Dometic HC4645H Bedienungsanleitung

Dometic Hydraulic Steering Systems

Troubleshooting Guide

WARNING

Cancer and Reproductive Harm

www.P65Warnings.ca.gov

HYDRAULIC STEERING

SYSTEMS

ii EN

All information, illustrations and specifications in this manual are based on

the latest information available at the time of publishing. The illustrations

used in this manual are intended as representative reference views only.

Moreover, because of our continuous product improvement policy, we

may modify information, illustrations and/or specifications to explain and/

or exemplify a product, service or maintenance improvement. We reserve

the right to make any change at any time without notice.

herein is the sole, exclusive and confidential property of Dometic and shall

not be disclosed, copied, reproduced or used in whole or in part for any

purpose other than as specifically authorized in writing by Dometic.

is a registered trademark of the American Boat &

Yacht Council (http://www.abycinc.org)

NMEA 2000® is a registered trademark of the National Marine

Electronics Association.

Optimus, Optimus 360, SeaStar, and BayStar are all trademarks of Dometic.

California

Proposition 65 Warning

Battery posts, terminals, and related accessories contain

lead and lead compounds, chemicals known to the state

of California to cause cancer and reproductive harm.

Wash hands aer handling.

This book contains:

• the troubleshooting information for Dometic hydraulic steering systems.

Thank you for choosing Dometic Hydraulic Steering. You have chosen a

state of the art steering system that will provide years of effortless and

trouble free steering performance.

About this Book

iii

Table of contents

1 Important safety information ................................................. 1

1.1 Explanation of symbols ..................................................... 2

1.2 Safety considerations and safe operation ............................ 3

2 How to use this manual.......................................................... 5

3 Common terms and definitions ............................................. 5

4 Manual troubleshooting........................................................ 6

4.1 Loss of fluid/fluid level not visible in helm pump ................... 6

4.2 Helm locks up completely................................................. 7

4.3 Difficulty purging the air from the system............................. 8

4.4 Steering wheel(s) are hard to turn at dock ............................ 9

4.5 Steering wheel(s) are hard to turn while underway

(easy at dock) ................................................................. 10

4.6 Steering wheel(s) freewheel(s) to one/both direction(s) ........ 11

4.7 Steering wheel(s) are bumpy when turning either direction..... 12

4.8 Boat drifts to one side or the other while underway ............. 13

5 Power Assist system troubleshooting .................................. 14

5.1 Steering wheel(s) “lock up” to one or both directions........... 14

5.2 Power Assist motor runs but NO power assist ..................... 15

5.3 Bumpy feeling at steering wheel(s) with power assist

turned ON ..................................................................... 16

6 System checks ...................................................................... 17

6.1 Checking for air in the steering system ............................... 17

6.2 System pressure test........................................................ 18

6.3 Cylinder/helm pump check.............................................. 19

6.4 Helm/cylinder & power assist checks ............................... 20

7 Routine maintenance........................................................... 22

8 Specifications and replacement parts .................................. 24

8.1 BayStar ......................................................................... 24

8.2 SeaStar......................................................................... 25

8.3 Fitting identification........................................................ 26

9 Advisory notice..................................................................... 27

9.1 Power Assist pumps ....................................................... 27

9.2 How to determine if your power assist is affected ............... 27

9.3 How to disable the power assist....................................... 28

9.4 How to obtain a service kit .............................................. 28

10 How to test the SeaStar power assist....................................29

10.1 Test procedure .............................................................. 29

iv EN

This page le intentionally blank.

1 Important safety

information

This troubleshooting guide is written using years of experience

troubleshooting the most common problems associated with our steering

systems. Most faults are directly related to installation and operating

manual(s) not being followed or incorrect parts being used.

The purpose of this troubleshooting guide is to systematically work your

way through the system, centering in on the most likely problem.

When you find a fault, it is good practice to determine “how” the fault was

created and “what” can be done to prevent this in the future.

Please carefully read and follow all instructions, guidelines and warnings

included in this product manual in order to ensure that you install, use and

maintain the product properly at all times. By using the product, you

hereby confirm that you have read this disclaimer, all instructions,

guidelines and warnings carefully and that you understand and agree to

abide by the terms and conditions as set forth herein. You agree to use this

product only for the intended purpose and application and in accordance

with the instructions, guidelines and warnings as set forth in this product

manual as well as in accordance with all applicable laws and regulations.

A failure to read and follow the instructions and warnings set forth herein

may result in an injury to yourself and others, damage to your product or

damage to other property in the vicinity. Dometic accepts no liability for

any loss, damage or injury incurred, directly or indirectly, from the

installation, use or maintenance of the product not in compliance with

the instructions and warnings in the product manual.

This troubleshooting guide, including the instructions, guidelines and

warning, and related documentation may be subject to changes and

updates. For up-to-date product information, please visit:

https://documents.dometic.com and https://www.dometic.com

2EN

The symbols below are used throughout this publication to alert you to

potential hazards involved with the operation and installation of this product.

Observe these warnings and notices carefully. The safety alerts alone

cannot eliminate hazards; strict compliance with any special instructions

during installation, operation, and maintenance, along with common sense

operation, are important measures to prevent hazardous situations.

1.1 Explanation of symbols

DANGER!

Safety instruction: Indicates a hazardous situation that, if not avoided,

will result in death or serious injury.

WARNING!

Safety instruction: Indicates a hazardous situation that, if not avoided,

could result in death or serious injury.

CAUTION!

Safety instruction: Indicates a hazardous situation that, if not avoided,

could result in minor or moderate injury.

NOTICE!

Indicates a situation that, if not avoided, can result in property damage.

NOTE

Supplementary information for operating the product.

1.2 Safety considerations and

safe operation

Before installation

The safe operation of the steering system is dependent upon proper

installation & maintenance, common sense, safe judgment and the

knowledge/expertise of the operator. Every installer/user should know the

following requirements before installing/using the steering system.

1. Read and understand the installation and operating manual provided

with your motor, steering system, and associated components.

Ensure that all components required to complete the installation are on hand.

3. Dometic components are highly engineered and safety tested to ensure

system integrity; do not substitute any component with non-Dometic

components as this may compromise system performance/reliability.

WARNING!

The safety information provided throughout this publication is intended to

inform you of the dangers that may be present during installation and use.

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

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

CAUTION!

Helms and cylinders that end with the suffix -3 use ORB fittings only. Do not

use NPT fittings. Irreparable damage will occur.

During installation

1. Install components as directed in all Installation Instructions.

2. Do not modify or substitute any component in any way without written

consent from Dometic.

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. Confirm that there is no interference between the steering cylinder(s),

tiebars and the transom, splashwell, outboard engine(s) 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 confirm that no interference occurs.

• If using a hydraulic jack plate the above must also be performed at

all the positions of the jackplate.

b. Repeat step 4a) with engine(s) tilted up.

c. Perform step 4a) with each engine in down/up positions confirming

that independent trim/tilt can be done without any interference.

5. Confirm that the steering cylinder(s) can be fully stroked in both

directions as well as full tilt and trim without stretching, chafing, rubbing

and/or kinking of the hydraulic hoses.

4EN

6. Outboard Systems: Confirm 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 in the component’s

installation manual.

NOTICE!

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

NOTICE!

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

Prior to every use

1. Check fluid level in highest helm pump. (Refer to installation and

operating manual for correct fluid 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 fittings for wear, kinking

and/or leaks.

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

During use

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

• Cleaning fluids containing ammonia, acids or any other corrosive

ingredients must not be used for cleaning any part of the hydraulic

steering system.

After use

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

• Cleaning fluids containing ammonia, acids or any other corrosive

ingredients must not be used for cleaning any part of the hydraulic

steering system.

Maintenance

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

2. See maintenance section in the component’s installation manual.

2 How to use this manual

3 Common terms and

deﬁnitions

Each fault will be labeled as a “Symptom” at the top of the page, followed

by possible “Causes”, and then followed by possible “Solutions”.

• Symptom = Problem reported

• Causes = Most likely cause that can lead to the symptom

• Reasons/Solutions = Cures for the symptoms

In cases where there are multiple “causes” a series of checks and tests will

be required. Go through these checks/tests in the order that they appear.

Doing so will quickly narrow in on specific areas. Skipping steps will only

lead to more time diagnosing the problem.

Helm Pump – Located at all steering locations. The steering wheel is

mounted to the helm pump.

Steering cylinder – Mounted to engine(s), rudder(s) and/or outdrive(s).

Manual System – Consists of helm(s), steering cylinder(s) and hoses only.

Power Assist – Electrically driven power pump plumbed into a manual system.

Balanced System – A steering cylinder that the piston rod goes in and

out of both sides of the barrel.

Unbalanced System – A steering cylinder that the piston rod only goes in

and out of one side of the barrel. NOTE: Cannot be used with a Pro helm.

Autopilot Pump (A/P Pump) – External pump plumbed into the steering

system and used in conjunction with an autopilot controller.

6EN

Manual troubleshooting

Causes

A. Leak in steering system.

B. Air remaining in system/system not properly bled originally/fluid level

set too low.

Solutions

4.1 Loss of ﬂuid/ﬂuid level not

visible in helm pump

WARNING!

Repair all leaks prior to use.

A. Check all fitting connections, hoses and steering components for any

signs of a leak. See system pressure test on page 18 to pinpoint

source of leak.

B. Bleed system free of air. Reference “Checking for air in the steering

system” on page 17. Fluid level is to be set be tween 1/4” – 1/2”

below the filler port threads.

Refer to section 4.3 If having difficulty purging.

NOTICE!

When using an unbalanced cylinder the fluid level is to be set and

inspected with the cylinder shaft fully “retracted”. Failure to have cylinder

rod fully retracted will result in fluid leakage at the helm filler port.

Root Causes

• Damage to a cylinder shaft (dings, dents, corrosion and/or scratches)

will lead to the tearing of a seal resulting in a leak. Replace any damaged

shaft and/or end gland.

NOTICE!

Replacement shafts are not available for purchase. Contact Authorized

Service Center for repair, or, replace steering cylinder(s).

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