HT
H1
H2
DCPOWER
UNIT
PRS
C1
C2 TNK
1/2" DASH 8 2000psi SAE 100R
SEASTAR OUTBOARD STEERING
HOSES AND/OR COPPER TUBING
Fi ure 10. Typical Plumbin Schematic.
NOTICE The drawing in figure 10 is used for visual purposes ONLY, refer to
page 9 to page 10 for your specific plumbing details.

12 SEASTAR Hydraulics
BATTERY +
BATTERY –
IGNITION
SIGNAL +
COVER SCRWS
PHILLIPS (6)
NOTICE
Step 2 Electrical Connections
Fi ure 11.
DC Power Unit Battery Connections
It is recommended that the DC Power unit be connected directly to
a main battery, or other on-board 2 -volt power source rated for 90
amps peak using an appropriate fuse or breaker.
1Remove electronics casing cover by removing the 6 Phillips head
screws. (Refer to Figure 11.)
2Insert positive battery lead through the upper strain relief fitting
on the electronics box. (Refer to Figure 11.)
3Remove the #10 Phillips head screw from the top-most terminal
inside the electronics enclosure. Securely fasten the positive
lead with ring connector to this terminal post torque to 25in-lbs.
4Insert negative battery lead through the lower strain relief fitting
on the electronics box. (Refer to Figure 11.)
5
Remove the #10 Phillips head screw from the bottom-most terminal
inside the electronics enclosure. Securely fasten the negative
lead with ring connector to this terminal post torque to 25in-lbs.
6Using a crescent wrench tighten the strain relief nuts until the
rubber sleeves form a seal with the wires. DO NOT OVER TIGHTEN.
7Connect the other ends of your battery leads to your breaker
box battery or other 24V power source rated for a minimum of
90A peak current.
Leave the electronics cover off for the moment you are not finished.
To avoid risk of fire, ensure that
the area in which any electrical
connection is being made is
vented and free of any fumes
that may cause fire or explosion.
WARNING
DO NOT REVERSE POLARITY.
The use of color coded (Red/
Black) wiring is highly recom-
mended to avoid reversing
polarity. Failure to comply may
result in damage to the unit.
WARNING
To avoid fire and/or poor
steering performance, ALL
electrical connections and
cable MUST comply with ABYC
wiring standards, be rated for
105 degrees C, and compliant
with SAE J112 . Battery leads
must be a MINIMUM of 6AWG
and a MAXIMUM of 30ft in
length, with an appropriate
fuse or breaker for fire
protection. If your application
requires longer battery leads,
please consult factory.
WARNING
NOTICE
It is recommended that ring-type crimp connections are used at each
end of the battery harness.
Use the correct ring terminal for the wire
gauge, and the appropriate crimping pliers.
2.1
DC POWER STEERING UNIT
NOTICE
Battery connections inside the
electrical
box should be made
using ring terminals sized for a
#10 stud.

DC Power Steering System 13
DC POWER STEERING UNIT
Ignition Connection
A minimum wire gauge of 16AWG is recommended for the ignition
trigger wire. Length of this wire is not critical.
1Insert ignition wire through the small strain relief fitting on the
electrical enclosure (see figure 11).
2Connect the ignition wire with a #8 ring connector to the IGN
post inside the electrical box. Torque to 15in-lbs (see figure 11).
3Using a crescent wrench tighten the strain relief fitting until a
seal is formed with the wire. DO NOT OVER TIGHTEN.
4Replace the cover on the electronics box with the 6 Phillips head
screws removed in step 2.1-1.
2.2
Autopilot Connections
When extending wire leads, marine best practices must be
followed. Solder and shrink wrap are highly recommended.
Appropriately sized and properly installed crimp connections with
shrink wrap protection are also acceptable. A minimum of 12AWG
wiring should be used for any extensions.
1The Red (+) and Black (-) leads from the autopilot motor should
be connected to your autopilot controller as specified in your
autopilot controller documentation.
NOTE: The polarity of the autopilot connections may need to be
reversed for correct operation in some installations.
Consult autopilot manufacturer’s documentation for full operation
instructions, EMC guidelines, etc.
2.3
NOTICE
NOTICE
NOTICE

14 SEASTAR Hydraulics
3.1 Purging Using Fast Purge Kit (HA2266)
1Fill DC Power Unit tank with SeaStar Steering Fluid to the "FULL"
line on sight glass DO NOT OVERFILL (refer to Figure 15 for
location of sight glass).
2Turn ignition ON to power DC Power Unit.
3Enter purge mode by holding down the purge button on the DC
Power Unit for 5 seconds. The unit’s main power pump will start
operating and the red purge LED will light up.
4Install Fast Purge Kit on steering cylinder and open all three
cylinder bleeder fittings a 1/4 turn. (Refer to Figure 12.)
5Open purge valve by rotating counter-clockwise until valve seats.
(Purge valve marked with the letter P on Power Unit refer to
Figure 15).
6
Allow the unit to run for approximately 5 minutes while monitoring
and filling the oil reservoir as needed. Take this opportunity to
check helms and hose connections for leaks.
7Start at the highest helm station; turn the wheel to port for at
least 10 wheel revolutions.
Repeat Step #7 to the starboard side.
9Repeat steps #7 and #8 for each helm station working from
highest to lowest.
10 If equipped with an autopilot jog the a/p controller in both
directions at this time.
11
At this time verify oil level again and wait approximately 2 minutes
while the unit purges the power circuit.
12 Using any steering station stroke cylinder from hard over to
hard over several times or until an air free stream of fluid is
seen through the bypass line.
If cylinder will not stroke at this time verify that the bleeders
opened in Step 4 are open 1/4 turn MAX.
13 Close Purge Valve completely. Torque to 80 in-lb. (Purge valve
marked with the letter P on Power Unit refer to Figure 15).
14 Close cylinder bleeder fittings (torque to 15 ft-lb) and remove
Fast Purge kit.
15
At this time if using front mount helms as shown in Figure 7 'burp'
each helm station by loosening the fill cap slightly to release any
trapped air. Loosen cap just enough to allow oil to start escaping
(DO NOT fully remove cap.) Use a rag to catch any oil spillage.
16 Exit “purge mode” by either pressing the purge button once or
by cycling the power unit ignition power.
17 Verify oil level and replace fill cap. With Power Unit on confirm
that the bleeding is completed by counting the number of wheel
turns from hard over to hard over. Use the chart on next page
to determine wheel turn amount.
NOTICE
The use of Fast Purge Kit
(HA2266) is highly recommended
and will improve speed and
quality of purge.
CAUTION
Monitor tank oil level during
purge. Failure to maintain MIN
oil level will allow air into the
system and may lead to
damage to the power pump.
Ensure purge valve is fully
closed and tightened to 0 in-lb before
operating vessel.
Failure to comply may lead to loss of steering
control causing property damage and/or personal injury or death.
Step 3 Filling & Purging the System
BLEED
BYPASS
Fi ure 12. Fast Pur e Kit HA2266.
DC POWER STEERING UNIT
WARNING

DC Power Steering System 15
DC POWER STEERING UNIT
Number of Wheel Turns by Installation
SYSTEM HC5801-2 HC5803-2 HC5805
SeaStar 1.4 4.3 Turns 5.3 Turns 4.3 Turns
SeaStar 1.7 3.6 Turns 4.4 Turns 3.6 Turns
If your wheel turns are not to within at least a 1/2 turn of the ones
shown above repeat bleeding procedure.
3.2
Purging Using Supplied Bleed Tubing (No Fast Purge Kit)
1Fill DC Power Unit tank with SeaStar steering fluid to the full line
on sight glass; DO NOT OVERFILL. (Refer to Figure 15 for location
of sight glass.)
2Turn ON DC Power Unit ignition.
3Enter purge mode by holding down the purge button on the DC
Power Unit for 5 seconds. The unit’s main power pump will start
operating and the red purge LED will light up.
4Connect the bleeder tube to the HP bleeder tee and the tank
bleeder fitting on the power steering cylinder (Refer to Figure 13.)
Open bleed fittings 1/4 – 1/2 turn. Use supplied spring clamps
to retain hose securely.
5Open the purge valve by rotating counter-clockwise until the
valve seats. (Purge valve marked with the letter P on Power Unit;
refer to Figure 15.)
6Allow the unit to run for approximately 5 minutes while monitoring
and filling the oil reservoir as needed. Take this opportunity to
check helms and hose connections for leaks.
TURN TO
PORT
TURN TO
STARBOARD
BA
AUXP AUXS
HP HS PRS TNK
Fi ure 13.
Failure to enter purge mode
prior to opening the purge valve
may result in damage to system.
WARNING
T
able 2

16 SEASTAR Hydraulics
DC POWER STEERING UNIT
7Referring to Table 1 and Figure 13 and starting at your highest
helm station turn the wheel starboard (configuration A) or port
(configuration B) until cylinder is fully retracted. If cylinder is
already fully retracted proceed to the next step.
Turn the wheel 10 turns in the opposite direction. The cylinder
may not move at this point this is OK. Repeat turning in the
same direction for each station from highest to lowest.
9If equipped with an autopilot jog the a/p controller in both
directions at this time.
TURN TO
PORT
TURN TO
STARBOARD
AB
AUXP AUXS
HP HS PRS TNK
Fi ure 14.
10 Close the cylinder bleed fittings. Remove the bleeder tube from
the HP bleeder tee and connect it to the HS bleeder tee on the
cylinder (Refer to Figure 14). Open bleed fittings 1/4 – 1/2 turn.
11 Referring to Table 1 and again starting at your highest helm
station
turn the wheel port (configuration A) or starboard
(configuration B)
until cylinder is fully extended. If cylinder is
already fully extended proceed to the next step.
12 Turn the wheel 10 turns in the opposite direction. The cylinder
may not move at this point this is OK. Repeat turning in the
same direction for each station from highest to lowest.
13 Repeat steps 7 through 11 4 times or until no air can be
seen in the bleeder tube when the cylinder is taken to full
extension/retraction.
14 Close all the cylinder bleed fittings (torque to 15 ft-lb).
15 Close the purge valve completely. Torque to 80 in-lb.
Ensure purge valve is fully
closed and tightened to 0 in-lb
before operating vessel.
Failure to comply may lead to
loss of steering control causing
property damage and/or
personal injury or death.
WARNING

DC Power Steering System 17
DC POWER STEERING UNIT
The DC Power Unit is supplied with the autopilot pump set to “full
speed” This will give approximate 60 cu in/min of flow. To adjust
the autopilot speed locate the adjusting screw (refer to Figure 15).
To reduce speed turn adjusting screw counter-clockwise until the
desired autopilot speed is achieved.
•
R efer to autopilot controller documentation for complete
autopilot system set-up
NOTICE
OIL LEVEL
INDICATOR
AUTOPILOT
FLOW
ADJUSTING
SCREW
(MARKED 'F')
PURGE VALVE
(MARKED 'P')
OIL FILL
PORT
Fi ure 15.
It is suggested that after an
adjustment is made, the
vessel be sea trialed in an
open area to determine
proper/safe hard over times.
NOTICE
Refer to autopilot controller
documentation for complete
autopilot system setup.
Step 4 Autopilot Tuning
16 At this time verify oil level in the reservoir and wait approximately
2 minutes while the unit purges the power circuit.
17
If using front mount helms as shown in Figure 7 ‘burp’ each helm
station by loosening the fill cap just far enough to allow oil to
start escaping (do not fully remove cap). Use a rag to catch oil
spillage. DO NOT REMOVE THE FITTING. Tighten fill cap.
1 Exit purge mode by either pressing the purge button once or
by cycling the power unit ignition power.
19 Verify oil level and replace fill cap.
With Power Unit on confirm that the bleeding is completed by
counting the number of wheel turns from hard over to hard over.
Use chart on page 15 to determine the correct number of turns.

18 SEASTAR Hydraulics
At this time you have successfully installed the DC Power Unit.
Verify that the system is operating properly and verify that turning
of the helm results in the correct movement of the cylinder shaft
and rudder(s).
Perform a 'System Leak Test' by taking the helm pump to hard
over. Once the hard over point is reached continue to force the
wheel an additional 1/2 turn to pressurize the system. Leave the
wheel in this position for at least 5 minutes then check ALL
connection points hoses helm cylinder etc. to ensure that no
leak is shown. Repeat to the opposite direction. DC Power Unit
may cycle on and off repeatedly while held at hard over. This
should be considered normal.
If a leak is noticed, it MUST be corrected prior to using the boat.
Failure to do so may lead to loss of steering causing property
damage, personal injury or death.
WARNING
WARNING
Step 5 System Verification & Operation Check
DC POWER STEERING UNIT
MAINTENANCE
The oil level in the Power Unit should be checked routinely. Any
loss of fluid indicates a leak somewhere in the system which must
be repaired immediately before operating the vessel.
Hoses should also be routinely inspected. Replace any hose(s)
showing signs of wear and remove the cause or reroute the hose(s).
Check all fittings and seal locations for leaks/damage and services
as necessary.
NOTICE
Failure to comply with maintenance checks may result in loss of
steering, causing property damage and/or personal injury.
Maintenance requirements will vary depending on usage and climate.
Bi-annual inspection by a qualified marine mechanic is required.