And Owner'S Manual: Installation Instructions

INSTALLATION INSTRUCTIONS
AND OWNER'S MANUAL
2.1
www.seastarsolutions.com
TWO POINT ONE

ISO 9001 Steering Cylinder Installation Manual
for Hydraulic Inboard and Sterndrive
Powered Vessels
do it you r way,
Before yopulease try it our way

To the Installer and End
User (Owner)
Thank you for choosing SeaStar Steering Systems by SeaStar
Solutions. 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;
WARNING 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.
CAUTION Hazards or unsafe practices which could result in minor injury or

product or property damage.
NOTICE Important information in regards to installation, use and maintenance

of the steering components.
NOTICE Marine Canada Acquisition Inc. DBA SEASTAR SOLUTIONS is referred

to as SeaStar Solutions throughout this publication.
These safety alerts alone cannot eliminate all of the hazards

that may be present while on the water. SeaStar Solutions
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.
WARNING Safety Information
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
SeaStar Solutions.
To reduce risk of severe injury or death. Always wear a Coast Guard
Approved personal flotation device (PFD) and use an engine shut-off
cord (lanyard).
Before installation 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, fittings, oil and the proper tools
required for the installation).
3. Substituting non SeaStar parts are not recommended as they
may compromise performance/reliability.
Installation 1. Install components as directed in all Installation Manuals

(including helm pumps, hoses and fitting kits).
2. DO NOT modify any component in any way without written
consent from SeaStar Solutions.
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.
- Cylinder MUST be able to withstand rudder loads.
4. Confirm that there is no interference between the steering cylinder(s)
and any other object by performing the following steps:
Stern drive applications:
a) With cylinder installed, turn steering wheel from hard over to
hard over and confirm that no interference occurs.
- If using external mount cylinders, confirm no interference
with drive in UP/DOWN positions.
Inboard applications:
a) Confirm that cylinder(s) fully extend/retract prior to hitting any
installed rudder stops.
5. Confirm that the steering cylinder can be fully stroked in both
directions without stretching, chafing, rubbing and/or kinking of
the hydraulic hoses.
6. Where required, 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 System Proof Test as outlined on page 28 of this manual.
Inboard & Sterndrive Powered Vessels i

WARNING Safety Information Continued
Prior to every use 1. Check Fluid level in highest helm pump (see page 28 for proper
fluid level setting).
2. Verify immediate steering response when turning steering wheel(s).
(Ensure drive(s)/rudder(s) 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.
5. Ensure operator(s) have taken an 'accredited boating course'.
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;
- Federal Laws/Regulations,
- State Laws/Regulations and
- Municipal Laws/Regulations.
DO NOT OPERATE BOAT IF ANY COMPONENT IS NOT IN PROPER

WORKING CONDITION.
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.

- See Routine Maintenance, page 29 of this manual.
Keep our waters clean for all current and future users. Dispose of
ALL fluids in accordance with your local regulations.
ii SEASTAR Hydraulics
INTRODUCTION
Before proceeding with the installation, read THESE instructions and
ALL other instructions included with the rest of your system (helm pumps,
Power Assist etc). SeaStar Solutions cannot accept responsibility for
installations where instructions have not been followed, where
substitute parts have been used, or modifications have been made to
our products. Warranty may be void if products other than SeaStar
Solutions products are used within the system.
NOTICE Due to a small amount of internal slip, a “Master Spoke” or

“centered” steering wheel cannot be maintained with a hydraulic
steering system. For best results, us an equal distance spoke
steering wheel.
WARNING DO NOT use a wire coil type trim switch with a hydraulic steering
system. Wire coil can wind up tight around the steering wheel
preventing further steering.
Index
Safety Information....................................................................... i
Introduction............................................................................... 1
System Overview Diagram........................................................... 2
Tools......................................................................................... 3
Things You Need to Know........................................................... 4
System Installation Overview....................................................... 5
Cylinder Mounting: All Inboard ATM & TM/TMC Models................. 6
Cylinder Mounting: Ball Joint Bracket Mount Cylinders................. 11
Cylinder Mounting: Sterndrive Engine Mount Cylinders................ 13
Hose and Tubing Installations................................................... 18
Additional Stations, Autopilots & SeaStar Power Assist Units...... 22
Manual Filling and Purging........................................................ 23
Oil Level and System Proof Check ............................................. 28
Routine Maintenance ............................................................... 29
Troubleshooting Guide.............................................................. 30
Technical Information............................................................... 32
Parts List................................................................................. 34
Statement of Limited Warranty.................................................. 44
Return Goods Procedure........................................................... 44
The following steering cylinders are covered within this manual.

HC1503-3, HC5303-3, HC5312-3, HC5313-3, HC5314-3, HC5322-3,
HC5323-3, HC5326-3, HC5328-3, HC5329-3, HC5330-3, HC5331-3,
HC5332-2, HC5339-3 and HC6324-3.
Inboard & Sterndrive Powered Vessels 1

Typical Inboard
Steering System
FILL AND VENT
SYSTEM HERE
CAUTION
DO NOT attempt to install NPT pipe
fittings directly into -3 helms or -3
steering cylinder hose fitting ports.
Doing so will lead to irreparable
damage to the helm/cylinder. ONLY
use ORB hose fittings provided by
SeaStar Solutions.
COMPENSATING LINE
SEASTAR
HOSE/TUBE
AND/OR
ADDITIONAL STEERING 3/8" COPPER
STATION TUBING
STARBOARD LINE (RIGHT)

PORT LINE (LEFT)
CAUTION
THIS HELM MUST BE FITTED
WITH A NON-VENT PLUG.
FAILING TO DO SO WILL
RESULT IN AN OIL LEAK.
ROD END BALL JOINT

IF COPPER TUBE IS USED FOR
GENERAL INSTALLATION, USE
CYLINDER HOSE KIT HERE.
TILLER ARM
MOUNTING FOOT
CYLINDER
Figure 1. Overview.
2 SEASTAR Hydraulics
TOOLS
Standard Helm Mounts You will need the following tools to complete your installation.
• 3" (77 mm) diameter Hole Saw or Key Hole Saw, for use with Front
Mount, Sport/Sport Plus Tilt helms.
• 5⁄16" (8 mm) dia. Drill.
• 7⁄16", 9⁄16", 5⁄8" and 3⁄4" Open End type Wrench/Spanner.
• 15⁄16" Socket.
Optional Helm Mounts • Square Bezel Backmount, HA5418, 4-1 ⁄2" (115 mm) Hole Saw
• Round Bezel Backmount, HA5478, 4-3⁄8" (112mm) Hole Saw
• Rear mount Helms, 1-1/6" (27mm) drill
• Classic Tilt Helms, 4-1 ⁄2" (115mm) Hole Saw
• 20° Wedge Kit HA5419
Additional Tools Needed 20° Mount Wedge

• 4" (102 mm) Key Hole or Sabre Saw
• 5⁄16" (8 mm) dia. Drill
• 1 ⁄2" Wrench/Spanner, Box or Open End type
• 7⁄16" Socket and Drive
Cylinder, ATM and TM Models
• 3⁄4" Wrench/Spanner, Box or Open End type, 2 required.
Cylinder, Ball Joint Bracket Mount Models
• 3/4" Wrench/Spanner, Box or Open End type, 2 required.
Cylinder, Model HC5328-3 (125-8EM)
• 1-5⁄16" Wrench/Spanner, Open or Adjustable type.
Cylinder, Other Models
• No special tools required.
CAUTION Do not remove protective caps from fittings and fitting ports until
hose or tube connections are made. Contaminants in the steering
system may cause premature wear and steering malfunctions.
NOTICE Disposing of excess, left over, or used fluid. If the original oil bottle
is unavailable, dispose of the steering fluid in an environmentally
conscientious manner, adhering to local and federal environmental
regulations.
Always wear safety glasses and protective clothing when working
around hydraulic fluid and components.

THINGS YOU NEED TO KNOW
WARNING DO NOT use SeaStar PRO helms with ANY unbalanced steering
cylinder. Use of a PRO helm with an unbalanced cylinder will lead
to a lock up of the steering wheel preventing further steering
control, resulting in collision with an obstacle causing property
damage, personal injury and/or death.
CAUTION SeaStar/SeaStar PRO Steering Hoses CANNOT be cut. Cutting

these hoses will render them useless and a new hose will be
required.
CAUTION BEFORE beginning with this installation, confirm that ALL

components have been acquired to complete the installation,
including; helm pump(s), hose and tube, oil, pipe sealant and any
other component required. DO NOT USE Teflon tape. ONLY use a
“liquid”, Teflon based pipe sealant (such as Loctite® 542).
CAUTION Take EXTREME care not to allow any foreign material or contamination
to enter the hydraulic steering system. Contamination is the main
cause of a hydraulic system to wear and or fail. Protect ALL hose/
tube ends until ready to make final connection to fitting.
WARNING Follow the maintenance procedures outlined on page 29 of this

manual as well as ALL other manuals included with the other
components of your steering system. Following these procedures,
in the time frame noted will keep you and your passengers safe
from the dangers that are present on the water. Failure to adhere
to ALL maintenance procedures included in ALL Installation and
Owner’s Manual may result in loss of steering control. Loss of
steering control may lead to unpredictable boat behavior, leading
to a collision with an obstacle and/or ejection from the boat,
resulting in property damage personal injury and/or death.
Before Starting Study this manual and ALL other manuals provided with your SeaStar
Steering System carefully and thoroughly to familiarize yourself with
all of the components and their intended or required mounting
locations. Ensure there is adequate space available for installation
of ALL components, hydraulic lines and easy access for service. It
is good practice to mount all components first, before running hoses;
this ensures the least chance of an error in hose/tube to fitting
connections. If you must run hoses first a system of marking the
various lines must be used. ALL hose/tube ends MUST be closed
off with tape or similar material to prevent contamination. Read ALL
BOLD print text, notes, cautions and warnings; reading these now
will help prevent unexpected surprises during the installation.
These instructions have been made as complete as possible, but
as brief as practical. If you have any questions please phone
SeaStar Solutions, Technical Support @ 604.248.3858
SYSTEM INSTALLATION
OVERVIEW
STEP 1 System Installation
• Install your SeaStar helm pump(s) onto the dash using the
installation instructions provided with your helm pump(s).
HELM HOSE
WARNING DO NOT use a SeaStar PRO helm with an
unbalanced cylinder.
• Install steering cylinder as per the instructions on the following
pages.
NOTICE Ensure that you follow the installation instructions
for YOUR Steering Cylinder.
CYLINDER
• Install hose/tube as per the plumbing diagrams shown on
page 19.
STEP 2 Filling and Purging Procedures

• Manual purging: Refer to page 23 of this manual for bleeding
details.
• Power Purging: Refer to Power Purge Installation Manual.
STEP 3 System Proof Check

• WARNING The System Proof Check shown on page 28 of this
manual MUST be completed after installation. Doing so will
ensure the safe operation of your steering system. Any fault
(leaks or malfunction) will present itself during this check.
Failure to perform this check may result in loss of steering
control. Loss of steering control may lead to unpredictable boat
behavior, leading to a collision with an obstacle and/or ejection
from the boat, resulting in property damage personal injury
and/or death.

CYLINDER MOUNTING
All Inboard ATM & TM/TMC Models
General Proper cylinder mounting is CRITICAL to the successful operation of
your hydraulic steering system. An incorrectly installed cylinder WILL
lead to rapid seal and bearing wear as well as non-repairable damage.
Select the diagram and dimensional data that corresponds with
your cylinder model. Note, not all possible cylinder mounting
configurations are shown, however, all necessary dimensions are
shown regardless of mounting configurations.
CAUTION If installing rudder stops, ensure that the cylinder(s) reach hard-
over BEFORE rudder stops are engaged.
WARNING Where applicable, cylinders should be secured with thru bolts,

NOT with lag screws. Failure to adhere to this warning may result
separation of steering components leading to loss of steering
control, which may result in unpredictable boat behavior, leading
to a collision with an obstacle and/or ejection from the boat,
resulting in property damage personal injury and/or death.
CAUTION Cylinder hose/bleeder fittings must always be installed in the

uppermost position. If this is not possible the cylinder must be
disconnected from mount to allow the bleeder fittings to be in the
up-right position, then, once all air is removed the cylinder can be
re-installed. Leaving air in the system will drastically affect
performance of your steering system.
CAUTION Protect cylinder shafts from nicks and scratches. A damaged

cylinder shaft can not be repaired and a new cylinder will need to
be purchased.
All parts used are corrosion resistant, however with extended

operation under extremely corrosive conditions, corrosion may
occur and affected parts should be replaced.
In order to avoid excess steering loads and to optimize steering
performance, outdrive trim tabs must be adjusted in accordance
with the engine manufacturer’s instructions for specific boat/motor
combinations. Failure to do so will drastically change the
performance and handling characteristics of your boat.
HYDRAULIC STEERING
INBOARD (ATM)
Inboard ATM Cylinder 1. Minimum side loading of cylinder rod and maximum cylinder
Models: performance of ATM and TM Models can be achieved as
illustrated below.
HC5312-3 (BA125-7ATM) An imaginary line drawn through the tiller arm hole at both hard
HC5313-3 (BA135-7ATM) over positions will create the cylinder centre line. With tiller arm
HC5314-3 (BA150-7ATM) at hard over positions, angle X and Y should be the same.
NOTICE To achieve MAXIMUM cylinder performance it is suggested that an

imaginary line is drawn though the tiller arm hole at both hard over
positions (see figure 2), this will create the “cylinder center line”.
With the tiller arm at hard over positions, angle X and Y should be
the same.
NOTICE CENTER LINE FOR CYLINDER

MOUNT
In order to obtain a correct push X Y
and pull angle between the tiller
arm and cylinder, or tiebar and
cylinder, the cylinder should be
TILLER ARM SHOWN IN HARD
parallel to the transom, tiebar or OVER AND MIDSHIP POSITIONS
the keel line (depending on your
mounting configuration) when Figure 2.
cylinder rod is fully extended (out)
or fully retracted (in). 2. Set rudder(s) in the fore and aft position and then attach rod
end ball joint to the tiller arm or tiebar.
3. Remove caps from cylinder hose fittings.
4. Extend cylinder rod to arrive at 20" (508 mm) from center of rod
end ball joint hole to the center of the mounting foot, (as shown
in figure 3 below).
2-1⁄4"
3-1⁄2" (89mm) (57mm) 2-1⁄4" (57mm)
TILLER
ARM
6"
(152mm) 4-3⁄4" (121mm)
20" (508mm)
8"
(203mm)
Attachment to Tiller Arm,
recommended per ABYC.
2" (51mm) 3-3⁄4"

6" (95mm)
(152mm)
20" (508mm)
Figure 3.

HYDRAULIC STEERING
INBOARD (ATM)
CAUTION There is NO adjustment for centering cylinder after installation.

Correct mounting is critical at this time. Total cylinder travel is 7"
(178mm).
NOTICE For twin rudders, the cylinder may be mounted directly to the tiebar
or to one of the tiller arms. ENSURE all measurements remain the
same as if mounting to a rudder arm.
5. Secure mounting foot to transom or mounting bracket using

four 5/16" (8mm) Grade 5 bolts (corrosion resistant) and self-
locking nuts.
6. BEFORE final hose/tube connection, swing rudder(s) back and
forth to ensure free movement of cylinder and that there is no
binding of the rod end ball joint.
WARNING Any binding and or interference MUST be corrected prior to use.

Failure to do so may lead to separation of components and/or
prevention of steering control. Separation of components or loss
of steering control may lead to unpredictable boat behavior and/
or a collision with an obstacle and/or ejection from vessel
resulting in property damage, personal injury and/or death.
CAUTION The cylinder ball mount allows up to 15 degrees of movement

MAX. Any movement beyond 15 degrees will result in premature
seal and/or bearing wear.
Jet Drive Cylinders: These cylinders are generally used in jet drive applications. ALL
warnings, cautions and notices shown on page 7 and this page are
HC1503-3 (BA150-3ATM), to be followed to ensure safe operation of the steering system.
HC5303-3 (BA125-3ATM) SeaStar Solutions does not make a recommendation as to the
HC6324-3 (BA150-3.5ATM) installation to a jet drive. The measurements shown below are used
to assist with the installation.
HC1503-3 (BA150-3ATM) & 2-1/4"

(57mm) 1/2"
HC5303-3 (BA125-3ATM)
(13mm)
HOLE
2-1/4"
(57mm)
RETRACTED = 12-1/4" (311mm)

EXTENDED = 15-1/4" (387mm)
MID-STROKE = 13-3/4" (349mm)
Figure 4.
HYDRAULIC STEERING
INBOARD (TM & TMC)
2-1/4"
HC6324-3 (BA150-3.5ATM) (57mm) 1/2"
(13mm)
HOLE
2-1/4"
(57mm)
RETRACTED = 12.485" (317mm)

EXTENDED = 15.978" (406mm)
MID-STROKE = 14.235" (362mm)
Figure 5.
Inboard, TM & TMC 1. To achieve MAXIMUM cylinder performance it is suggested that

Cylinder Models: an imaginary line is drawn though the tiller arm hole at both hard
over positions (see figure 6), this will create the “cylinder center
HC5318 (BA150-7TM) line”. With the tiller arm at hard over positions, angle X and Y
HC5319 (BA175-7TM) should be the same.
HC5369 (BA150-9TM) CENTER LINE FOR CYLINDER
HC5373 BA175-9TM) MOUNT
X Y
TILLER ARM SHOWN IN HARD

OVER AND MIDSHIP POSITIONS
Figure 6.
2. Set rudder(s) in the fore and aft position and then attach rod
end ball joint to the tiller arm or tiebar.
3. Remove caps from cylinder hose fittings.
4. Extend cylinder rod to arrive at 21" (533 mm) or 23-1/4" (591 mm)
from center of rod end ball joint hole to the center of the mounting
foot. See figure 7.
NOTICE In order to obtain a correct push and pull angle between the tiller arm
and cylinder, or tiebar and cylinder, the cylinder should be parallel
to the transom, tiebar or the keel line (depending on your mounting
configuration) when cylinder rod is fully extended (out) or fully retracted (in).
CAUTION There is NO adjustment for centering cylinder after installation.

Correct mounting is critical at this time. Total cylinder travel is
7" or 9" (depending on your cylinder model)
NOTICE For twin rudders, the cylinder may be mounted directly to the tiebar
or to one of the tiller arms. ENSURE all measurements remain the
same as if mounting to a rudder arm.

HYDRAULIC STEERING
INBOARD (TM & TMC)
HC5318 (BA150-7TM)
3-1⁄2" (89mm) 1-9⁄16" (40mm)
4" (102mm)
6" 4-3⁄4"
(152mm) 21" (533mm) (121mm)
8"
(203mm)
HC5319 (BA175-7TM)
3" (76mm) 4-1⁄4"

6"
(152mm) (108mm)
21" (533mm)
29" (736mm)
HC5369 (BA150-9TM)
HC5373 (BA175-9TM)
9"
(228mm) 7-3⁄4"
23-1⁄4" (590mm) (197mm)
Figure 7.
5. Secure mounting foot to transom or mounting bracket using
four 3/8” (10mm) Grade 5 bolts (corrosion resistant) and self-
locking nuts.
6. BEFORE final hose/tube connection, swing rudder(s) back and
forth to ensure free movement of cylinder and that there is no
binding of the rod end ball joint.
WARNING Any binding and or interference MUST be corrected prior to use.

Failure to do so may lead to separation of components and/or
prevention of steering control. Separation of components or loss
of steering control may lead to a collision with an obstacle and/
or ejection from vessel resulting in property damage, personal
CAUTION The cylinder ball mount allows up to 15° of movement MAX. Any
movement beyond 15° will result in premature seal and/or bearing wear.
HYDRAULIC STEERING
BALL JOINT BRACKET MOUNT
Ball Joint Bracket Mount Cylinders

NOTICE These cylinders replace the Hynautic K-18 (HC5322-3) and K-19
(HC5323-3) steering cylinders.
CAUTION These cylinders are not intended for use on any racing and/or
aggressive type applications.
Important Notes 1. At ALL times protect cylinder shafts from nicks and scratches. A
damaged cylinder shaft cannot be repaired and MUST be replaced.
2. To achieve MAXIMUM performance, cylinder is to be mounted at
a right angle (90°) to the rudder arm when in the center position
(refer to Figure 8 below).
3. Ball joint connections allow for no-load pivoting and minor
misalignment. Ball joint connections are NOT designed to handle
steering loads when significantly misaligned.
4. Mounting area MUST be able to withstand significant forces in
excess of 2000 lb. There must be NO binding or interference of
the ball joints at any point in the steering arc.
HC5322-3
MIDSTROKE 28" (711mm) RUDDER ARM IN
EXTENDED 31-1/2" (800 mm) CENTERED POSITION
RETRACTED 24-1/2" (622 mm)
HC5323-3
MOUNTING BRACKET MIDSTROKE 33.0" (838 mm)
(INCLUDED WITH
EXTENDED 37-1/2" (953 mm)
CYLINDER)
1 RETRACTED 28-1/2" (724 mm) 90°
A
B
PLANE 'A' TO BE PARALLEL TO PLANE 'B'.

90° RUDDER
3/8" HOLES (CYLINDER AND RUDDER ARM TO SWING ARM
TOGETHER IN PARALLEL PANES.)
Figure 8. Correct Cylinder to Rudder Arm Mounting Orientation.

HYDRAULIC STEERING
BALL JOINT BRACKET MOUNT
Cylinder Mounting – Rod 1. Determine rudder arm hole location using Table 1 below.
End to Tiller Connection 2. Lightly grease the bolts being installed into the rudder arm and
mounting bracket.
3. Assemble 1/2" x 2–1/4" bolt (item 2) and washers (items 3) into
rod end assembly and rudder arm, as shown in Figure 9.
4. Torque nuts (item 4, Figure 9) to 43 ft-lb (58.3Nm).
5. Place rudder in midstroke position and extend cylinder to mid
stroke (see Figure 8).
6. Temporarily install the other rod end into the mounting bracket
(item 1, Figure 8). Using the bracket as a template, mark off the
positions of the two 3/8" holes on the mounting surface.
7. Once the mounting location is chosen and marked, confirm that
there are no obstructions on the opposite side of the backing
surface and drill the required mounting holes.
8. Mount the bracket (item 1, Figure 8) with through bolts,
washers and nuts (not supplied by SeaStar Solutions). DO NOT
USE LAG BOLTS.
9. Attach rod end to mounting bracket as described in Steps 3 & 4.
10. BEFORE final hose/tube connection, swing rudder back and
forth to ensure free movement of the cylinder and that the ball
joint connections are not binding.
WARNING INBOARD RUDDER ARM HOLE LOCATION

Total Rudder Arc Dimension – Center of Rudder arm to Center of bolt
Any binding and/or interference
MUST be corrected prior to use. HC5323-3 (9"stroke) HC5322-3 (7" stroke)
Failure to do so may lead to 60 degrees 9" 7"
separation of components and/or 70 degrees 8" 6"
prevention of steering control. Table 1.
Separation of components and/or
prevention of steering control may
lead to unpredictable boat behavior 2
resulting in property damage,
personal injury and/or death. 3
ROD END ASSEMBLY
RUDDER ARM
3
4
Figure 9. Attaching Rod End Assembly to Rudder Arm.
HYDRAULIC STEERING
STERNDRIVE
Sterndrive Engine Mount Cylinders

WARNING DO NOT use SeaStar PRO helm(s) with an unbalanced cylinder.
Using a PRO helm with an unbalanced cylinder WILL lead to steering
wheel “lock-up”. Lock-up may lead to collision with an obstacle
resulting in property damage, personal injury and/or death.
NOTICE Sterndrive cylinders are designed for use, in conjunction with, the engine
manufacturer’s power steering system. DO NOT Install into an application
that does not use the engine manufacturers power steering.
General 1. A support tube and/or cable support tube provided by the engine
manufacturer MUST be used for these three steering cylinders.
These cylinders are mounted to the sterndrives support/tube
guide support in the same manner as a steering cable.
2. Thoroughly lubricate support tube/cable guide tube, and cylinder
rod with a high quality, anti-corrosive type marine grease (such
as OMC Triple Guard or equivalent) BEFORE mounting cylinder to
support tube.
3. Slide well greased cylinder rod into and through well greased
support/cable guide tube and thread cylinder fully onto support
tube as shown below.
Sterndrive Engine HC5328-3 (125-8EM)

Mounted Power Assisted HC5329-3 (128-8VEM)
Steering Models
HC5328-3
(125-8EM)
HC5328-3 = 17-1⁄4" (438mm) MAX. 9" (228mm)
HC5329-3 HC5329-3 = 21-5⁄8" (549mm) MAX.
(128-8VEM)
Figure 10. HC5328-3 (125-8EM) and HC5329-3 (128-8VEM), NOT for use with SeaStar PRO helm(s).

HYDRAULIC STEERING
STERNDRIVE
HC5331-3 (92VPS) Referring to Figure 11 please observe the following:

• Rotate Cable Tube item 1 into threads of Item 2 until tight.
• Torque setscrew (item 7) to 90 in-lbs and tube insert (item 8)
until tight.
• Item 3 must pass through items 4 and 5 before being secured
by Item 6.
• Always mount cylinder in lower mount position of item 2 and
without spacer item 9, unless mechanical interference prevents
you from doing so.
• If using upper mount position, install spacer, item 9 below item 4.
CAUTION Cut Clevis Pin, (item 3 Figure 11) to a length of 2" when mounting
cylinder in lower position.
NOTE: 9 3
If using upper
mount position,
install spacer, 5
item 9 below
item 4.
2
4
7 6
1
Figure 11. HC5331-3 (92-VPS), NOT for use with SeaStar PRO helm(s).
NOTICE The SeaStar HC5331-3 steering cylinder is NOT compatible with some
early model power steering rams. Although the cylinder will still mount
to these rams, loss of articulation and possible damage to the steering
ram may result. Please identify your power steering cylinder by
comparing your clevis bracket to the 4 drawings shown below. The
HC5331-3 IS compatible with units identified by figures 10 to 12, it is
NOT compatible with the clevis bracket shown in figure 15.
HYDRAULIC STEERING
STERNDRIVE
ALWAYS INSTALL CYLINDER

NOTICE HC5331 IN THE OUTER HOLE
✓ ✓
SHOWA HOERBIGER
(LATE MODEL)
COMPATIBLE COMPATIBLE
Figure 12. Figure 13.
✓ ✗SEASTAR
COMPATIBLE
SHOWA
(EARLY MODEL
PRE 1992)
NOT COMPATIBLE
Figure 14. Figure 15.
HC5339-3 (125-6.5EM) 1. Move the main steering ram to the fully retracted position.
2. Insert the long rod of the HC5339-3 cylinder into the clevis
Installation Instructions bracket until the through hole in the rod is aligned with the hole
Mercury Bravo I and II ONLY
in the clevis bracket. Refer to figure 16.
3. Insert the 1/4" NF socket cap screw through the hole and install
the shoulder nut. Torque to 72 in.lb.
4. Extend HC5339-3 cylinder as required and insert the short rod
into the tilt tube as shown in figure 17.
5. Tighten the large mounting nut to 150 in.lb. Use wrench flats to
stop the tilt tube from turning.
6. Install hoses and purge the system as shown on page 23.

HYDRAULIC STEERING
STERNDRIVE
WARNING If Mercruiser power steering fails, service unit immediately or

complete loss of steering may result.
HC5339-3 (125-6.5EM)
CAP SCREW
Figure 16.
HC5339-3
(125-6.5EM)
MOUNTING NUT WRENCH FLATS
Figure 17.
Sterndrive Engine mounted, A Support Tube Mount – Requires support/cable tube from engine
NON-Power Steering models: manufacturer for installations.
NOTICE HC5326-3 is designed for use with 1984 – DATE
HC5330-3 (BA125-8EMV) Mercruiser and MOV Cobra NON-Power Assisted steering
Support Tube Mount
sterndrives (OMC Cobra requires SeaStar part# HA5424 to complete
installation). DO NOT USE on a power assisted application.
HC5330-3 (BA125-8EMV) SUPPORT TUBE

(PROVIDED BY ENGINE
23" (584mm) MAXIMUM MANUFACTURER)
34.22" (869mm) OVERALL
Figure 18. HC5330-3 (BA125-8EMV), manual, non-power steering.

HYDRAULIC STEERING
STERNDRIVE
HC5326-3 (BA150-7EM) A Transom Bracket Mount – Mounts directly to the transom bracket
Transom Bracket Mount
and tiller arm.
This cylinder is designed for use with 1984 to date Mercruiser, and
OMC Cobra non power assisted steering sterndrives (OMC Cobra
requires SeaStar part HA5424). Sterndrives equipped with optional
power assist steering require Cylinder Model 125-8EM.
NOTICE Mastry Engine part # SUN144 is required to complete cylinder

connection to Mercruiser sterndrives. This part is not available from
SeaStar Solutions.
CAUTION When connecting the cylinder to a Mercruiser the two washer spacers
must be installed between the cylinder and mounting bracket.
When connecting the cylinder to an OMC Cobra, the two bushings
must be inserted to the cylinder mounting holes.
HC5326-3 TRANSOM MOUNT CYLINDER CONNECTION

(BA150-7EM) (PROVIDED BY ENGINE DETAIL FOR OMC
22" (559mm) MAXIMUM MANUFACTURER)
MASTRY
PART # SUN144 PART # HA5424
Figure 19. HC5326-3 (BA150-7EM), manual, non-power steering.
A Transom Bracket Mount – Mounts directly to the transom

HC5332-2 (BA135-7EM) bracket and tiller arm.
Transom Bracket Mount
NOTICE HC5332-2 requires the use of SeaStar OUTBOARD
hoses ONLY.
HC5332-2
(BA135-7EM)
TRANSOM MOUNT
(PROVIDED BY ENGINE
MANUFACTURER)
Figure 20. HC5332-2 (BA135-7EM) manual, non-power assist.
NOTICE For cylinder model HC5332-2 If engine outdrive is NOT equipped with a
torque tab on the underside of the lower leg, one must be installed to
reduce prop torque.
CAUTION HC5332-2 cylinder MUST use SeaStar Outboard Hoses. DO NOT

install extruded nylon tubing or copper tubing directly to this cylinder.
HOSE AND TUBING
INSTALLATIONS
General Proper steering hose/tube is required for the best performance and
safe operation of your steering system. Use of a hose/tube other
than that recommended by SeaStar Solutions may drastically effect
performance and the safe operation of your system. SeaStar
Solutions cannot be responsible for ANY consequences resulting
from the use of a substitute tube or hose.
WARNING Use of a substitute hose and/or tube may lead to hose breakage
or rupture resulting in loss of steering control. Loss of steering
control may lead to unpredictable boat behavior and/or a collision
with an obstacle and/or ejection from boat, resulting in property
NOTICE Sterndrive, non-power assist cylinder part # HC5332 and HC5332-2

requires the use of SeaStar Outboard style HOSE. Do NOT use
extruded nylon tubing with this cylinder.
Copper Tubing SeaStar Solutions recommends the use of copper tubing where
steering tube runs exceed 40 feet (see copper specifications below).
Failure to install copper tubing in these applications may result in
stiff/unresponsive steering. A series of copper tubing and flexible
connections must be used, copper tubing CANNOT be connected
directly to a steering cylinder. A flexible connection MUST be used.
Copper Tubing specifications
• 3/8" (OD).
• Seamless Copper Tube for Air Conditioning and Refrigeration
made under ASTM B-280.
• Compression fittings shipped with steering cylinder(s) will work
with the above specifications.
CAUTION Never attach copper tubing or any other rigid type tube directly to
the cylinder. Cylinders require a flexible link to allow for vibration
and cylinder movement during steering articulation.
Positional O-Ring Horizontal 1 . Back off lock nut (item 1, figure 21), counter-clockwise, until it stops.
2. Thread fitting into cylinder body until fitting washer (item 2, figure 21)
and Vertical Tee Fitting contacts the face of the cylinder port. Tighten hand tight,
Installation/Realignment DO NOT TORQUE FITTING INTO GLAND.
(if required) 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 21) and torque to 40–43 ft-lb.
5. Purge system as per your cylinder instruction manual.
CAUTION DO NOT attempt to install NPT pipe fittings into the cylinder hose
fitting ports on any -3 model cylinder. Doing so will lead to
irreparable damage to the cylinder. ONLY use ORB hose fittings
provided by SeaStar Solutions.
HYDRAULIC STEERING
HOSE & TUBE INSTALLATION
WARNING Failure to properly tighten the locknut (item 1, figure 21) may lead
to loss of steering control. Loss of steering control may result in
unpredictable boat behavior, collision with an obstacle and/or
ejection from vessel, leading to property damage, personal injury
and/or death.
WARNING SeaStar Solutions recommends that the hose and hose fittings are
checked on a regular basis to ensure the safe operation of the
steering system.
SECURE WITH SECURE WITH

WRENCH HERE WRENCH HERE
WHILE TIGHTENING WHILE TIGHTENING
LOCKNUT (ITEM 1) LOCKNUT (ITEM 1)
1 1
2 2
Figure 21.
THREAD FITTING BY HAND UNTIL WASHER,

ITEM 2, CONTACTS THIS FACE.
Figure 22.
System Connection 1. Refer to figure 23 on page 20 for hose/tube to fitting connection.

2. If not already completed, install fittings into helm as per specific
instructions suppled with your helm pump.
CAUTION There is NO requirement for pipe sealant of any kind when using
an ORB fittings. A "LIQUID" Teflon based pipe sealant IS required
when using NPT type fittings. DO NOT use Teflon Tape or any other
tape type sealers.

HYDRAULIC STEERING
VENTED PLUG
COMPENSATING LINE
NON-VENTED PLUG
TILLER ARM
CYLINDER
Figure 23. Dual Station.
TO PORT SIDE OF TO STARBOARD SIDE

HELM PUMP OF HELM PUMP
Figure 24. HC5332-2 Cylinders ONLY. Hoses are crossed when plumbing.
3. The following considerations MUST be taken into account when

planning and routing steering hose/tubes.
a) Cut nylon/copper tubing using an appropriate tube cutter.
A straight and level cut is required for proper sealing.
CAUTION DO NOT CUT SeaStar Outboard, flexible, hoses. Cutting these will
render them useless and a new hose will need to be ordered.
b) Do not allow hose/tube to come into contact or come to close
to any source of extreme heat. Extreme heat WILL lower burst
pressure and/or melt hose/tubing resulting in the immediate
loss of steering control. Loss of steering control may lead to a
collision with an obstacle and/or ejection from boat resulting
in property damage, personal injury and/or death.
HYDRAULIC STEERING
c) Hose/Tube must be routed so that it will not interfere with any

other functional equipment; (such as, hatches, doorways or in
a walking path where it may become a tripping hazard).
d) Hose/Tube MUST be installed with a gradual rise from the
steering cylinder to the helm pump(s). If hose/tube is not installed
with a gradual rise, air removal from system will be difficult.
e) Hose/tube should be secured at regular intervals using non-
metallic type ties.
f) Do not allow tubing to rest or chafe against any abrasive material.
NOTICE Fiberglass although soft to the touch can be extremely abrasive.

Care MUST be taken when securing hose/tubing.
g) Ensure that hose/tube ends are covered prior to passing through
bulkheads, cable tubes and any other blind area. Failure to do
so may allow contamination to enter the steering system.
WARNING If hose/tubing is kinked during and/or after installation it MUST be

replaced prior to operation. SeaStar Outboard hose cannot be cut
and must be replaced with a new hose completely. SeaStar extruded
nylon tubing can have the damaged section removed and a union
fitting put into place. Failure to replace any damaged hose/tube
may result in loss of steering control. Loss of steering control may
lead to unpredictable boat behavior and/or a collision with an obstacle
and/or ejection from vessel, resulting in property damage, person
COMPONENT FITTING TUBE NUT
DO NOT USE 3/8" NYLON OR

PIPE SEALANT HERE COPPER TUBE
3/8"
Figure 25.
4. Connection
a) SeaStar Outboard Hose – While holding the fitting body securely
CAUTION with a wrench, torque the hose end nut to 15 ft-lbs.
Ensure that the tubing is pushed b) SeaStar extruded Nylon tubing and Copper Tubing.
ALL the way in.
• Slide tube nut over tubing.
• Push tubing into bottom of component fittings.
• Hand tighten tube nut, ensuring that the tube is bottomed
out against the fitting while tightening.
• After hand-tight, turn an additional 1-1/2 turn with a 5/8” wrench.

ADDITIONAL STATIONS,
AUTOPILOTS AND SEASTAR
POWER ASSIST UNITS
General ALL SeaStar helm pumps are fitted with internal check valves. These
valves allow the installation of multiple steering stations and autopilots.
ALWAYS check with autopilot manufacturers to confirm use with a
SeaStar Steering System.
SeaStar offers the following “add a station fitting kits” for easy installation.
• HF6007 For systems fitted with SeaStar ORB helm pumps plumbing
with SeaStar Outboard, flexible, hoses ONLY. NOTE: this kit comes
with a 25’ cut to fit nylon tubing that is to be used for the return
line ONLY. Another set of SeaStar Steering hoses, part # HO51xx
will be required to complete this installation.
NOTICE SeaStar NPT helms use kit HF5501.
• HF6010 For systems fitted with SeaStar ORB helm pumps plumbing
with SeaStar Extruded Nylon tubing and/or copper tubing. Designed
to splice into existing tubing.
NOTICE SeaStar NPT helms use kit HF5502.
NOTICE The following points should be taken into consideration when

installing additional steering stations and/or autopilots. Following
these simple points before installation will allow for easier trouble
shooting in the future if required
• Shut-Off valves should be installed into each additional station.

Installation of these now will allow for simplified trouble shooting
and servicing at a later date.
• Autopilot must be compatible with SeaStar Steering Fluid, MUST
have a pressure relief setting of 1000psi (6.9MPa) and MUST
work with an unbalanced cylinder if equipped.
• A “return” or “compensating” line will be REQUIRED between all
helms, autopilot pumps and SeaStar Power Assist Units. Failure
to install this line will lead to improper bleeding, resulting in poor
performance by both the steering system and autopilots.
• The “return” or "compensating" line MUST have a gradual rise
between steering stations. If hose/tube is not installed with a
gradual rise, air removal from system will be difficult.
• SeaStar Power Assist Units can be installed into an inboard type
system. If installing a SeaStar Power Assist please be sure to
read and understand the installation manual that will come with
your SeaStar Power Assist.
• Helms of different displacements can be used in a multiple station
system, however; use of a higher or lower displacement will result
in more/less wheel turns and easier/heavier effort at each wheel.
MANUAL FILLING AND
PURGING
NOTICE Power Purge Users. Please refer to the instructions included with
your power purge unit.
Power Assist Users. You MUST refer to the bleeding instructions
included with your SeaStar Power Assist Unit.
Liquid Tiebar Users (Catamarans). You MUST refer to the bleeding
instructions included with your Liquid Alignment/Tiebar Valve.
Read First Steps 1 – 5 noted on page 25 refer to a single station, single cylinder
installation. For twin station and/or twin cylinder installations you
MUST perform steps 1 – 5 first, then, see page 26 and page 27 to
complete the removal of air from the system.
NOTICE 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 filling procedure, oil must be visible in the filler tube.
Do NOT allow the oil level to disappear into the helm pump, as this
may introduce air into the system and increase your filling time.
Hydraulic Fluid SeaStar Solutions recommends the use of SeaStar Steering Fluid ONLY.
SeaStar Steering Systems have been engineered and validated
using our proprietary SeaStar Hydraulic Fluid.
WARNING Any non-approved fluid may cause serious damage to the steering
system resulting in possible loss of steering, causing property
Emergency Use Fluids In an emergency, SeaStar EPS Fluid, any MD-3/4 rated ATF or MIL-PRF-
5606H equivalent fluid that is filtered through a fine mesh screen can
be used. The system MUST be thoroughly flushed as soon as possible
with genuine SeaStar Steering Fluid after using an emergency fluid. In
an EXTREME emergency, any non-toxic, non-flammable fluid that is
filtered through a fine mesh screen may provide temporary steering.
WARNING Never fill or mix brake fluids, trigycerides or polyalkylene glycols

within a hydraulic steering system.
Vent Plug • Must be used with helm pump on all

single steering station systems.
Part # HP6126 (5 per kit) • Must be used on upper-most helm pump
only on multi-steering station systems.
• Vent hole: actual size as shown.
• Colour: threads, silver – cap, black.
Figure 26.
HYDRAULIC STEERING
FILLING AND PURGING
Non-Vent Plug • Must be used on all helm pumps other

than upper-most helm pump on multi-
Part # HP6000 (5 per kit) steering station systems.
• This non-vent plug is supplied with
additional station fitting kit no. HF6007
CAUTION and HF6010.
• Actual size shown.
Failure to install a non-vent plug
• Colour: black.
in ALL lower helms of multi-helm
systems will result in fluid
leaking out of the vent cap. Figure 27.
Hydraulic Oil Requirements 2 bottles (2 quarts or litres) for single station and single cylinder
systems.
1 additional bottle for each additional helm, cylinder, or auto pilot.
NOTICE These instructions will result in hydraulic oil flushed in and out of the
system. Oil can be re-used if filtered through a fine mesh screen such
as used for gasoline. If unable to filter oil, an additional bottle of oil
is required.
NOTICE “Bleeder” refers to cylinders fitted with bleed tee fittings. If fitted with
bleed tee fitting, open bleeder by unscrewing bleed nipple nut two turns.
CAUTION Unbalanced Cylinders.

The oil level in the helm must be set with the cylinder rod fully
retracted. Failing to observe this caution will result in an oil spill
at the helm.
NOTICE PUSH PIN

Filling the helm full of oil can be
done faster if oil is poured into FILLER PLUG
(REMOVED)
the helm prior to connecting filler
tube and oil bottle to the helm.
FILLER KIT
DO NOT LET
OIL LEVEL
FALL BELOW
THIS POINT
HELM FILL
PORT
Figure 28.
HYDRAULIC STEERING
Single Station One Cylinder FILLING AND PURGING
Figure 29.
Step 1
• Screw the threaded end of the • Fill the helm pump full of oil (Oil
filler tube into the helm filler hole. should always be visible in the
• Remove the cap from the oil filler tube). Use the next bottle at
bottle and holding upright, any time throughout the procedure
screw into the filler tube bottle when the oil level drops in the
cap. Poke hole in the bottom filler tube. Do not proceed with
of the bottle. step two until helm is full of oil.
Figure 30.
Step 2 TURN
CLOCKWISE
• Turn the steering wheel clock-
wise until the cylinder rod is
fully extended on the Port side
of the cylinder. OPEN PORT SIDE
BLEEDER
• Open Port side bleeder.
Figure 31.
Step 3
TURN COUNTER-
• Holding the cylinder rod (to • While continuing to turn the CLOCKWISE
prevent it from moving back into wheel, close the Port side
the cylinder) turn the steering bleeder and let go of the
wheel counter-clockwise until a cylinder rod. CLOSE PORT SIDE
BLEEDER
steady stream of air free oil
comes out of the bleeder.
(Drain out approx. 1/2 bottle
of oil or as required.)
Figure 32.
Step 4
TURN COUNTER-
• Continue turning the steering CLOCKWISE
wheel counter-clockwise until OPEN
the cylinder rod is fully extended STARBOARD
SIDE
to Starboard. (Steering wheel BLEEDER
will come to a stop.)
• Open the Starboard bleeder.
Figure 33.
Step 5 TURN
CLOCKWISE
• Holding the cylinder rod (to • While continuing to turn the
prevent it from moving back wheel, close the Starboard
into the cylinder) turn the side bleeder and let go of the CLOSE
STARBOARD
steering wheel clockwise until cylinder rod. SIDE BLEEDER
a steady stream of air free oil
comes out of bleeder.
Fill and purge is now complete.

HYDRAULIC STEERING
FILLING AND PURGING
Oil Level Set CAUTION FILLER

ASSEMBLY
OIL IN
For unbalanced cylinders the TUBE
• Proper oil level set can be oil level in the helm must be
obtained by opening Starboard set with the cylinder rod fully
bleeder and turning steering retracted. Failing to observe PLASTIC
wheel to Starboard until fluid this caution will result in an FITTING
level reaches top of plastic oil spill at the helm. ONE WHEEL ROTATION
filler fitting and then turning TOP OF ON HELM WILL DROP
HELM PUMP FLUID THIS MUCH TO
wheel one more full turn. SET FLUID LEVEL
Figure 34.
Twin Station
STATION NO.2
NOTICE Refer to Oil
Level and System Proof
Single Cylinder Check on page 28.
• Perform steps 1 through 5 at STATION NO.1
station no.1. Then repeat
steps 1 – 5 at station no.2.
• Oil requirements 4 – 5 bottles.
Figure 35.
Single Station NOTICE Refer to Oil

Level and System Proof
Twin Cylinder Check on page 28.
• When performing steps 1
through 5, perform instructions
in each step first on cylinder
no.1 and then on cylinder no.2,
before proceeding to the next
step. ie: Perform instructions
referring to Starboard side of
cylinder first on cylinder no.1
and then on cylinder no.2.
• Oil requirements 4 – 5 bottles.

CYLINDER NO.2 CYLINDER NO.1
Figure 36 .
HYDRAULIC STEERING
FILLING AND PURGING
Twin Station
STATION NO.2
Twin Cylinder
• Follow same procedure as STATION NO.1
instructed for single-station/

twin-cylinders, beginning at
station no.1, and repeat entire
procedure at station no.2.
CYLINDER NO.2 CYLINDER NO.1
Figure 37.

OIL LEVEL AND SYSTEM
PROOF CHECK
STEP 1 Oil Level Setting
WARNING The oil level MUST be checked and maintained BEFORE each use
to ensure the safe operation of your steering system. Failure to
adhere to this warning 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.
CAUTION
• Helms mounted with the wheel shaft completely horizontal MUST
When setting fluid level in a
be filled to the bottom of the filler hole AT ALL TIMES.
system fitted with an unbalanced
DO NOT allow oil level to drop more than 1/4" below the filler
cylinder, the cylinder shaft MUST
port threads.
be fully retracted (IN). Failure to
have cylinder shaft retracted (IN) • For helms mounted on a 20° angle, or, with wheel shaft in the
will lead to very stiff steering and/ vertical position the oil level must be no lower than 1/2" below filler
or oil spillage at the helm pump. port threads and no higher than 1/8" below filler port threads.
STEP 2 System Proof Check

The System Proof Check MUST be completed after installation.
WARNING Doing so will ensure the safe operation of your steering system.
Any fault (leaks or malfunction) will present itself during this check.
Failure to adhere to this check may result in loss of steering control.
Loss of steering control may lead to unpredictable boat behavior,
leading to a collision with an obstacle and/or ejection from the
boat, resulting in property damage personal injury and/or death.
• Turn steering wheel hard over to hard over to confirm unrestricted

movement of steering components.
NOTICE If equipped with a tilting helm, repeat this step in "EVERY" tilt position.
• Confirm that rudder(s) and outdrive(s) are turning to the proper
direction.
• If no interference is noticed and rudder(s) and/or outdrive(s) are
turning to the proper direction, go to next point
• Take steering wheel hard over to starboard. Once the wheel
reaches its stop point, force the wheel another 1/4 – 1/2 turn
past stop. Leave wheel in this position while you inspect ALL
fittings, helms and hose/tubes for any signs of a leak.
• Repeat above step to the starboard side of each steering station
• Repeat above steps to the port side of each steering station.
• If ANY leaks are noticed they MUST be repaired BEFORE operating
your boat.
WARNING Failure to correct ANY problem that becomes present during the
'System Proof Check' may lead to loss of steering control. Loss of
steering control can lead to unpredictable boat behavior and/or
collision with obstacle and/or ejection from vessel resulting in
property and/or personal injury or death.
WARNING ROUTINE MAINTENANCE
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.
1. Owner(s) (End Users) Prior to every use.

1. Check fluid level in highest helm pump (see page 28) for proper
fluid level setting).
2. Verify immediate steering response when turning steering wheel(s).
(Ensure drive(s)/rudder(s) move when steering wheel(s) are 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.
WARNING DO NOT operate boat if any component is not in proper working

condition.
2. Qualified Marine After first 20 hours, then every 100 hours or 6 months thereafter
Mechanic (which ever comes first).
• All points noted above.
• Check tightness of ALL fasteners throughout the steering system.
Tighten as required.
WARNING • Check for mechanical play or slop throughout steering system,
correct as required.
Any work being performed with
the steering system MUST be
completed by a qualified After every 200 hours or 12 months (which ever comes first).
mechanic with the working • All points noted above.
knowledge of the system. • Power Assisted Drives:
- Remove cylinder from power assist steering tube. Clean steering
tube and re-grease using a good quality marine grease.
• Inboard:
- Grease ball joint (rudder connection) using a good quality
marine grease.
- Ensure rudder(s) are able to be moved freely by hand.
• Remove steering wheel and re-grease wheel shaft using a good
quality marine grease.
• Inspect hydraulic oil for cleanliness, flush if required.

TROUBLESHOOTING GUIDE
SeaStar hydraulic steering will provide years of safe reliable
performance with a minimum of service if properly installed with
correct cylinder.
SeaStar steering systems have been designed with protection
against over-pressure situations, by a pressure relief valve, to
minimize the possibility of total loss of steering.
Most faults occur when the installation instructions are not followed
and usually show up immediately upon filling the system. Provided
below, are the most common faults encountered and their likely
cause and solution. The term “Rudder” also applies to stern drives,
when applicable.
Sometimes when returning the wheel from a hardover 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.
WARNING Whenever in the following text, a solution calls for removal from
vessel and/or dismantling of steering system components, 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 CAUSE SOLUTION

1 During Filling, the helm • Blockage in the line between • Make certain that tubing has
becomes completely jammed. the helm(s) and the cylinder(s). not collapsed during installation.
If so, the collapsed section
must be removed and re-fitted
with a new piece with the aid
of tube connectors. Check
fittings for incomplete holes.
Fittings with incomplete holes,
however, are not common.
2 System is very difficult to fill. • Cylinder(s) has been mounted • Mount cylinder(s) correctly,
Air keeps burping out top of upside down. This causes air to according to cylinder
helm even after system be trapped in the cylinder(s). installation instruction. Ports
appears full. should always be kept in
uppermost position.
• Air in system. • Review filling instructions.
HYDRAULIC STEERING
TROUBLESHOOTING

3 Steering is stiff and hard to • Rudder post glands are too • To test, disconnect cylinder(s)
turn, even when the vessel is tight or rudder post is bent, from the tiller arm and turn
not moving. causing mechanical binding. the steering wheel. If it turns
The same applies to tiller easily, correct above mentioned
arm and linkage on outdrives. problems. Please note that
excessively loose connections
to tiller arm or tie-bar can also
cause mechanical binding.
• Restrictions in hose, copper • Find restriction and correct.
tubing, piping or fittings. Note: Collapsing of copper
tubing during bending is
enough to cause restrictions.
• Air in oil. • See filling instructions
supplied with helm units.
• Wrong oil has been used to • Drain system and fill with
fill steering system, like A.T.F. SeaStar Steering Fluid.
(automatic transmission fluid,
or any other oil with a high
viscosity factor).
• Support tube corroded or • Remove cylinder, clean and
seized restricting movement re-grease.
of hydraulic cylinder.
4 One helm unit in system is • Dirt in inlet check of • Contact Authorized repair
very bumpy and requires too helm pump. center and/or replace helm
many turns from hardover to pump.
hardover.
5 Steering is easy to turn at the • Steering wheel is too small. • Fit larger wheel if possible,
dock, but becomes hard to see installation instructions.
turn when vessel is underway. If the problem cannot be
rectified by the above
mentioned solution, proceed
with next cause and solution
or consult factory.
• Cylinder(s) too small. • Replace with larger cylinder(s).
• Incorrect setting of trim • Adjust tab(s).
tab(s) on stern drive.
• Incorrectly designed or • Seek professional help. Have
adjusted rudders, causing competent, qualified marine
binding on rudder post and/ mechanic correct problem.
or tie bar at cruising speeds. • Fit system with SeaStar Power
Assist. NOTE: SeaStar Power
Assist is not intended to comp-
ensate for a weak, or improperly
installed steering cylinder.

HYDRAULIC STEERING
TROUBLESHOOTING

6 Rudder drifts to port or • Dirt in check valves. • Contact authorized repair
starboard while vessel is center and/or replace helm
underway, even when wheel pump.
is not being turned.
7 Turning one wheel causes the • See fault No. 6. • See fault No. 6.
second steering wheel to
rotate.
8 Consistent wearing of rod end • Excess vibration at rudder. • Consult with boat builder
ball and or mounting foot. and/or Naval architect for
vibration cure.
9 Sterndrive system is hard to • Engine driven power steering • This is normal in a power
turn with engine off. pump not operating. steering application.
SeaStar Technical Phone: 604-248-3858

Support Contacts Web: www.seastarsolutions.com
e -mail: [email protected]
Hours: 05:00 – 15:30 PST
TECHNICAL INFORMATION
Bolt Torque Specifications 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.
Values are stated in: in/lbs (N.m)
Bolt Size 18-8SS Brass Bolt Size 18-8SS Brass Bolt Size 18-8SS Brass
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 4.4 (.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/lbs (N.m)

Bolt Size 18-8SS Brass Bolt Size 18-8SS Brass Bolt Size 18-8SS Brass
/16”-14
7 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)
7/16”-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)
TORQUE
Cylinder
STROKE VOLUME 1000psi–70 BAR–35˚
HC5303-3 BA125-3ATM inboard type 3” (76 mm) 3.1 cu.in. (51 cc) N/A
HC6324-3 BA150-3.5ATM inboard type 3.5” (89 mm) 5 cu.in. (82 cc) N/A
HC5339-3 125-6.5EM sterndrive type 6.5” (165mm) 7.9 cu.in. (129 cc) N/A
HC5312-3 BA125-7ATM, inboard type 7" (178 mm) 7.2 cu.in. (118.0 cc) 5024 in/lbs (58Kg)
HC5318 BA150-7TM, inboard type 7" (178 mm) 10.2 cu.in. (167.1 cc) 7117 in/lbs (82Kg)
HC5326-3 BA150-7EM, sterndrive type 7" (178 mm) 10.2 cu.in. (167.1 cc) 7117 in/lbs (82Kg)
HC5328-3 125-8EMV, sterndrive type 8" (203 mm) 8.5 cu.in. (139.2 cc) 5850 in/lbs (67Kg)
HC5329-3 125-8VPEM, sterndrive type 8" (203 mm) 8.5 cu.in. (139.2 cc) 5850 in/lbs (67Kg)
HC5330-3 BA125-8EMV, sterndrive type 8" (203 mm) 8.5 cu.in. (139.2 cc) 5850 in/lbs (67Kg)
HC5331-3 92VPS, sterndrive type 8" (203 mm) 8.5 cu.in. (139.2 cc) N/A (N/A)
HC5332-2 BA135-7EM, sterndrive type 7" (178 mm) 8.2 cu.in. (134.4 cc) 5741 in/lbs (66Kg)
Fittings SeaStar cylinder and all other fittings are 3⁄8" compression type fittings.
Threads are 9⁄16" x 24 extra fine. A brochure on all SeaStar fittings is
available from SeaStar.
SeaStar and SeaStar PRO • SeaStar and SeaStar PRO hose inside diameter – 5⁄16" (8 mm).
• SeaStar Hose, 1000psi WP
• SeaStar PRO Hose, 1500psi WP

PARTS LIST
HC5318 and HC5318CAT (BA150-7TM)
3
1
2
2
NOTICE
5
SeaStar Solutions does not sell
internal parts. Contact Authorized
repair center for repair and/or
replace cylinder.
WARNING
When replacing any seals, make
sure shaft is clear of any abrasions.
Figure 38.
ITEM PART # QTY DESCRIPTION ITEM PART # QTY DESCRIPTION

1 HP6068 1 Trunnion Assembly
2 HS5182 1 Seal Kit (does not include
internal seals)
3 HF5518 1 Bleeder/Tee Assembly
4 HP6093 1 Rod End Ball for HC5318 and
HC5318CAT
5 HP5615 1 Clevis Connection Kit
HYDRAULIC STEERING
PARTS LIST
HC5369 (BA150-9TM)
3
1
2
2
NOTICE
5
replace cylinder.
WARNING
Figure 39.

internal seals)
4 HP6093 1 Rod End Ball for HC5369

HYDRAULIC STEERING
PARTS LIST
HC5319 and HC5319CAT (BA175-7TM)
3
1
2
2
NOTICE
5
replace cylinder.
WARNING
Figure 40.

internal seals)
4 HP6013 1 Rod End Ball for HC5319 and
HC5319CAT
HYDRAULIC STEERING
PARTS LIST
HC5373 (BA175-9TM)
3
1
2
2
NOTICE
5
replace cylinder.
WARNING
Figure 41.

internal seals)
4 HP6013 1 Rod End Ball for HC5373

HYDRAULIC STEERING
PARTS LIST
HC5303-3 and HC5312-3
1 2
2
NOTICE
replace cylinder.
WARNING
Figure 42.

1 HP5611 1 Aluminum Mounting Foot
2 HP6026 1 End Gland
3 HF6001 1 Bleeder/Tee Assembly, Horizontal
(2 per kit)
HF6002 1 Bleeder/Tee Assembly, Vertical
(2 per kit)
4 HP6013 1 Rod End Ball
HYDRAULIC STEERING
PARTS LIST
HC5322-3 and HC5323-3
1 1
3
4
2 2
Figure 43.

(2 per kit)
(2 per kit)
HF6003 1 Bleeder/Tee Assembly, Hynautic
(2 per kit)
2 HP6023 1 Side Mount Gland Kit
3 HP6077 1 Rod End Ball 1/2", 1/2–20
4 HP6137 1 Rod End Ball 1/2", 7/16–20

HYDRAULIC STEERING
PARTS LIST
HC5328-3, HC5329-3 and HC5330-3
1 1
NOTICE
replace cylinder.
WARNING
Figure 44.

(2 per kit)
(2 per kit)
2 HP6027 1 End Gland Seal Kit
HYDRAULIC STEERING
PARTS LIST
HC5326-3
1 1
NOTICE
replace cylinder.
WARNING
Figure 45.

(2 per kit)
(2 per kit)


HYDRAULIC STEERING
PARTS LIST
HC1503-3, HC5313-3, HC5314-3 and HC5324-3
1 2
2
NOTICE
replace cylinder.
WARNING
Figure 46.

1 HP5611 1 Aluminum Mounting Foot
2 HP6025 1 End Gland Seal Kit
(2 per kit)
(2 per kit)
4 HP6077 1 Rod End Ball
HYDRAULIC STEERING
PARTS LIST
HC5331-3
7 1
6
3
10
2
1
12
11 9
TORQUE TO CABLE TUBE
90 IN.LB.
(10.4 Nm)
13
14
Figure 47.

*1 731720 2 Nut 7/16" NF *8 562923 1 Clevis Pin
*2 731625 1 Washer 7/16" *9 020926 1 Cotter Pin
*3 343051 1 Support Bracket
*10 343052 1 Clevis Block
*4 343057 1 Mounting Stud
*11 790625 1 Set Screw, 1/4"
5 HF6002 2 Hose/Bleed Fitting (2 per kit) 12 HP6092 1 Tube Support
*6 343608 1 Barrel
*13 321446 1 Support Rod
*7 343424 1 Piston Shaft
*14 963721 1 Clevis Block
* Replacement parts cannot be ordered by individual part number. Contact an authorized repair center.

Statement of Limited 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 U.S.A. From Canada

RGA # ? RGA # ?
SeaStar Solutions SeaStar Solutions
c/o UPS-SCS 3831 No.6 Road
19308 70th Ave S. Richmond, B.C.
Kent, WA 98032 Canada V6V 1P6
Technical Support Phone: 604-248-3858

email: [email protected]
Hours: Monday to Friday 05:00 – 15:30 PST
Web: www.seastarsolutions.com
SEASTAR SOLUTIONS
3831 NO.6 ROAD
RICHMOND, B.C.
CANADA V6V 1P6
FAX 604-270-7172
www.seastarsolutions.com
ISO 10592
© 2006 MARINE CANADA ACQUISITION INC.

DBA SEASTAR SOLUTIONS
PRINTED IN CANADA
FORM NO. 343319 REV. L 2000–12/15

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INSTALLATION INSTRUCTIONS

AND OWNER'S MANUAL

TWO POINT ONE

WARNING Hazards or unsafe practices which could result in severe personal

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

CAUTION Hazards or unsafe practices which could result in minor injury or

NOTICE Important information in regards to installation, use and maintenance

NOTICE Marine Canada Acquisition Inc. DBA SEASTAR SOLUTIONS is referred

These safety alerts alone cannot eliminate all of the hazards

Installation 1. Install components as directed in all Installation Manuals

Inboard & Sterndrive Powered Vessels i

DO NOT OPERATE BOAT IF ANY COMPONENT IS NOT IN PROPER

During use 1. WEAR A COAST GUARD-APPROVED PERSONAL FLOTATION

DO NOT OPERATE BOAT IF ANY COMPONENT IS NOT IN PROPER

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

NOTICE Due to a small amount of internal slip, a “Master Spoke” or

The following steering cylinders are covered within this manual.

Inboard & Sterndrive Powered Vessels 1

STARBOARD LINE (RIGHT)

ROD END BALL JOINT

Additional Tools Needed 20° Mount Wedge

Inboard & Sterndrive Powered Vessels 3

CAUTION SeaStar/SeaStar PRO Steering Hoses CANNOT be cut. Cutting

CAUTION BEFORE beginning with this installation, confirm that ALL

WARNING Follow the maintenance procedures outlined on page 29 of this

STEP 2 Filling and Purging Procedures

STEP 3 System Proof Check

Inboard & Sterndrive Powered Vessels 5

WARNING Where applicable, cylinders should be secured with thru bolts,

CAUTION Cylinder hose/bleeder fittings must always be installed in the

CAUTION Protect cylinder shafts from nicks and scratches. A damaged

All parts used are corrosion resistant, however with extended

NOTICE To achieve MAXIMUM cylinder performance it is suggested that an

NOTICE CENTER LINE FOR CYLINDER

2" (51mm) 3-3⁄4"

Inboard & Sterndrive Powered Vessels 7

CAUTION There is NO adjustment for centering cylinder after installation.

5. Secure mounting foot to transom or mounting bracket using

WARNING Any binding and or interference MUST be corrected prior to use.

CAUTION The cylinder ball mount allows up to 15 degrees of movement

HC1503-3 (BA150-3ATM) & 2-1/4"

RETRACTED = 12-1/4" (311mm)

RETRACTED = 12.485" (317mm)

Inboard, TM & TMC 1. To achieve MAXIMUM cylinder performance it is suggested that

TILLER ARM SHOWN IN HARD

CAUTION There is NO adjustment for centering cylinder after installation.

Inboard & Sterndrive Powered Vessels 9

3" (76mm) 4-1⁄4"

WARNING Any binding and or interference MUST be corrected prior to use.

Ball Joint Bracket Mount Cylinders

PLANE 'A' TO BE PARALLEL TO PLANE 'B'.

Figure 8. Correct Cylinder to Rudder Arm Mounting Orientation.

Inboard & Sterndrive Powered Vessels 11

WARNING INBOARD RUDDER ARM HOLE LOCATION

ROD END ASSEMBLY