And Owner'S Manual: Installation Instructions

INSTALLATION INSTRUCTIONS
AND OWNER'S MANUAL
80
www.seastarsolutions.com
EIGHTY
ISO 9001
Hydraulic Engine Controls – 04 Series
do it you r way,
Before yopulease try it our way

Notice to Boat Manufacturer
or Installer
Throughout this publication, Warnings and Cautions (accompanied
by the International Hazard Symbol ) are used to alert the
manufacturer or installer to special instructions concerning a
particular service or operation that may be hazardous if performed
incorrectly or carelessly.
Observe Them Carefully!
These “safety alerts” alone, cannot eliminate the hazards that they
signal. Strict compliance to these special instructions when
performing the installation and maintenance plus “common sense”
operation are major accident prevention measures.
DANGER WARNING CAUTION NOTICE
Immediate hazards Hazards or unsafe Hazards or unsafe Information which
which WILL result in practices which practices which is important to
severe personal injury COULD result in COULD result in proper installation or
or death. severe personal injury minor injury or maintenance, but is
or death. product or property not hazard-related.
damage.
WARNING Cleaning fluids containing ammonia, acids or any other corrosive

ingredients must not be used for cleaning any part of this Hydraulic
Steering System. Failure to comply will cause serious damage to
the steering system, resulting in possible loss of steering, causing
property damage, personal injury and/or death.
Don’t compromise performance... use genuine

Hynautic parts only!
• Hynautic Control Senders • Hynautic Control Slave Units
• Hynautic Control Reservoirs • Hynautic Control Tubing
• Hynautic Control Fluid
Substituting non Hynautic parts in any part of the Hynautic hydraulic
steering system, may seriously compromise system performance.
This manual should be kept on board your vessel

Index
Introduction ............................................................................... ii
Preparation for Installation........................................................... 1
Component Installation................................................................ 1
Sender Installation................................................................. 1
Throttle Slave Installation........................................................ 3
Clutch Slave Installation.......................................................... 6
R-13 Reservoir Installation...................................................... 8
R-04 Reservoir Installation...................................................... 8
MCV-04 Charging Valve Installation.......................................... 9
Tubing Installation and Connection............................................. 10
Rules for Routing Tubing....................................................... 10
Install Tubing Between Senders and Slaves............................ 11
Copper Tubing...................................................................... 12
Filling and Bleeding the System...................................................15
Filling the System................................................................. 15
Bleeding the System, at Slave............................................... 15
Bleeding the System, at Senders........................................... 16
System Fluid............................................................................. 17
Making the System Operational . ............................................... 17
Synchronizing the Controls.................................................... 17
Connecting Engine Controls.................................................. 17
Operation & Maintenance.......................................................... 18
Throttle Senders.................................................................. 18
Clutch Senders.................................................................... 18
Maintenance Schedule......................................................... 18
Parts List.................................................................................. 19
System Parts List (Nylon Tubing)............................................ 19
System Parts List (Copper Tubing)......................................... 20
Sender Assembly................................................................. 21
Ball & Tee Handle Installation................................................ 22
ST-06 Throttle Slave Assembly.............................................. 23
SS-04 Transmission Slave Assembly..................................... 24
Optional Neutral Safety Switch Kit SSH-01.................................. 25
Templates................................................................................. 29
CDF-04 Mounting Plate.............................................................. 31
Tubing Diagrams ..................................................................... 33
Plan I – Twin Engine, One Station........................................... 33
Plan II – Twin Engine, Two Station......................................... 34
Plan III – Twin Engine, Three Station....................................... 35
Plan IV – Twin Engine, Four Station........................................ 36
Supplemental Throttle Control Circuits........................................ 37
Plan I-S................................................................................ 37
Plan II-S............................................................................... 37
Plan III-S............................................................................. 38
Plan IV-S............................................................................. 38
Troubleshooting Guide............................................................... 39
Technical Information................................................................ 42
Statement of Limited Warranty.................................................. 43
Installation Instructions & Owner's Manual i

INTRODUCTION
CAUTION This system does NOT use oil or Steering Fluid. Use HA5455
Hynautic shift and throttle control fluid ONLY. DO NOT use
stop-leak type anti-freeze.
SeaStar Solutions Engine The movement of a sender’s control arm transmits mechanical energy
to an internal piston which in turn pushes hydraulic fluid through the
Control System — Why it other corresponding control senders and single control slave. This
Works movement of hydraulic fluid drives a piston in each of the senders
and slave. The movement of the individual pistons causes shaft
rotation in each unit.
The piston in each of the individual control senders and slaves has
two small valves which are opened when the piston reaches the end
of its stroke, allowing additional fluid to pass through the system. By
allowing this flow of hydraulic fluid, the controls may be synchronized
with each other by moving the control arm at one control station
from stop to stop.
The control slave is very similar to the control sender, except the
body is a rectangular block. An over-travel bungee is used in the
linkage between the slave arm and engine control arm to assure
that the slave can reach the end of its stroke in each direction. The
slave for the transmission has a built-in detent mechanism to
indicate neutral position.
On most engines the throttle exerts considerable force to return to
the idle position. Each throttle slave is equipped with a pilot check
valve which locks the throttle slave in the position it has taken in
response to the sender. The throttle slave can be driven only by the
sender, it cannot drive the sender.
Extra hydraulic fluid and a pressure head for the system is maintained
by the system’s reservoir. The reservoir is charged with 80 psi of air
over the hydraulic fluid within it. This keeps the entire system under
pressure at all times and prevents a vacuum from existing on the
back side of any piston when the system is operated.
Fluid-flow to and from the reservoir is regulated by a charging valve
located on the bottom of the reservoir. This valve is necessary to
keep the system under pressure, and to prevent excessive pressures
caused by the expansion of fluid when the fluid becomes warm.
Nylon tubing is used to pipe the system for two reasons: (1) ease of
installation, (2) nylon tubing expands and contracts in very much the
same manner as the hydraulic fluid (a most important factor). The
expansion and contraction of the tubing reduces drift of the controls
as temperature changes, thereby helping to keep all the components
of the system synchronized. The tubing is virgin nylon, which has
been heat and light stabilized and contains no plasticizers. The burst
pressure of the tubing is in excess of 1200 psi.
ii Hynautic Hydraulic Engine Controls – 04 Series

PREPARATION FOR
INSTALLATION
CAUTION Dirt and foreign matter in the hydraulic system cause damage and
malfunction. It is extremely important to keep tubing and fittings
clean when installing and connecting components. Cut tube cleanly
and tape the open end while running tubing.
Before installation is started, the parts list should be checked to verify
that a complete system has been received. Parts lists are located on
page 19 and page 20.
It is advised that all system components be installed, (senders, shift,
throttle slaves, and reservoir) prior to running the system tubing. This
allows the tubing to be run between two definite points with less
chance of an error.
Should it become necessary for the tubing to be strung first, a system
of marking the different tubing runs should be used.
COMPONENT INSTALLATION
Components have red plastic plugs installed in their ports to keep out
foreign matter. As you remove these red plastic plugs, replace them
immediately with the proper adapter; then install the red plugs into the
adapters until you are ready to connect tubing.
Use Loctite® hydraulic sealant on all NPT fittings prior to installation.
DO NOT use teflon tape or pipe dope.
Sender Installation 1 Locate sender on panel so that the control arm’s arc will not interfere
with the ship’s wheel or panel. Be certain that access is available
to the small bleeder screw at the top of each sender head.
The design of the new Engine Control "T" handle requires a
minimum distance between control heads to provide adequate
handle clearance when two sets of controls are mounted side by
side. See Figure 1.
NOTICE This minimum distance does not apply to installations using the
optional "knob" style control handles.
2 Using the template provided in the appendix, mark and cut a hole
for the sender. Page 29 shows the proper templates for the
single head and side by side sender mounting options. Refer to
Figure 1 for minimum distance required when mounting two sets
of controls side by side.
3 Drill 7/16" holes in the panel for the mounting bolts.
4 Set sender in place and check to see if all mounting holes match up.
Installation Instructions & Owner's Manual 1

HYNAUTIC CONTROLS
NOTICE 5 The sender’s ports are tapped 1/4" NPTF. Suitable adapters
must be installed to accept the tubing used. It is more convenient
If the area under the control to install these adapters prior to mounting the senders.
panel is too confined to allow (Instructions for copper tubing installations are onpage 12.)
the tubing to be connected with
6 Secure senders per Figure 2 for single head, or Figure 3 for side
moderate ease, do not secure
by side mounting.
the sender at this time. Proceed
with the installation of the 7 The sender’s handle position may be set within limits by loosening
remaining senders per Steps 1 the tightening screw (using a 1/4" allen wrench) in the lower end
through 5. The sender may be of the arm and then rotating the arm as desired and resetting the
secured after the tubing has screw. After the arm is set, it will have a 115° maximum arc.
been connected to it. 8 Secure the remaining senders per Steps 1 through 7.
NOTICE
The minimum distance
does not apply to 3.5" MINIMUM
installations using BETWEEN PLATES
the "knob style"
control handles.
3.75" MINIMUM
BETWEEN HEADS
Figure 1. Mounting "T" Handle Controls Side by Side.
PANEL CDF-04
MOUNTING
PLATE
CONTROL WASHER
WASHER PANEL
MOUNTING
MOUNTING
BOLT
BOLT
Figure 2. Single Head Sender. Figure 3. Side-By-Side Senders.
2 Hynautic Hydraulic Engine Controls – 04 Series

HYNAUTIC CONTROLS
Throttle Slave Installation SeaStar Solutions throttle slaves must be mounted so that at the
mid-stroke of both the engine’s throttle arm and the slave’s control
arm, they are: 1) In the same plane; 2) parallel to each other; and 3)
right angles will be formed between the connecting linkage and each
arm. See Figure 4.
NOTICE
If these criteria are met, an ideal installation will result.
The standard SeaStar Solutions
A spring bungee-ball joint assembly is furnished with each throttle
System, MC-04, uses the ST-06
slave. It is installed in the slave arm-to- throttle linkage according to
Integrated Throttle Slave. You may
Figure 4. It allows up to 3/16" slave arm over-travel in each direction.
have chosen to order a non-
This over-travel lets the slave cylinder travel its full stroke and still
standard system which includes
provide full travel to the throttle arm. You must use almost all of the
the ST-04 Throttle Slave and
slave travel, or about 75°, to operate the throttle. The slave must go
STV-10 Lock-out Valve. Depending
full stroke in each direction in order to synchronize the system.
on which system you have, follow
the corresponding installation The throttle slave’s arm may be set to any desired position by loosening
instructions in this section. the tightening screw (using a 3/16" allen wrench) in the lower end of
the arm and then rotating the arm as desired and resetting the screw.
After the arm is set, it will have a 78° maximum arc.
CAUTION The Throttle Slave must not be mounted to any surface exceeding
220° F (103° C). If mounting in a "hot spot" is unavoidable, the
slave must be insulated from the heat.
BUNGEE-BALL
JOINT ASSEMBLY
BALL JOINT (850081)
(670010)
LOCK NUTS
(1/4-20)
SLAVE
ARM
90˚ 1/4-20 90˚

THREADED
ROD
THROTTLE ARM
Figure 4. Throttle Slave to Throttle Arm Installation.
Steps 1 through 8 apply to both ST-04 and ST-06 Systems

1 Secure the mounting bracket to the engine. A suitable bracket
must be fabricated.
2 Secure the throttle slave to the mounting bracket using 3/8-16
mounting bolts.
3 Install a lock nut and bungee-ball joint on the end of a 1/4-20
stainless or brass threaded rod.

HYNAUTIC CONTROLS
4 Position the throttle slave to its mid-stroke and connect the

bungee end of the 1/4-20 threaded rod to it (not provided).
5 Position the engine’s throttle arm to its mid-stroke. Determine
the length of threaded rod required and cut off the excess.
6 Connect a lock nut and a ball-joint to the engine’s throttle arm
and the free end of the threaded rod.
7 Find the proper hole in the slave arm to provide a linkage length
combination that will allow idle to full throttle on the engine,
using all but a few degrees of slave arm travel in each direction.
By adjusting the ball-joint and bungee, a fine adjustment in both
directions can be achieved. Be sure the slave arm can over-travel
through the bungee to the end of its stroke in each direction.
8 After determining the correct rod length, securely lock the ball-
joint and bungee assembly to the threaded rod with lock nuts
provided. Disconnect the linkage from the throttle slave’s arm.
ST-06 System ONLY

9 To prevent engine retard due to governor spring or vibration, a
pilot check valve is built into the ST-06 Throttle Slave.h the
bungee to the end of its stroke in each direction.
NOTICE This built-in valve will lock the slave arm in place allowing it to be
moved only by the sender.
10 Locate a tee and bleeder valve on the throttle slave and install
suitable adapters to accept tubing, per Figure 5.
NOTICE Tube connectors are installed on the tubing per instructions under
“Tubing Installation” and “Connection” on page 10.
11 Verify all fittings installed have been tightened. Repeat these
throttle slave installation procedures for the second engine.
CAUTION Dirt and foreign matter in the hydraulic system cause damage and
malfunction. It is extremely important to keep tubing and fittings
clean when installing and connecting components.
ST-04 System ONLY
9 To prevent engine retard due to governor spring or vibration, a
separate STV-10 lock-out valve is used with the ST-04 Throttle
Slave.
NOTICE If the throttle slave is in a limited space, it may be removed from the
bracket during the lock-out valve installation. The STV-10 Lock Out
Valve must be plumbed as shown in Figure 6. The lock-out valve will
lock the slaves arm and allow it to be moved by only the sender.
The check valve and slave must be mounted in close proximity to
one another. If they're not, abnormal locking action and poor
performance will result.
10 Install the lock-out valve on the throttle slave and secure it using
clean lubricant or Loctite hydraulic sealant on the threads.
Install appropriate adapters to accept tubing. Refer to Figure 6.

HYNAUTIC CONTROLS
TO CONTROL STATIONS NYLON TUBING

5/16" O.D. N-2
HYNAUTIC TUBE FITTING ASSEMBLY
NUT (530015) ADAPTER 1/4" PIPE X 5/16 TUBE
LOCK RING (530025) (530175)
INSERT (530045)
O-RING (002222) BLEEDER ASSEMBLY
(690010)
1/4" PIPE TEE 1/4" PIPE NIPPLE

(690441) (690551)
78˚
CONTROL ARM MAY BE ROTATED

TO ANY ANGLE ON SHAFT
Figure 5. ST-06 Integrated Throttle Slave with Tee and Bleeder Valve Installation.
NOTICE Tube connectors are installed on the tubing per instructions under
“Tubing Installation” and “Connection.”
11 Using a short piece of tubing provided, connect the open port on
the tee to the S2 port on the lock-out valve. See Figure 6. (See
Figure 15 for Copper Tubing connection.) Plug open fittings at
the V1 and V2 ports.
12 Verify all fittings installed have been tightened. Repeat these

throttle slave installation procedures for the second engine.
ADAPTER 1/4" PIPE NUT (530015)

BLEEDER 5/16" TUBE
ASSEMBLY LOCK RING (530025)
(530175) INSERT (530045)
(690010)
O-RING (002222) ADAPTER 1/4" PIPE
1/4" PIPE TEE 5/16" TUBE
(690441) HYNAUTIC TUBE (530175)
FITTING ASSEMBLY
NIPPLE 1/4" PIPE NYLON TUBING
(690551) 5/16" O.D. N-2
NYLON TUBING
78˚
S2
V2
5/16" O.D. N-2 NIPPLE 1/4" TO CONTROL

PIPE STATIONS
(690551)
S1
V1
HYNAUTIC TUBE
FITTING ASSEMBLY
1/4" PIPE TEE
(690441)
CONTROL ARM MAY ADAPTER 1/4"
BE ROTATED TO ANY STV-10 LOCK-OUT VALVE
ST-04 PIPE 5/16" TUBE (950119)
POSITION ON SHAFT (530175)
THROTTLE SLAVE ASSEMBLY
Figure 6. ST-04 Throttle Slave with STV-10 Lock-Out Valve.

HYNAUTIC CONTROLS
Clutch Slave Installation The SeaStar Solutions clutch slave must be mounted so that when the
engine’s transmission is in neutral and the Morse clutch slave’s arm is
at its mid-stroke, both arms will be: 1) in the same plane; 2) parallel to
each other; and 3) right angles will be formed between connecting
linkage and each arm, see Figure 7.
SLAVE ARM
LOCK NUT
BALL JOINT
LOCK NUT (670010)
BALL JOINT
(670010)
90˚ 1/4-20 90˚

THREADED
ROD
CLUTCH ARM
Figure 7. Proper Clutch Slave to Throttle Arm Installation.
NOTICE
The clutch slave’s arm may be set to any desired position by
loosening the tightening screw (using a 3/16" allen wrench) in the
lower end of the arm. Rotate arm as desired and reset the screw.
After the arm is set it will have a 78° maximum arc.
1 Secure mounting bracket to the engine. A suitable bracket must
be fabricated.
2 Secure the transmission slave to the mounting bracket using the
3/8-16 mounting bolts.
3 Set the transmission in the neutral position, and the clutch
slave’s arm at its mid-stroke.
4 Loosen the set screw in the detent ring on the clutch slave and
rotate the detent ring to the full detent position. To locate the
detent ring, see Figure 8.
5 Secure detent ring in this position by tightening the set screw.
6 Install a lock nut and ball joint on the end of the 1/4-20 stainless
steel or brass threaded rod (not provided).
7 Position the clutch slave to its mid-stroke and connect the ball
joint end of the 1/4-20 threaded rod to it.
8 Position the engine’s clutch arm to neutral, determine the proper
length of the threaded rod required and cut off the excess.
9 Install a lock nut and ball joint on the other end of the threaded rod.

HYNAUTIC CONTROLS
DETENT RING
CONTROL ARM LOCK-SCREW

DETENT RING LOCK-SCREW
240357
Figure 8. Detent Ring Location.
10 By locating the slave arm ball-joint in its proper hole and adjusting
both ball joint on the threaded rod, find the correct length of
linkage that will allow both "full- forward" and "fullreverse" on
the transmission for full throw on the clutch slave arm.
11 After determining the correct linkage length, securely lock the
ball-joints to the threaded rod with lock-nuts provided. Disconnect
the linkage from the clutch slave’s arm.
12 Locate and secure in place two tees, two bleeder valves, and
two tubing adapters, per Figure 9.
13 Repeat this clutch slave installation procedure for the second engine.
NOTICE
HYNAUTIC TUBE FITTING
ASSEMBLY The tube fitting and
ADAPTER 1/4" NUT (530015) bleeder valve may be
BLEEDER PIPE 5/16" TUBE reversed on the pipe
LOCK RING (530025)
ASSEMBLY (530175) tee to allow for easier
INSERT (530045) tube connection.
(690010)
O-RING (002222)
TO CONTROL
STATIONS
1/4" PIPE TEE ADAPTER 1/4" PIPE
(690551) 5/16" TUBE
NIPPLE 1/4" PIPE (530175)
(690551)
TO CONTROL
STATIONS
CONTROL ARM MAY NYLON TUBING

BE ROTATED TO ANY BLEEDER 5/16" O.D. N-2
POSITION ON SHAFT NIPPLE 1/4" PIPE
(690551) ASSEMBLY
(690010)
Figure 9. SS-04 Shifter Slave - Bleeder Valve and Tubing Adapters Installation.

HYNAUTIC CONTROLS
NOTICE The standard SeaStar Solutions System, MC-04, uses the R-13
Integrated Reservoir. You may have a different system which includes
the R-04 Reservoir and an MCV-04 Charging Valve. Depending on
which system you have, follow the corresponding installation
instructions in this section.
NOTICE If your installation includes two reservoirs (one for each engine), or is a
single-engine installation, special plumbing will required which is not
covered in this manual. Contact SeaStar Solutions for this information.
R-13 Reservoir Installation The reservoir should be located in the ship’s engine room in an
accessible location. In locating the reservoir the following conditions
should be met:
1 Reservoir must be in a vertical position with pressure gauge on top.
2 Sight glass must be visible and easy to read.
3 Pressure gauge must be visible and easily read.
4 The operator must have easy access to the air filler valve on the
top of the tank.
5 The operator must have easy access to the fill port on top of the tank.
6 The operator must have easy access to charging valve on bottom
of reservoir.
7 Reservoir must be mounted to the bulkhead, wall, or post, using
either bolts or screws.
NOTICE
The charging valve is located on
the bottom of the reservoir. The
plug located on the charging valve
holds the fluid filter in place. This
plug and filter can be removed to
drain the reservoir’s fluid. See
Figure 10.
FILTER/
DRAIN PLUG
FILTER (380574)
ELEMENT
(160113)
Figure 10. Charging Valve on R-13 Reservoir.
R-04 Reservoir Installation The reservoir should be located in the ship’s engine room in an
accessible location. In locating the reservoir the following conditions
should be met:
1 Reservoir must be in a vertical position with pressure gauge on top.
2 Sight glass must be visible and easy to read.
3 Pressure gauge be visible and easily read.

HYNAUTIC CONTROLS
4 The operator must have easy access to the air filler valve on the
top of the tank.
5 The operator must have easy access to the fill port on top of the tank.
6 Reservoir must be mounted to the bulkhead, wall or post using
either bolts or screws.
NOTICE
There are two ports located on the
bottom of the reservoir. One is
plugged and can be used as a
drain port. The other has a filter
assembly and is used for
connecting to the system. See
Figure 11.
FILTER PLUG
ASSEMBLY
(380070)
DRAIN PLUG
TO SYSTEM
Figure 11. Ports on Bottom of R-04 Reservoir.
MCV-04 Charging Valve The charging valve should be located in the general vicinity of the reservoir.
Installation 1 Install appropriate adapters for the tubing used. For port locations
see Figure 12.
2 Mount the charging valve using two screws or bolts.
ADAPTER 1/4"
PIPE 5/16" TUBE
(530175)
TO
RESERVOIR
MOUNTING HOLES
Figure 12. MCV-04 Charging Valve.

TUBING INSTALLATION AND
CONNECTION
CAUTION Four tubing installation plans are provided in the Tubing Diagrams
Cut tube cleanly and tape the Section later in this manual:
open end while running tubing. 1 Twin Engine, One Station, (Plan I)
2 Twin Engine, Two Station, (Plan II)
3 Twin Engine, Three Station, (Plan III)
4 Twin Engine, Four Station, (Plan IV)
Before beginning to run the tubing, it is recommended that each tube
be assigned a number which is marked on both ends, and
correspondingly, marked at the origin and destination of that tube.
These designations should also be recorded on the chosen plan
diagram for future reference.
Rules for Routing Tubing 1 Keep tubing free of dirt and foreign matter.
2 Keep tubing away from batteries, since battery acid is corrosive
to the tubing.
NOTICE 3 Tie the tubing down at regular intervals using non-metallic ties
The instructions and illustrations and clamps.
in this section apply to nylon 4 Do not allow tubing to become kinked. If it does, replace that
tubing ONLY. Information on use particular run of tubing.
of Copper Tubing may be found 5 String tubing so that it will not interfere with hatchways or
on page 12. machinery removal.
6 Use only nylon tubing supplied with system from SeaStar Solutions.
Assemble tubing connectors on every tube end as described below

and illustrated in Figure 13.
NOTICE The roll of tubing should be laid in a horizontal position and moved as
little as possible to avoid kinking and tangling.
1 Cut tubing using a tube cutter, leaving the cutoff end as square
as possible.
2 Slip the nut over the tubing end—(nut should slide freely).
3 Push the lock over the end of the tubing and move it back at
least one insert length from the end. The lock may slide on freely
or require a light press or screw-on action. (The lock has a left
hand thread)
CAUTION 4 Install the seal over the end of the tubing and against the lock.
Refer to Caution.
Ensure the seal is not twisted 5 Then force the insert into the end of the tubing by pushing it
during installation. against a clean, flat surface.
6 Push the nut and the lock by hand toward the end of the tube as
far as possible.
7 Insert the tube end assembly into the proper cavity and tighten it
down. Tighten only to a solid feel on the wrench.

HYNAUTIC CONTROLS
TUBING INSTALLATION
CAUTION
TUBING
Extreme care MUST be taken to NUT
avoid any contamination from 530015
entering the tubing. Failure to do
so may lead to system failure. LOCK
530025
O-RING
002222
INSERT
530045
1/32"
Figure 13. Assembling Tubing Connectors.
Install Tubing Between 1 Locate the tubing roll in a convenient location.

Senders and Slaves 2 Starting at the highest control station, begin running tubing from
(See page 33 to page 38 for the upper tubing port of the right most sender to its connecting
Plumbing Circuits.) point as shown on the diagram.
NOTICE Tubing may be run from the sender to connecting point or from
connecting point to sender, whichever is easier.
3 Secure each end of the newly run tube by Inserting the tube end
assembly into the proper adapter (#530175), previously installed
in components. Tighten down only until there is firm resistance
felt on the wrench.
4 Run the tubing from the lower port of the same sender, repeating
the previous steps.
5 Progress leftward across the control panel until all lines have been
run and secured. Then go to the next lower station and run tubing
NOTICE from it in the same manner as it was from the upper station.
When securing tubing with clamps, 6 If the boat has more than two stations, continue running tubing
do not over- tighten clamps or from them in the same manner, still following the tubing diagram.
ties, as overtightening will crimp 7 At this point all tubing should be run and connected. Now, secure
the tubing causing poor system tubing using ties and clamps. This should be done prior to filling
operation. the system.

HYNAUTIC CONTROLS
TUBING INSTALLATION
Copper Tubing Use these instructions in conjunction with this Manual's Section on
Tubing Installation, page 10.
1 Use 5/16" OD soft copper refrigeration type tubing.
2 Use standard 45° flares for fittings. Be careful to make good flares
and do not allow dirt or chips into the system. DO NOT use pipe dope
on fitings. Refer to cautions in this manual.
3 All tubing runs outside the engine room should be run together.
(Single-bundled)
4 Inside the engine room, lengths of tubing on each side of the same
circuit should be essentially the same length.
5 If desired, short lengths (maximum 24") of Aeroquip 2651-5 Hose with
401-5B Fittings may be used for the transition from hull-mounted to
engine-mounted tubing. This will prevent work-hardening of the copper
from flexing and vibration. Again, make sure no dirt or chips are
introduced into the hose ends or damage and malfuntion of the
system may occur.
The following figures illustrate the proper connections for copper
tubing installation between components of the Engine Contol System.
COPPER TUBING
5/16" O.D.
ADAPTER-FILTER
(690080)
FILTER/
DRAIN PLUG
(380574)
TUBE NUT (690621)
Figure 14. Charging Valve on Bottom of R-13 Integrated Reservoir.

HYNAUTIC CONTROLS
TUBING INSTALLATION
TO CONTROL STATIONS
COPPER TUBING 5/16" O.D.

TUBE NUT (690621)
5/16", 45˚ FLARE

UNION (691601)
5/16" FLEXIBLE HOSE WITH

45˚ FEMALE FLARE SWIVELS
NOTE: MUST USE A MIN. OF
ADAPTER-FILTER (691601) 12" OF FLEX HOSE
ADAPTER 1/4" PIPE 5/16"

TUBE (530175) ADAPTER 1/4" PIPE – 5/16" TUBE (530175)
BLEEDER ASSEMBLY (690010) BLEEDER ASSEMBLY

(690010)
1/4" PIPE TEE (690551) NIPPLE 1/4" PIPE (690551)
CONTROL ARM MAY

COM.
BE ROTATED TO ANY SHAFT’S RANGE

N.O.
N.C.
POSITION ON SHAFT OF ROTATION

IS 78˚
Figure 15. ST-06 Integrated Throttle Slave.
ADAPTER 1/4" PIPE

5/16" TUBE ADAPTER
(530175) (690631)
TUBE NUT (690621) ADAPTER ADAPTER- 45˚ FEMALE FLARE SWIVELS
NIPPLE (690631) FILTER NOTE: MUST USE A MIN.
1/4" PIPE (690080) OF 12" OF FLEX HOSE
(690551)
TUBE NUT
(690621)
S2
COPPER TUBING
V2
78˚ 5/16" O.D. NIPPLE 1/4"

PIPE
(690551)
V1
S1
(950119) 5/16", 45˚ FLARE

UNION (691601)
ADAPTER 1/4"
ST-04
PIPE 5/16" TUBE BLEEDER ASSEMBLY COPPER TUBING
(530175) (690010) 5/16" O.D.
Figure 16. ST-04 Throttle Slave with STV-10 Lock-Out Valve.

HYNAUTIC CONTROLS
TUBING INSTALLATION
COPPER TUBING
5/16" O.D.
ADAPTER-
FILTER
(690080) TO
RESERVOIR
FILTER PLUG
ADAPTER ASSEMBLY
(530175) (380070)
TUBE NUT
DRAIN PLUG (690621) COPPER TUBING TUBE NUT MOUNTING
(690010) 5/16" O.D. (690621) HOLES
Figure 17. Ports on Bottom of R-04 Reservoir. Figure 18. MCV-04 Charging Valve.

ADAPTER-FILTER (690080) 12" OF FLEX HOSE
1/4" PIPE TEE (690441) 5/16" 45˚

TUBE NUT (690621) FLARE UNION
(691601)
BLEEDER ASSEMBLY
(690010)
TO CONTROL
STATIONS TUBE NUT
(690621)
COPPER TUBING
5/16" 45˚
5/16" O.D.
FLARE UNION
ADAPTER 1/4" (691601) COPPER
PIPE 5/16" TUBE 1/4" PIPE TEE TUBING
(530175) (690441) 5/16" O.D.
ADAPTER-FILTER
(690080)
NIPPLE 1/4" TO
PIPE (690551) CONTROL
STATIONS
ADAPTER
1/4" PIPE
CONTROL ARM MAY 5/16" TUBE
BE ROTATED TO ANY (530175)
POSITION ON SHAFT NIPPLE 1/4" PIPE (690551)
BLEEDER 12" OF FLEX HOSE
ASSEMBLY
(690010)
Figure 19. SS-04 Shifter Slave.

FILLING AND BLEEDING THE
SYSTEM
Filling the System 1 Verify that all sender arms are free to traverse their complete arc.
2 Verify that all bleeder valves on the throttle and clutch slaves are
closed, and linkages disconnected.
NOTICE See section on “System Fluid” for fluid specifications on page 17.
3 Remove fill port plug from the reservoir and fill the reservoir
within one inch of the top of the sight tube with HA5455 water
glycol fluid. Replace fill port plug.
4 Pressurize reservoir to 100 +/-10 psi through the air filler valve in
the top of the reservoir.
5 The system will now begin to fill with fluid. As the system fills the
fluid level in the reservoir will become lower. When the fluid level
is between 1 to 2 inches from the bottom of the sight glass
release the pressure and refill the tank, as in Step 4.
6 Repressurize the system and repeat this procedure of filling the
reservoir as required until no fluid drop is noted. At this point, the
system is filled and must now be bled.
7 Check entire system for leaks and correct as required.
Bleeding the System 1 Fill the reservoir as required.

at Slave 2 Using the bleeder tube provided and a clean, empty container,
insert the bleeder tube in the bleeder valve at one side of a
NOTICE slave. Open the bleeder valve about one turn and bleed system
until no air bubbles are evident in the flowing fluid. When the fluid
Verify that linkage is disconnected, is clear, close the bleeder valve. During the bleed operation
and sender’s handles are free maintain the system pressure above 60 psi, and the fluid level in
to move. While bleeding, move the sight gauge above the two-inch mark. Should the fluid level
the slave arm and verify that the drop below two inches close the bleeder valve and release the
piston has bottomed. pressure from the system. Refill the reservoir with the fluid that
has been bled off, repressurize the system and continue
bleeding. Bleed long enough that no air or foam remains in this
branch of the system. Draw at least a full reservoir of fluid
through each side of each circuit.
NOTICE Since there are two positions at each slave to be bled and four slaves,
the reservoir must be filled at least 8 times during the bleed operation.
The fluid which has been bled off should be used to efill the reservoir.
3 Tighten bleeder valve after the bleed operation.
NOTICE 4 Bleed the second port of the slave as described in Steps 1, 2,
The bleeding procedure is much and 3.
easier for two people to perform 5 Repeat steps 1 through 4 with a second person at the sender
than one. (one keeping reservoir moving the handles back and forth slowly five to ten times
filled and under pressure, while the 6 Continue performing the preceding five steps for each remaining
other one bleeds the system.) slave.

HYNAUTIC CONTROLS
FILLING AND BLEEDING
Bleeding the System at After bleeding system at each slave bleeder valve, each sender
must now be bled. A small amount of air will be trapped at the high
Senders point in each sender head.
1 Refill reservoir if required (fill tank at this time to between 1/2 and
2/3 full), and leave about 100 psi on the pressure gauge.
NOTICE Place a rag over the bleeder hole on the sender, to prevent fluid from
spilling on the console.
2 Very slowly open the bleeder plug using a 3/16" allen wrench.
See Figure 10 for location of bleeder screw.
GASKET
BLEEDER SCREW
Figure 20. Bleeder Screw.
3 Allow the fluid to bleed out until the fluid is clear without air
bubbles.
4 Tighten the bleeder screw after bleeding.
5 Repeat Steps 1 to 4 above, for each sender.
6 The reservoir level should be between 1/2 and 2/3 full. If the
level is below this, the reservoir should be filled to this level.
Verify that pressurize in the reservoir is between 80 and 85 psi.

SYSTEM FLUID
The fluid recommended for use in the system is a 50/50 mixture by
volume of distilled water and ethylene glycol. The type of ethylene
glycol used is very important for proper operation of your system
and especially the synchronization (charging) valve. Some additives,
especially silicone additives, are very thick in consistency and will clog
the elements in the synchronization valve. If this occurs your system
will be unable to maintain synchronization between sender and slave.
The ethylene glycol chosen for use should be as pure (no additives)
as possible, proportionately mixed with distilled water then filtered
to assure its purity. NEVER USE STOP LEAK TYPE ANTI-FREEZE.
Filtration is accomplished by passing the fluid through a 5 micron
filter before using in the system.
Field service pre-filtering can be accomplished by using a “Mr. Coffee”
or equivalent paper filter placed in a funnel and then pouring the
ethylene glycol solution through it.
One paper filter will filter approximately 1/2 gallon of ethylene glycol
solution.
The HA5455 fluid provided by SeaStar Solutions is proportionately
mixed and filtered to assure its purity and is ready for use.
MAKING THE SYSTEM

OPERATIONAL
Synchronizing the Controls The system is now operational except for synchronizing the controls.
1 Go to one control station and move each sender’s arm from stop
to stop, 3 to 5 complete cycles. Each sender should be
synchronized at this time.
NOTICE This synchronization can be performed at any of the control stations.

2 If the position of the sender’s handle requires an awkward motion
by the user, adjust the handle by loosening the set screw (using a
1/4" allen wrench) and rotating the handle so that the user has
more of a direct push-pull motion. Do not position handle so that it
binds against the sender body at either end of its stroke.
3 Should one of the controls not come into synchronization, go to
that station which is out of synchronization and perform Step 1.
Connecting Engine Controls 1 Connect throttle linkages to the throttle slave. Repeat for both engines.
2 Connect clutch linkages to the clutch slave. Repeat for both engines.
NOTICE For any operational problems at this point, consult the trouble-
shooting section.

OPERATION & MAINTENANCE
Throttle Senders Forward Motion — Increases Throttle.
Aft Motion — Decreases Throttle.
WARNING When working on engine and operating the engine throttle arm by
hand, disconnect throttle linkage from the control slave. If linkage
is not disconnected the pilot check valve will not allow a throttle
retardation unless a sender arm is actuated to decrease the throttle.
NOTICE Prior to starting engines, both throttles and clutches should be synchronized.
This is done by moving the sender’s control arm in a complete cycle fore
and aft, stop to stop. This needs to be done at only one station.
Clutch Senders Forward Position — Forward Direction

Center Position — Neutral
Aft Position — Reverse Direction
Maintenance Schedule The clutch and throttle sender bodies are made of 6061-T6
aluminum, which has been anodized. To clean them, a warm soapy
solution should be used. Do not attempt to use an abrasive
compound as is done when shining brass.
Every 30 Days:
1 Check hydraulic fluid level (should be between 1/2 and 2/3 full
on the sight glass).
2 Check system pressure (pressure should be between 70–90 psi),
see note below concerning reservoir pressure.
NOTICE The reservoir pressure will vary between 70-90 psi due to temperature
changes. There is no reason to become alarmed unless the pressure
drops below 70 psi, then the system should be repressurized to 80+
psi. If the pressure loss is over a relatively short period check for air
leakage. Should the pressure loss from full pressure to minimal
operation pressure be over an extended time period just repressurize
the system. This extended pressure loss is normal and may be
compared to the same type pressure loss one experiences with a
good set of automotive tires after an extended time.
Every 6 Months:
1 Check fluid level in the reservoir (level should be approximately
1/2 to 2/3 of sight glass).
2 Check system pressure, it should be between 70-90 psi. Consult
the note above about system pressure change.
3 The system is self-lubricating, but the ball-joints on control
linkages should be oiled.
4 Check mounting bolts on the control slaves (clutch and throttle)
to verify that vibration has not loosened them.
5 Check lock nuts on control linkages; verify that they are tight.
6 Check fitting connections for any leakage.
7 Where tubing runs are exposed and are bordering heavy traffic
areas, check for damage and repair as required.

PARTS LIST
Nylon Tubing
SINGLE ENGINE TWIN ENGINE
ndle)
ndle)
)
ndle)
)
ndle)
a n dl e
a n dl e
)
)
ndle)
ndle)
ndle)
a n dl e
a n dl e
l e
T " Ha
T " Ha
T " Ha
d
T " Ha
(" T " H
(" T " H
a n
T " Ha
a
(" T " H
(" T " H
(" T " H
(" T " H
2D ( "
3D ( "
"
1D ("
"
(
2 (" T
D
4-T 2D
4-T 3D
S1 ( "
1
-T4-S
S
-T4-S
4 -S 3
4 - S1
-T4-T
4-T 2
4-T 3
-
-T4-S
4
C-T4-
MC-T
MC-T
MC-T
MC-T
MC-T
MC-T
MC-T
C
or M C
C
M
C
M
) or M
M
r
le) or
le) or
le) or
le) or
o
le) or
le) or
le) or
le) or
le) or
ndle)
ndle)
e
H an d
H an d
H an d
H an d
l
H an d
H an d
H an d
H an d
H an d
H an d
ll Ha
ll Ha
l
(Ball
(Ball
(Ball
l
D (B a
a
(Ball
D (B a
(Ball
(Ball
(Ball
(Ball
(Ball
( B
4-S1D
4-T 2D
4-T 3D
4-T 1D
4 -S 3
4 -S2
4 - S1
4 -S 3
4 -S2
4-T 1
4-T 2
4-T 3
MC -B
MC -B
MC -B
MC -B
MC -B
MC -B
MC -B
MC -B
MC -B
MC -B
MC -B
MC -B
COMPONENT DESCRIPTION
R-13 Reservoir & Charging Valve 1 1 1 1 1 1 1 1 1 1 1 1
MCVF-04 Charging Valve Fittings - - - - - - 1 1 1 1 1 1
MCVF-05 Charging Valve Fittings 1 1 1 1 1 1 - - - - - -
CL-B4 or Control-Left (Ball Handle) or 1 1 2 2 3 3 2 2 4 4 6 6
CL-T4 Control-Left ("T" Handle)
CR-B4 or Control-Right (Ball Handle) or 1 1 2 2 3 3 2 2 4 4 6 6
CR-T4 Control-Right ("T" Handle)
CDF-04 Dual Mounting Plate - 1 - 2 - 3 - 2 - 4 - 6
CF-04 Control Fittings 2 2 4 4 6 6 4 4 8 8 12 12
SS-04 Shift Slave 1 1 1 1 1 1 2 2 2 2 2 2
SSF-04 Slave Fittings 1 1 1 1 1 1 2 2 2 2 2 2
ST-06 Throttle Slave & Double 1 1 1 1 1 1 2 2 2 2 2 2
Pilot Check Valve
STF-12 Slave Fittings 1 1 1 1 1 1 2 2 2 2 2 2
ADDITIONAL REQUIREMENTS - NOT INCLUDED IN SYSTEMS
MCEF-04 Extra Fittings Package 1 1 1 1 1 1 1 1 1 1 1 1
MCT-02 100' Nylon Tube 2* 2* 2* 2* 3* 3* 3* 3* 4* 4* - -
MCT-05 500' Nylon Tube - - - - - - - - - - 1* 1*
HA5455 Hydraulic Fluid* 2* 2* 2* 2* 3* 3* 2* 2* 3* 3* 4* 4*
*As Required

HYNAUTIC CONTROLS
PARTS LIST
Copper Tubing
SINGLE ENGINE TWIN ENGINE
ndle)
ndle)
)
le)
)
dle)
a n dl e
a n dl e
)
)
H an d
ndle)
ndle)
le)
a n dl e
a n dl e
" H an
l
T " Ha
T " Ha
d
d
(" T " H
(" T " H
n
n
a
T " Ha
T " Ha
T " Ha
"
(" T " H
(" T " H
T
D (" T
2D ( "
3D ( "
"
"
T 2D (
2 (" T
D
5-T 3D
S1 ( "
T 3 ("
"
1
1
(
-T 5-S
S
-T 5-S
5-S 3
5 - S1
T
5-T 2
-
-T 5-S
C-T 5-
C-T 5-
5
C-T 5-
C-T 5-
MC-T
MC-T
MC-T
MC-T
MC-T
C
or M C
M
C
M
M
) or M
M
M
r
le) or
le) or
le) or
le) or
o
le) or
le) or
le) or
le) or
le) or
ndle)
ndle)
e
H an d
H an d
H an d
H an d
l
H an d
H an d
H an d
H an d
H an d
H an d
ll Ha
ll Ha
l
(Ball
(Ball
(Ball
l
D (B a
a
(Ball
D (B a
(Ball
(Ball
(Ball
(Ball
(Ball
( B
5-S1D
5-T 2D
5-T 1D
5-T 3D
5-S 3
5-S2
5 - S1
5-S 3
5-S2
5-T 3
5-T 1
5-T 2
MC -B
MC -B
MC -B
MC -B
MC -B
MC -B
MC -B
MC -B
MC -B
MC -B
MC -B
MC -B
COMPONENT DESCRIPTION
R-13 Reservoir & Charging Valve 1 1 1 1 1 1 1 1 1 1 1 1
MCVF-10 Charging Valve Fittings - - - - - - 1 1 1 1 1 1
MCVF-11 Charging Valve Fittings 1 1 1 1 1 1 - - - - - -
CL-B4 or Control-Left (Ball Handle) or 1 1 2 2 3 3 2 2 4 4 6 6
CL-T4 Control-Left ("T" Handle)
CR-B4 or Control-Right (Ball Handle) or 1 1 2 2 3 3 2 2 4 4 6 6
CR-T4 Control-Right ("T" Handle)
CDF-04 Dual Mounting Plate - 1 - 2 - 3 - 2 - 4 - 6
CF-05 Control Fittings 2 2 4 4 6 6 4 4 8 8 12 12
SS-04 Shift Slave 1 1 1 1 1 1 2 2 2 2 2 2
SSF-06 Slave Fittings 1 1 1 1 1 1 2 2 2 2 2 2
ST-06 Throttle Slave & Double 1 1 1 1 1 1 2 2 2 2 2 2
Pilot Check Valve
STF-13 Slave Fittings 1 1 1 1 1 1 2 2 2 2 2 2
ADDITIONAL REQUIREMENTS - NOT INCLUDED IN SYSTEMS
HA5455 Hydraulic Fluid* 2 2 2 2 3 3 2 2 3 3 4 4
Copper Tubing, 5/16" O.D.*
*As Required

HYNAUTIC CONTROLS
PARTS LIST
Sender Assembly CR-B4 Control (Right, Red), CR-T4 Control (Right, Red),
CL-B4 Control (Left, Black), CL-T4 Control (Left, Black)
† OPTIONAL HANDLE 11 12
Red Knob, Kit Part # CK-01
Black Knob, Kit Part # CK-02 10
NOTE: Ball is not available as a separate part.
1
9
†
7
8
7
* *
6 14 26
5
15
† 25
* 16
*
*
4 13
3
* 17
2 *
27
28
*
23
*INCLUDED IN SEAL KIT ECS-05:
2 x Valves 160011 20
1 x O-Ring 223729
*
1 x O-Ring 345926 18
2 x O-Ring 211024 *
1 x O-Ring 211027 19
1 x O-Ring 008821 * 24
18
1 x Seal 224011
2 x Ring 252121 *
1 x Gasket 390028 21
1 x Wiper 642921 22
Figure 21.
ITEM PART # QTY DESCRIPTION ITEM PART # QTY DESCRIPTION

1 610120 Tee Handle Assembly (Red) *14 345926 1 0-Ring
610130 Tee Handle Assembly (Black) 15 560114 1 Cylinder End (CL-B4 & CL-T4)
*2 642921 Wiper 560104 1 Cylinder End (CR-B4 & CR-T4)
*3 223729 0-Ring *16 211024 1 0-Ring
*4 224011 Quad Seal 17 600080 1 Piston Assembly
5 630044 Bushing *18 252121 2 Teflon Back-up Ring
*6 211027 0-Ring *19 008821 1 0-Ring
7 190005 Bearing Race 20 500034 1 Cylinder Tube
8 190002 Bearing *21 211024 1 0-Ring
9 720130 Pinion Assembly 22 560244 1 Cylinder End
10 900644 Body (CL-B4 & CL-T4) *23 520014 1 Plate
900634 Body (CR-B4 & CR-T4) 24 240727 2 Bolt
11 240317 Screw 25 045320 2 Screw
*12 390028 Gasket 26 260157 2 Washer
13 500610 Cylinder Assembly (CL-B4 & CL-T4) *27 160011 2 Dill Valve
500600 Cylinder Assembly (CR-B4 & CR-T4) 28 740018 1 Washer

HYNAUTIC CONTROLS
PARTS LIST
Ball & Tee Handle

Installation
CAUTION When Installing Ball Handle DO NOT torque screw to more than
10 ft-lbs.
CAUTION When installing Tee Handle DO NOT torque screw to more than
14 ft-lbs.
NOTICE Standard hand-tightening with 1/4” short arm hex key wrench will
not over-torque screw.
BALL HANDLE
TEE HANDLE
TORQUE TO
90–110 IN-LBS
(10–12.5 Nm)
TORQUE TO
90–110 IN-LBS
(10–12.5 Nm)
Figure 22.

HYNAUTIC CONTROLS
PARTS LIST
ST-06 Throttle Slave

Assembly

2 x Dill Valve 160061 12
2 x O-Ring 002222
1 x O-Ring 223729
1 x O-Ring 345926
1 x O-Ring 211027
†
2 x O-Ring 211028 (1 extra) 11
1 x O-Ring 924022
1 x O-Ring 211125
1 x Seal 224011
2 x Ring 252125 †
1 x Wiper 642921 9
*
8
*
†
7 14
*
6 †
15 13
* 10
5
*
4
1 3 *
22
* *
16 23
21
* 17
26
†
2
22
† INCUDED IN SHIFT SLAVE REPAIR

KIT# 68352K:
1 x Lever Arm 610024 24
1 x Screw 240057 *
18
1 x Bushing 630044
2 x Bearing Race 190005 *
19 25
1 x Bearing 190002
1 x Pinon Assy 720150 *
18
20 25
Figure 23.

1 610024 1 Lever Arm
†

*14 345926 1 O-Ring
†2 240057 1 Screw 15 560034 1 Cylinder End (Eccentric)
3 540018 1 Spacer
*16 211028 1 O-Ring
*4 642921 1 Wiper 17 600070 1 Piston Assembly
*5 223729 1 O-Ring
*18 252125 2 Teflon Back-Up Ring
*6 224011 1 Quad Seal
*19 211125 1 O-Ring
†7 630044 1 Bushing 20 500131 1 Cylinder Tube
*8 211027 1 O-Ring 21 500164 1 Tube
†9 190005 2 Bearing Race
*22 002222 2 O-Ring
†10 190002 1 Bearing
*23 924022 1 O-Ring
†11 720150 1 Pinion Assembly 24 520634 1 Plate
12 901054 1 Body 25 240717 2 Bolt
13 501120 1 Cylinder Assembly
*26 160061 2 Dill Valves

HYNAUTIC CONTROLS
PARTS LIST
SS-04 Transmission Slave

Assembly
† INCUDED IN SHIFT SLAVE REPAIR

KIT# 68352K: 19
1 x Lever Arm 610024
1 x Screw 790323
1 x Cam Detent 730014
1 x Set Screw 240357 †
18
1 x Spring 430296
1 x Washer 740018
1 x End Gland 630044 9 16
2 x Bearing Race 190005 8 †
17
1 x Bearing 190002 7
†
16
1 x Pinon Assy 720150 * 15
†
* 21
14
6 22
†
1 †
20
†
3 5
* 13 * 23
† * 12
2 *11
29
†
10 24
*
† 31
4

2 x Dill Valve 160061 27
(Red)
2 x O-Ring 002222 (Not Used) * 25
1 x O-Ring 223729
1 x O-Ring 345926 *
26 30
1 x O-Ring 211027
2 x O-Ring 211028 *
25
1 x O-Ring 924022 (Not Used)
1 x O-Ring 211125 * 23
1 x Seal 224011
2 x B/U Ring 252125 28
1 x Wiper 642921
Figure 24.

†1 610024 1 Lever Arm †17 190002 1 Bearing
†
2 790323 1 Screw †18 720150 1 Pinion Assembly
†3 730014 1 Cam Detent 19 900254 1 Body
†4 240357 1 Set Screw 20 500120 1 Slave Cylinder Assembly
†5 430296 1 Spring *21 345926 1 O-Ring
6 240337 2 Screw 22 560034 1 Cylinder End
7 703720 2 Washer *23 211028 2 O-Ring
8 730020 2 Detent Assembly 24 600070 1 Slave Piston Assembly
9 630051 2 Bushing *25 252125 2 B/U Ring
†10 740018 1 Washer *26 211125 1 O-Ring
*11 642921 1 Wiper 27 500131 1 Cylinder Tube
*12 223729 1 O-Ring 28 560064 1 Cylinder End
*13 224011 1 Quad Seal 29 520014 1 Plate
†14 630044 1 End Gland 30 240717 2 Bolt, HHCS, 3/8”NC x 3-1/4” SS
*15 211027 1 O-Ring *31 160061 2 Dill Valves (Red)
†16 190005 2 Bearing Race

OPTIONAL NEUTRAL SAFETY
SWITCH KIT SSH-01
Installation 1 Before wiring the Switch, determine the best routing for the wires
as they lead away from the switch.
2 Break out an appropriate knock-out in the Switch Cover and feed
the wires through before placing cover on Switch. When positioning
the wiring be sure that it will not interfere with the mechanical
function of the switch or slave.
2 Using the “common” and “normally closed” Switch Terminal Screws,
wire the switch into the circuit between the Starter Solenoid and
the Starter Key Switch in accordance with the engine manufacturers
recommendations.
3 Using #6-32 screws (p/n 240857), #6 flat washers (p/n 260147),
#6 lock washers (p/n 260107), and #6-32 hex nuts (p/n 270177),
mount Switch to Plate as shown in drawing. (Do not tighten screws
at this time.)
4 Using #8-32 round head screws (p/n 240201) and #8 lock washers
(p/n 260052), mount the Plate to the slave body as shown in
drawing. (Do not tighten screws at this time.)
5 Shift the transmission to “Forward” or “Reverse” so that the Cam
Follower Wheels are out of the Detents and the Arms are in the “UP”
position as shown in the drawing.
6 Make adjustments to the Switch and Plate so that the Switch
makes contact when the slave arm is in the “UP” position.
7 After making necessary adjustments, tighten all four mounting screws.
Be sure the slave arm does not cause too much overtravel on the
Switch causing possible damage to the switch arm.
SWITCH PLATE (520524)
SWITCH COVER (870220)

SCREW
(240857)
FLAT WASHER (260147)
HEX NUT (270177)
LOCK WASHER (260107)
MICRO SWITCH (870240)
SCREW
(240201) ARM (SHOWN IN “UP”
POSITION
LOCK WASHER (260052)
DETENT CAM FOLLOWER WHEEL
Figure 25.

HYNAUTIC CONTROLS
SWITCH KIT SSH-1
GEAR
RACK
DILL
VALVE DILL
VALVE PILOT
CHECK
VALVE
Figure 26. Clutch Slave. Figure 27. Throttle Slave.
PRESSURE DILL VALVE

GAUGE (160031)
FILL PLUG ASSY O-RING
(160052) (360020) (211910)
PLUG
GROMMET (380574)
4 REQ’D LABEL
(180079) FILTER ELEMENT
(140029)
(160113)
SIGHT TUBE POPPET ASSY*
NUT 4 REQ’D
(150088) (530015) (450040)
BODY
LOCK RING (901044)
O-RING* 4 REQ’D
(530025) (211016)
SPACER
4 REQ’D O-RING
(540184) SPRING* 4 REQ’D
(211910) (430546)
INSERT PLUG* 4 REQ’D

CHARGING VALVE
(530045) (380514)
(900430)
*INCLUDED IN SEAL KIT RS-01: *INCLUDED IN FITTING KIT MCVF-08:

2 x O-Ring 002222 2 x O-Ring 211910 4 x O-Ring 014624 4 x Poppet Assy 450040
1 x O-Ring 015824 2 x Seal 224014 4 x Plug 380514 1 x Reservoir Plug 380030
1 x O-Ring 220523 1 x Inst. Sheet 181033 4 x Spring 430546 1 x Inst. Sheet 180054
2 x O-Ring 211206
Figure 28. R-13 Integrated Reservoir. Figure 29. Charging Valve on R-13 Integrated Reservoir.

HYNAUTIC CONTROLS
SWITCH KIT SSH-1
SPRING (4) MCV-04 CHARGING VALVE

430546*
PLUG (4)
380514*
O-RING (4)
014624*
POPPET
ASSEMBLY(4)
450040*
BODY 900664
*INCLUDED IN FITTING KIT MCVF-08: FILL PLUG

4 x O-Ring 014624
4 x Plug 380514 PRESSURE
4 x Spring 430546 GAUGE AIR FILLER
4 x Poppet Assy 450040 VALVE
1 x Reservoir Plug 380030
1 x Inst. Sheet 180054
LIQUID LEVEL
MOUNTING SIGHT TUBE
PADS
DRAIN PLUG
FILTER PLUG
MCV-04
CHANGING VALVE
Figure 30. R-04 Reservoir with MCV-04 Charging Valve.

TEMPLATES
LINE INDICATES OUTER EDGE OFCONTROL SENDER
DRILL 7/16" DIA. HOLES DRILL 7/16" DIA. HOLES

2 PLACES 4 PLACES
REMOVE THIS AREA REMOVE THIS AREA

FROM THE PANEL FROM THE PANEL
SINGLE HEAD SIDE-BY-SIDE MOUNTING

This page intentionally blank to allow
removal/use of template.

CDF-04 MOUNTING PLATE
This plate simplifies mounting of 1-CL and 1-CR control as a dual unit.
1 Select mounting location, checking for adequate handle clearance
throughout full arc. Also check for access to the allen screw bleeders
in the control heads and clearance below the mounting surface.
2 When location is determined, use the plate as a templete and mark
position of the 4 mounting bolt holes and outline of material to
be removed.
3 Remove plate from dash. Drill 4-7/16" diameter holes. Remove
material from shaded area as shown.
4 Proceed with sender mounting per installation manual.
1/8" THICK PLATE

This page intentionally blank to allow
removal/use of template.

TUBING CIRCUITS
Plan I – Twin Engine, Throttle plumbing shown in diagram advances throttle in a clockwise
One Station direction. For a counter-clockwise throttle advance see supplemental
diagram Plan I-S and replumb throttle citcuits accordingly.
FORWARD
Figure 31.

HYNAUTIC CONTROLS
TUBING CIRCUITS
Plan II – Twin Engine, Throttle plumbing shown in diagram advances throttle in a clockwise
Two Station direction. For a counter-clockwise throttle advance see supplemental
diagram Plan II-S, and replumb throttle citcuits accordingly.
FORWARD
Figure 32.

HYNAUTIC CONTROLS
TUBING CIRCUITS
Plan III – Twin Engine, Throttle plumbing shown in diagram advances throttle in a clockwise
Three Station direction. For a counter-clockwise throttle advance see supplemental
diagram Plan II-S, and replumb throttle citcuits accordingly.
FORWARD
Figure 33.

HYNAUTIC CONTROLS
TUBING CIRCUITS
Plan IV – Twin Engine, Throttle plumbing shown in diagram advances throttle in a clockwise
Four Station direction. For a counter-clockwise throttle advance see supplemental
diagram Plan IV-S, and replumb throttle citcuits accordingly.
FORWARD
Figure 34.

SUPPLEMENTAL THROTTLE
CONTROL CIRCUITS
Plan I-S Plan II-S
Single Station Counterclockwise Throttle Advance. Two Station Counterclockwise Throttle Advance.
FORWARD FORWARD
Figure 35. Figure 36.

HYNAUTIC CONTROLS
SUPPLEMENTAL THROTTLE
Plan III-S Plan IV-S

Three Station, Counterclockwise Throttle Advance. Four Station, Counterclockwise Throttle Advance.
FORWARD FORWARD
Figure 37. Figure 38.

TROUBLESHOOTING GUIDE
WARNING Whenever in the following text, a solution calls for removal from
vessel and/or dismantling of steering Hydraulic Shift and Throttle,
such work must only be carried out by a qualified marine hydraulic
mechanic. SeaStar Solutions offers the following as a guide only
and is not responsible for any consequences resulting from
incorrect dismantling repairs.
FAULT CAUSE SOLUTION

1 Spongy Controls (Entire • Air in System • Check reservoir and verify
System) that there is fluid and
pressure is 80 psi.
• Inspect for fluid leaks at all
connections.
• Check for air leaks in the
reservoir (use soapy water
solution)
• Bleed entire system.
• Synchronize controls on one
clutch or throttle system.
2 Spongy Controls on one • Air in that singular system. • Check reservoir, verify that
clutch or throttle system. there is fluid and throttle
system. pressure is 80 psi.
• Inspect for fluid leaks at all
connections of the system in
question.
• Bleed system in question.
• Synchronize controls.
3 Sender arm wants to stop at • Controls out of synchronization. • Synchronize controls.

its mid-stroke.
4 FuII throttle on the sender • Throttle linkage length out of • Re-adjust length of the
will not achieve maximum adjustment. throttle linkage.
throttle RPM on Engine. • Engine out of tune. • Service Engine.
5 Full idIe on sender will not • Throttle linkage length out of • Re-adjust length of the
achieve idle RPM on engine. adjustment. throttle linkage.
• Engine governor out of • Service Engine.
adjustment.
• Engine out of tune.

HYNAUTIC CONTROLS
TROUBLESHOOTING

6 Engine Throttle tends to • Pilot check valve • Remove pressure from
creep toward idle. malfunctioning. system.
• Re-pressurize the system.
• Re-purge the system of air.
• Slave's internal piston seals • Remove pressure from system.

or synchronizing valves leaking • Rebuild or replace throttle slave.
due to wear or debris. • Re-pressurize the system.
• Re-purge the system of air.
7 Full Throttle on sender gives • System tubing connected • Remove pressure from the
idle on engine. backward. system.
• Reverse tubing at the throttle
slave.
• Pressurize system.
• Synchronize throttle control.
8 After a long running period • Slave is located at an engine Several Suggested Remedies:
the Throttle tends to go out hot spot which has caused • The use of heat resistant
of synchronization. excessive heating of the gasket material (approximately
throttle slave, which in turn 1/8’ Thick) between the
has caused the slave to mounting bracket and engine.
develop a vapor lock. • Spaces between the bracket
and engine, and slave and
bracket.
• Shielding around the throttle
slave.
• Re-mounting of the throttle
slave in a less hot area.
• Contamination in pilot check • Remove pressure from

valve keeping it from system.
functioning properly. • Re-pressurize the system.
• Re-purge system of air.
• If twin engines are equipped • Re-adjust springs proper

with synchronizer, governor or tension.
synchr onizer's tension springs
are out of adjustment. NOTE: excessive tension in either
throttle extremes will cause
synchronization problems.
9 Loss of system pressure but • Air leak in reservoir. • While pressure is on system,
not loss of fluid. use a soapy water solution to
find an air leak on the tank.
NOTE: System pressure will vary as much as +10 psi due to When leak is found remove
temperature changes. When system pressure drops below 70 psi pressure and repair,
a leak should be checked for. re-pressurize system to 80 psi.

HYNAUTIC CONTROLS
TROUBLESHOOTING

10 Loss of pressure and fluid • System leak. • With pressure on system
on system. check for fluid leaks at all
connections.
• When found repair leak. If a
tubing connection is leaking
remove and replace 0-ring (if
leak persists see section of
trouble shooting which
concerns leaks at fittings for
further repair procedures).
• Pressurize system, bleed
system, filling as required.
11 Sender arm moved at one • Improper reversed tubing • Recheck tubing connections
station resuIts in the wrong connections. made against tubing diagram
arm movement at the other used.
station(s). • Remove pressure from the
system.
• Reconnect tubing as required.
• Re-pressurize and bleed
system.
12 Sender arm moved at one • Tubing runs improperly • Compare tubing connections
station resuits in another connected. Prime area for made with tubing diagram used
arm moving at the same improper connection would (check area of charging valve).
station. be at the charging valve. • Remove pressure from
system.
• Reconnect tubing as required.
• Pressurize system, bleed
system.
13 Crimp or kink in tubing. • Numerous. • Cut out kinked or crimped

portion of line.
• Splice line together using
tube connectors and union.
14 Leak at a fitting. • Bad 0-Ring. • Remove fitting, replace 0-ring,

replace fitting, pressurize
system, and check for leakage.
If Leakage continues replace
entire tubing connector and
adapter as required.

TECHNICAL INFORMATION
Bolt Torque Specifications 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)
SeaStar Solutions Technical Phone: 604-248-3858

Support Contacts: e-mail: [email protected]
Hours: Monday to Friday 05:00 – 15:30 PST
Web: www.seastarsolutions.com

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–Supply Chain Solutions Inc. 3831 No.6 Road
Door A37 Richmond, B.C.
1201 C Street NW, Auburn, WA, Canada V6V 1P6
98001

SEASTAR SOLUTIONS
3831 No. 6 Road
Richmond, B.C.
Canada V6V 1P6
FAX 604-270-7172
www.seastarsolutions.com
ISO 10592
© 2009 Marine Canada Acquisition INC.

DBA SEASTAR SOLUTIONS
PRINTED IN CANADA
form no. 182042 12/13 REV. C

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INSTALLATION INSTRUCTIONS

AND OWNER'S MANUAL

WARNING Cleaning fluids containing ammonia, acids or any other corrosive

Don’t compromise performance... use genuine

This manual should be kept on board your vessel

Installation Instructions & Owner's Manual i

ii Hynautic Hydraulic Engine Controls – 04 Series

Installation Instructions & Owner's Manual 1

Figure 1. Mounting "T" Handle Controls Side by Side.

Figure 2. Single Head Sender. Figure 3. Side-By-Side Senders.

2 Hynautic Hydraulic Engine Controls – 04 Series

90˚ 1/4-20 90˚

Figure 4. Throttle Slave to Throttle Arm Installation.

Steps 1 through 8 apply to both ST-04 and ST-06 Systems

Installation Instructions & Owner's Manual 3

4 Position the throttle slave to its mid-stroke and connect the

ST-06 System ONLY

4 Hynautic Hydraulic Engine Controls – 04 Series

TO CONTROL STATIONS NYLON TUBING

1/4" PIPE TEE 1/4" PIPE NIPPLE

CONTROL ARM MAY BE ROTATED

12 Verify all fittings installed have been tightened. Repeat these

ADAPTER 1/4" PIPE NUT (530015)

5/16" O.D. N-2 NIPPLE 1/4" TO CONTROL

Figure 6. ST-04 Throttle Slave with STV-10 Lock-Out Valve.

Installation Instructions & Owner's Manual 5

90˚ 1/4-20 90˚

Figure 7. Proper Clutch Slave to Throttle Arm Installation.

6 Hynautic Hydraulic Engine Controls – 04 Series

CONTROL ARM LOCK-SCREW

Figure 8. Detent Ring Location.

CONTROL ARM MAY NYLON TUBING

Installation Instructions & Owner's Manual 7

Figure 10. Charging Valve on R-13 Reservoir.

8 Hynautic Hydraulic Engine Controls – 04 Series

Figure 11. Ports on Bottom of R-04 Reservoir.

Figure 12. MCV-04 Charging Valve.

Installation Instructions & Owner's Manual 9

Assemble tubing connectors on every tube end as described below

10 Hynautic Hydraulic Engine Controls – 04 Series

Figure 13. Assembling Tubing Connectors.

Install Tubing Between 1 Locate the tubing roll in a convenient location.

Installation Instructions & Owner's Manual 11

TUBE NUT (690621)

Figure 14. Charging Valve on Bottom of R-13 Integrated Reservoir.

12 Hynautic Hydraulic Engine Controls – 04 Series

COPPER TUBING 5/16" O.D.

5/16", 45˚ FLARE

5/16" FLEXIBLE HOSE WITH

ADAPTER 1/4" PIPE 5/16"

BLEEDER ASSEMBLY (690010) BLEEDER ASSEMBLY

1/4" PIPE TEE (690551) NIPPLE 1/4" PIPE (690551)

CONTROL ARM MAY

BE ROTATED TO ANY SHAFT’S RANGE

POSITION ON SHAFT OF ROTATION

Figure 15. ST-06 Integrated Throttle Slave.

ADAPTER 1/4" PIPE

78˚ 5/16" O.D. NIPPLE 1/4"

(950119) 5/16", 45˚ FLARE

INCLUDED IN SEAL KIT RS-01: INCLUDED IN FITTING KIT MCVF-08: