Hydraulic Steering: Easy Installation Guide For Your Boat

Hydraulic steering systems are a reliable and widespread feature on boats, except for those that use a tiller, cable, or other forms of mechanical steering. They are made up of three components: a pump with an integral reservoir for hydraulic oil, a ram that connects to a rudder or outboard engine, and connecting lines that transmit inputs from the steering pump to the steering ram. The main elements of the hydraulic steering system are a steering wheel with a pump, two hydraulic hoses, and the engine-mounted steering bracket and cylinder.

Upgrading to hydraulic steering from cable steering is a simple DIY project. The BayStar kit from SeaStar Solutions for outboards up to 150 hp is one of the least expensive ways to upgrade. It includes a helm pump, a front-mount cylinder, and two sets of hydraulic tubing that you cut to length.

1. Remove the cable system by disconnecting the steering cable at both the engine and helm, and then removing the cable from the boat.

2. Pull the hydraulic tubes using pull-cords to feed the hoses along the rigging path from the stern to the helm.

3. Install the cylinder by following the manufacturer's instructions.

4. Create the holes for the helm by using a supplied template to drill new holes for the mounting bolts and to enlarge the central hole.

5. Connect the tubing to the helm by removing the helm and pulling the tubing out through the central hole, then cutting the tubing to length and sliding a tube nut over each end.

6. Fill and bleed the system by removing the cap on top of the helm pump and using the supplied hydraulic fluid and filler kit to fill the system, then bleeding the system of air with the help of a friend.

The benefits of hydraulic steering

Hydraulic steering systems are a popular choice for boats, offering a range of benefits that enhance the boating experience. Here are some advantages of hydraulic steering systems:

Feather-Light Steering Experience

Hydraulic steering systems provide a smooth and effortless steering experience. The hydraulic system allows for precise control, making it easier to manoeuvre your boat in tight spaces or choppy waters. This level of control is particularly advantageous for larger boats that require more force to turn. With hydraulic steering, you can steer your boat with just your fingertips, thanks to its ability to deal with all torque conditions.

Increased Maneuverability

Hydraulic steering offers superior manoeuvrability, allowing you to easily adjust the position of your boat. This makes docking and navigating in narrow channels more efficient. The quick response time and smooth handling of hydraulic steering make it a perfect choice for all types of boats, including outboards, inboards, and stern drives, whether for recreational or commercial use.

Reduced Operator Fatigue

Steering a boat can be physically demanding, especially in rough seas or strong currents. Hydraulic steering systems significantly reduce the physical effort required, helping you maintain control without experiencing fatigue. This is crucial for long trips or when navigating challenging waters, ensuring you can stay focused and in control during extended periods of steering.

Durability and Reliability

Hydraulic steering systems are known for their durability and reliability. They are less prone to wear and tear compared to other steering systems, reducing the need for maintenance and repairs. This means you can spend more time on the water with peace of mind, knowing your steering system will perform consistently.

Customisation and Versatility

Hydraulic steering systems are highly versatile and can be customised to suit your specific needs. They can be adapted to different boat sizes and types, as well as different steering configurations. Whether you own a small fishing boat or a large commercial vessel, hydraulic steering can be tailored to meet your unique requirements.

Simple Installation and Maintenance

Upgrading to hydraulic steering is a straightforward process that can even be done as a DIY project. The installation process is relatively simple, and regular maintenance helps ensure the system remains in optimal condition. While some maintenance tasks should be left to professionals, many boat owners find that basic hydraulic steering care is manageable, keeping their boats running smoothly.

Installation instructions

Before installing hydraulic steering on your boat, it is important to select a system that is appropriately sized for your boat. Consider the horsepower involved, whether you have a single or multiple-engine installation, your expected speeds, and the size of your boat. Ensure that the system you choose meets the load requirements for your boat.

When installing the steering wheel, make sure that the mounting location does not interfere with other moving equipment, such as throttle and shift levers. There should be a minimum of 2.5 inches of clearance between the outer diameter of the steering wheel and these other control levers. Use a mounting template to facilitate accurate drilling and positioning.

Before drilling, confirm that any previously installed equipment will not be damaged by the new holes in your console. The manufacturers of these systems will typically supply all the nuts, bolts, and other associated hardware required for installation. Do not substitute this hardware with anything else, as it has been specifically engineered to handle the expected loads.

When installing the helm pump, ensure that the hydraulic fill port is located at the top to facilitate any air bleeding upon filling the system. Follow the manufacturer's instructions for torque values when tightening nuts and bolts, and be careful not to overtighten.

Next, route and connect the hydraulic hoses to the back of the pump, using only the vendor-supplied fittings. Understand that the hydraulic chambers must be kept clean at all times, as any contamination or blockage of the small holes inside the pistons and pumps can wreak havoc on steering control.

Carefully measure the length of the hydraulic hoses, ensuring that they do not come into contact with sharp edges that could damage the hose jacketing and allowing for a minimum of radius bends.

Follow the manufacturer's recommendations when choosing the correct cylinder and associated hardware for your specific engine(s). Again, follow the torque values provided to ensure trouble-free service.

Fill your system with the factory-recommended hydraulic oil and bleed any air out of the system. This process may require a helper, so enlist assistance if needed. Refer to the shop manual for detailed instructions on filling and bleeding the system.

Once the system is filled and bled, perform a system air test by placing the engine in the center position and manually pushing it from side to side. Observe the steering cylinder body; if it moves more than 1/8”, this indicates that there is still air in the system, and further bleeding is required.

Maintenance

Regular maintenance of your hydraulic steering system is crucial to ensure its proper operation and your safety. Here are some key maintenance tasks to perform:

• Regularly check the hydraulic fluid level and top it up as needed.
• Inspect your hoses and connection points for any signs of fluid leaks.
• Check for binding, loose, or worn components in the system.
• After 100 hours or every six months, confirm the tightness of all nuts and bolts based on the installation instructions.
• Look for any excess play in the system, which should not exceed 1/8".
• Inspect for any signs of corrosion, which may require professional intervention.
• After 200 hours or every 12 months, remove the steering support rod from the engine and thoroughly clean and regrease the engine steering/tilt tube.
• Grease all the points in the system with a good-quality marine grease.
• Remove the steering wheel and lightly grease the tapered mounting surface.
• Inspect the hydraulic oil for cleanliness and flush the system, replacing the fluid if necessary.

Bleeding the system

Bleeding the hydraulic steering system is critical for a boat to handle as expected. It is important to note that air doesn't mysteriously appear in a boat's properly functioning hydraulic steering system. If there is air in the system, it is likely that there is a leak at a connection point. Therefore, before bleeding the system, check every connection point and seal, and fix any leaks.

To bleed the system, you will need two people: one at the helm and another at the steering cylinder. First, prepare some oil-absorbent pads in case any hydraulic fluid spills. Then, open the reservoir at the helm and top it off. Connect the filler tube and oil bottle, and invert the oil bottle so that the filler tube fills with hydraulic steering fluid. Puncture the bottom of the inverted bottle to allow the fluid to run into the system. The person at the helm should keep turning the wheel to force the fluid through the system.

Next, turn the wheel all the way to starboard. The person at the cylinder should then open the starboard-side bleeder valve and prepare a container to catch the fluid that comes out. They should hold the cylinder in place while the person at the helm turns the wheel to port, until air bubbles stop coming out of the bleeder valve. Once no more air is coming through, the valve can be closed. Repeat this process with the portside bleeder valve.

To check if the system is fully purged, try turning the wheel smoothly from lock to lock. There should be no bumps or hesitations.

Routine maintenance

Hydraulic steering systems are easy to maintain, but they do require regular checks to ensure they remain in good working order. Here is a detailed routine maintenance checklist for your hydraulic steering system:

Inspect Hoses and Connections

Check the hydraulic hose connections at the helm pump and the steering cylinder for any signs of leaks, kinks, or wear and tear. Ensure that the hydraulic fluid in the helm pump is at the correct level. If the fluid is at the correct level and the hoses show no signs of leaks or damage, no further action is required.

Conduct a Steering Test

Feel how the boat is handling by turning the steering wheel. Is the steering precise, or does it feel soft and slow? Check for any play between turning the wheel and the outboard’s response. Soft steering and play in the wheel indicate air in the hydraulic system. To remedy this, open the bleed valves in the steering cylinder one at a time, turning the wheel to pump out the old hydraulic fluid and any trapped air. Refill the helm with new hydraulic fluid during this process.

Tighten the Tiller Bolt

Check the tiller bolt, which keeps the outboard under control, by putting a wrench on the nyloc nut holding it. If the bolt is loose, it is better to replace the nyloc nut with a new one, as they are not designed to be reused.

Check for Leaks

If a hydraulic hose is leaking, tighten the connection and check again. If the leak persists, replace the hose, along with any hoses that are kinked or worn. If the steering cylinder seals are leaking, remove the steering cylinder rod, replace the seals, and then reinstall the rod and bleed the system.

Grease and Clean

Every six months or 100 miles, check that all fittings and fasteners are tight. Every 12 months or 200 miles, remove the steering support rod from the tilt tube, clean and regrease the rod and tube, and grease the tiller bolt and the support bracket.

Annual Inspection

It is recommended to conduct a thorough inspection of your hydraulic steering system annually or every 200 hours of operation. This includes checking the hydraulic seals on the ram, the hydraulic oil, the helm for fluid, the number of turns lock-to-lock, the hoses and connections, and the hoses for wear or cracking.

Flushing the system

Flushing the hydraulic steering system is a crucial aspect of boat maintenance. Here are some detailed steps to effectively flush the system:

Step 1: Check the Hydraulic Fluid

It is important to regularly inspect the hydraulic fluid in your boat's steering system. Look for any signs of contamination, such as dirt or debris. Additionally, check the colour of the fluid; it should be clear and light-coloured. If it appears dark or black, it's time to flush the system and replace the fluid.

Step 2: Prepare for Flushing

Gather the necessary tools and materials, including a jack, jack stands, a disposable pan, gloves, eye protection, and new hydraulic fluid. Ensure you have a clear workspace and that your boat is securely supported.

Step 3: Drain the Old Fluid

Locate the low-pressure hose connected to the steering pump. Place the disposable pan underneath the hose to catch the old fluid. Carefully disconnect the hose at its lowest point, allowing the fluid to drain into the pan. Be prepared for the fluid to flow out immediately, and take the necessary safety precautions.

Step 4: Refill with New Fluid

Once the old fluid has been drained, it's time to refill the system with new hydraulic fluid. Start by pouring in approximately half of the manufacturer's recommended amount. You will need to turn on the boat's engine and keep adding fluid to maintain the reservoir at the halfway mark while the old fluid continues to drain.

Step 5: Bleed the System

After refilling the system, turn the boat's engine on again and manipulate the steering wheel from lock to lock several times. This will help remove any air bubbles from the system and ensure the new fluid is properly circulated. Turn the engine off once you've completed several cycles.

Step 6: Final Checks and Top-Up

Check the fluid level in the reservoir after the bleeding process. It's likely that the fluid level will have dropped, so top up the reservoir with new hydraulic fluid until it reaches the recommended level. Finally, start the engine and test the steering wheel to ensure it operates smoothly and responds appropriately.

Remember to always refer to your boat's user manual for specific instructions and safety guidelines when performing any maintenance tasks, including flushing the hydraulic steering system.

Frequently asked questions