Compact Hydraulic Steering
Contents
1. well lubricated Where Used Part Number Upper and lower pivot bolts 92 802865A1 threads Page 6B 6 90 863160 1 JUNE 2003 SERVICE MANUAL NUMBER 28 COMPACT HYDRAULIC STEERING 4 Install steering cylinder assembly as follows a Position steering cylinder assembly so that upper and lower pivot bolts with tab washers and spacers can be threaded by hand into transom plate b Ensure that tab washer tangs straddle the ridge on transom plate c Ensure steering cylinder assembly pivots freely d Torque pivot bolts Bend washer tabs against corresponding flats on bolt heads NOTE It may be necessary to tighten pivot bolts further to align flats on bolt with tabs on tab washer cw 76087 Steering cylinder assembly Pivot bolt Tab washer Spacer Tab Transom plate Ridge on transom plate Tab washer tangs straddle ridge samo ao0ooaowo 90 863160 1 JUNE 2003 Page 6B 7 COMPACT HYDRAULIC STEERING SERVICE MANUAL NUMBER 28 Page 6B 8 IMPORTANT Do not connect clevis to steering lever at this time Bleed and purge the system before connecting clevis to steering lever 5 Connect hoses to steering cylinder as follows a Apply a small amount of clean lubricant to the hydraulic hose end O ring area b Push port and starboard hoses completely into fittings c Hand tighten hose fittings d Torque hose fittings Oo 76085 a Port T fitting b Starboard T fitting c Hose O r2. and the during installation If so the jammed cylinders hose must be removed and replaced 2 System is very difficult to fill Air keeps burping out top of helm even after system appears full A Review filling AAI oyetan instructions A To test disconnect clevis from steering lever and turn the steering wheel If it does A Steering cylinder pivot not turn easily correct bushings are too tight or mentioned causes Please trunnion is bent causing note that excessively loose mechanical binding connections to steering cylinder or steering lever can also cause mechanical binding B Restrictions in hoses B Find restrictions and correct C Air in hydraulic fluid C Refer to filling and purging instructions D Wrong hydraulic fluid has been used to fill steering system 3 Steering is stiff and hard to turn even when the vessel is not moving D Drain system and fill with approved hydraulic fluid 4 The helm unit or one in the system is very bumpy as fe and requires too many aaa ae check of turns from port hard over peep to starboard hard over A Replace helm unit Page 6B 16 90 863160 1 JUNE 2003 SERVICE MANUAL NUMBER 28 COMPACT HYDRAULIC STEERING Troubleshooting Chart continued A Fit larger wheel if possible see installation instructions If the problem 5 Steering is easy to turn A Steering wheel is too cannot be rectified by the at the dock but becomes Small above ment
3. not listed below Hydraulic hose end O ring area 15 130 Pivot al ee 1 Amount specified is MINIMUM Do not exceed 22 Nm 200 Ib in Lubricants Sealants Adhesives 1 Avoid serious bodily injury or death due to loss of steering control Any non approved fluid used in this system may cause irreparable damage loss of steering and cancellation of warranty Never use brake fluid in this hydraulic steering system Use only approved hydraulic fluids Description Where Used Part Number l Hydraulic hose end O ring area Hydraulic Helm Steering Fluid 92 862014Q1 Hydraulic steering system Clevis pin and clevis Special Lubricant 101 92 802865A1 Hydraulic Helm Steering Fluid 92 862014Q1 SeaStar Hydraulic Fluid HA5430 Chevron Aviation Fluid TETOR E E E Mobile Aero HEA Ween Sbtain locally Shell Aero 4 Fluid meeting MIL Specification H5606C Page 6B 2 90 863160 1 JUNE 2003 SERVICE MANUAL NUMBER 28 COMPACT HYDRAULIC STEERING Introduction The system design incorporates a pressure relief valve to protect against internal fluid pressure becoming greater than individual system components are capable of sustaining without bursting or similar failure This design minimizes the possibility of total loss of steering The steering cylinder is referred to as an unbalanced cylinder In any position there always remains a difference in the volume between port and starboard cylinder chambers This is import
4. Cylinder FILLING IMPORTANT Hydraulic fluid must be visible in the filler tube during the entire filling procedure Do not allow the bottle of fluid used for filling to empty causing the filler tube to empty This may introduce air into the system and cause additional filling and purging to be needed Approximately 2 bottles 2 quarts or liters of approved hydraulic fluid are required for this single station and single cylinder system The length of hydraulic hoses required will cause the amount to vary 1 Remove venit fill plug from helm 2 Using a Filler Kit ordered separately screw the filler tube into vent fill plug hole Hand tighten 3 Screw bottle of hydraulic fluid into the filler tube bottle cap end Turn bottle upside down and poke a hole in bottom of bottle Hydraulic Helm Steering Fluid Hydraulic steering system 92 862014Q1 4 Ensure hydraulic fluid is always visible in filler tube and fill helm pump Install next bottle while fluid is still visible in filler tube but first bottle is empty 90 863160 1 JUNE 2003 Page 6B 9 COMPACT HYDRAULIC STEERING SERVICE MANUAL NUMBER 28 5 The helm is full when air bubbles no longer appear in filler tube Stop filling 76089 Standard helm Sport helm a Helm b Vent fill plug c Filler tube d Bottle cap end e Hydraulic fluid bottle f Pin to pierce bottle Hydraulic Helm Steering Fluid Hydraulic steering system 92 862014Q1 IMPORTANT Do no
5. SERVICE MANUAL NUMBER 28 STEERING SYSTEMS COMPACT HYDRAULIC STEERING Section 6B Compact Hydraulic Steering Table of Contents Important Information About Connecting The Clevis 6B 13 Through the Transom Exhaust 6B 2 Hydraulic Fluid Level 6B 14 Torque Specifications 6B 2 Setting Fluid Level 6B 14 Lubricants Sealants Adhesives 6B 2 Maintaining Fluid Level 6B 14 Introduction 2 0eeeeeeeees 6B 3 System Check ee eee eens 6B 14 Through the Transom Exhaust 6B 3 Maintenance 000eeeee eee 6B 15 Removal sssaaa sabia eee 6B 4 Troubleshooting Guide 6B 15 Installing The Steering Cylinder 6B 6 Important Information 6B 15 Filling And Purging The System 6B 9 Troubleshooting Chart 6B 16 Twin Station and or Twin Cylinder 6B 9 Standard Tilt Helm Single Station With Single Cylinder 6B 9 Mounting Template 6B 18 Purging 6 ssc0cn0ce eben he 90 863160 1 JUNE 2003 Page 6B 1 COMPACT HYDRAULIC STEERING SERVICE MANUAL NUMBER 28 Important Information About Through the Transom Exhaust NOTICE This hydraulic steering system is not designed for use with through the transom exhaust systems Do not use this hydraulic steering system with a through the transom exhaust system Torque Specifications NOTE Securely tighten all fasteners
6. ant when setting the hydraulic fluid level as outlined later This precision built product may not function properly if dirt or contaminants are introduced into the system Avoid product malfunction and diminished steering control Dirt and contamination introduced into the hydraulic system can result in damage to internal parts of steering system Do not allow dirt or contamination to enter the helm lines or cylinder of this steering system IMPORTANT Due to a small amount of internal hydraulic fluid transfer slip a master spoke or centered steering wheel cannot be maintained with a hydraulic steering system For best results use an equal distance spoke steering wheel Avoid serious bodily injury or death due to loss of steering control Extreme heat will lower burst pressure or melt hydraulic hoses In either case instant loss of steering may occur Do not allow hydraulic hoses to contact hot engine Through the Transom Exhaust This Compact Hydraulic Steering System is not designed for use with through the transom exhaust systems Do not use this hydraulic steering system with a through the transom exhaust system 90 863160 1 JUNE 2003 Page 6B 3 COMPACT HYDRAULIC STEERING SERVICE MANUAL NUMBER 28 Removal Avoid product malfunction and diminished steering control Dirt and contamination introduced into the hydraulic system can result in damage to internal parts of steering system Do not allow dirt or contamination t
7. ed cylinder assembly will not stop leaks A damaged cylinder shaft must be replaced immediately Troubleshooting Guide Important Information Whenever a troubleshooting solution calls for removal from vessel and or dismantling of steering system components such work must be carried out by a qualified marine mechanic The following is offered as a guide only and neither Mercury MerCruiser nor the helm manufacturer are responsible for any consequences resulting from incorrect repairs Most faults occur when the installation instructions are not followed and usually show up immediately upon filling the system The following trouble shooting chart provides the most common faults encountered and their likely cause and solution Sometimes when returning the steering wheel from a hard over position a slight resistance may be felt and a clicking noise may be heard This should not be mistaken as a fault as it is a completely normal situation caused by the releasing of the lockspool in the system Avoid serious injury or death due to FIRE or EXPLOSION Ensure that engine compartment is well ventilated and that no gasoline vapors are present to prevent the possibility of a FIRE or EXPLOSION 90 863160 1 JUNE 2003 Page 6B 15 COMPACT HYDRAULIC STEERING SERVICE MANUAL NUMBER 28 Troubleshooting Chart A Ensure that hoses were 1 During filling the helm A Blockage in the line not kinked or pinched becomes completely between the helms
8. he steering cylinder Continue to turn steering wheel until a stream of air free fluid is visible out of bleeder Continuing to slowly turn the steering wheel while closing the PORT bleeder 9 Turn the steering wheel COUNTERCLOCKWISE until the cylinder rod is fully retracted Steering wheel will come to a stop 10 Open STARBOARD bleeder 11 Hold cylinder rod to prevent extension Continue to turn steering wheel COUNTERCLOCKWISE until a stream of air free fluid is visible out of bleeder 12 Close the bleeder while continuing to turn steering wheel 13 Filling and purging is complete Refer to Hydraulic Fluid Level to set fluid level and to check the system after connecting the clevis a Starboard T fitting b Starboard bleeder valve c Cap Page 6B 12 90 863160 1 JUNE 2003 SERVICE MANUAL NUMBER 28 COMPACT HYDRAULIC STEERING Connecting The Clevis 1 Lubricate clevis pin and clevis Special Lubricant 101 Clevis pin and clevis 92 802865A1 2 Connect clevis to steering lever Spread both ends of cotter pin IMPORTANT Ensure that the clevis is positioned as shown below The angled notch in the clevis must face the rear 76087 a Clevis b Clevis pin and cotter pin c Steering lever 90 863160 1 JUNE 2003 Page 6B 13 COMPACT HYDRAULIC STEERING SERVICE MANUAL NUMBER 28 Hydraulic Fluid Level 1 Avoid serious bodily injury or death due to loss of steering control This system o
9. ing d Port hose from helm P e Starboard hose from helm S Hydraulic Helm Steering Fluid Hydraulic pel O ring 92 862014a1 Description Description m ins Steering hycrauichosetiings e SP 1 Amount specified is MINIMUM Do not exceed 22 Nm 200 Ib in 90 863160 1 JUNE 2003 SERVICE MANUAL NUMBER 28 COMPACT HYDRAULIC STEERING Filling And Purging The System NOTE Due to system design one technician may not be able to completely purge all the air from the system after installation This will result in spongy and unresponsive steering Two technicians are required for successful filling and purging of any system Twin Station and or Twin Cylinder Avoid serious injury or death resulting from a loss of steering control Improper venting or plugging of hydraulic helm pump reservoir can cause loss of fluid or introduction of air into hydraulic system resulting in insufficient hydraulic pump pressure for proper steering control If more than one steering station is being installed the vent fill plug on all but the uppermost helm must be replaced with a non vent plug which is included in a dual station fitting kit For twin station and or twin cylinder filling and purging bleed instructions follow instructions provided by SeaStar Refer to single station with single cylinder for instruction on how to fill and purge a single station with single cylinder system Single Station With Single
10. ioned solution hard to turn when vessel proceed with next cause is underway and solution or consult factory B Incorrect setting of trim l tabs if equipped B Adjust tabs if equipped A Remove check valve plugs These are the larger plugs on either side on rear of helm Clean ball seats 6 Drive drifts to port or and balls and reassemble starboard while vessel is A Dirt in check valves Note Be prepared to lose underway even when a certain amount of wheel is not being turned hydraulic fluid during this procedure Have a small can available Refill system when check balls have been re assembled 7 Turning one wheel causes second wheel to A Refer to Number 6 A Refer to Number 6 rotate A The helm has a field replaceable wheel shaft seal that can readily be 8 Seals will sometimes replaced by removing the leak if steering system is steering wheel and seal not vented at uppermost A Mefar TO Solution cover held in place by three helm small screws Quad ring No 210 is found in Seastar Helm Seal Kit HS5151 9 Vent fill plug leaks A Cylinder rod extended A Ensure cylinder rod is when turning to port during filling retracted during filling 90 863160 1 JUNE 2003 Page 6B 17 COMPACT HYDRAULIC STEERING SERVICE MANUAL NUMBER 28 Standard Tilt Helm Mounting Template Helm Flange Outline for Reference Only 4 HOLES 5 16 in 8 mm 2 25 32 in 70 mm Diameter 46
11. mm 1 13 16 in 2 17 32 in 64 mm 4 in 102 mm 5 32 in 131 mm 79260 Page 6B 18 90 863160 1 JUNE 2003
12. ntained check all port fittings and hose connections Ensure that there are no leaks If leaks are present correct before using 3 Turn steering wheel any wheel on multi steering station very hard to starboard to pressurize system 4 While pressure is maintained check all starboard fittings and hose connections Ensure that there are no leaks If leaks are present correct before using NOTE Observing a significant drop in the fluid level at the helm while performing the system check may mean you are compressing air and further filling and purging would be required 5 Ifno leaks are present the system is ready for service Page 6B 14 90 863160 1 JUNE 2003 SERVICE MANUAL NUMBER 28 COMPACT HYDRAULIC STEERING Maintenance 1 Avoid serious bodily injury or death due to loss of steering control Failure to comply with maintenance checks may result in a loss of hydraulic pressure due to insufficient hydraulic fluid or proper mechanical function necessary for steering control Check the hydraulic fluid level in the helm pump Check for leaks A minimum of two times a year or at the Check mechanical linkages and first sign or indication that the steering connections Tighten loose parts and system is not operating normally or replace badly worn parts correctly whichever occurs first Check cylinder shaft for nicks and scratches 2 2 A damaged cylinder shaft can cause seal failure and leaks Replacing seals on a damag
13. o enter the helm lines or cylinder of this steering system Avoid serious bodily injury or death due to loss of steering control Extreme heat will lower burst pressure or melt steering system hydraulic hoses Stress on hose fittings or kinks in the hose may cause hose failure In any case instant loss of steering may occur Route the hydraulic hoses to avoid extreme heat stress on hose fittings and hose kinks 1 Loosen hose fittings and remove hoses from steering cylinder T fittings 2 Plug hose ends to prevent fluid loss 76085 a Steering cylinder b Hoses c T fittings d Hose fittings Page 6B 4 90 863160 1 JUNE 2003 SERVICE MANUAL NUMBER 28 COMPACT HYDRAULIC STEERING 3 Remove cotter pin from port clevis pin and remove clevis pin 4 Bend pivot bolt tab washer tabs away from bolts 5 Remove pivot bolts 76087 a Pivot bolts b Port clevis pin c Tab washer d Tab e Spacer pivot bolt bearing 6 Remove steering cylinder from transom 90 863160 1 JUNE 2003 Page 6B 5 COMPACT HYDRAULIC STEERING SERVICE MANUAL NUMBER 28 Installing The Steering Cylinder 1 Ensure that bushings are clean 2 Lubricate the bushings Ss 76087 a Bushings b Steering cylinder assembly Where Used Part Number A Special Lubricant 101 92 802865A1 3 Remove upper and lower pivot bolts spacer and tab washers Ensure that threads are
14. perates with an unbalanced steering cylinder volume Proper fluid level in the helm can only be set or checked with the cylinder rod fully retracted Do not set or check hydraulic fluid level in helm with cylinder rod extended Setting Fluid Level System must be filled and purged as outlined previously before setting fluid level 1 Ensure cylinder rod is fully retracted 2 With filler tube screwed into helm filler plug hole fill tube approximately 1 2 full of air free fluid 3 Open starboard bleeder valve and slowly turn steering wheel CLOCKWISE until fluid level in filler tube is at the top of the plastic filler fitting Continue turning steering wheel CLOCKWISE 1 4 turn more and stop Close bleeder 4 Remove filler tube Fluid level should be at bottom of filler hole Install vent fill plug Maintaining Fluid Level To maintain proper fluid level observe the following e Do not allow fluid level to drop more than 6 mm 1 4 in below bottom of filler hole e Check fluid level periodically System Check The system must be checked for proper connections possible leaks and complete purging of air after filling purging and setting the fluid level IMPORTANT In the following turn the wheel with enough force to exceed the pressure relief valve in the helm This should not harm the helm or the system 1 Turn steering wheel any wheel on multi steering station very hard to port to pressurize system 2 While pressure is mai
15. t proceed to the next step until helm is full of hydraulic fluid Ensure that no air is visible in filler tube 6 Leave bottle of fluid connected to helm for use in purging system of air Page 6B 10 90 863160 1 JUNE 2003 SERVICE MANUAL NUMBER 28 COMPACT HYDRAULIC STEERING Purging NOTE Turning the steering wheel in direction shown moves the cylinder rod as indicated by arrow 1 a Port bleeder valve b Starboard bleeder valve Remove caps from bleeder valves on T fittings at cylinder assembly NOTE Place temporary hoses obtain locally clear hose is recommended on bleeder outlets and position these hoses in a container to avoid spills and air returning to bleeder 2 90 863160 1 JUNE 2003 Turn the steering wheel slowly CLOCKWISE while your assistant opens the STARBOARD bleeder valve Continue to turn steering wheel CLOCKWISE until a stream of air free hydraulic fluid is visible out of bleeder a Cap b Starboard fitting c Starboard bleeder valve d Temporary hose Page 6B 11 COMPACT HYDRAULIC STEERING SERVICE MANUAL NUMBER 28 4 While continuing to slowly turn the steering wheel close the STARBOARD bleeder 5 Turn steering wheel CLOCKWISE until cylinder rod is fully extended Ensure that the steering lever does not interfere with cylinder clevis 6 Turn the steering wheel slowly COUNTERCLOCKWISE while your assistant opens the PORT bleeder valve on t
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