Dometic HC4645H, Troubleshooting Manual

Page 1: ...Dometic Hydraulic Steering Systems Troubleshooting Guide REVISION C Form No SL61501 2020 Dometic Corporation WARNING Cancer and Reproductive Harm www P65Warnings ca gov EN HYDRAULIC STEERING SYSTEMS ...

Page 2: ...losed 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 Bat...

Page 3: ...t 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...

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Page 5: ...ll 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...

Page 6: ...on 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 ...

Page 7: ...ms 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 engi...

Page 8: ...tting 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 c...

Page 9: ... 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 ...

Page 10: ... 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 shaf...

Page 11: ...way as well B 2 Tilt Helm Installations a Confirm that the steering wheel hub is not interfering with the tilt cover Correct as required b Disassemble tilt covers and inspect tilt mechanism for any loose or separated components Inspect socket head bolts holding the coupler together to make sure they are tight and not allowed to contact any other parts of the steering assembly Correct as required H...

Page 12: ...plumbed properly D Steering cylinder MUST hit hard over E Remove power pump from power purge unit Clean screen filters located on pump pick up tubes inside the reservoir Dometic recommends the use of Power Purge service kit part HP6125 for this procedure Root Causes A There are several variations catamarans as well as additions autopilots and power assist pumps Each system may have a unique step a...

Page 13: ... may lead to heavier steering Use SeaStar steering fluid only E Consult with Installation and Operating Manual confirming that the cylinder is the correct one for the application and is installed correctly F Disconnect steering cylinder from engine then using your hands push engine back and fourth You should easily be able to swing the engine throughout its turning arc If engine is NOT easy to tur...

Page 14: ... engine is being trimmed properly and that the cavitation plate is set correctly for the hull C See Solution B D Reduce steering effort by increasing your mechanical advantage add more wheel turns by decreasing your helm displacement adding additional steering cylinder if possible installing a SeaStar power assist for fingertip steering install larger steering wheel 4 5 Steering wheel s are hard t...

Page 15: ...id Flush system as noted on page 21 C Conduct the cylinder helm pump test on page 20 4 6 Steering wheel s freewheel s to one both direction s NOTICE On multiple helm applications there is a possibility to enter a slow freewheel situation if 1 helm is turned 1 direction and then the opposite helm is slowly turned the opposite direction This is normal and can be stopped by performing a quick partial...

Page 16: ...as been installed C Check following a Confirm tilt mechanism has been installed correctly b Check all possible tilt settings 4 7 Steering wheel s are bumpy when turning either direction NOTICE If the problem goes away in other tilt settings replace tilt mechanism D Replace and or repair helm pump E Replace and or repair helm pump NOTE A timing issue within a helm pump is very rare Most timing rela...

Page 17: ... by performing a quick partial turn of the wheel to fully close a hydraulic valve NOTICE If helm cylinder pass the test and there is not autopilot on board the boat should be sea trialed while conducting the following test WARNING Dometic does not recommend the disassembly of any helm pump Contact an Authorized Service Center or replace helm pump CAUTION A system that is not responding must be dia...

Page 18: ...motor does NOT run Causes A Fuse at battery or in rear of power assist blown B Blown breaker C Incorrect wiring to from battery D Low battery voltage E Faulty electronics Solutions A Check fuse located at battery as well as fuses installed behind the rear cover of the power assist pump B Check all breakers for proper working condition C Check that all wiring is correct and in good working order co...

Page 19: ...ad screws from top of power assist motor Lift motor straight UP Hold top and bottom to ensure motor does not come apart Inspect coupling that joins the motor to the valve body Replace if worn and or broken 5 2 Power Assist motor runs but NO Power Assist 1 1 4 5 2 3 Figure 5 1 Item Description 1 5 16 Hex Head Screw 2 Wire Do not disconnect 3 0 Rings x2 Ensure O rings are in place prior to installat...

Page 20: ...operating manual for proper filling and purging details B Hoses installed between the helm pump and power assist should be at least 6 feet long 5 3 Bumpy feeling at steering wheel s with Power Assist turned ON NOTICE Above Causes and Solutions are under the assumption that the bumpy feeling only happens when the power assist is turned on For bumpy feeling with the power assist on off see section 4...

Page 21: ...he system and further bleeding is required Wheel turn test Note your helm pump and steering cylinder part number Count your steering wheel s turns from hard over to hard over consult the quick reference turns tables below Results Wheel turns should be very close to the wheel turn chart numbers If you are well over these numbers further bleeding is required If your wheel turns are at the correct nu...

Page 22: ... helm greater than 2 4 in3 rev power assist requires dual SPA s in parallel Displacement is total effective cylinder volume assumes cylinders are plumbed in parallel not series Includes Tournament Series and 3 outboard cylinders Table 6 2 Table 6 3 The test noted below is to assist with locating a leak within the steering system any leak that is found within the steering system MUST be corrected p...

Page 23: ...her testing If engine falls over only partially then air is in the system If the engine falls to both directions quickly then the cylinder or autopilot is at fault and will need to be replaced See further testing Remove autopilot from the system and repeat the tests If problem stops replace autopilot If problem continues replace helm cylinder Further testing Assuming system is free of air remove h...

Page 24: ...d in the tables on page 17 and page 18 by more than 1 2 turn with the power assist OFF this is a sign that there is air in the system 3 Bleed steering system Consult with your power assist owner s manual for bleeding details 4 Torque end glands Using a torque wrench and the pin wrench available from Dometic torque ALL end glands to 50 ft lb 5 Check cylinders for leaks Visually inspect ALL areas of...

Page 25: ...e cylinder body only Torque fitting to the appropriate value If you see fluid leaks coming from the bleeder fittings Tighten bleeder fitting If leak persists replace bleeder fitting with part HF5548 9 Flush steering system DO NOT re use any of the fluid used to flush the system out Dexron III ATF can be used for flushing but should not be used for the final bleeding procedures Dispose of fluid in ...

Page 26: ...d fittings for wear kinking and or leaks 4 Check for binding loose worn or leaking steering components Qualified Marine Mechanic After first 20 hours then every 100 hours or 6 months thereafter whichever comes first 1 All points noted above 2 Check tightness of ALL fasteners fittings throughout the steering system Tighten to correct torque specifications as required 3 Check for mechanical play or ...

Page 27: ...23 EN Figure 7 1 Item Description 1 Grease Support ROD tilt tube and support bracket HOLE 1 1 1 1 ...

Page 28: ...u in Design Balanced cylinder 4 5 2 3 1 Item Description 1 Seal kits P N HP4600 H models P N HP4601 3 models both kits do NOT include the center internal seal 2 Bleed Hose fittings P N HF4202 H models 2 per kit P N HF4203 3 models 2 per kit 3 L Support rod P N HP6050 2 per kit comes with mounting nut and clip 4 Tiller bushing kit P N HA5820 5 Pivot mount plate kits various parts HC4645H P N HA4640...

Page 29: ...67 does NOT include wrench or center internal seal 2 Bleeder fittings P N HF5548 2 per kit covers not included 3 Support brackets P N HP6018 2 per kit HP6014 3 models Support brackets ships with support rod Support rod P N HP6016 HP6014 3 models Support brackets ships with support rod 5 Hose elbow fittings P N HF6145 non 3 cylinders P N HF6004 3 cylinders 6 Tiller bushing kit P N HA5820 non 3 cyli...

Page 30: ...er side of ORB fittings NOTICE The 3 8 tube side of the fittings are the same for NPT and ORB fittings and SeaStar hoses will fit both Figure 8 3 Figure 8 4 Figure 8 5 1 4 NPT 3 8 TUBE 1 4 NPT 3 8 TUBE 1 4 NPT 3 8 TUBE Straight Fitting Elbow Fitting 45 Fitting Straight Fitting Elbow Fitting 45 Fitting 5 ORB 3 8 TUBE 5 ORB 3 8 TUBE 5 ORB 3 8 TUBE 5 ORB 3 8 SAE NPT ORB 3 8 NPT 45 FLARE 3 4 UNF BLEED...

Page 31: ...teering wheel turns 1 2 a turn then sticks 1 Inspect the colored cap shown in figure 9 1 item 3 a If blue no further action is required b If black proceed to item 2 below 2 Inspect Part No Serial No shown in figure 9 1 item 1 and item 2 a If your Part No Serial No is listed in table 9 1 have your dealer contact Dometic warranty department and follow instructions below to disable the power assist b...

Page 32: ...nual steering mode resulting in higher steering effort If you need assistance with this contact our marine technical support department at 604 248 3858 End User Contact dealer for service kit Dealer Contact Dometic Dometic will provide a service kit HA1220 and a predetermined cost of labour to service the unit 9 3 How to disable the power assist 9 4 How to obtain a service kit Item Description 1 P...

Page 33: ...as required Record the voltage 6 At point C With an assistant turning the steering wheel check the voltage The voltage should be variable Before the wheel is turned voltage should be near zero The voltage should rise as the wheel is turned 7 Turn the wheel quickly and note the maximum voltage This reading should be comparable with that recorded at point B 8 If there is low or no voltage at this po...

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Page 35: ...CAL SUPPORT dometic com contact YOUR LOCAL SALES OFFICE dometic com sales offices A complete list of Dometic companies which comprise the Dometic Group can be found in the public filings of DOMETIC GROUP AB Hemvärnsgatan 15 SE 17154 Solna Sweden ...

Page 36: ...NTED IN CANADA 12 20 Please scan this QR code and watch our latest Boating Safety video ISO 25197 2012 Mobile living made easy DOMETIC VANCOUVER 3831 NO 6 ROAD RICHMOND B C CANADA V6V 1P6 TECHNICAL SUPPORT Tel 604 248 3858 www dometic com ...