Seastar Solutions BayStar User manual

INSTALLATION INSTRUCTIONS
SUPPLEMENTAL
7 .1
Hydraulic Steering
HELMS
DASHBOARD MOUNTING TEMPLATE
Before youdoityour way,
pleasetryitour way
SEASTAR SOLUTIONS
3831 NO.6 ROAD
RICHMOND, B.C.
CANADA V6V 1P6
FAX [phone]
www.seastarsolutions.com
©2014 MARINE CANADA ACQUISITION INC.
DBA SEASTAR SOLUTIONS
PRINTED IN CANADA 5000–08/14
ISO 10592
3" DIA.
(76 mm)
FILLER PORT 3/4" STANDARD TAPER ORB PORTS (4)
3-15/16"
(100 mm)
1-15/16"
(50 mm)
ALL HELMS
6-1/16" (155 mm)
SEASTAR/BAYSTAR PLUS
HELMS 4-7/16" (113 mm)
BAYSTAR HELMS 4-5/8" (118 mm)
WARNING
DO NOT use ANY SeaStar PRO helm pump with
"unbalanced" steering cylinder as a steering lock
up WILL result.
WARNING
CAUTION
SEVEN
P O I N T O N E
I S O 9 0 0 1
If a 20° mounting wedge is used, cut out dash as
per mounting wedge template and mount helm
directly to the 20° wedge.
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.
w w w . s e a s t a r s o l u t i o n s . c o m
Figure 1. SeaStar helm shown, BayStar and BayStar Plus similar.
Figure 2.
PRIOR TO EVERY USE
SAFETY INFORMATION
The safety information provided below is intended
to inform you of the dangers that may be present
before, during and after use. It is critical that you
read and understand ALL the points noted.
WARNING
1. Ch ck Fluid l v l in high st h lm pump (s pag 2
for prop r fluid l v l s tting).
2.V rify imm diat st ring r spons wh n turning
st ring wh l(s). Ensur ngin (s), rudd r(s) and/or
outdriv (s) turn wh n all st ring wh ls ar turn d.
3. Visually insp ct all st ring hos s and fittings for
war, kinking and/or l aks.
. Ch ck for binding, loos , worn or l aking st ring
compon nts.
DO NOT OPERATE BOAT IF ANY COMPONENT IS NOT
IN PROPER WORKING CONDITION.
DURING USE
1. WEAR A COAST GUARD-APPROVED PERSONAL
FLOTATION DEVICE (PFD).
2. ATTACH ENGINE SHUT-OFF CORD (LANYARD) TO
YOUR PFD.
3. N v r allow anyon not familiar with th
op ration of th st ring syst m op rat th
boat at any tim .
. Know and adh r to th op rator r strictions for
your ar a including;
- F d ral Laws/R gulations,
- Stat Laws/R gulations and
- Municipal Laws/R gulations.
DO NOT OPERATE BOAT IF ANY COMPONENT IS NOT
IN PROPER WORKING CONDITION.
AFTER USE
1. Rins off st ring syst m thoroughly using
'fr sh, cl an wat r only'.
MAINTENANCE
1. Maintain st ring syst m at a minimum of twic
p r y ar.
- Du to th many diff r nt syst ms th s h lm
pumps ar us d in, pl as r f r to your Installation
and Own r's Manual provid d with your st ring
cylind r.
Keep our waters clean for all current and future users.
Dispose of ALL fluids in accordance with our local
regulations.
Mounting template for Standard Front Mount
applications only.
CAUTION
If photocopied check ALL measurements using a
measuring device to ensure accuracy.
Now with
positionable O-ring
hose fittings
This helm pump is fitted with Re-posi-
tional O-ring hose fittings (ORB).
NOTICE
FORM NO. 998002 R v. B

OIL LEVEL & SYSTEM CHECK
FILLER PLUG
(REMOVED)
FILLER KIT
HELM FILL
PORT
DO NOT LET
OIL LEVEL
FALL BELOW
THIS POINT
PUSH PIN
HYDRAULIC FLUID
Rcomm nd d oils for your st ring syst m ar ;
•S aStar Hydraulic Fluid, part# HA5430
•T xaco HO15
•Sh ll A ro Fluid #41
•Esso Univis N15
•Ch vron Aviation Fluid A
•Mobil A ro HFA
•Fluids m ting MIL-PRF-5606H sp cifications.
•Automatic transmission fluid D xron II may b
us d in an m rg ncy.
WARNING
NOTICE
Never use brake fluid. Any non-approved fluid may
cause irreparable damage, loss of steering, and
cancellation of warranty.
In cas s of xtr m m rg ncy any non-toxic, non-
flammabl fluid may provid t mporary st ring.
The oil level MUST be checked and maintained BEFORE
EACH use to ensure safe steering operation. Failure
to adhere to this warning may lead to loss of steering
control resulting in persons being ejected from vessel
or collision with an obstacle, leading to property
damage, personal injury and/or death.
WARNING
Side mount and Splashwell mount cylinders are unbal-
anced. To set the oil level in the helm pump the
cylinder rod MUST be fully “retracted (cylinder shaft
all the way in the cylinder body). Failure to adhere
to this caution WILL result in oil spillage at the helm
filler port and/or stiff steering operation.
CAUTION
•H lms mount d with th wh l shaft compl t ly
horizontal MUST b fill d to th bottom of fill r
hol AT ALL TIMES. DO NOT allow oil l v l to drop
mor than 1/4” b low fill r thr ads.
•For h lms mount d on a 20 d gr angl , or, with
wh l shaft in th v rtical position, oil l v l should
b within 1/2” of fill r hol .
•
Turn st ring wh l hard ov r to hard ov r to confirm
unr strict d mov m nt of th st ring syst m and
hos s. R p at this proc dur in ALL trim/tilt positions
of th ngin (s). If int rf r nc occurs, or, hos s
ar b ing str tch d this MUST b r mov d prior to
op rating your boat.
• Confirm that ngin (s) ar st ring to th prop r
dir ction wh n st ring wh l is turn d.
• If no int r f r nc is notic d, or, any int rf r nc
is corr ct d, go to n xt st p.
STEP 2 – System Chec
STEP 1 – Oil Level Setting
The system check MUST be completed after installation.
Doing so will ensure the safe operation of your steering.
Any fault/leak will be shown during this check. Failure
to adhere to this warning/check may result in loss of
steering control resulting in persons being ejected from
vessel or collision with an obstacle, leading to property
damage, personal injury and/or death.
WARNING
Failure to properly tighten the lock- nut (item 1) 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.
WARNING
SeaStar Solutions recommends that the hose and
hose fittings are checked on a regular basis to
ensure the safe operation of the steering system.
WARNING
Failure to complete the above noted step or, failure
to correct a problem may result in loss of steering
control leading to ejection from the vessel or collision
with an obstacle resulting in property damage,
personal injury and/or death.
WARNING
NOTICE
This step will NOT harm the s stem and an noise
made during this step should not be considered a
fault in the steering s stem.
• Tak st ring wh l hard ov r to starboard (any
h lm can b us d on a multi-station boat). Onc
th wh l r ach s its stop point (cylind r is fully
strok d out), continu to forc th wh l on (1)
full turn past stop. L av wh l in this position
whil you ch ck all conn ctions, fittings, s als
and hos s for l aks.
• R p at to th Port dir ction and insp ct ALL
conn ctions, fittings, s als and hos s for l aks.
• If l aks ar notic d th y MUST b r pair d prior
to op rating boat. Aft r r pair r p at bl ding
proc dur s as outlin d in th st ring cylind r
manual.
POSITIONABLE ORB HOSE FITTING INSTALLATION/REALIGNMENT
NOTE: for straight ORB fittings simply torque fitting
to 18 ft-lbs. Fitting re-orientation not required.
1.
Back off lock nut (it m 1), count r-clockwis , until it
stops. NOTE: O-ring must be fully on sealing surface
and cannot contact any threads. Do not use Teflon
tape or any liquid pipe sealant with ORB fittings.
2. Thr ad fitting into h lm port until fitting wash r
(it m 2) contacts th fac of th h lm port.
Tight n hand tight. DO NOT USE A WRENCH.
Re-Positionable Pump Fitting Installation (if required.)
Installation
Figure 5. Figure 6.
Figure 4.
Ensuring that th st ring wh l will not int rf r with
any oth r functional quipm nt and you hav ad quat
spac “b hind” th dash for fittings and st ring lin
conn ctions, d t rmin your d sir d mounting position.
MOUNTING THE HELM
NOTICE
The helm ma be mounted with the helm shaft horizontal,
vertical or an angle between.
At ALL times the fluid cap MUST be in the
uppermost position.
ORB HOSE
FITTING
SECURE WITH
WRENCH HERE
WHILE TIGHTENING
LOCKNUT (ITEM 1)
2
1
CAUTION
-3 helm pumps are fitted with positionable O-ring style
hose fitting ports (referred throughout this manual as
ORB). Do NOT attempt to install an NPT pipe fitting
into a -3 helm hose fitting port. Doing so will lead to
irreparable damage to the helm. ONLY use SeaStar
Solutions O-ring style hose fittings (ORB).
Figure 3.
Filling the helm full of oil can be done faster if oil is
poured into the helm prior to connecting filler tube
and oil bottle to the helm.
•Tap mounting t mplat to dash and us a c nt r
punch for locating r quir d hol s.
•
Drill th 3” diam t r hol and th four 5/16” diam t r
mounting hol s, position d as shown.
• To as installation, install your h lm hos fittings
into th h lm pump prior to mount.
See Positionable ORB Hose Fitting Installation.
•Ensuring th fill port is in th upp rmost position,
install h lm pump onto dash.
•
Install th four wash rs and four nuts onto th mounting
studs of th h lm pump. Torqu nuts to 110 in-lb.
THREAD FITTING BY HAND UNTIL
WASHER CONTACTS THIS FACE
•Using a good quality marin gr as , lightly gr as
tap r of th h lm pump shaft and mount st ring
wh l to h lm. Tight n wh l shaft nut to 150 in-lb.
• Install hos s as dir ct d in your st ring cylind r
installation manual.
• Fill and Purg st ring syst m as outlin d in your
st ring cylind r installation manual.
3. R -position fitting to d sir d ori ntation by turning
it count r-clockwis to a MAXIMUM of 1 full turn.
.
Whil holding th fitting body s cur ly with a wr nch,
torqu th lock nut (it m 1) to 18 ft-lbs.
5.Whil holding th fitting body s cur ly with a
wr nch, torqu th hos nd nut to 15 ft-lbs.
6. Purg syst m p r applicabl instruction manual.