SeaStar Tournament HC6845 Hydraulic Steering Installation Instructions and Owner's Manual

MANUFACTURED BY

TELEFLEX CANADA LIMITED

PARTNERSHIP

48

I S O 9 0 0 1

INSTALLATION INSTRUCTIONS

AND OWNERS MANUAL

w w w . s e a s t a r s t e e r i n g . c o m

Hydraulic Steering for Outboard

Powered Vessels

Front Mount Tournament Cylinder HC6845

Befo please tr our way

, y it our way

WARNING

CAUTION

NOTICE

To the Installer and End

User (Owner)

Thank you for choosing SeaStar Steering Systems by Telefl ex Marine.

This Installation and Owner’s Manual contains all the information that you and others will require for the safe installation and use of your steering system and MUST remain on board the boat. Throughout this manual, information for the safe installation and operation of the steering system will be distinguished in one of the following ways;

Hazards or unsafe practices which could result in severe personal injury or death.

Failure to adhere to a warning may lead to loss of steering control.

Loss of steering control may result in unpredictable boat behavior, leading to ejection from boat causing property damage, personal injury and/or death.

Hazards or unsafe practices which could result in minor injury or product or property damage.

Important information in regards to installation, use and maintenance of the steering components.

These safety alerts alone cannot eliminate all of the hazards that may be present while on the water. Telefl ex Marine recommends that all users of the steering system take an accredited 'boating safety course', follow safe boating practices and are made aware of the environment that they will be in.

Front Mount Tournament Cylinders

INDEX

2.0 Introduction ..................................................................... 4

2.1 Important Information/Technical Support Contact ........ 4

2.2 Parts List .................................................................. 4

2.3 Tools Required ........................................................... 5

2.4 Tournament Series Application Guide, all engine makes – 200+ HP ...................................... 5

3.0 Installation ...................................................................... 8

3.1 System Installation Overview ...................................... 8

3.2 Drive Bracket Installation ........................................... 9

3.3 Cylinder Installation ................................................. 10

3.4 Bracket Installation .................................................. 14

3.5 Tiebar Adjustment and Installation ............................. 18

3.6 Hose Installation ...................................................... 21

3.7 Filling and Purging .................................................... 26

3.8 Oil Level and System Check ..................................... 32

3.9 Interference Inspections ........................................... 32

4.0 Maintenance ................................................................... 33

5.0 Troubleshooting ............................................................... 34

6.0 Replacement Parts .......................................................... 36

7.0 Warranty ......................................................................... 37

7.1 Statement of Limited Warranty ................................... 37

7.2 Return Goods Procedure ............................................ 37 i

ii SeaStar Hydraulic Steering

1.0 INFORMATION

WARNING

Before installation

Installation


The safety information provided below is intended to inform you of the dangers that may be present before, during and after the installation.

It is critical that you read and understand ALL the points noted.

The safe operation of the steering system is dependant upon proper installation and maintenance, common sense, safe judgment and the knowledge/expertise of the operator. Every installer/user of the steering system should know the following requirements 'before' installing/using the steering system.

If you have any questions regarding any of these warnings, contact

Telefl ex Marine.

To reduce risk of severe injury or death. Always wear a Coast Guard

Approved personal fl otation device (PFD) and use an engine shut-off cord (lanyard).

1. Read and understand the Installation and Owner’s Manuals provided with your steering components.

2. Ensure that all components required to complete the installation are on hand (including hoses, fi ttings, oil and the proper tools required for the installation).

3. SeaStar components are highly engineered and safety tested to ensure system integrity, DO NOT substitute any component with non-SeaStar components as this may compromise system performance/reliability.

1. Install components as directed in all Installation Manuals

(including helm pumps, hoses and fi tting kits).

2. DO NOT modify or substitute any component in any way without written consent from Telefl ex Marine.

3. Comply with all system ratings/regulations (boat/engine, U.S.C.G.).

- Cylinder MUST be compatible with engine(s) installed.

- Cylinder MUST be rated for use on the engine(s) installed.

4. Confi rm that there is no interference between the steering cylinder(s), tiebars and the transom, splashwell, outboard engine or jackplate or any combination of these parts by performing the following steps; to hard over and confi rm that no interference occurs.

at all the positions of the jack plate.

b) Repeat step 4a) with engines tilted UP.

c) Perform step 4a) with each engine in DOWN/UP positions confi rming that independent TRIM/TILT can be done without any interference.

5. Confi rm that the steering cylinder can be fully stroked in both directions as well as full tilt and trim without stretching, chafi ng, rubbing and/or kinking of the hydraulic hoses.

6. Confi rm 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.

8. Conduct Oil Level and System Check as outlined on page 32 of this manual.

1

HYDRAULIC STEERING

TOURNAMENT CYLINDERS

WARNING

Safety Information Continued

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.

Prior to every use

1. Check Fluid level in highest helm pump (see page 32 for proper fl uid level setting).

2. Verify immediate steering response when turning steering wheel(s).

(Ensure engine turns when steering wheel is turned.)

3. Visually inspect all steering hoses and fi ttings for wear, kinking and/or leaks.

4. Check for binding, loose, worn or leaking steering components.

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 PDF.

3. Never allow anyone not familiar with the operation of the steering system operate the boat at any time.

4. Know and adhere to the operator restrictions for your area including;

- State Laws/Regulations and

DO NOT OPERATE BOAT IF ANY COMPONENT IS NOT IN PROPER

WORKING CONDITION.

After use

Maintenance

1. Rinse off steering system thoroughly using 'fresh, clean water only'.

- Cleaning fl uids containing ammonia, acids or any other corrosive

ingredients MUST NOT be used for cleaning any part of the

hydraulic steering system.

1. Maintain steering system at a minimum of twice per year.

- See Maintenance, page 33 of this manual.

Keep our waters clean for all current and future users. Dispose of

ALL fl uids in accordance with your local regulations.

2 SeaStar Hydraulic Steering

WARNING

Important Labels



Safety Information Continued

The safety information provided below is intended to inform you of the warning information on your products. Contact Telefl ex if labels are missing.

NOTICE

Many fi gures throughout this manual show blanking plates installed onto the cylinder. The steering cylinder is NOT shipped with these plates. The purchase of an additional "hardware" kit is required regardless of your application.


Figure 1.

1

CAUTION

Prior to removing end glands, both bolts (item 1) must be removed. Failure to remove will lead to irreparable damages to the cylinder.

3

4

To assist with the installation and maintenance of this steering system, Telefl ex Marine recommends that;

• You read and understand ALL installation manuals before your start the installation process (cylinders, helms, power assist, etc.).

Knowing the correct order of installation and location of components will drastically reduce installation time as well as inform you of common installation errors.

• Read and understand ALL Safety Information that is noted in this manual and ALL other Installation Manuals.

If you run into any problems before, during or after the installation of the steering system, please contact Technical Support for assistance.

Technical Support

Web: www.seastarsteering.com

Email: info@telefl ex.bc.ca

Phone: 604.248.3858

Fax: 604.279.2202

Before proceeding, confi rm that you have all the necessary components required to complete the installation of the steering system.

• Helm Pump(s).

• Power Assist and Autopilot Pumps (if applicable).

• Steering Hoses.

• Steering Cylinder(s).

• Tiebar(s).

• Hardware Kits.

• Appropriate Fittings.

• Fluid.

NOTE: Telefl ex recommends the use of SeaStar Steering Fluid ONLY.

For other 'acceptable' brands, refer to page 26 of this manual.

• Steering Wheel(s).

SeaStar Hydraulic Steering

NOTICE



The following tools are required to complete this installation. Having tools on site and ready will decrease installation time drastically.

These tools are 'in addition' to the tools required to mount your helm pump and steering hoses.

• 9/16”, 1/2”, 5/8” and 3/4”

Open end or box type wrench

• Torque wrench

• 5/32”, 5/16", 3/8", 3/16",

7/16" Allen Key/Wrench

• 5/8", 3/4" Socket

• 9/16" Long Socket and socket extension

• Good quality marine grease

all engine makes – 200+ HP

PART#

N/A

QTY

NOTES

N/A 1

TRIPLE ENGINE –

DUAL CYLINDER

QUAD ENGINE –

DUAL CYLINDER

QUINTUPLET

ENGINE (Plus)

NOTES

HC6845 2 HA6804

HC6845

HC6845

2

2

HA6806

HA6811

1

871 mm – 1092 mm HO6823

1 Consult Telefl ex Technical Service

Consult Telefl ex Technical Service

25.0" – 27.9"

28.0" – 36.0"

1. Installation may vary according to the following factors: engine mounting height, transom thickness, use of transom savers, tiller bolt location, engine tilt range, and engine size.

2. For center engine drops greater than 3 inches (76mm), please consult

Telefl ex Technical Service.

3. Tiebar length may vary depending on toe in/toe out setup. To allow for toe, add or subtract from your nominal engine center to center distance.

635 mm – 650 mm HO6821

653 mm – 777 mm HO6822

780 mm – 991 mm HO6823

635 mm – 673 mm

676 mm – 744 mm

747 mm – 869 mm

635 mm – 709 mm

711 mm – 914 mm

HO6820

HO6821

HO6822

HO6822

HO6823

1

1

1

1

1

1

1

2

2

1, 3, 4, 5

1, 3, 4, 5

1, 3, 4, 5

1, 3, 4, 5

1, 3, 4, 5

1, 3, 4, 5

1, 3, 4, 5

1, 2, 3, 4, 5, 6

1, 2, 3, 4, 5, 6

1, 2, 3, 4, 5

1, 2, 3, 4, 5

4. Based on recommended engine manufacturer minimum center to center distances. Deviating from these recommendations may require stroke limiting cylinders and/or engine tilt limiting, please consult Telefl ex

Technical Service.

5. Cylinder's must be plumbed in parallel only, no series connections.

Only exception is if cylinders are utilizing a liquid tie bar.

6. Maximum drop: ≤ 3 inches (76mm).

Front Mount Tournament Cylinders 5



Single Engine – Single Cylinder

NOTICE

Figure 2.

Twin Engine – Single Cylinder (Starboard)

This application requires installation of the drive bracket "BEFORE" installing the steering cylinder onto the engine. (Refer to page 9.)

Figure 3.


Figure 4.

Triple Engine – Dual Cylinder

Figure 5.


Twin Engine – Dual Cylinder



7

CYLINDER

HELM

3.1 System Installation Overview

Components Installation

• If you are running a Twin Engine – Single cylinder, install drive bracket

(see page 6) onto steering cylinder (see section 3.2 on page 9 for more information).

• Install steering cylinder(s) onto engine as per Section 3.3, page

10 of this manual.

• Install "Bracket(s)" as per Section 3.4, page 14 of this manual.

• Install "Tiebar(s)" as per Section 3.5, page 18 of this manual.

• Install Helm pump(s), Power Assist Pumps and/or Autopilot pumps.

• Install steering hoses as per Section 3.6, page 21 of this manual.

Filling and Purging

• Refer to page 26 for general fi lling and oil requirements.

• Power Purge users refer to Section 3.7.2, page 26 of this manual.

• Manual purging users refer to Section 3.7.3, page 27 of this manual.

Final System Check/Inspections

• Refer to Section 3.8, page 32 of this manual for setting oil level in helm pump and performing the 'system pressure test' to ensure steering system is ready for use.

• Conduct interference inspections as per Section 3.9, page 32 of this manual.


NOTICE

NOTICE



3.2 Drive Bracket Installation

Used only in a Twin Engine – Single Cylinder installation. Cylinder is to be installed onto the starboard engine only.

Requires Kit # HA6802.

4

*

*

3

*

2

1

REMOVE

Figure 6. Twin Engine - Single Cylinder.

* USED DURING TIEBAR

INSTALLATION,

SEE PAGE 18 OF THIS

MANUAL

1. Remove cap plug (item 1) from cylinder.

2. Apply thread locker to the threads of the drive bracket assembly

(Item 2).

3. Thread drive bracket assembly onto cylinder and torque to 30ft-lb.

4. Apply thread locker to the threads of item 4. Install washer and bolts torque to 20ft-lb.




10

NOTICE

NOTICE

Refer to page 12 – page 13 for your specifi c engine.

If used in a saltwater application, install end of ground strap to midsection steering bracket hole (see Figure 7, page 11).

STEP 1

Using a good quality marine grease with anti-corrosion additives, liberally lubricate the engine steering/tilt tube and support rod(s) (item 9).

Slide lubricated support rod(s) into engine steering/tilt tube.

WARNING If engine manufacturer has installed caps, plugs, and/or screws into the tiller arm, these caps, plugs and/or screws MUST be removed prior to installation of the steering cylinder.

STEP 2

Lightly grease the tiller bolt (item 2) and thread into the appropriate engine tiller arm hole. Ensure tiller bolt threads completely through the tiller arm hole. Remove bolt.

STEP 3

NOTE: Locate the correct orientation of your steering cylinder(s) and tiller nut/bolt as shown in Figures 8 through 9.

• Lightly grease tiller bolt.

• Install steering cylinder onto the correct side of the tiller arm.

• Thread tiller bolt fully into tiller arm and torque to 21ft-lb.

• While holding tiller bolt with a wrench to prevent loosening, install

and torque tiller nut (item 1) to 21ft-lb.

WARNING The tiller bolt (item 2) is a custom, high strength tiller bolt. DO NOT substitute with any other bolt. Ensure tiller bolt is properly torqued and does NOT loosen when installing nut (item 1).

STEP 4

• Thread adjusting nut (item 10) completely onto steering/tilt tube.

• Install stainless steel washers (item 11) onto both sides of the support rod (item 9).

• Install plastic spacers (items 7 and 8) as per your engine details.

• To assist with the installation grease and install keys (item 14) into support rod (item 9).

• Grease and secure support brackets (item 12) to the support rod and the cylinder rod.

• Install washers (items 3 and 4)

• If using a ground strap, complete install of strap as shown in

Figure 7, page 11.

• Install nuts (item 5 and 6) torque to 50ft-lb.

STEP 5

Eliminate free play in the support rod by rotating the adjusting nut

"counter-clockwise" until all the slack is remove from support rod hardware. Lock the adjusting nut in place by tightening the hexagon set screw.




NOTICE

FOR SALT WATER APPLICATIONS

CAUTION

Ensure ground strap is routed ‘under’ the tilt tube. Installation of the strap

‘above’ the tilt tube may lead to a hang up, or restriction.

Ground Strap Installation

Teleflex strongly recommends use of a ground strap on any outboard hydraulic steering cylinder with an exposed shaft (such as Teleflex tournament steering cylinders) where the vessel will be used in salt water. This ground strap will provide added protection against corrosion caused by stray current.

• Attach end terminal to the starboard side lower midsection steering bracket hole (wire facing downwards) using correct fasteners. Torque to 94 in-lb.

• Route ground strap UNDER the tilt tube. Install ground strap large end terminal to cylinder as per Figure 7.

• Install cylinder shaft nut and torque to 50ft.lb.

• Attach small middle terminal to unused hole in rear of cylinder support bracket. Orient terminal as shown in Figure 7. Torque to 45 in-lb.

• Ensure there is enough slack in the strap to allow the engine to pivot freely in ALL trim/tilt positions and throughout the entire steering range of the engine.

MIDSECTION

STEERING BRACKET

HOLES

END TERMINAL

FACE WIRE DOWN

GROUND

STRAP

GROUND STRAP ROUTED 'UNDER'

TILT TUBE = CORRECT

SMALL MIDDLE

TERMINAL

SMALL #10-24

FASTENER

(INCLUDED IN KIT)

TORQUE TO 45 IN-LB

CYLINDER SHAFT NUT

TORQUE TO: 50 ft.lb

LARGE END

TERMINAL

Figure 7. Ground Strap Installation.


RE-USE THIS

WASHER

YAMAHA

USE M6 X 1.0 FASTENERS

(INCLUDED IN KIT)

TORQUE TO 94 IN-LB

EVINRUDE

USE FASTENERS ALREADY

INSTALLED IN STEERING

BRACKET HOLES

TORQUE TO 94 IN-LB

ALL OTHERS

USE 1/4"-28 FASTENERS

(INCLUDED IN KIT)

TORQUE TO 94 IN-LB

GROUND STRAP ROUTED 'OVER'

TILT TUBE = INCORRECT

11



ENGINE

MANUFACTURER YEAR

EVINRUDE 2007 TO DATE

MODEL

3.3L V6 200–250HP

3.4L V6 250HP H.O.– 300HP

HC6845

HC6845

G = GREASE

POINT

14

12

G

10

G

3

5

6

4

7

11

G

Figure 8.

ITEM QTY DESCRIPTION

1

*2

1

1

Nut, 3/8" NF Nyloc ® , SS

3/8" UNJF x 1.35 HS

3 2

4 2

5 2

6 2

7 2

1/2" Washer, Flat, SS, Thick

1/2" Washer, Flat, SS, Thin

1/2" NF Nut, Thick

1/2" NF Nut, Thin

Plastic Spacer, Thick

12

9

1

2*

13

1

7

G

MOUNT UNDER TILLER ARM AND

IN REAR HOLE

12 3

5

6

4

G

11

G

G

13

2* SEE WARNING

WARNING

* ITEM 2 is a custom, high strength tiller bolt. DO NOT substitute with any other bolt.


8 0 Plastic Spacer, Thin (Not Used)

9 1 Support

10 1 Adjusting

11 2 5/8" Washer, Flat, SS

12 2 Support

13 1 Steering

14 2 Key




ENGINE

MANUFACTURER YEAR

YAMAHA 2007 TO DATE

MODEL

F300-350HP 4-Stroke, V8, 5.3L

F225-300HP 4-Stroke, V6 4.2L

HC6845

HC6845 Offshore

G = GREASE

POINT

14

12

G

10

G

3

5

6

4

8

11

G

Figure 9.


1

*2

1

1

Nut, 3/8" NF Nyloc ® , SS

3/8" UNJF x 1.35 HS

3 2

4 2

5 2

6 2

7 2

1/2" Washer, Flat, SS, Thick

1/2" Washer, Flat, SS, Thin

1/2" NF Nut, Thick

1/2" NF Nut, Thin

Plastic Spacer, Thick


9

1

2*

MOUNT OVER TILLER ARM AND IN

REAR HOLE

1

12 3

5

7 G

6

13

4

11

7

G

G

13

G

2* SEE WARNING

WARNING

* ITEM 2 is a custom, high strength tiller bolt. DO NOT substitute with any other bolt.


8 1 Plastic Spacer, Thin

9 1 Support

10 1 Adjusting

11 2 5/8" Washer, Flat, SS

12 2 Support

13 1 Steering

14 2 Key

13



NOTICE

WARNING

WARNING

NOTICE

Depending on engine, the cylinder may be mounted different than shown here.

Single Engine – Single Cylinder


Blanking plates MUST be installed prior to use.

1. Apply thread locker (item 2) to the threads of item 1. NOTE: Thread locker (item 2) is included with the hardware kit.

Thread locker MUST be installed onto all four bolts (item 1).

Failure to do so may lead to separation of components.

2. Mount blanking plates (item 3) to both sides of steering cylinder

(item 4) as shown in Figure 10.

3. Torque bolts to 50ft-lb.

1*

4

Figure 10.


*1 4 Mounting Bolt

1 Locker

2 Plate

1 Cylinder

3

1*

2

3

* CUSTOM BOLTS

DO NOT SUBSTITUTE

NOTES

Custom bolts, DO NOT substitute

Must be applied

Must be installed




NOTICE

NOTICE

WARNING

WARNING

Item 6a & 6b are custom, high strength tiller bolts. DO NOT substitute with any other bolt.

Twin Engine – Single Cylinder

This application requires installation of the drive bracket "BEFORE" installing the steering cylinder onto the engine. (Refer to page 9.)


Blanking Plate Installation (items 1–3)

1. Apply thread locker (item 2) to the threads of item 1.

NOTE: Thread locker (item 2) is included with the hardware kit.

Thread locker MUST be installed onto all four bolts (item 1).


2. Mount blanking plates (item 3) to both sides of steering cylinder

(item 4) as shown in Figure 11.


Engine Bracket Installation (items 5–7)

1. Mount engine bracket (item 5) to the port engine tiller arm (see inset).

2. Lightly grease item 6 (a and b). Thread 6a into far aft hole and

6b into forward hole in engine tiller arm and torque to 21ft-lb.

3. While holding the head of the bolt (items 6a and 6b) with a wrench, tighten and torque nuts (items 7) to 21ft-lb.

7

4

3

1*

2

3

1*

* CUSTOM BOLTS


G = GREASE

POINT

G

ENGINE

BRACKET

6a

5 †

G

6b

† NOTE ORIENTATION

OF ENGINE BRACKET

WHEN INSTALLING

TILLER

ARM

YAMAHA = ABOVE TILLER ARM

EVINRUDE = BELOW TILLER ARM

Figure 11.

NOTICE

Depending on engine, the cylinder may be mounted different than that shown here.


*1 4 Mounting Bolt

1 Locker

2 Plate

1 Cylinder

1 Bracket

6 2

7 2

Bracket Tiller Bolt

3/8” Locking Nut


NOTES


Must be applied

Must be installed

15



NOTICE

WARNING

Twin Engine – Dual Cylinder




Thread locker MUST be installed onto all eight bolts (item 1).


2. Mount tiebar and blanking plates (item 3 and 4) to both sides of steering cylinder (item 5) as shown in Figure 12.

3. Torque bolts to 50ft-lb

A**

1*

B**

A**

1*

1*

B**

2

5

3

1* * CUSTOM BOLTS


4 ** PLATE ORIENTATION

A = YAMAHA

B = EVINRUDE

Figure 12.

NOTICE



*1 8 Mounting Bolt

1 Locker

2 Plates

2 Plate

2 Cylinder

NOTES


Must be applied

Must be installed




NOTICE

WARNING

WARNING

Item 6a & 6b are custom, high strength tiller bolts. DO NOT substitute with any other bolt.

Triple Engine – Dual Cylinder


Tiebar Bracket Installation (items 1–4)



Thread locker MUST be installed onto all eight bolts (item 1).


2. Mount tiebar and blanking plates (item 3 and 4) to both sides of steering cylinder (item 8) as shown in Figure 13.


Engine Bracket Installation (items 5–7)

1. Mount engine bracket (item 5) to the center engine tiller arm.

2. Lightly grease item 6 (a and b). Thread 6a into far aft hole and

6b into forward hole in engine tiller arm and torque to 21ft-lb.

3. While holding the head of the bolt (items 6a and 6b) with a wrench, tighten and torque nuts (items 7) to 21ft-lb.

A ** 1*

B **

7

5 †

† NOTE ORIENTATION

OF ENGINE BRACKET

WHEN INSTALLING

G

G

A **

B **

1*

6a

6b

1*

2

* CUSTOM BOLTS


4 ** PLATE ORIENTATION

A = YAMAHA

B = EVINRUDE

G = GREASE

POINT

ENGINE

BRACKET

1*

TILLER

ARM

ALL APPLICATIONS MOUNT ENGINE

BRACKET UNDER TILLER ARM

8

Figure 13.

3

NOTICE



1 8 Mounting Bolt

1 Locker

2 Plate

2 Plate

1 Bracket

6 2

7 2

Bracket Tiller Bolt

3/8” Locking Nut

2 Cylinder

NOTES


Must be applied

Must be installed




3.5 Tiebar Adjustment and Installation

WARNING

• Determine engine center distance. Note: Ensure that any toe

IN/OUT is taken into account.

• Adjust tiebar to correct distance by rotating as shown in Figure 14.

If a RED O'ring appears during the tiebar adjustment you MUST order a longer tiebar to complete the installation. DO NOT install tiebar if the RED O'ring appears.

• Install adjusted tiebar onto steering cylinder/bracket as per

3.5.2/3.5.3.

SEE O-RING

WARNING

ABOVE

Figure 14.

3.5.2 Tiebar to Drive Bracket Installation

Twin Engine – Single

Cylinder

• Install bushing into tiebar joint.

• Slide tiebar (with bushing installed) into drive bracket.

• Install shoulder bolt and nut, torque to 11ft-lb.

G = GREASE

POINT

TIEBAR

NOTICE

* Parts included with hardware kit.

G

*NUT

*BUSHING

DRIVE BRACKET

G

*SHOULDER BOLT

Figure 15.




3.5.3 Tiebar to Cylinder Installation

YAMAHA

• Position tiebar in place.

• Apply thread locker to shoulder bolt SHORT and install. Torque to 70ft-lb.

• While holding shoulder bolt SHORT with your key/wrench, install and tighten nut to 70ft-lb.

NOTICE


G = GREASE

POINT

G

YAMAHA

*NUT

NOT USED

G

*SPACER

.150"

*PLATE

*SHOULDER BOLT

SHORT

TIEBAR

Figure 16. Yamaha Tiebar to Cylinder Installation.

EVINRUDE

• Position tiebar in place.

• Install .150" spacer for Evinrude.

• Apply thread locker to shoulder bolt SHORT and install. Torque to 70ft-lb.

• While holding shoulder bolt SHORT with your key/wrench, install and tighten nut to 70ft-lb.

NOTICE


G = GREASE

POINT

G

EVINRUDE

*PLATE

*NUT

* SHOULDER BOLT

SHORT

G

*SPACER .150"


TIEBAR

Figure 17. Evinrude Tiebar to Cylinder Installation.

19



3.5.4 Tiebar to Engine Bracket Installation

Twin Engine – Single

Cylinder

• Note installation hole as per your engine make (A or B) see fi gure 18.

• Install .100" spacer.

• Position tiebar into appropriate hole.

• Apply thread locker to shoulder bolt LONG and install. Torque to 70ft-lb.

• While holding shoulder bolt LONG with your key/wrench, install and tighten nut to 70ft-lb.

NOTICE


G = GREASE

POINT

B

*NUT A

*ENGINE BRACKET

*SPACER .100"

G

TIEBAR

G

A = YAMAHA

(Tiebar mounts BELOW engine bracket)

B = EVINRUDE

(Tiebar mounts ABOVE engine bracket)

*SHOULDER

BOLT LONG

Figure 18.

Triple Engine – Dual

Cylinder

• Note installation hole as per your engine make (A, B, or C).

• Install .350" spacer.

• Position tiebar into appropriate hole.

• Apply thread locker to shoulder bolt LONG and install. Torque to 70ft-lb.

• While holding shoulder bolts LONG with your key/wrench, install and tighten nut to 70ft-lb.

NOTICE


G = GREASE

POINT *NUT *ENGINE BRACKET

20

G

TIEBAR

G

Figure 19.

*SHOULDER

BOLT LONG G

G

* SPACER .350" USED IN

ALL APPLICATIONS

TIEBAR

ALL APPLICATIONS

MOUNT THE TIEBAR BELOW

ENGINE BRACKET IN

FORWARD HOLE




WARNING

WARNING

NOTICE


Steering hoses and how they are installed are critical to the safe operation of your steering system. Telefl ex Marine recommends the use of SeaStar Steering hoses ONLY. Use of any other hose may drastically reduce system performance and safety.

Do not cut SeaStar steering hoses, cutting these hoses will render them useless.

Before continuing on with the installation of your steering hoses, please ensure that you read and understand the important points shown below;

• DO NOT install any pipe sealant onto the "hose" side of a fi tting.

• DO NOT remove protective end covers until the hoses have been routed and are ready to be connected to the helm pump, hose fi tting or steering cylinder(s).

• Before, during and after installation the hoses MUST be protected from chaffi ng, rubbing, and contact or interference with assembly screws or sharp edges of any type.

• DO NOT install hoses in an area where they will be exposed to high heat, such as engine manifolds, engine compartments or highly corrosive areas such as battery fumes or electrical connections.

• If possible, route hoses through a protective PVC cover.

• Secure hoses in minimum 2' increments.

• DO NOT bend hoses tighter than a 3-1/2” (89mm) radius.

• Provide suffi cient hose lengths to allow for cylinder movement throughout the turning arc and UP/DOWN trim/tilt settings of the engine(s).

• DO NOT allow hoses to hang free in an area where they could become a safety hazard.

• DO NOT use extruded nylon tubing for plumbing an outboard system

Extruded nylon tubing can only be used for return/compensating lines between power assist and/or autopilot pumps and the helm pump.

• Where possible, route hoses in an area where they can be easily inspected for wear on a regular basis.

Continuous kinking, rubbing, chafi ng or twisting of a steering hose may eventually weaken the hose(s) to a point where it could rupture.

Rupture of a hose will lead to loss of steering control.

Your SeaStar helm and steering cylinder(s) are shipped with the appropriate hose fi ttings and are for use with SeaStar Steering hoses only. All SeaStar Steering components are highly engineered and safety tested to ensure system integrity, do NOT substitute any component with non-SeaStar components as this may compromise system performance/reliability.

21



22

NOTICE

STEP 1 Set Up

• See fi gures 22 through 25 on the following pages to locate your plumbing diagrams.

• Mark each end of the hose to ensure proper connection.

Hoses are crossed from the helm pump(s) to the steering cylinder(s).

Port side helm connection will be installed onto the starboard fi tting on the cylinder, and the Starboard side helm connection will be installed onto the port side fi tting on the cylinder.

STEP 2

CAUTION

NOTICE

CAUTION

WARNING

Routing

Throughout the hose installation, ensure the protective caps remain installed onto the end of the hoses. Doing so will prevent contamination from entering the system

• Route steering hoses so that the hose bend restrictor will be located at the steering cylinder(s).

• Route steering hoses so that they have a gradual rise from the steering cylinder(s) to the helm pump.

• If routing hoses through a blind area, ensure that the area is free and clear of any sharp edge, screw or any other object that may damage the hose.

• Secure hoses every 2’.

When securing hoses, ensure that the securing device being used does NOT crimp down too tight on the steering hoses. This may lead to a restriction in the system.

The hose fi tting port on the steering cylinder is that of an ORB and

NOT an NPT. Installing an NPT fi tting into an ORB port will result in irreparable damage to the steering cylinder.

If you wish to re-orientate the hose fi tting, please refer to page 23 of this manual for the re-orientation steps.

Substituting brass fi ttings into the steering cylinder may result in galvanic corrosion and irreparable damage to the cylinder as well as affect system integrity.

STEP 3

WARNING

Hose to fi tting installation

• Remove protective covers.

• Install hose end fi tting onto intended fi tting, tighten hand tight.

• While holding the receiving fi tting with a wrench, tighten hose fi tting to 15ft-lb.

When installed, confi rm that the hoses are not being pulled or kinked over by pushing the engine(s) back and fourth. Hoses must NOT be pulled on at any time.




ORB Hose Fitting

Reorientation (if required)

1 Back off lock nut (item 1, Figure 20), counter-clockwise, until it stops.

2 Thread fitting into cylinder body until fitting washer (item 2, Figure 20) contacts the face of the cylinder port. Tighten hand tight,

DO NOT TORQUE FITTING INTO GLAND.

3 Position fitting to desired orientation by turning it counter-clockwise to a MAXIMUM of 1 full turn.

4 While holding fitting with a wrench, tighten the locknut (item 1,

Figure 20) and torque to 40–43ft-lb.

WARNING

WARNING

Failure to properly tighten the locknut (item 1, Figure 20) 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.

Teleflex recommends that the hose and hose fittings are checked on a regular basis to ensure the safe operation of the steering system.

SECURE WITH

WRENCH HERE

WHILE TIGHTENING

LOCKNUT (ITEM 1)

1

NOTICE

Complete removal of hose fi tting requires the cylinder bleed nipple to be removed.

Figure 20.

Figure 21.

THREAD FITTING BY HAND UNTIL

WASHER CONTACTS THIS FACE


2

23



Hose Installation

Plumbing Diagrams

SINGLE CYLINDER

MANUAL SYSTEM

The plumbing diagrams shown in the following pages outline typical ways to plumb a SeaStar Steering system fi tted with autopilot and power assist pumps. Wheel turns are counted with the Power Assist

Pump turned OFF.

Single Cylinder Applications

(including Twin Engine – Single Cylinder)

SINGLE CYLINDER

POWER ASSIST WITH AUTOPILOT

1 1

P S

2

P

R

S

2

5

P

R

S

H1

R

H2

C1 C2

4

3

Figure 22.


1 As Req. Helm Pump, various styles and displacements

2 As Req. SeaStar Steering Lines

3 As Req. Steering Cylinder*

4 As Req. SeaStar Power Assist Pump

5 N/A

24

Figure 23.

HELM PUMP MODEL

1.7 cu.in. per revolution



3

WHEEL TURNS

REQUIRED

5

4

3.5




Dual Cylinder Applications

(Including Triple/Quad Engines – Dual Cylinder)

1

DUAL CYLINDER

MANUAL, PLUMBED IN PARALLEL

P S

2

5

1

DUAL CYLINDER

POWER ASSIST WITH AUTOPILOT,

PLUMBED IN PARALLEL

P

R

S

2

P

R

S

H1

R

H2

C1 C2

4

3

Figure 24.

3


1 As Req. Helm Pump, various styles and displacements

2 As Req. SeaStar Steering Lines

3 As Req. Steering Cylinder*

4 As Req Power Assist Pump

5 N/A

3

Figure 25.

HELM PUMP MODEL




3

WHEEL TURNS

REQUIRED

10

8

7




NOTICE

NOTICE

NOTICE

NOTICE

CAUTION

Never use brake fl uid. Any non-approved fl uid may cause irreparable damage, loss of steering, and cancellation of warranty.

3.7 Filling and Purging

3.7.1 Hydraulic Oil Requirements

2 bottles (2 quarts or liters) for single station and single cylinder systems. One additional bottle for each cylinder, helm, power assist and/or autopilot pump added to the system.

Longer hose runs will require more fl uid than that shown above.

Oil can be re-used if fi ltered through a fi ne mesh screen such as that used for gasoline. If unable to fi lter oil, an additional bottle of fl uid is required.

"Bleeder" refers to cylinder or P/A unit fi tted with bleed fi ttings. Bleed fi ttings can be opened by unscrewing bleed nipple nut two turns.

Protect your boating environment by ensuring that all used oil is disposed of properly.

Recommended oils for your steering system are:

• SeaStar Hydraulic Fluid, part no. HA5430 (1 quart),

HA5440 (1 Gallon)

• Texaco HO15

• Aero Shell Fluid #41

• Esso Univis N15

• Chevron Aviation Fluid A

• Mobil Aero HFA

• Fluids meeting Mil H5606 specifi cations.

• Automatic transmission fl uid

Dexron ll may be used in an emergency.

In cases of extreme emergency any non-toxic, non-fl ammable fl uid may provide temporary steering.

VENT PLUG – Part No. HA5431

SUPPLIED WITH SEASTAR HELM

• MUST BE USED WITH HELM PUMP ON

ALL SINGLE STEERING STATION

SYSTEMS.

• MUST BE USED ON UPPERMOST HELM

PUMP ON MULTI STEERING STATION

SYSTEMS.

NON-VENT PLUG – Part No. HA5432

• MUST BE USED ON ALL HELM PUMPS

OTHER THAN UPPER MOST HELM

PUMP ON MULTI STEERINGSTATION

SYSTEMS.

• THIS NON-VENT PLUG IS SUPPLIED

WITH ADDITIONAL STATION FITTING

KIT NO. HF5501 AND HF5502.

Figure 26.

3.7.2 Power Purge Users

NOTICE

STEP 1

Removing Air from Return Line.

CAUTION

Refer to your Power Purge installation manual for important

Warnings and Notices while using the Power Purge Units.

26

If the application is NOT fi tted with a SeaStar Power Assist, start at

Step 2, point 2.

• Install the helm adapter into the helm pump and attach the helm hose from the power purge unit.

• Connect one of the fl uid return hoses (cylinder lines) from the

Power Purge unit to the Reservoir bleed fi tting on the P/A unit.

(see Figure 27 on page 28 for bleed fi tting location).

• Using a 1/2" wrench open reservoir bleed fi tting 1-turn.




NOTICE

DO NOT OPEN MANUAL BLEED VALVE WHEN USING A POWER PURGER

• Turn ON the Power Purge unit and continue to run until NO air is visible leaving the P/A unit.

• Turn OFF Power Purge unit.

• Close reservoir bleed fi tting and continue on with the following steps.

NOTICE

STEP 2

STEP 3

• Ensure the reservoir bleed fi tting is closed then remove the hose from the reservoir bleed fi tting and connect to the steering cylinder bleeder fi ttings. Ensure the quick connect is locked onto the fi tting.

• If using Dual Cylinder Purge Kit (part # HA5461), connect cylinder bleed hoses to every bleeder fi tting, then, open fi tting 1-turn using a 1/2" wrench.

• If using a single cylinder Purge Kit, begin with the starboard bleeder fi tting on each cylinder, open bleeder fi tting 1-turn using a 1/2" wrench.

Repeat on the port side bleeder fi tting.

DO NOT OPEN MANUAL BLEED VALVE WHEN USING A POWER PURGER

• Turn Power Purge unit ON.

• Oil should fl ow into and out of the helm pump. Wait twenty seconds for the helm to fi ll with oil.

• Turn the steering wheel clockwise until the cylinder rod is fully extended (you may have to manually push the cylinder rod). SLOWLY continue to turn the wheel to hold the cylinder in this position for approximately 30 seconds. Ensure there are NO air bubbles escaping through the cylinder hoses.

• Turn the steering wheel counter-clockwise until the cylinder rod is fully extended (you may have to manually push the cylinder rod).

SLOWLY continue to turn the wheel to hold the cylinder in this position for approximately 30 seconds. Ensure there are NO air bubbles escaping through the cylinder hoses.

• Turn OFF Power Purge unit

• Tighten ALL bleed fi ttings on the steering cylinder(s)

• Repeat above steps with the Power Assist unit ON.

Continue on with Oil Level and System Check on page 32.

3.7.3 Manual Filling and Purging


These instructions show how to fi ll and purge a SeaStar Steering

System with the P/A unit installed. The same steps apply to ALL cylinders with the exception of which bleed fi tting to open and close and the direction the cylinder rod moves. These variations are shown in inset diagrams at each step. For multiple steering stations, start with the lowest station while going through Steps 1 – 7, repeat at each higher station until complete.

27



CAUTION

DO NOT turn ON P/A unit until manual portion is completed.

This procedure requires two people. One person may not be able to remove all the air from the system, which will result in spongy, unresponsive steering.

During the entire fi lling procedure, oil MUST be visible in the fi ller tube. DO NOT allow oil level to disappear into the helm pump, as this may introduce air into the system and increase your fi lling time.

Figure 27.

28

NOTICE

NOTICE

STEP 1

BEFORE bleeding the main steering system (helm, hoses and cylinders), the RETURN line will need to be purged.

Removing Air From Return Line

• Install the fi ll tube and fl uid fi ll bottle into the helm pump.

Filling the helm full of fl uid prior to connecting the fi ller tube and oil bottle will decrease purge time.

• Open the manual bleed valve and reservoir bleed fi tting (see Figure

27) on the power assist unit. The manual bleed valve should be opened two full turns.

• Fill helm with fl uid, then, turn steering wheel to the starboard side until a steady stream of "air-free" oil comes out of the reservoir bleed fi tting on the Power Assist Unit.

• Close reservoir bleed fi tting.

• Continue to turn the wheel to starboard another 15 turns after closing the reservoir bleed fi tting and prior to closing the manual bleed valve.

• Close manual bleed valve and continue with Steps 2 – 5.

PUSH PIN

FILLER PLUG

(REMOVED)

RESERVOIR BLEED FITTING

FILLER KIT

HELM FILL PORT

MANUAL BLEED VALVE

DO NOT LET

OIL LEVEL

FALL BELOW

THIS POINT

R

H2 H1




STEP 2

• Turn the steering wheel clockwise until the cylinder rod is fully extended on the right side of the cylinder.

• Open bleed fi tting as per your installation.

TURN CLOCKWISE

OPEN RIGHT SIDE BLEEDER

Figure 28. Outboard Front Mount & HC5332 Cylinder.

STEP 3

• Holding the cylinder body (Front Mount cylinder) or rod (Side Mount cylinder) to prevent the body/rod from moving, turn the steering wheel counter-clockwise until a steady stream of air free oil comes out of the bleeder. (Drain approx. 1/2 bottle of oil or as required).

Do not use anything other than your hands to restrain the cylinder body/rod.

• While continuing to turn the wheel close the bleed fi tting for your application and let go of the cylinder body/rod.

TURN COUNTER-CLOCKWISE

CLOSE RIGHT SIDE BLEEDER



29



STEP 4

• Continue turning the steering wheel counter-clockwise until the cylinder rod is fully extended to the left. (Steering wheel will come to a stop).

• Open bleed fi tting as per your installation.

TURN COUNTER-CLOCKWISE

OPEN LEFT SIDE BLEEDER


STEP 5

• Holding the cylinder body (Front Mount cylinder) or rod (Side Mount cylinder) to prevent the body/rod from moving, turn the steering wheel clockwise until a steady stream of air free oil comes out of the bleeder.

• While continuing to turn the wheel close the bleed fi tting for your application and let go of the cylinder body/rod.

CAUTION

Prior to operating system, perform

Oil Level System Check, refer to page 32.

TURN CLOCKWISE

CLOSE LEFT SIDE BLEEDER

30


NOTICE

STEP 6

• Complete electrical connections as outlined in your Installation

Owner’s Manual.

• Repeat Steps 2 – 5 of purging instructions with the P/A unit "ON"

Be sure to remove ALL air from the autopilot reservoir line.

If the system has an autopilot installed, ensure that the autopilot pump is run for at least 10 seconds in both directions during Step 3 & Step 5.




Perform Steps 1 – 6 at station no. 1. Then repeat Steps 2 – 5 at station no. 2.

Note: Refer to Oil Level &

System Check on page 32.

STATION NO.2

STATION NO.1

P/A UNIT

CYLINDER

Figure 32.

When performing Steps 2 – 5, perform instructions in each step fi rst on cylinder no. 1 and then on cylinder no. 2, before proceeding to the next step. ie:

Perform instructions referring to right side of cylinder fi rst on cylinder no. 1 and then on cylinder no. 2.



Figure 33.

CYLINDER NO.2

Follow same procedure as instructed for single stationtwin cylinders, beginning at station no. 1, and repeat entire procedure at station no. 2.



STATION NO.2

STATION NO.1


Figure 34.

CYLINDER NO.2

P/A UNIT

CYLINDER NO.1

P/A UNIT

CYLINDER NO.1

31



3.8 Oil Level and System Check

• Refer to your helm pump installation manual for proper fl uid level setting.

• At this time the steering system must be checked for proper connections hose and fi ttings, possible leaks, and air removal.

Please complete the following steps with the P/A Unit OFF.

• Turn steering wheel to hard over, then force the wheel another one quarter to one half turn past the stop point. Check all connections including the following areas for evidence of a leak.

- Helm fi tting connections.

- P/A fi tting connections

- Cylinder fi tting connections

• Repeat above steps to the other steering direction.

• Any sign of a leak MUST be repaired prior to operating the boat.

• While turning steering wheel observe fl uid level in the helm pump.

If fl uid level drops and rises as the wheel is being turned there is still air in the system. Complete bleeding instructions again until no obvious fl uid level change is noticed.

32

WARNING The following steps MUST be completed with an assistant BEFORE operating the boat. Failure to conduct this important step may lead to damage or separation of components. ANY fault and/or interference with any other object MUST be corrected prior to use.

1. Confi rm that there is no interference between the steering cylinder(s), tiebars and the transom, splashwell, outboard engine or jackplate or any combination of these parts by performing the following steps; a) With engine fully tilted DOWN, turn steering wheel from hard over to hard over and confi rm that no interference occurs.

at all the positions of the jack plate.

b) Repeat step 1a) with engines tilted UP.

c) Perform step 1a) with each engine in DOWN/UP positions

confi rming that independent TRIM/TILT can be done without

2. Confi rm that the steering cylinder(s) can be fully stroked in both directions as well as full tilt and trim without stretching, chafi ng rubbing and/or kinking of the hydraulic hoses.

3. Confi rm that the steering wheel can rotate freely from hard over to hard over.

If using tilt type helms, this step must be performed in all tilt positions.


WARNING

1. Owner(s) (End Users)

WARNING

Following the routine maintenance schedules as outlined below, in the time frame noted will ensure years of service from your SeaStar

Steering System, as well as keep you and your passengers safe from the dangers that are present on and off the water.

Prior to every use.

1. Check Fluid level in highest helm pump (see page 32 for proper fl uid level setting).

2. Verify immediate steering response when turning steering wheel(s).

(Ensure engine turns when steering wheel is turned.)

3. Visually inspect all steering hoses and fi ttings for wear, kinking and/or leaks.

4. Check for binding, loose, worn or leaking steering components.

DO NOT operate boat if any component is not in proper working condition.

2. Qualifi ed Marine

Mechanic

WARNING

Any work being performed with the steering system MUST be completed by a qualifi ed mechanic with the working knowledge of the system.

After fi rst 20 hours, then every 100 hours or 6 months thereafter

(which ever comes fi rst).

1. All points noted above.

2. Check tightness of ALL fasteners/fi ttings throughout the steering system. Tighten to correct torque specifi cations as required.

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 Telefl ex Marine

After every 200 hours or 12 months (which ever comes fi rst).

1. All points noted above.

2. Remove support rod from engine steering/tilt tube. Clean engine steering/ tilt tube and re-grease using a good quality marine grease.

3. Grease support rod liberally

4. Grease all contact points shown in the cylinder and tiebar installations '

G

'. DO NOT remove tiller bolt to re-grease.

5. Remove steering wheel and re-grease wheel shaft using a good quality marine grease.

6. Inspect hydraulic oil for cleanliness, fl ush if required.


WARNING

If properly installed and maintained, your SeaStar Steering System will provide years of safe and reliable performance. Our systems have been designed with protection against over-pressure situations by a pressure relief valve. Most faults occur when installation instructions have not been followed and in most cases will present themselves immediately upon fi lling the system. Below are the most common faults and their likely cause and solution. Extreme caution must be exercised when diagnosing and correcting a fault. These troubleshooting guides may seem simple in text, however these MUST be completed by a qualifi ed marine mechanic that has working knowledge of the steering system.

Telefl ex does NOT recommend disassembly of a helm pump, or, removing a steering cylinder rod/shaft at any time. Doing so may cause more damage, leading to irreparable damage and costly replacements.

FAULT

1. During filling, helm becomes completely locked up.

CAUSE SOLUTION

• Mechanical interference with other components.

• Blockage in the steering lines.

• Tilting mechanism not installed properly.

• Engine(s) are restricted.

• Power Assist H1, or H2 line crossed with R line.

• Check ALL areas for interference, correct as required.

• Remove all steering lines. Blow air through lines. Any line not allowing good air flow may should be replaced.

• Confirm tilt mechanism is installed correctly.

• Confirm that engines are able to be moved freely with cylinder not connected.

• Confirm system is plumbed correctly.

2. System is very difficult to fill, air keeps burping out top of helm, even after system appears full.

• Air remaining in system.

• Bleed fitting leaking.

• Coiled hose.

• Reservoir/compensating lines not purged free of air.

• Bleed steering system again.

• Tighten bleeder, replace if leak continues.

• DO NOT cut hoses. Lessen coil, or, replace with shorter lines.

• Bleed air from reservoir/compensating lines.

3. Steering is hard to turn even when boat is not moving and engines are OFF.

• Adjusting nut on support rod is overtightened.

• Restrictions on hoses

(see Fault 1).

• Mechanical interference with other components

(see Fault 1).

• Nut should be hand-tight.

• See fault 1.

• See fault 1.




3. Continued.

Steering is hard to turn even when boat is not moving and engines are OFF.

• Air in system (yes, air will lead to heavy steering).

• Incorrect fluid has been used to fill system.

• Damaged steering cylinder body.

• Too small of a steering hoses being used.

• Steering wheel is too small.

• Tilt bellows interference.

• Bleed Steering System.

• Drain and flush, fill and bleed with

SeaStar fluid.

• Replace steering cylinder(s) completely.

• Remove and re-plumb system using

SeaStar outboard hoses.

• Wheel should be 15" & larger (MAX 26").

• Confirm no interference with rubber tilt bellows on steering wheel hub.

• Remove cylinder, re-install as per the steps noted.

• Cylinder installation procedure not followed correctly.

• Cylinder mounting plate is too tight.

• With cylinder not connected, the plate must move UP/DOWN freely. Replace if hard to move.

4. One helm in system is very bumpy and requires too many turns.

• Air in system.

• Dirt/debris in system.

• Dirt/debris in autopilot

(if fitted).

• Bleed system.

• Replace helm pump, flush system

(DO NOT attempt repair of helm).

• Replace autopilot pump.


1

4

6

CAUTION

Prior to removing end glands, both bolts (item 7) must be removed. Failure to remove will lead to irreparable damages to the cylinder.

8

2

3

7 5

Figure 35.

ITEM PART # QTY DESCRIPTION

PER

(Includes mounting hardware)

2 HF5548 2 Bleeder

3 HF6004 2 Hose (ORB fi tting.)

4 HA5820 1 Tiller Bushing Kit

(c/w High strength tiller bolt.)

5 Various N/A Hardware

(Refer to Application Chart, page 5 for details.)

36

ITEM PART # QTY DESCRIPTION

PER

7 HP6063 4

8 HP6160 2

(c/w mounting hardware and

Tiebar Plate Bolts

End Gland Seal Kit


7.1 Statement of Limited Warranty

NOTICE

Help protect your boating environment by ensuring that all used oil is disposed of properly.

We warrant to the original retail purchaser that Telefl ex Canada

Limited Partnership products have been manufactured free from defects in materials and workmanship. This warranty is effective for two years from date of purchase, excepting that where Telefl ex

Canada Limited Partnership products are used commercially or in any rental or income producing activity, then this warranty is limited to one year from the date of purchase.

We will provide replacement product without charge, for any Telefl ex

Canada Limited Partnership product meeting this warranty, which is returned (freight prepaid) within the warranty period to the dealer from whom such product were purchased, or to us at the appropriate address. In such a case Telefl ex Canada Limited Partnership products found to be defective and covered by this warranty, will be replaced at Telefl ex’s option, and returned to the customer.

The above quoted statement is an extract from the complete

Telefl ex Canada Limited Partnership products warranty statement.

A complete warranty policy is available in our Telefl ex Canada

Limited Partnership products catalogue.

7.2 Return Goods Procedure

Prior to returning product to Telefl ex Canada Limited Partnership under warranty, please obtain a Return Goods Authorization number

(claim number).

Be sure to label the goods with: a) the name and address of the sender, and b) the return goods authorization number (claim number)

Please address the returned goods as follows:

From U.S.A.

RGA # ?

Telefl ex Canada Limited Par tnership c/o UPS–Supply Chain Solutions Inc.

Door A37

1201 C Street NW

Auburn, WA, 98001

From Canada

RGA # ?

Telefl ex Canada

3831 No. 6 Road

Richmond, B.C.

Canada V6V 1P6



TELEFLEX CANADA

3831 NO. 6 ROAD

RICHMOND, B.C.

CANADA V6V 1P6

FAX 604-270-7172 www.seastarsteering.com

ISO 10592

© 2010 TELEFLEX CANADA LIMITED PARTNERSHIP

PRINTED IN CANADA

FORM NO. 383110 02-11 Rev. A

SeaStar Tournament HC6845 Hydraulic Steering Installation Instructions and Owner's Manual

Assistant Bot

INSTALLATION INSTRUCTIONS

AND OWNERS MANUAL

w w w . s e a s t a r s t e e r i n g . c o m

Hydraulic Steering for Outboard

Powered Vessels

Front Mount Tournament Cylinder HC6845

Befo please tr our way

, y it our way

To the Installer and End

User (Owner)

INDEX

1.0 INFORMATION

Before installation

Installation

Safety Information Continued

Prior to every use

During use

After use

Maintenance

Important Labels

Safety Information Continued

all engine makes – 200+ HP

Single Engine – Single Cylinder

Twin Engine – Single Cylinder (Starboard)

Triple Engine – Dual Cylinder

Twin Engine – Dual Cylinder

3.1 System Installation Overview

Components Installation

Filling and Purging

Final System Check/Inspections

3.2 Drive Bracket Installation

Requires Kit # HA6802.

STEP 1

STEP 2

STEP 3

STEP 4

STEP 5

FOR SALT WATER APPLICATIONS

Ground Strap Installation

Single Engine – Single Cylinder

Twin Engine – Single Cylinder

Twin Engine – Dual Cylinder

Triple Engine – Dual Cylinder

3.5 Tiebar Adjustment and Installation

3.5.2 Tiebar to Drive Bracket Installation

Twin Engine – Single

Cylinder

3.5.3 Tiebar to Cylinder Installation

YAMAHA

YAMAHA

EVINRUDE

EVINRUDE

3.5.4 Tiebar to Engine Bracket Installation

Twin Engine – Single

Cylinder

A = YAMAHA

B = EVINRUDE

Triple Engine – Dual

Cylinder

ALL APPLICATIONS

STEP 1 Set Up

STEP 2

Routing

STEP 3

Hose to fi tting installation

ORB Hose Fitting

Reorientation (if required)

Hose Installation

Plumbing Diagrams

Single Cylinder Applications

(including Twin Engine – Single Cylinder)

Dual Cylinder Applications

(Including Triple/Quad Engines – Dual Cylinder)

3.7 Filling and Purging

3.7.1 Hydraulic Oil Requirements

3.7.2 Power Purge Users

STEP 1

STEP 2