installation instructions and owner`s manual
Contents
1. 33 Plan Il Twin Engine Two Station 34 Plan 1 Twin Engine Three Station 35 Plan Twin Engine Four Station 36 Supplemental Throttle Control Circuits 37 MI Serat HE 37 MINES 37 CM E 38 MIA 38 Troubleshooting Guide 39 Technical Information 42 Statement of Limited Warranty 43 Installation Instructions amp Owner s Manual INTRODUCTION A CAUTION This system does NOT use oil or Steering Fluid Use HA5455 Hynautic shift and throttle control fluid ONLY DO NOT use stop leak type anti freeze SeaStar Solutions Engine Control System Why it Works The movement of a sender s control arm transmits mechanical energy to an internal piston which in turn pushes hydraulic fluid through the other corresponding control senders and single control slave This movement of hydraulic fluid drives a piston in each of the senders and slave The movement of the individual pistons causes shaft rotation in each unit The piston in each of the individual control senders and slaves has two small valves which are opened when the piston reaches the end of its stroke allowing additional fluid to pass through the system By allowing this flow of hydraulic fluid the cont2. CONTROL ARM LOCK SCREW DETENT RING LOCK SCREW 240357 Figure 8 Detent Ring Location 10 By locating the slave arm ball joint in its proper hole and adjusting both ball joint on the threaded rod find the correct length of linkage that will allow both full forward and fullreverse on the transmission for full throw on the clutch slave arm 11 After determining the correct linkage length securely lock the ball joints to the threaded rod with lock nuts provided Disconnect the linkage from the clutch slave s arm 12 Locate and secure in place two tees two bleeder valves and two tubing adapters per Figure 9 13 Repeat this clutch slave installation procedure for the second engine HYNAUTIC TUBE FITTING ASSEMBLY The tube fitting and ADAPTER 1 4 NUT 530015 bleeder valve may be BLEEDER PIPE 5 16 TUBE LOCK RING 530025 reversed on the pipe ASSEMBLY 530175 INSERT 530045 tee to allow for easier 690010 ET O RING 002222 tube connection 2 II 1 4 PIPE TEE P 4 NIPPLE 1 4 PIPE c CONTROL CL stations ADAPTER 1 4 PIPE 5 16 TUBE 690551 530175 690551 Cent TO CONTROL STATIONS CONTROL ARM MAY NYLON TUBING BE ROTATED TO ANY QPP quint B amp B BLEEDER 5 16 0 D N 2 POSITION ON SHAFT pem ASSEMBLY 690010 Figure 9 SS 04 Shifter Slave Bleeder Valve and Tubing Adapters Install
3. mproper reversed tubing connections Recheck tubing connections made against tubing diagram used Remove pressure from the system Reconnect tubing as required Re pressurize and bleed system Synchronize controls 12 Sender arm moved at one station resuits in another arm moving at the same station Tubing runs improperly connected Prime area for improper connection would be at the charging valve Compare tubing connections made with tubing diagram used check area of charging valve Remove pressure from system Reconnect tubing as required Pressurize system bleed system Synchronize controls 13 Crimp or kink in tubing e Numerous Cut out kinked or crimped portion of line Splice line together using tube connectors and union 14 Leak at a fitting Bad O Ring Installation Instructions amp Owner s Manual Remove fitting replace O ring replace fitting pressurize system and check for leakage If Leakage continues replace entire tubing connector and adapter as required TECHNICAL INFORMATION Bolt Torque Specifications Values are stated in in Ibs N m These are the recommended maximum torque values for reusable dry bolts Bolts should be torqued to this value 0 20 For lubricated bolts multiply the dry bolt torque values by 75 Bolt Size 18 8SS Brass Bolt Size 18 8SS Brass Bolt Size 18 8SS Brass
4. INSTALLATION INSTRUCTIONS AND OWNER S MANUAL www seastarsolutions com Hynaulic Hydraulic Engine Controls 04 Series d 4 SEASTAR PX SOLUTIONS your WAY Before r x it our WAY Notice to Boat Manufacturer or Installer 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 DANGER A WARNING A CAUTION NOTICE Immediate hazards Hazards or unsafe Hazards or unsafe Information which which WILL result in practices which practices which is important to severe personal injury COULD result in COULD result in proper installation or or death severe personal injury minor injury or maintenance but is or death product or property not hazard related damage A WARNING 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 s
5. 4 x Plug 380514 PRESSURE 4 x Spring 430546 GAUGE FILLER 4 x PoppetAssy 450040 VALVE 1 x Reservoir Plug 380030 1 x Inst Sheet 180054 LIQUID LEVEL MOUNTING L SIGHT TUBE PADS DRAIN PLUG FILTER PLUG 0 CHANGING VALVE Figure 30 R 04 Reservoir with MCV 04 Charging Valve Installation Instructions amp Owner s Manual Hynautic Hydraulic Engine Controls 04 Series TEMPLATES LINE INDICATES OUTER EDGE OFCONTROL SENDER lt e e oe co at e ul e lt ro zl REMOVE THIS AREA FROM THE PANEL REMOVE THIS AREA FROM THE PANEL SIDE BY SIDE MOUNTING SINGLE HEAD Installation Instructions amp Owner s Manual This page intentionally blank to allow removal use of template Hynautic Hydraulic Engine Controls 04 Series CDF 04 MOUNTING PLATE 1 8 THICK PLATE This plate simplifies mounting of 1 CL 1 CR control as a dual unit 1 Select mounting location checking for adequate handle clearance throughout full arc Also check for access to the allen screw bleeders in the control heads and clearance below the mounting surface 2 When location is determined use the plate as a templete and mark position of the 4 mounting bolt holes and outline of material to be removed 3 Remove plate
6. ROD TS CLUTCH ARM Figure 7 Proper Clutch Slave to Throttle Arm Installation NOTICE The clutch slave s arm may be set to any desired position by loosening the tightening screw using a 3 16 allen wrench in the lower end of the arm Rotate arm as desired and reset the screw After the arm is set it will have a 78 maximum arc 1 Secure mounting bracket to the engine A suitable bracket must be fabricated 2 Secure the transmission slave to the mounting bracket using the 3 8 16 mounting bolts 3 Set the transmission in the neutral position and the clutch slave s arm at its mid stroke 4 Loosen the set screw in the detent ring on the clutch slave and rotate the detent ring to the full detent position To locate the detent ring see Figure 8 5 Secure detent ring in this position by tightening the set screw 6 Install a lock nut and ball joint on the end of the 1 4 20 stainless steel or brass threaded rod not provided 7 Position the clutch slave to its mid stroke and connect the ball joint end of the 1 4 20 threaded rod to it 8 Position the engine s clutch arm to neutral determine the proper length of the threaded rod required and cut off the excess 9 Install a lock nut and ball joint on the other end of the threaded rod Hynautic Hydraulic Engine Controls 04 Series HYNAUTIC CONTROLS COMPONENT INSTALLATION DETENT RING
7. Slave Hynautic Hydraulic Engine Controls 04 Series FILLING AND BLEEDING THE SYSTEM Filling the System 1 2 Verify that all sender arms are free to traverse their complete arc Verify that all bleeder valves on the throttle and clutch slaves are closed and linkages disconnected NOTICE See section on System Fluid for fluid specifications on page 17 3 Remove fill port plug from the reservoir and fill the reservoir within one inch of the top of the sight tube with HA5455 water glycol fluid Replace fill port plug Pressurize reservoir to 100 10 psi through the air filler valve in the top of the reservoir The system will now begin to fill with fluid As the system fills the fluid level in the reservoir will become lower When the fluid level is between 1 to 2 inches from the bottom of the sight glass release the pressure and refill the tank as in Step 4 Repressurize the system and repeat this procedure of filling the reservoir as required until no fluid drop is noted At this point the system is filled and must now be bled Check entire system for leaks and correct as required Bleeding the System at Slave NOTICE Verify that linkage is disconnected and sender s handles are free to move While bleeding move the slave arm and verify that the piston has bottomed Fill the reservoir as required Using the bleeder tube provided and a clean empty container inse
8. U S A From Canada RGA RGA SeaStar Solutions SeaStar Solutions c o UPS Supply Chain Solutions Inc 3831 No 6 Road Door A37 Richmond B C 1201 C Street NW Auburn WA Canada V6V 1P6 98001 Installation Instructions amp Owner s Manual SEASTAR SOLUTIONS SEASTAR SOLUTIONS 3831 NO 6 ROAD RICHMOND B C CANADA V6V 1P6 FAX 604 270 7172 www seastarsolutions com ISO 10592 C 2009 MARINE CANADA ACQUISITION INC DBA SEASTAR SOLUTIONS PRINTED IN CANADA FORM 182042 12 13
9. adjustment in both directions can be achieved Be sure the slave arm can over travel through the bungee to the end of its stroke in each direction 8 After determining the correct rod length securely lock the ball joint and bungee assembly to the threaded rod with lock nuts provided Disconnect the linkage from the throttle slave s arm ST 06 System ONLY 9 To prevent engine retard due to governor spring or vibration a pilot check valve is built into the ST O6 Throttle Slave h the bungee to the end of its stroke in each direction NOTICE This built in valve will lock the slave arm in place allowing it to be moved only by the sender 10 Locate a tee and bleeder valve on the throttle slave and install suitable adapters to accept tubing per Figure 5 NOTICE Tube connectors are installed on the tubing per instructions under Tubing Installation and Connection on page 10 11 Verify all fittings installed have been tightened Repeat these throttle slave installation procedures for the second engine A CAUTION Dirt and foreign matter in the hydraulic system cause damage and malfunction It is extremely important to keep tubing and fittings clean when installing and connecting components ST 04 System ONLY 9 To prevent engine retard due to governor spring or vibration a separate STV 10 lock out valve is used with the ST 04 Throttle Slave NOTICE If the throttle slave is in a limited space it may
10. diagram At this point all tubing should be run and connected Now secure tubing using ties and clamps This should be done prior to filling the system Installation Instructions amp Owner s Manual HYNAUTIC CONTROLS TUBING INSTALLATION Copper Tubing Use these instructions in conjunction with this Manual s Section on Tubing Installation page 10 1 Use 5 16 OD soft copper refrigeration type tubing 2 Use standard 45 flares for fittings Be careful to make good flares and do not allow dirt or chips into the system DO NOT use pipe dope on fitings Refer to cautions in this manual 3 All tubing runs outside the engine room should be run together Single bundled 4 Inside the engine room lengths of tubing on each side of the same circuit should be essentially the same length 5 If desired short lengths maximum 24 of Aeroquip 2651 5 Hose with 401 5B Fittings may be used for the transition from hull mounted to engine mounted tubing This will prevent work hardening of the copper from flexing and vibration Again make sure no dirt or chips are introduced into the hose ends or damage and malfuntion of the system may occur The following figures illustrate the proper connections for copper tubing installation between components of the Engine Contol System COPPER TUBING 5 18 0 D ADAPTER FILTER ET v FILT
11. of reservoir 7 Reservoir must be mounted to the bulkhead wall or post using either bolts or screws zeit FILTER FILTER DRAIN PLUG ELEMENT 380574 160113 Figure 10 Charging Valve on R 13 Reservoir R 04 Reservoir Installation The reservoir should be located in the ship s engine room in an accessible location In locating the reservoir the following conditions should be met 1 Reservoir must be in a vertical position with pressure gauge on top 2 Sight glass must be visible and easy to read 3 Pressure gauge be visible and easily read Hynautic Hydraulic Engine Controls 04 Series HYNAUTIC CONTROLS COMPONENT INSTALLATION 4 The operator must have easy access to the air filler valve on the top of the tank 5 The operator must have easy access to the fill port on top of the tank 6 Reservoir must be mounted to the bulkhead wall or post using either bolts or screws NOTICE There are two ports located on the bottom of the reservoir One is plugged and can be used as a drain port The other has a filter assembly and is used for connecting to the system See 2 e 11 oe FILTER PLUG L ASSEMBLY 380070 DRAIN PLUG 5 5 Figure 11 Ports on Bottom of R 04 Reservoir MCV 04 Charging Valve The charging valve should be located in the general v
12. 15 Bleeding the System at Slave 15 Bleeding the System at Senders 16 System FUT iri Eme REA 17 Making the System Operational 17 Synchronizing the Controls 17 Connecting Engine Controls 17 Operation amp Maintenance 18 Throttle Senders 18 Clutch Senders 18 Maintenance Schedule 18 Parts EE 19 System Parts List Nylon Tubing 19 System Parts List Copper Tubing 20 Sender Assembly 4 474 4 42 4 21 Ball amp Tee Handle Installation 22 51 06 Throttle Slave Assembly 23 55 04 Transmission Slave Assembly 24 Optional Neutral Safety Switch Kit 55 01 25 Templates M yy toe E RU d ES 29 CDF 04 Mounting Plate 31 TUBING DIagratTis teed Aida 33 Plan Twin Engine One Station
13. 17 Screw 25 045320 2 Screw 12 390028 Gasket 26 260157 2 Washer 13 500610 Cylinder Assembly CL B4 amp CL T4 27 160011 2 Dill Valve 500600 Cylinder Assembly CR B4 amp CR T4 28 740018 1 Washer Installation Instructions amp Owner s Manual EB HYNAUTIC CONTROLS PARTS LIST Ball amp Tee Handle Installation A CAUTION When Installing Ball Handle DO NOT torque screw to more than 10 ft lbs A CAUTION When installing Tee Handle DO NOT torque screw to more than 14 ft lbs NOTICE Standard hand tightening with 1 4 short arm hex key wrench will not over torque screw BALL HANDLE TEE HANDLE TORQUE TO 90 110 IN LBS 10 12 5 Nm TORQUE TO 90 110 IN LBS 10 12 5 Nm Figure 22 Hynautic Hydraulic Engine Controls 04 Series HYNAUTIC CONTROLS PARTS LIST ST 06 Throttle Slave Assembly INCLUDED IN SEAL KIT ECS 06 2 x DillValve 160061 2 x O Ring 002222 1 x O Ring 223729 1 x O Ring 345926 1 x O Ring 211027 2 x O Ring 211028 1 extra 1 x O Ring 924022 1 x O Ring 211125 1 x Seal 224011 2 x Ring 252125 1 x Wiper 642921 INCUDED IN SHIFT SLAVE REPAIR KIT 68352K 1 x Lever Arm 610024 1 x Screw 240057 1 x Bushing 630044 2 x Bearing Race 190005 1 x Bearing 190002 1 x PinonAssy 720150 Figure 23 ITEM PART QTY DESCRIPTION ITEM PART QTY DESCRIPT
14. 2 56 2 5 282 2 0 226 6 32 9 6 1 08 4 9 554 5 16 18 132 0 14 91 107 0 12 10 2 64 3 0 338 2 5 282 6 40 12 0 1 35 9 9 1 12 5 16 24 142 0 16 04 116 0 13 11 3 48 3 9 440 3 2 361 8 32 20 0 2 25 16 0 1 81 3 8 16 236 0 26 66 192 0 21 71 3 56 44 497 3 6 407 8 36 22 0 2 48 18 0 2 03 3 8 24 259 0 29 20 212 0 23 97 4 40 5 2 587 4 3 486 10 24 23 0 2 59 19 0 2 14 4 48 6 6 740 5 4 610 10 32 32 0 3 61 26 0 2 94 5 40 7 7 869 6 3 712 1 4 20 75 0 8 47 62 0 7 01 5 44 9 4 1 06 7 7 869 1 4 28 94 0 10 6 77 0 8 70 Values are stated in ft Ibs N m Bolt Size 18 855 Brass Bolt Size 18 8SS Brass Bolt Size 18 8SS Brass 7 16 14 31 0 42 00 26 0 35 25 5 8 11 93 0 126 09 76 0 103 04 1 8 287 0 389 12 235 0 318 62 7A6 20 33 0 44 74 27 0 36 61 5 8 18 104 0 141 00 85 0 115 24 1 14 259 0 351 16 212 0 287 43 1 2 13 43 0 58 30 35 0 47 45 3 4 10 128 0 173 55 104 0 141 00 1 2 20 45 0 61 01 37 0 50 17 3 4 16 124 0 168 12 102 0 138 29 9 16 12 57 0 77 28 47 0 63 72 7 8 9 194 0 236 03 159 0 215 58 9 16 18 63 0 85 42 51 0 69 15 7 8 14 193 0 261 67 158 0 214 22 p aura SeaStar Solutions Technical Phone 604 248 3858 Support Contacts e mail seastar seastarsolutions com Hours Monday to Friday 05 00 15 30 5 Web www seastarsolutions com Hynautic Hydraulic Engine Controls 04 Series Statement of Li
15. 2 hex nuts p n 270177 mount Switch to Plate as shown in drawing Do not tighten screws at this time 4 Using 8 32 round head screws p n 240201 and 8 lock washers p n 260052 mount the Plate to the slave body as shown in drawing Do not tighten screws at this time 5 Shift the transmission to Forward or Reverse so that the Cam Follower Wheels are out of the Detents and the Arms are in the UP position as shown in the drawing 6 Make adjustments to the Switch and Plate so that the Switch makes contact when the slave arm is in the UP position 7 After making necessary adjustments tighten all four mounting screws Be sure the slave arm does not cause too much overtravel on the Switch causing possible damage to the switch arm sene SWITCH COVER 870220 240857 zs TN FLAT WASHER 260147 SWITCH PLATE 520524 LOCK WASHER 260107 MICRO SWITCH 870240 SCREW 240201 ARM SHOWN IN UP LOCK WASHER 260052 POSITION DETENT CAM FOLLOWER WHEEL Figure 25 Installation Instructions amp Owner s Manual HYNAUTIC CONTROLS SWITCH KIT SSH 1 RACK DILL VALVE 1 sia a DILL VALVES PILOT EB CHECK VALVE Figure 26 Clutch Slave Figure 27 Throttle S
16. BLEEDER ASSEMBLY COPPER TUBING 530175 690010 5 16 0 0 Figure 16 ST 04 Throttle Slave with STV 10 Lock Out Valve Installation Instructions amp Owner s Manual HYNAUTIC CONTROLS TUBING INSTALLATION _ 50 i d c d COPPER TUBING 5 16 0 D ADAPTER FILTER _ 690080 RESERVOIR E FILTER PLUG C ADAPTER T ASSEMBLY 380070 530175 TEN TUBE NUT E DRAIN PLUG 690621 COPPER TUBING TUBE MOUNTING 690010 5 16 0 0 690621 HOLES Figure 17 Ports on Bottom of R 04 Reservoir Figure 18 MCV 04 Charging Valve 5 16 FLEXIBLE HOSE WITH 45 FEMALE FLARE SWIVELS NOTE MUST USE A MIN OF ADAPTER FILTER 690080 12 OF FLEX HOSE 5 16 45 1 4 PIPE TEE 690441 TUBE NUT 690621 SEE ii 691601 BLEEDER ASSEMBLY 690010 STATIONS TUBE NUT 21 5 16 45 COPPER TUBING FLARE UNION 516 0 0 ADAPTER 1 4 691601 NUR COPPER PIPE 5 16 TUBE TUBING 530175 5 690441 ADAPTER FILTER ST DD NIPPLE 1 4 i PIPE 690551 dij 1 STATIONS N ADAPTER 14 CONTROL ARM n a ROTATED TO ANY POSITION ON SHAFT 1 4 PIPE 690551 REDE ID d NOTE MUST USE A MIN OF BLEEDER 12 OF FLEX HOSE ASSEMBLY 690010 Figure 19 SS 04 Shifter
17. CLUDED SYSTEMS MCEF 04 Extra Fittings Package 111 1171111 da ya 02 100 2 2 2 2 3 3 3 3 4 4 MCT 05 500 Nylon Tube 1 1 1 41 HA5455 Hydraulic Fluid 2 2 2 2 3 3 2 2 3 3 4 4 As Required Installation Instructions amp Owner s Manual HYNAUTIC CONTROLS PARTS LIST Copper Tubing SINGLE ENGINE TWIN ENGINE s 2 8 la 2 8 SJS JE S S E ES E S S FE FE S E F JS 8 js E IRES S I J Re s Blo J Jo R S s 5 D 5 aJa Il LL s s a STE my sim ERES EY Es S c c S S lt COMPONENT DESCRIPTION R 13 Reservoir amp Charging Valve 1 11971717 107071 MCVF 10 Charging Valve Fittings 111511 111111 MCVF 11 Charging Valve Fittings 1 CL B4 Control Left Ball Handle or 1 2121414 6 6 Control Left T Handle CR B4 or Control Right Ball Handle or 1 2121414 6 6 Control Right Handle CDF 04 Dual Mounting Plate 12 41 16 CF 05 Control Fittings 2 41418 8 12 12 55 04 Shift Slave 1 2 21 12121212 SSF 06 Slave Fittings 1 22 22 2 2 ST 06 Throttle Slave amp Double 1 212121212102 Pilot Check Valve STF 13 Slave
18. ER DRAIN PLUG 380574 TUBE NUT 690621 Figure 14 Charging Valve on Bottom of R 13 Integrated Reservoir Hynautic Hydraulic Engine Controls 04 Series HYNAUTIC CONTROLS TUBING INSTALLATION TO CONTROL STATIONS COPPER TUBING 5 16 0 0 ____ TUBE NUT 690621 5 16 45 FLARE UNION 691601 lt 5 16 FLEXIBLE H0SE WITH 45 FEMALE FLARE SWIVELS NOTE MUST USE MIN 12 OF FLEX HOSE ADAPTER FILTER 691601 ADAPTER 1 4 PIPE 5 16 TUBE 530175 ADAPTER 1 4 PIPE 5 16 TUBE 530175 A BLEEDER ASSEMBLY 690010 on e fi BLEEDER ASSEMBLY 690010 25 G D 1 4 PIPE TEE 690551 i NIPPLE 1 4 PIPE 690551 A B CONTROL ARM NEG BE ROTATED TO ANY SAI T o ANGEL POSITION ON SHAFT OF ROTATION 1578 Figure 15 57 06 Integrated Throttle Slave ADAPTER 1 4 PIPE 5 1 3 TUBE ADAPTER 530175 NS 690631 5 16 FLEXIBLE HOSE WITH TUBE NUT 690621 45 FEMALE FLARE SWIVELS NIPPLE 690631 FILTER NOTE MUST USE A MIN 1 4 PIPE 690080 OF 12 OF FLEX HOSE 690551 N TUBE NUT COPPER TUBING e iub 5 16 0 0 NIPPLE 1 4 PIPE qid 1 690551 E de S 950119 5 16 45 FLARE 7 UNION 691601 ADAPTER 1 4 ST 04 i PIPE 5 16 TUBE
19. Fittings 1 2 ADDITIONAL REQUIREMENTS NOT INCLUDED IN HA5455 Hydraulic Fluid 2 2 2 3 Copper Tubing 5 16 0 0 As Required Hynautic Hydraulic Engine Controls 04 Series HYNAUTIC CONTROLS PARTS LIST Sender Assembly CR B4 Control Right Red CR T4 Control Right Red CL B4 Control Left Black CL T4 Control Left Black t OPTIONAL HANDLE Red Knob Kit Part CK 01 Black Knob Kit Part CK 02 NOTE Ball is not available as a separate part INCLUDED IN SEAL KIT ECS 05 2 x Valves 160011 1 x O Ring 223729 1 x O Ring 345926 2 x O Ring 211024 1 x O Ring 211027 1 x O Ring 008821 1 x Seal 224011 2 x Ring 252121 1 x Gasket 390028 1 x Wiper 642921 Figure 21 ITEM PART QTY DESCRIPTION ITEM PART QTY DESCRIPTION 1 610120 Tee Handle Assembly Red 14 345926 1 0 Ring 610130 Tee Handle Assembly Black 15 560114 1 Cylinder End CL B4 amp CL T4 2 642921 Wiper 560104 1 Cylinder End CR B4 amp CR T4 3 223729 0 Ring 16 211024 1 O Ring 4 224011 Quad Seal 17 600080 1 Piston Assembly 5 630044 Bushing 18 252121 2 Teflon Back up Ring 6 211027 0 Ring 19 008821 1 O Ring 7 190005 Bearing Race 20 500034 1 Cylinder Tube 8 190002 Bearing 21 211024 1 O Ring 9 720130 Pinion Assembly 22 560244 1 Cylinder End 10 900644 Body CL B4 amp CL T4 23 520014 1 Plate 900634 Body CR B4 amp CR T4 24 240727 2 Bolt 11 2403
20. ION t1 610024 1 Lever Arm 14 345926 1 O Ring 9 240057 1 Screw 15 560034 1 Cylinder End Eccentric 3 540018 1 Spacer 16 211028 1 O Ring 4 642921 1 Wiper 17 600070 1 Piston Assembly 5 223729 1 O Ring 18 252125 2 Teflon Back Up Ring 6 224011 1 Quad Seal 19 211125 1 O Ring 7 630044 1 Bushing 20 500131 1 Cylinder Tube 8 211027 1 O Ring 21 500164 1 Tube 9 190005 2 Bearing Race 22 002222 2 O Ring 40 190002 1 Bearing 23 924022 1 O Ring 81 1720150 1 Pinion Assembly 24 520634 1 Plate 12 901054 1 Body 25 240717 2 Bolt 13 501120 1 Cylinder Assembly 26 160061 2 Dill Valves Installation Instructions amp Owner s Manual ES HYNAUTIC CONTROLS PARTS LIST 55 04 Transmission Slave Assembly INCUDED IN SHIFT SLAVE REPAIR KIT 68352K 1 x Lever Arm 610024 1 x Screw 790323 1 x CamDetent 730014 1 x SetScrew 240357 1 x Spring 430296 1 x Washer 740018 1 x End Gland 630044 2 x Bearing Race 190005 1 x Bearing 190002 1 x PinonAssy 720150 INCLUDED IN SEAL KIT ECS 06 2 x Dill Valve 160061 Red 2 x O Ring 002222 Not Used 1 x O Ring 223729 1 x O Ring 345926 1 x O Ring 211027 2 x O Ring 211028 1 x O Ring 924022 Not Used 1 x O Ring 211125 1 x Seal 224011 2 x B URing 252125 1 x Wiper 642921 Figure 24 ITEM PART QTY DESCRIPTION ITEM PART QTY DESCRIPTION t1 610024 1 Lever Arm 17 190002 1 12 790323 1 Screw 18 1720150 1 P
21. UTION The Throttle Slave must not be mounted to any surface exceeding 220 F 103 C If mounting in a hot spot is unavoidable the slave must be insulated from the heat BUNGEE BALL JOINT ASSEMBLY BALL JOINT 670010 LOCK NUTS 850081 1 O 1 4 20 THREADED lle ROD THROTTLE ARM Figure 4 Throttle Slave to Throttle Arm Installation Steps 1 through 8 apply to both ST 04 and ST 06 Systems 1 Secure the mounting bracket to the engine A suitable bracket must be fabricated 2 Secure the throttle slave to the mounting bracket using 3 8 16 mounting bolts 3 Install lock nut and bungee ball joint on the end of a 1 4 20 stainless or brass threaded rod Installation Instructions amp Owner s Manual HYNAUTIC CONTROLS COMPONENT INSTALLATION 4 Position the throttle slave to its mid stroke and connect the bungee end of the 1 4 20 threaded rod to it not provided 5 Position the engine s throttle arm to its mid stroke Determine the length of threaded rod required and cut off the excess 6 Connect a lock nut and a ball joint to the engine s throttle arm and the free end of the threaded rod 7 Find the proper hole in the slave arm to provide a linkage length combination that will allow idle to full throttle on the engine using all but a few degrees of slave arm travel in each direction By adjusting the ball joint and bungee a fine
22. WARNING Whenever in the following text a solution calls for removal from vessel and or dismantling of steering Hydraulic Shift and Throttle such work must only be carried out by a qualified marine hydraulic mechanic SeaStar Solutions offers the following as a guide only and is not responsible for any consequences resulting from incorrect dismantling repairs FAULT 1 Spongy Controls Entire System CAUSE Air in System SOLUTION Check reservoir and verify that there is fluid and pressure is 80 psi Inspect for fluid leaks at all connections Check for air leaks in the reservoir use soapy water solution Bleed entire system Synchronize controls on one clutch or throttle system 2 Spongy Controls on one clutch or throttle system e Air in that singular system Check reservoir verify that there is fluid and throttle system pressure is 80 psi Inspect for fluid leaks at all connections of the system in question Bleed system in question Synchronize controls 3 Sender arm wants to stop at its mid stroke e Controls out of synchronization Synchronize controls 4 Full throttle on the sender will not achieve maximum throttle RPM on Engine e Throttle linkage length out of adjustment Engine out of tune Re adjust length of the throttle linkage Service Engine 5 Full idle on sender will not achieve idle RPM on engine e Throttle linkage length out of adjust
23. ation Installation Instructions amp Owner s Manual HYNAUTIC CONTROLS COMPONENT INSTALLATION NOTICE The standard SeaStar Solutions System MC 04 uses the R 13 Integrated Reservoir You may have a different system which includes the 4 Reservoir and MCV 04 Charging Valve Depending which system you have follow the corresponding installation instructions in this section NOTICE If your installation includes two reservoirs one for each engine is single engine installation special plumbing will required which is not covered in this manual Contact SeaStar Solutions for this information R 13 Reservoir Installation NOTICE The charging valve is located on the bottom of the reservoir The plug located on the charging valve holds the fluid filter in place This plug and filter can be removed to drain the reservoir s fluid See Figure 10 The reservoir should be located in the ship s engine room in an accessible location In locating the reservoir the following conditions should be met 1 Reservoir must be in a vertical position with pressure gauge on top 2 Sight glass must be visible and easy to read 3 Pressure gauge must be visible and easily read 4 The operator must have easy access to the air filler valve on the top of the tank The operator must have easy access to the fill port on top of the tank The operator must have easy access to charging valve on bottom
24. be removed from the bracket during the lock out valve installation The STV 10 Lock Out Valve must be plumbed as shown in Figure 6 The lock out valve will lock the slaves arm and allow it to be moved by only the sender The check valve and slave must be mounted in close proximity to one another If they re not abnormal locking action and poor performance will result 10 Install the lock out valve on the throttle slave and secure it using clean lubricant or Loctite hydraulic sealant on the threads Install appropriate adapters to accept tubing Refer to Figure 6 Hynautic Hydraulic Engine Controls 04 Series HYNAUTIC CONTROLS COMPONENT INSTALLATION TO CONTROL STATIONS NYLON TUBING MM M 5 16 0 0 N 2 HYNAUTIC TUBE FITTING ASSEMBLY 5 5 NUT 530015 ADAPTER 1 4 PIPE X 5 16 TUBE LOCK RING 530025 530175 INSERT 530045 BLEEDER ASSEMBLY 0 RING 002222 690010 680010 1 4 Q 1 4 PIPE NIPPLE 690441 li COCCOCO Cm CONTROL ARM MAY BE ROTATED lt 0 ANY ANGLE SHAFT M Figure 5 ST 06 Integrated Throttle Slave with Tee and Bleeder Valve Installation NOTICE Tube connectors are installed on the tubing per instructions under Tubing Installation and Connection 11 Using a short piece of tubing provided connect the open port on the tee to the S2 port on the lock out valve See Figure 6 See Figur
25. bing Failure to do so may lead to system failure HYNAUTIC CONTROLS TUBING INSTALLATION TUBING NUT 930015 LOCK 530025 O RING 002222 INSERT 530045 Figure 13 Assembling Tubing Connectors Install Tubing Between Senders and Slaves See page 33 to page 38 for Plumbing Circuits 1 2 Locate the tubing roll in a convenient location Starting at the highest control station begin running tubing from the upper tubing port of the right most sender to its connecting point as shown on the diagram NOTICE NOTICE When securing tubing with clamps do not over tighten clamps or ties as overtightening will crimp the tubing causing poor system operation Tubing may be run from the sender to connecting point or from connecting point to sender whichever is easier 3 Secure each end of the newly run tube by Inserting the tube end assembly into the proper adapter 530175 previously installed in components Tighten down only until there is firm resistance felt on the wrench Run the tubing from the lower port of the same sender repeating the previous steps Progress leftward across the control panel until all lines have been run and secured Then go to the next lower station and run tubing from it in the same manner as it was from the upper station If the boat has more than two stations continue running tubing from them in the same manner still following the tubing
26. dvance see supplemental diagram Plan 11 5 and replumb throttle citcuits accordingly FORWARD Figure 33 Installation Instructions amp Owner s Manual ES HYNAUTIC CONTROLS TUBING CIRCUITS Plan IV Twin Engine Throttle plumbing shown in diagram advances throttle in a clockwise Four Station direction For a counter clockwise throttle advance see supplemental diagram Plan IV S and replumb throttle citcuits accordingly FORWARD Figure 34 Hynautic Hydraulic Engine Controls 04 Series SUPPLEMENTAL THROTTLE CONTROL CIRCUITS fJ Plan 5 Plan 1 5 Single Station Counterclockwise Throttle Advance Two Station Counterclockwise Throttle Advance FORWARD FORWARD 35 Figure 36 Installation Instructions amp Owner s Manual HYNAUTIC CONTROLS SUPPLEMENTAL THROTTLE Plan Ill S Plan IV S Three Station Counterclockwise Throttle Advance Four Station Counterclockwise Throttle Advance FORWARD A S FORWARD KON 286 200 0 9109 0 Figure 37 Figure 38 ES Hynautic Hydraulic Engine Controls 04 Series TROUBLESHOOTING GUIDE A
27. e 15 for Copper Tubing connection Plug open fittings at the V1 and V2 ports 12 Verify all fittings installed have been tightened Repeat these throttle slave installation procedures for the second engine ADAPTER 1 4 PIPE NUT 530015 ASSEMBLY 5 16 TUBE LOCK RING 530025 690010 8 530175 INSERT 530045 O RING 002222 ADAPTER 1 4 PIPE HYNAUTIC TUBE 530175 690441 FITTING ASSEMBLY NIPPLE 1 4 PIPE NYLON TUBING 690551 2 0 D N 2 4 NYLON TUBING 78 5 16 0 0 N 2 NIPPLE 1 4 dt IEE 27 STATIONS lt lt HYNAUTIC TUBE FITTING ASSEMBLY 1 4 PIPE TEE 690441 NTROL ARM MAY BE ROTATED ANY inel B STV 10 LOCK OUT VALVE POSITION ON SHAFT PIPE 5 16 TUBE 950119 THROTTLE SLAVE 530175 ASSEMBLY Figure 6 ST 04 Throttle Slave with STV 10 Lock Out Valve Installation Instructions amp Owner s Manual HYNAUTIC CONTROLS COMPONENT INSTALLATION Clutch Slave Installation The SeaStar Solutions clutch slave must be mounted so that when the engine s transmission is in neutral and the Morse clutch slave s arm is at its mid stroke both arms will be 1 in the same plane 2 parallel to each other and 3 right angles will be formed between connecting linkage and each arm see Figure 7 SLAVE ARM LOCK NUT LOCK NUT BALL JOINT BALL JOINT 670010 670010 1 4 20 THREADED
28. etallic ties and clamps 4 Do not allow tubing to become kinked If it does replace that particular run of tubing 5 String tubing so that it will not interfere with hatchways or machinery removal 6 Use only nylon tubing supplied with system from SeaStar Solutions Assemble tubing connectors on every tube end as described below and illustrated in Figure 13 NOTICE A CAUTION Ensure the seal is not twisted during installation The roll of tubing should be laid in a horizontal position and moved as little as possible to avoid kinking and tangling 1 Cut tubing using a tube cutter leaving the cutoff end as square as possible 2 Slip the nut over the tubing end nut should slide freely 3 Push the lock over the end of the tubing and move it back at least one insert length from the end The lock may slide on freely or require a light press or screw on action The lock has a left hand thread 4 Install the seal over the end of the tubing and against the lock Refer to Caution 5 Then force the insert into the end of the tubing by pushing it against a clean flat surface 6 Push the nut and the lock by hand toward the end of the tube as far as possible 7 Insert the tube end assembly into the proper cavity and tighten it down Tighten only to a solid feel on the wrench Hynautic Hydraulic Engine Controls 04 Series A CAUTION Extreme care MUST be taken to avoid any contamination from entering the tu
29. from dash Drill 4 7 16 diameter holes Remove material from shaded area as shown 4 Proceed with sender mounting per installation manual Installation Instructions amp Owner s Manual This page intentionally blank to allow removal use of template Hynautic Hydraulic Engine Controls 04 Series TUBING CIRCUITS Plan Twin Engine Throttle plumbing shown in diagram advances throttle in a clockwise One Station direction For a counter clockwise throttle advance see supplemental diagram Plan I S and replumb throttle citcuits accordingly FORWARD E 14 EAN LAN 9 v LAN Figure 31 Installation Instructions amp Owner s Manual ES HYNAUTIC CONTROLS TUBING CIRCUITS Plan Il Twin Engine Throttle plumbing shown in diagram advances throttle in a clockwise Two Station direction For a counter clockwise throttle advance see supplemental diagram Plan 11 5 and replumb throttle citcuits accordingly FORWARD ji Figure 32 Hynautic Hydraulic Engine Controls 04 Series HYNAUTIC CONTROLS TUBING CIRCUITS Plan 111 Twin Engine Throttle plumbing shown in diagram advances throttle in a clockwise Three Station direction For a counter clockwise throttle a
30. ht Check fitting connections for any leakage 7 Where tubing runs are exposed and are bordering heavy traffic areas check for damage and repair as required Hynautic Hydraulic Engine Controls 04 Series PARTS LIST Nylon Tubing SINGLE ENGINE TWIN ENGINE r gt FER ST S 5 5 x S S le e m 7 2 SES EEE J 12 12 4 22 8 2122 S S x ax cx 5 s 2 ILES S E SESS SEE S JE 8 LS S E e S a TAE 2 4 8 8 4 3 3 3 a a S S S S S S COMPONENT DESCRIPTION s R 13 Reservoir amp Charging Valve 1111111 MCVF 04 Charging Valve Fittings 1111111 MCVF 05 Charging Valve Fittings 1 11 31 4 Control Left Ball Handle 1111212 212 14 14 CL T4 Control Left Control Right Ball Handle or 1 1 2 2 212 4 CR T4 Control Right T Handle CDF 04 Dual Mounting Plate EE 21 14 04 Control Fittings 2 2 4 4 414 8 8 55 04 Shift Slave 1111111 2121212 55 04 Slave Fittings 1 BIN 3 2 1212 2 51 06 Throttle Slave amp Double 1111111 2121212 Pilot Check Valve STF 12 Slave Fittings i 2 1212 2 ADDITIONAL REQUIREMENTS NOT IN
31. icinity of the reservoir Installation 1 Install appropriate adapters for the tubing used For port locations see Figure 12 2 Mount the charging valve using two screws or bolts ADAPTER 1 4 Cue s cg PIPE 5 16 TUBE 530175 Fe TO OOOO Bre N MOUNTING HOLES Figure 12 MCV 04 Charging Valve Installation Instructions amp Owner s Manual EN TUBING INSTALLATION AND CONNECTION A CAUTION Cut tube cleanly and tape the open end while running tubing Four tubing installation plans are provided in the Tubing Diagrams Section later in this manual 1 Twin Engine One Station Plan 2 Twin Engine Two Station Plan 11 3 Twin Engine Three Station Plan 111 4 Twin Engine Four Station Plan IV Before beginning to run the tubing it is recommended that each tube be assigned a number which is marked on both ends and correspondingly marked at the origin and destination of that tube These designations should also be recorded on the chosen plan diagram for future reference Rules for Routing Tubing NOTICE The instructions and illustrations in this section apply to nylon tubing ONLY Information on use of Copper Tubing may be found on page 12 1 Keep tubing free of dirt and foreign matter 2 Keep tubing away from batteries since battery acid is corrosive to the tubing 3 Tie the tubing down at regular intervals using non m
32. inion Assembly 13 730014 1 Cam Detent 19 900254 1 14 240357 1 Set Screw 20 500120 1 Slave Cylinder Assembly 15 430296 1 Spring 21 345926 1 O Ring 6 240337 2 Screw 22 560034 1 Cylinder End 7 703720 2 Washer 23 211028 2 O Rin 8 730020 2 Detent Assembly 24 600070 1 Slave Piston Assembly 9 630051 2 Bushing 25 252125 2 B U Ring 80 740018 1 Washer 26 211125 1 O Ring 11 642921 1 Wiper 27 500131 1 Cylinder Tube 12 223729 1 0 28 560064 1 Cylinder End 113 224011 1 Quad Seal 29 520014 1 44 630044 1 End Gland 30 240717 2 Bolt HHCS 3 8 NC x 3 1 4 SS 15 211027 1 O Ring 31 160061 2 Dill Valves Red 16 190005 2 Bearing Race Hynautic Hydraulic Engine Controls 04 Series OPTIONAL NEUTRAL SAFETY SWITCH KIT SSH 01 Installation 1 Before wiring the Switch determine the best routing for the wires as they lead away from the switch 2 Break out an appropriate knock out in the Switch Cover and feed the wires through before placing cover on Switch When positioning the wiring be sure that it will not interfere with the mechanical function of the switch or slave 2 Using the common and normally closed Switch Terminal Screws wire the switch into the circuit between the Starter Solenoid and the Starter Key Switch in accordance with the engine manufacturers recommendations 3 Using 6 32 screws p n 240857 6 flat washers p n 260147 6 lock washers p n 260107 and 6 3
33. ion NOTICE The standard SeaStar Solutions System MC 04 uses the 5 06 Integrated Throttle Slave You may have chosen to order a non standard system which includes the ST 04 Throttle Slave and STV 10 Lock out Valve Depending on which system you have follow the corresponding installation instructions in this section SeaStar Solutions throttle slaves must be mounted so that at the mid stroke of both the engine s throttle arm and the slave s control arm they are 1 In the same plane 2 parallel to each other and 3 right angles will be formed between the connecting linkage and each arm See Figure 4 If these criteria are met an ideal installation will result A spring bungee ball joint assembly is furnished with each throttle slave It is installed in the slave arm to throttle linkage according to Figure 4 It allows up to 3 16 slave arm over travel in each direction This over travel lets the slave cylinder travel its full stroke and still provide full travel to the throttle arm You must use almost all of the slave travel or about 75 to operate the throttle The slave must go full stroke in each direction in order to synchronize the system The throttle slave s arm may be set to any desired position by loosening the tightening screw using a 3 16 allen wrench in the lower end of the arm and then rotating the arm as desired and resetting the screw After the arm is set it will have a 78 maximum arc A CA
34. lave PRESSURE DILL VALVE GAUDE 160031 FILL PLUG ASSY laj 360020 EM LABEL 140029 180019 T SIGHT TUBE NUT 150088 530015 LOCK RING 530025 SPACER 4 REQ D O RING 54018 5000 211910 INSERT CHARGING VALVE 000430 530045 INCLUDED SEAL RS 01 2 x O Ring 002222 2 x O Ring 211910 1 O Ring 015824 2 Seal 224014 1 x O Ring 220523 1 x Inst Sheet 181033 2 x O Ring 211206 gt P 0 RING lt 211910 PLUG 380574 FILTER ELEMENT 160113 POPPET ASSY 4 REQ D 450040 BODY di SSS 901044 O RING 4 REQ D 211016 SPRING 4 REQ D 430546 PLUG 4 REQ D 380514 INCLUDED IN FITTING KIT MCVF 08 4 xO Ring 014624 4x Poppet Assy 450040 4 x Plug 380514 1 x Reservoir Plug 380030 4 xSpring 430546 1 x Inst Sheet 180054 Figure 28 R 13 Integrated Reservoir Figure 29 Charging Valve on R 13 Integrated Reservoir Hynautic Hydraulic Engine Controls 04 Series HYNAUTIC CONTROLS SWITCH KIT SSH 1 SPRING 4 MCV 04 CHARGING VALVE 430546 I ze pua PLUG 4 380514 Sd O RING 4 014624 c isl FN POPPET ASSEMBLY 4 490040 BODY 900664 INCLUDED IN FITTING KIT MCVF 08 FILL PLUG 4 x O Ring 014624
35. licone additives are very thick in consistency and will clog the elements in the synchronization valve If this occurs your system will be unable to maintain synchronization between sender and slave The ethylene glycol chosen for use should be as pure no additives as possible proportionately mixed with distilled water then filtered to assure its purity NEVER USE STOP LEAK TYPE ANTI FREEZE Filtration is accomplished by passing the fluid through a 5 micron filter before using in the system Field service pre filtering can be accomplished by using a Mr Coffee or equivalent paper filter placed in a funnel and then pouring the ethylene glycol solution through it One paper filter will filter approximately 1 2 gallon of ethylene glycol solution The HA5455 fluid provided by SeaStar Solutions is proportionately mixed and filtered to assure its purity and is ready for use MAKING THE SYSTEM OPERATIONAL Synchronizing the Controls The system is now operational except for synchronizing the controls 1 Go to one control station and move each sender s arm from stop to stop 3 to 5 complete cycles Each sender should be synchronized at this time NOTICE This synchronization can be performed at any of the control stations 2 Ifthe position of the sender s handle requires an awkward motion by the user adjust the handle by loosening the set screw using a 1 4 allen wrench and rotating the handle so that the user has m
36. ment Engine governor out of adjustment Engine out of tune Installation Instructions amp Owner s Manual Re adjust length of the throttle linkage Service Engine HYNAUTIC CONTROLS TROUBLESHOOTING FAULT 6 Engine Throttle tends to creep toward idle CAUSE e Pilot check valve malfunctioning SOLUTION e Remove pressure from system e Re pressurize the system e Re purge the system of air e Slave s internal piston seals or synchronizing valves leaking due to wear or debris Remove pressure from system Rebuild or replace throttle slave e Re pressurize the system e Re purge the system of air 7 Full Throttle on sender gives idle on engine System tubing connected backward e Remove pressure from the system e Reverse tubing at the throttle slave e Pressurize system e Synchronize throttle control 8 After a long running period the Throttle tends to go out of synchronization Slave is located at an engine hot spot which has caused excessive heating of the Several Suggested Remedies The use of heat resistant gasket material approximately throttle slave which in turn has caused the slave to develop a vapor lock e Contamination in pilot check valve keeping it from functioning properly 1 8 Thick between the mounting bracket and engine Spaces between the bracket and engine and slave and bracket Shielding around
37. mited Warranty We warrant to the original retail purchaser that Marine Canada Acquisition Inc DBA SEASTAR SOLUTIONS herein forward referred to as SeaStar Solutions 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 SeaStar Solutions 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 SeaStar Solutions 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 SeaStar Solutions products found to be defective and covered by this warranty will be replaced at SeaStar Solutions option and returned to the customer The above quoted statement is an extract from the complete SeaStar Solutions products warranty statement A complete warranty policy is available in our SeaStar Solutions products catalogue Return Goods Procedure Prior to returning product to SEASTAR SOLUTIONS 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
38. on tubing expands and contracts in very much the same manner as the hydraulic fluid a most important factor The expansion and contraction of the tubing reduces drift of the controls as temperature changes thereby helping to keep all the components of the system synchronized The tubing is virgin nylon which has been heat and light stabilized and contains no plasticizers The burst pressure of the tubing is in excess of 1200 psi Hynautic Hydraulic Engine Controls 04 Series PREPARATION FOR INSTALLATION CAUTION Dirt and foreign matter in the hydraulic system cause damage and malfunction It is extremely important to keep tubing and fittings clean when installing and connecting components Cut tube cleanly and tape the open end while running tubing Before installation is started the parts list should be checked to verify that a complete system has been received Parts lists are located on page 19 and page 20 It is advised that all system components be installed senders shift throttle slaves and reservoir prior to running the system tubing This allows the tubing to be run between two definite points with less chance of an error Should it become necessary for the tubing to be strung first a system of marking the different tubing runs should be used COMPONENT INSTALLATION Components have red plastic plugs installed in their ports to keep out foreign matter As you remove these red plastic plugs re
39. ore of a direct push pull motion Do not position handle so that it binds against the sender body at either end of its stroke 3 Should one of the controls not come into synchronization go to that station which is out of synchronization and perform Step 1 Connecting Engine Controls 1 Connect throttle linkages to the throttle slave Repeat for both engines 2 Connect clutch linkages to the clutch slave Repeat for both engines NOTICE For any operational problems at this point consult the trouble shooting section Installation Instructions amp Owner s Manual OPERATION amp MAINTENANCE Throttle Senders Forward Motion Increases Throttle Aft Motion Decreases Throttle A WARNING When working on engine and operating the engine throttle arm by hand disconnect throttle linkage from the control slave If linkage is not disconnected the pilot check valve will not allow a throttle retardation unless a sender arm is actuated to decrease the throttle NOTICE Prior to starting engines both throttles and clutches should be synchronized This is done by moving the sender s control arm in a complete cycle fore and aft stop to stop This needs to be done at only one station Clutch Senders Forward Position Forward Direction Center Position Neutral Aft Position Reverse Direction Maintenance Schedule The clutch and throttle sender bodies are made of 6061 T6 aluminum
40. place them immediately with the proper adapter then install the red plugs into the adapters until you are ready to connect tubing Use Loctite hydraulic sealant on all NPT fittings prior to installation DO NOT use teflon tape or pipe dope Sender Installation 1 Locate sender on panel so that the control arm s arc will not interfere with the ship s wheel or panel Be certain that access is available to the small bleeder screw at the top of each sender head The design of the new Engine Control T handle requires a minimum distance between control heads to provide adequate handle clearance when two sets of controls are mounted side by side See Figure 1 NOTICE This minimum distance does not apply to installations using the optional knob style control handles 2 Using the template provided in the appendix mark and cut a hole for the sender Page 29 shows the proper templates for the single head and side by side sender mounting options Refer to Figure 1 for minimum distance required when mounting two sets of controls side by side 3 Drill 7 16 holes in the panel for the mounting bolts 4 Set sender in place and check to see if all mounting holes match up Installation Instructions amp Owner s Manual HYNAUTIC CONTROLS COMPONENT INSTALLATION NOTICE If the area under the control panel is too confined to allow the tubing to be connected with moderate ease do not secure the sender at this
41. rols may be synchronized with each other by moving the control arm at one control station from stop to stop The control slave is very similar to the control sender except the body is a rectangular block An over travel bungee is used in the linkage between the slave arm and engine control arm to assure that the slave can reach the end of its stroke in each direction The slave for the transmission has a built in detent mechanism to indicate neutral position On most engines the throttle exerts considerable force to return to the idle position Each throttle slave is equipped with a pilot check valve which locks the throttle slave in the position it has taken in response to the sender The throttle slave can be driven only by the sender it cannot drive the sender Extra hydraulic fluid and a pressure head for the system is maintained by the system s reservoir The reservoir is charged with 80 psi of air over the hydraulic fluid within it This keeps the entire system under pressure at all times and prevents a vacuum from existing on the back side of any piston when the system is operated Fluid flow to and from the reservoir is regulated by a charging valve located on the bottom of the reservoir This valve is necessary to keep the system under pressure and to prevent excessive pressures caused by the expansion of fluid when the fluid becomes warm Nylon tubing is used to pipe the system for two reasons 1 ease of installation 2 nyl
42. rt the bleeder tube in the bleeder valve at one side of a slave Open the bleeder valve about one turn and bleed system until no air bubbles are evident in the flowing fluid When the fluid is clear close the bleeder valve During the bleed operation maintain the system pressure above 60 psi and the fluid level in the sight gauge above the two inch mark Should the fluid level drop below two inches close the bleeder valve and release the pressure from the system Refill the reservoir with the fluid that has been bled off repressurize the system and continue bleeding Bleed long enough that no air or foam remains in this branch of the system Draw at least a full reservoir of fluid through each side of each circuit NOTICE NOTICE The bleeding procedure is much easier for two people to perform than one one keeping reservoir filled and under pressure while the other one bleeds the system Since there are two positions at each slave to be bled and four slaves the reservoir must be filled at least 8 times during the bleed operation The fluid which has been bled off should be used to efill the reservoir 3 4 5 Tighten bleeder valve after the bleed operation Bleed the second port of the slave as described in Steps 1 2 and 3 Repeat steps 1 through 4 with a second person at the sender moving the handles back and forth slowly five to ten times Continue performing the preceding five steps for each remaining slave Ins
43. tallation Instructions amp Owner s Manual HYNAUTIC CONTROLS FILLING AND BLEEDING Bleeding the System at Senders After bleeding system at each slave bleeder valve each sender must now be bled A small amount of air will be trapped at the high point in each sender head 1 Refill reservoir if required fill tank at this time to between 1 2 and 2 3 full and leave about 100 psi on the pressure gauge NOTICE Place a rag over the bleeder hole on the sender to prevent fluid from spilling on the console 2 Very slowly open the bleeder plug using a 3 16 allen wrench See Figure 10 for location of bleeder screw GASKET BLEEDER SCREW Figure 20 Bleeder Screw 3 Allow the fluid to bleed out until the fluid is clear without air bubbles 4 Tighten the bleeder screw after bleeding Repeat Steps 1 to 4 above for each sender 6 The reservoir level should be between 1 2 and 2 3 full If the level is below this the reservoir should be filled to this level Verify that pressurize in the reservoir is between 80 and 85 psi ol Hynautic Hydraulic Engine Controls 04 Series SYSTEM FLUID The fluid recommended for use in the system is a 50 50 mixture by volume of distilled water and ethylene glycol The type of ethylene glycol used is very important for proper operation of your system and especially the synchronization charging valve Some additives especially si
44. teering causing property damage personal injury and or death Don t compromise performance use genuine Hynautic parts only Hynautic Control Senders Hynautic Control Slave Units Hynautic Control Reservoirs e Hynautic Control Tubing Hynautic Control Fluid Substituting non Hynautic parts in any part of the Hynautic hydraulic steering system may seriously compromise system performance This manual should be kept on board your vessel Index RE ii Preparation for Installation 1 Component 1 Sender Installation 1 Throttle Slave Installation 3 Clutch Slave Installation 6 R 13 Reservoir Installation 8 R 04 Reservoir Installation 8 MCV 04 Charging Valve Installation 9 Tubing Installation and Connection 10 Rules for Routing Tubing 10 Install Tubing Between Senders and Slaves 11 Copper 2 2 accen eere none aya sag one ee 12 Filling and Bleeding the System 15 Filling the System R AA a DS a ua uqa
45. the throttle slave Re mounting of the throttle slave in a less hot area Remove pressure from system Re pressurize the system Re purge system of air e f twin engines are equipped with synchronizer governor or synchr onizer s tension springs are out of adjustment Re adjust springs proper tension NOTE excessive tension in either throttle extremes will cause synchronization problems 9 Loss of system pressure but Air leak in reservoir not loss of fluid NOTE System pressure will vary as much as 410 psi due to temperature changes When system pressure drops below 70 psi a leak should be checked for While pressure is on system use a soapy water solution to find an air leak on the tank When leak is found remove pressure and repair re pressurize system to 80 psi Hynautic Hydraulic Engine Controls 04 Series HYNAUTIC CONTROLS TROUBLESHOOTING SOLUTION FAULT 10 Loss of pressure and fluid on system CAUSE e System leak With pressure on system check for fluid leaks at all connections When found repair leak If a tubing connection is leaking remove and replace O ring if leak persists see section of trouble shooting which concerns leaks at fittings for further repair procedures Pressurize system bleed system filling as required Synchronize controls 11 Sender arm moved at one station results in the wrong arm movement at the other station s
46. time Proceed with the installation of the remaining senders per Steps 1 through 5 The sender may be secured after the tubing has been connected to it The sender s ports are tapped 1 4 NPTF Suitable adapters must be installed to accept the tubing used It is more convenient to install these adapters prior to mounting the senders Instructions for copper tubing installations are onpage 12 Secure senders per Figure 2 for single head or Figure 3 for side by side mounting The sender s handle position may be set within limits by loosening the tightening screw using a 1 4 allen wrench in the lower end of the arm and then rotating the arm as desired and resetting the screw After the arm is set it will have a 115 maximum arc Secure the remaining senders per Steps 1 through 7 The minimum distance does not apply to installations using 3 5 MINIMUM BETWEEN PLATES the knob style control handles 3 75 MINIMUM BETWEEN HEADS Figure 1 Mounting Handle Controls Side by Side 2 WASHER MOUNTING BOLT CDF 04 MOUNTING R 7 Z PLATE d WASHER PANEL MOUNTING 9 Q BOLT Figure 2 Single Head Sender Figure 3 Side By Side Senders Hynautic Hydraulic Engine Controls 04 Series HYNAUTIC CONTROLS COMPONENT INSTALLATION Throttle Slave Installat
47. which has been anodized To clean them a warm soapy solution should be used Do not attempt to use an abrasive compound as is done when shining brass Every 30 Days 1 Check hydraulic fluid level should be between 1 2 2 3 full on the sight glass 2 Check system pressure pressure should be between 70 90 psi see note below concerning reservoir pressure NOTICE The reservoir pressure will vary between 70 90 psi due to temperature changes There is no reason to become alarmed unless the pressure drops below 70 psi then the system should be repressurized to 80 psi If the pressure loss is over a relatively short period check for air leakage Should the pressure loss from full pressure to minimal operation pressure be over an extended time period just repressurize the system This extended pressure loss is normal and may be compared to the same type pressure loss one experiences with a good set of automotive tires after an extended time Every 6 Months 1 Check fluid level in the reservoir level should be approximately 1 2 to 2 3 of sight glass 2 Check system pressure it should be between 70 90 psi Consult the note above about system pressure change 3 The system is self lubricating but the ball joints on control linkages should be oiled 4 Check mounting bolts on the control slaves clutch and throttle to verify that vibration has not loosened them 5 Check lock nuts on control linkages verify that they are tig
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