Signs Your Hydraulic Valve Has Failed
Hydraulic valves are essential components of any hydraulic system, as they control the flow and pressure of the fluid. However, like any other mechanical device, they can fail due to various reasons, such as wear and tear, contamination, temperature changes, or improper installation. When a hydraulic valve fails, it can cause serious problems for the system, such as loss of efficiency, leakage, noise, overheating, or even damage to other components. Therefore, it is important to be able to recognize the signs of a hydraulic valve failure and take the necessary steps to troubleshoot and fix the problem.
In this article, we will discuss some of the common signs of a hydraulic valve failure, their possible causes, and their potential solutions. We will also provide a table that summarizes the information for your convenience.
Sign 1: Abnormal or Excessive Noise
One of the most noticeable signs of a hydraulic valve failure is abnormal or excessive noise from the system. This noise can be caused by several factors, such as:
- Cavitation: This occurs when the fluid pressure drops below the vapor pressure, causing bubbles to form and collapse in the fluid. This can create a loud knocking or hammering sound, as well as damage the valve and other components. Cavitation can be caused by low fluid level, high fluid viscosity, high pump speed, or restricted inlet flow.
- Aeration: This occurs when air enters the fluid, causing it to become foamy and compressible. This can create a whining or hissing sound, as well as reduce the system performance and efficiency. Aeration can be caused by loose or leaky connections, low fluid level, or faulty pump shaft seal.
- Misalignment or Loose Coupling: This occurs when the valve is not properly aligned or connected to the pump or the actuator, causing vibration and noise. This can also affect the system performance and cause premature wear and tear. Misalignment or loose coupling can be caused by improper installation, maintenance, or adjustment.
The possible solutions for these noise problems are:
- Cavitation: Replace dirty strainers, clean clogged inlet lines, fill the reservoir to the proper level, use the recommended fluid viscosity, and adjust the pump speed and the relief valve setting.
- Aeration: Tighten or replace the leaky connections, fill the reservoir to the proper level, bleed the air from the system, and replace the pump shaft seal.
- Misalignment or Loose Coupling: Realign or tighten the coupling, check the condition of the seals and bearings, and replace them if necessary.
Sign 2: Excessive Heat
Another common sign of a hydraulic valve failure is excessive heat from the system. This heat can be caused by several factors, such as:
- Fluid Thinning: This occurs when the fluid temperature rises above the optimal range, causing the fluid to lose its viscosity and lubrication properties. This can increase the internal leakage, friction, and wear in the system, as well as reduce the system efficiency and performance. Fluid thinning can be caused by high ambient temperature, inadequate cooling, or overloading the system.
- Relief Valve Malfunction: This occurs when the relief valve is set too low or too high, causing the fluid to bypass the valve and generate heat. This can also affect the system pressure and performance, as well as damage the valve and other components. Relief valve malfunction can be caused by improper setting, adjustment, or calibration.
- Flow Losses: This occurs when the fluid flow is restricted or obstructed between the pressure and the return sides of the system, causing the fluid to lose energy and generate heat. This can also affect the system performance and efficiency, as well as damage the valve and other components. Flow losses can be caused by defective valves, clogged filters, or bent or kinked hoses.
The possible solutions for these heat problems are:
- Fluid Thinning: Use the recommended fluid viscosity, check and replace the fluid regularly, install or improve the cooling system, and avoid overloading the system.
- Relief Valve Malfunction: Use a pressure gauge to adjust the relief valve to the correct setting, check and calibrate the valve regularly, and repair or replace the valve if necessary.
- Flow Losses: Check and replace the defective valves, clean or replace the clogged filters, and straighten or replace the bent or kinked hoses.
Sign 3: Incorrect Flow
Another common sign of a hydraulic valve failure is incorrect flow from the system. This flow can be either too low or too high, depending on the type of valve and the problem. This can be caused by several factors, such as:
- Pump Failure: This occurs when the pump is not delivering the required flow to the system, causing the system to operate slowly or erratically. This can also affect the system pressure and performance, as well as damage the pump and other components. Pump failure can be caused by low fluid level, dirty or contaminated fluid, worn or damaged pump parts, or incorrect pump speed or rotation .
- Valve Failure: This occurs when the valve is not controlling the flow properly, causing the system to operate too fast or too slow, or not at all. This can also affect the system pressure and performance, as well as damage the valve and other components. Valve failure can be caused by improper valve selection, installation, or adjustment, worn or damaged valve parts, or contamination or blockage in the valve .
- Actuator Failure: This occurs when the actuator is not receiving or responding to the flow properly, causing the system to operate too fast or too slow, or not at all. This can also affect the system pressure and performance, as well as damage the actuator and other components. Actuator failure can be caused by improper actuator selection, installation, or adjustment, worn or damaged actuator parts, or contamination or blockage in the actuator .
The possible solutions for these flow problems are:
- Pump Failure: Fill the reservoir to the proper level, check and replace the fluid regularly, repair or replace the pump parts, and adjust the pump speed and rotation .
- Valve Failure: Choose the right valve for the system, install and adjust the valve correctly, repair or replace the valve parts, and clean or remove the contamination or blockage in the valve .
- Actuator Failure: Choose the right actuator for the system, install and adjust the actuator correctly, repair or replace the actuator parts, and clean or remove the contamination or blockage in the actuator .
How the Series 5000 Operator System Enables Higher Pressures and Increased Flow Rates for Industrial Fluid Applications
Solenoid valves are essential components for controlling the flow of fluids and gases in various industrial applications. However, not all solenoid valves are created equal. Some applications require higher pressures and increased flow rates than standard solenoid valves can handle. For these applications, a reliable, high-performance solenoid solution is needed.
That’s where the Series 5000 Operator System from Spartan Scientific comes in. The Series 5000 Operator System is a new product line that is designed to meet the demands of applications requiring higher pressures and increased flow rates. Featuring a range of orifice sizes from 0.6 to 4.0 mm, and available in both 2-way and 3-way configurations, the Series 5000 offers versatility to suit a wide range of industrial fluid applications. With options including DIN spaded or flying lead coils, and a future provision for a 12 mm connection option, the system provides flexibility and ease of integration into existing setups.
The Series 5000 Operator System is constructed with all stainless-steel tubes and multiple seal materials, making it durable and reliable in demanding environments. Its robust design ensures longevity and consistent performance, making it an ideal choice for critical applications across various industries.
But how does the Series 5000 Operator System achieve higher pressures and increased flow rates? The answer lies in its innovative design and engineering. The Series 5000 Operator System uses a unique solenoid coil that is specially designed to handle higher currents and voltages. This allows the coil to generate a stronger magnetic field that can overcome the higher forces and pressures exerted by the fluid or gas. The coil also has a low inductance, which means it can switch faster and more efficiently, resulting in lower heat generation and power consumption.
The Series 5000 Operator System also uses a specially designed plunger and tube assembly that is optimized for higher flow rates. The plunger has a larger diameter and a longer stroke than standard plungers, which allows it to open and close the valve more effectively. The tube has a larger inner diameter and a smoother surface than standard tubes, which reduces the friction and turbulence of the fluid or gas passing through. The combination of these features results in a higher flow coefficient (Cv) for the Series 5000 Operator System, which measures the flow capacity of the valve.
The table below compares the Cv values of the Series 5000 Operator System with some of the standard solenoid valves from Spartan Scientific.
| Orifice Size (mm) | Series 5000 Operator System Cv | Standard Solenoid Valve Cv |
|---|---|---|
| 0.6 | 0.04 | 0.02 |
| 1.0 | 0.12 | 0.06 |
| 1.5 | 0.25 | 0.12 |
| 2.0 | 0.45 | 0.22 |
| 2.5 | 0.75 | 0.36 |
| 3.0 | 1.10 | 0.53 |
| 4.0 | 1.90 | 0.95 |
As the table shows, the Series 5000 Operator System has significantly higher Cv values than the standard solenoid valves, indicating its superior flow capacity. For example, the Series 5000 Operator System with a 4.0 mm orifice size has a Cv value of 1.90, which is twice as high as the standard solenoid valve with the same orifice size.
The Series 5000 Operator System is not only capable of handling higher pressures and increased flow rates, but also offers other benefits such as lower noise levels, lower maintenance costs, and higher safety standards. The Series 5000 Operator System is compliant with the RoHS, REACH, and CE directives, and has a protection class of IP65, which means it is dust-tight and water-resistant.
The Series 5000 Operator System represents Spartan Scientific’s commitment to innovation and meeting the evolving needs of its customers. With its combination of high-pressure handling capabilities, increased flow rates, and versatile configurations, the Series 5000 Operator System delivers exceptional value and performance to its customers.
For more information about the Series 5000 Operator System, please visit the Spartan Scientific website or contact them at 330-758-8446 or sales@spartanscientific.com.
Lightweight Hydraulic Low-Speed, High-Torque Motors
Hydraulic motors are devices that convert hydraulic pressure and flow into rotational motion and torque. They are widely used in applications that require high power density, efficiency, and reliability, such as vehicle propulsion, winches, augers, and boom rotate.
There are different types of hydraulic motors, such as gear, vane, piston, and orbital motors. Among them, orbital motors are especially suitable for low-speed, high-torque (LSHT) applications, as they can deliver high output torque throughout their speed range, without the need for additional speed reducers.
Orbital motors are also known as gerotor or geroler motors, depending on the design of their internal gear set. A gerotor motor has a toothed inner rotor that meshes with a toothless outer stator, while a geroler motor has a roller-bearing inner rotor that rolls along a toothed outer stator. Both designs use a spool valve to distribute the hydraulic fluid to the chambers formed by the rotor and stator, creating pressure differences that cause the rotor to rotate.
One of the advantages of orbital motors is their compact and lightweight design, which makes them easy to install and operate in limited spaces. However, not all orbital motors are equally lightweight. Some factors that affect the weight of an orbital motor are:
- The size and displacement of the motor. Larger motors have higher displacement and torque, but also higher weight.
- The material and construction of the motor. Some motors use aluminum or plastic components to reduce weight, while others use steel or iron for durability and strength.
- The features and accessories of the motor. Some motors have additional features such as integrated brakes, valves, sensors, or shaft seals, which can increase the weight and complexity of the motor.
To help you compare and choose the best orbital motor for your application, we have compiled a table of some of the most popular and lightweight hydraulic LSHT motors available in the market, along with their specifications and features.
| Model | Manufacturer | Displacement | Max. Torque | Max. Pressure | Max. Speed | Weight | Features |
|---|---|---|---|---|---|---|---|
| FM4 | FluiDyne Fluid Power | 80 – 500 cc/rev | 1,575 – 6,363 lbf-in | 2,538 – 1,730 psi | 850 – 144 rpm | 6.6 – 18.7 lbs | Gerotor design, high efficiency, 18-month warranty |
| TG | Parker Hannifin | 141 – 959 cc/rev | 4,692 – 11,227 lbf-in | 1,500 – 4,000 psi | 118 – 660 rpm | 9.5 – 25.5 lbs | Geroler design, high durability, high pressure shaft seal |
| OMS | Danfoss | 80 – 475 cc/rev | 1,770 – 6,950 lbf-in | 2,610 – 1,740 psi | 800 – 195 rpm | 8.8 – 19.8 lbs | Geroler design, smooth operation, integrated valve options |
| 2000 | Eaton | 80 – 400 cc/rev | 1,770 – 5,650 lbf-in | 2,900 – 2,000 psi | 945 – 300 rpm | 9.9 – 17.6 lbs | Gerotor design, low noise, high side load capacity |
As you can see, there are many options for lightweight hydraulic LSHT motors, each with its own advantages and disadvantages. Depending on your application requirements, you may prefer a motor that has higher torque, lower speed, higher efficiency, lower noise, or other features. You should also consider the compatibility, availability, and cost of the motor before making your final decision.
How to Boost Mobile Machine Performance with Electrohydraulics
Electrohydraulics is the combination of electrical and hydraulic technologies to control fluid power systems. Electrohydraulic systems are widely used in mobile machines, such as construction, agricultural, and mining equipment, because they offer high power density, precise control, and fast response. However, electrohydraulic systems also face challenges, such as energy consumption, noise, and emissions, especially in the context of electrification and environmental regulations. Therefore, there is a need to improve the efficiency and performance of electrohydraulic systems using advanced techniques and solutions.
Components Level
One way to increase the efficiency of electrohydraulic systems is to optimize the design and performance of the components, such as pumps, valves, cylinders, and motors. For example, Bosch Rexroth has developed a new A10VO Series 60 pump that is tailored for electric drives and electronic control. The pump has a compact and lightweight housing, a pre-compression volume to reduce pulsation and noise, a higher nominal pressure and rotary speed to increase power density, and pressure and angle sensors to enable power management. The pump also offers two options for control: mechanical or electronic, allowing flexibility for the user. Compared to the previous product, the new pump has a relative efficiency improvement of 7%, which in turn increases the operation time by almost 7%.
Another example of component optimization is the use of proportional valves, which can modulate the flow and pressure of the hydraulic fluid according to the input signal. Proportional valves can improve the accuracy, stability, and responsiveness of the electrohydraulic system, as well as reduce energy losses and heat generation. Proportional valves can be either direct or pilot operated, depending on the required flow and pressure range. Direct operated proportional valves have a simple and robust structure, but they have limited flow capacity and are sensitive to pressure variations. Pilot operated proportional valves have a higher flow capacity and are less affected by pressure changes, but they have a more complex and expensive structure and require a pilot pressure supply.
Systems Level
Another way to increase the efficiency of electrohydraulic systems is to integrate and coordinate the components into a complete system that can perform the desired functions and tasks. For example, Parker Hannifin has developed a hybrid hydraulic drive system that can recover and store the braking energy of a vehicle and use it to assist the engine during acceleration. The system consists of a hydraulic pump/motor, a high-pressure accumulator, a low-pressure reservoir, and a controller. The system can operate in four modes: propulsion, where the engine drives the pump/motor to propel the vehicle; regeneration, where the pump/motor acts as a generator and charges the accumulator with the kinetic energy of the vehicle; boost, where the pump/motor acts as a motor and assists the engine with the stored energy from the accumulator; and idle, where the engine is shut off and the pump/motor maintains the system pressure. The system can reduce the fuel consumption and emissions of the vehicle by up to 40%, as well as improve the performance and drivability.
Another example of system integration is the use of load-sensing technology, which can adjust the pump output according to the load demand of the system. Load-sensing systems consist of a variable displacement pump, a load-sensing directional valve, and a pressure compensator. The load-sensing valve can sense the highest pressure in the system and send a feedback signal to the pump. The pressure compensator can regulate the pump displacement and output flow to match the load pressure plus a constant margin. Load-sensing systems can eliminate the throttling losses and excess flow in the system, as well as reduce the heat generation and noise. Load-sensing systems can also improve the controllability and stability of the system, as well as enable independent and simultaneous operation of multiple actuators.
Software Level
Another way to increase the efficiency of electrohydraulic systems is to implement software functions and algorithms that can optimize the control and operation of the system. For example, Danfoss has developed a software function called Adaptive Load Sensing, which can dynamically adjust the pressure margin of a load-sensing system based on the system conditions and requirements. The software function can measure the flow and pressure signals of the system and calculate the optimal pressure margin for each actuator. The software function can then control the pump and the valves to achieve the desired pressure margin, which can be either constant or variable. The software function can reduce the energy consumption and heat generation of the system, as well as improve the responsiveness and smoothness of the system.
Another example of software optimization is the use of model-based control, which can use a mathematical model of the system to predict and regulate the system behavior and performance. Model-based control can be either feedforward or feedback, depending on the use of measurement and error signals. Feedforward control can use the model to calculate the optimal control input for a given reference output, without relying on measurement and error signals. Feedback control can use the model to estimate the system state and output, and compare them with the measurement and error signals to correct the control input. Model-based control can improve the accuracy, robustness, and adaptability of the system, as well as compensate for the nonlinearities, uncertainties, and disturbances of the system.
The Limits of Pressure: What Factors Affect the Maximum Pressure of Liquids, Gases, and Supercritical Fluids
Pressure is the force exerted by a fluid per unit area on a surface. Fluids can be liquids or gases, and they can be used to transmit power in fluid power systems. Fluid power systems are composed of four basic components: reservoir/receiver, pump/compressor, valve, and cylinder/motor. The pump/compressor creates the pressure by forcing the fluid through the system, the valve controls the direction and amount of flow, and the cylinder/motor converts the fluid pressure into mechanical work.
But is there a limit to how much pressure a fluid can generate or withstand? The answer depends on several factors, such as the type of fluid, the design of the system, and the external conditions. In this article, we will explore some of these factors and their implications for fluid power applications.
Type of fluid
The type of fluid affects the maximum pressure that can be achieved or tolerated in a fluid power system. Generally, liquids are more incompressible than gases, meaning that they do not change their volume significantly when pressure is applied. This makes liquids more suitable for high-pressure applications, as they can transmit more force with less fluid volume. However, liquids also have a higher bulk modulus, which is a measure of how much they resist compression. This means that liquids require more energy to increase their pressure, and they also generate more heat when compressed.
Gases, on the other hand, are more compressible than liquids, meaning that they change their volume significantly when pressure is applied. This makes gases more suitable for low-pressure applications, as they can transmit less force with more fluid volume. However, gases also have a lower bulk modulus, which means that they require less energy to increase their pressure, and they also generate less heat when compressed.
The maximum pressure that a fluid can reach is determined by its critical point, which is the temperature and pressure at which the fluid can no longer be distinguished as a liquid or a gas. Beyond the critical point, the fluid becomes a supercritical fluid, which has properties of both liquids and gases. For example, water has a critical point of 374°C and 22.1 MPa, while air has a critical point of -140.6°C and 3.8 MPa. Therefore, water can reach higher pressures than air before becoming a supercritical fluid.
Design of the system
The design of the system also affects the maximum pressure that can be achieved or tolerated in a fluid power system. The system must be designed to withstand the internal and external forces that act on it, as well as to prevent leaks, bursts, or failures. The system must also be compatible with the fluid that is used, as different fluids may have different chemical, physical, or thermal properties that may affect the system’s performance or durability.
Some of the design factors that influence the maximum pressure of a fluid power system are:
- The size and shape of the components: The components must be sized and shaped to accommodate the fluid flow and pressure, as well as to minimize friction, turbulence, or cavitation. The components must also be strong enough to resist deformation, fatigue, or rupture under high pressure. For example, larger pipes or hoses can carry more fluid volume, but they also require more material and space, and they may be more prone to bending or buckling. Smaller pipes or hoses can carry less fluid volume, but they also require less material and space, and they may be more resistant to bending or buckling. However, smaller pipes or hoses may also increase the fluid velocity and pressure drop, and they may be more susceptible to clogging or erosion.
- The material and quality of the components: The components must be made of materials that can withstand the fluid pressure, temperature, and corrosion, as well as to provide adequate sealing, lubrication, and insulation. The components must also be of high quality, meaning that they are free of defects, flaws, or impurities that may compromise their strength, reliability, or efficiency. For example, steel is a common material for fluid power components, as it is strong, durable, and resistant to corrosion. However, steel may also be heavy, expensive, or difficult to shape. Plastic is another common material for fluid power components, as it is light, cheap, or easy to shape. However, plastic may also be weak, brittle, or prone to degradation.
- The safety and efficiency of the system: The system must be designed to operate safely and efficiently, meaning that it can deliver the desired output without wasting energy, causing damage, or posing risks. The system must also be equipped with safety devices, such as relief valves, pressure gauges, or filters, that can prevent or mitigate the effects of overpressure, underpressure, or contamination. The system must also be maintained and inspected regularly, to ensure that it is functioning properly and that any problems are detected and corrected before they become serious or irreversible.
External conditions
The external conditions also affect the maximum pressure that can be achieved or tolerated in a fluid power system. The external conditions refer to the environmental or operational factors that may influence the fluid pressure, such as temperature, altitude, or load. The external conditions may vary depending on the location, time, or purpose of the system, and they may require adjustments or adaptations to the system’s design or operation.
Some of the external factors that influence the maximum pressure of a fluid power system are:
- The temperature of the fluid or the environment: The temperature affects the density, viscosity, and compressibility of the fluid, as well as the expansion, contraction, or stress of the components. Higher temperatures tend to decrease the density and viscosity of the fluid, making it easier to flow and compress. However, higher temperatures also tend to increase the expansion and stress of the components, making them more likely to leak, crack, or fail. Lower temperatures tend to increase the density and viscosity of the fluid, making it harder to flow and compress. However, lower temperatures also tend to decrease the expansion and stress of the components, making them more stable and durable.
- The altitude or pressure of the environment: The altitude or pressure affects the atmospheric pressure, which is the force exerted by the weight of the air on a surface. Higher altitudes or lower pressures tend to decrease the atmospheric pressure, making it easier for the fluid to expand and vaporize. However, lower atmospheric pressure also tends to decrease the boiling point of the fluid, making it more prone to cavitation or boiling. Lower altitudes or higher pressures tend to increase the atmospheric pressure, making it harder for the fluid to expand and vaporize. However, higher atmospheric pressure also tends to increase the boiling point of the fluid, making it more resistant to cavitation or boiling.
- The load or demand of the system: The load or demand affects the amount of work or power that the system needs to produce or consume. Higher loads or demands tend to increase the fluid pressure, as more fluid is required to move or lift the load. However, higher loads or demands also tend to increase the friction, heat, or wear of the system, making it less efficient or durable. Lower loads or demands tend to decrease the fluid pressure, as less fluid is required to move or lift the load. However, lower loads or demands also tend to decrease the speed, responsiveness, or accuracy of the system, making it less effective or precise.
ATAM boosts its production of encapsulated coils with new overmoulding presses
ATAM, a leading manufacturer of encapsulated coils and industrial connectors for pneumatic and hydraulic applications, has recently upgraded its overmoulding presses at its Agrate Brianza plant in Italy. The company has added six new machines, each with a different tonnage, to replace the majority of its old presses. This significant investment aims to enhance the company’s production capacity, flexibility, and quality control of overmoulding, which is one of the most critical phases of the entire production process of encapsulated coils.
Encapsulated coils are electromagnets that are activated by electric currents and are used in solenoid valves, generators, motors, and other devices. They are typically protected by outer casings made of plastic or metal to withstand harsh environmental conditions, such as moisture, vibration, salt, water, and grease. Overmoulding is a process that involves injecting molten plastic or metal over the coil and its casing, creating a seamless and durable bond that improves the coil’s performance, reliability, and appearance.
The six new overmoulding presses that ATAM has acquired are custom-made by DM Industrial Srl – TURRA Division, a long-term partner of the company. They are based on a basic structure that is shared with the manufacturer, but they have been specifically tailored to meet ATAM’s requirements and expertise in the production of encapsulated coils and machinery management software. The co-design project focused on several aspects, such as the layout, the technical details, the operator’s ergonomics and safety, and the integration with the internal process methods, control parameters, and data analysis procedures.
The new overmoulding presses have various advantages over the old ones, such as:
- Higher productivity: The new presses have optimized the operator’s cycle time and reduced the time to market, thanks to the automatic mould loading system and the dual monitors that allow the operator to have constant visual control of the machine and the product parameters in real time.
- Greater flexibility: The new presses have different tonnages, ranging from 50 to 300 tons, which enable the company to produce different sizes and types of encapsulated coils, from small to large, and switch from one production to another with ease. This feature is especially important for ATAM, which specializes in customized and medium-low volume production lines.
- Total process control: The new presses have improved the overall control of the overmoulding process, as they monitor the process, automatically keep all set parameters under control, and communicate with the ERP System, sending compliance feedback during the process itself.
The table below summarizes the main features and benefits of the new overmoulding presses:
| Feature | Benefit |
|---|---|
| Different tonnages | Ability to produce different sizes and types of encapsulated coils |
| Automatic mould loading system | Increased processing speed and reduced time to market |
| Dual monitors | Constant visual control of the machine and the product parameters in real time |
| Customized layout and technical details | Optimized operator’s cycle time, ergonomics, and safety |
| Integration with internal process methods, control parameters, and data analysis procedures | Improved overall control of the overmoulding process |
With this major investment, ATAM has demonstrated its commitment to innovation and quality in the field of encapsulated coils and industrial connections. The company has also strengthened its position as a reliable and competitive partner for its customers, offering them high-performance and customized solutions for their pneumatic and hydraulic applications.
BayStar Hydraulic Steering: A Comprehensive Guide
BayStar hydraulic steering is a popular choice for single outboard powered boats up to 150 horsepower. It is a more robust and reliable system than cable steering, and it offers a number of advantages, including:
- Smoother and more effortless steering
- Reduced feedback from the engine
- Increased maneuverability
- Improved handling in rough seas
- Reduced wear and tear on the steering system
- How BayStar Hydraulic Steering Works
BayStar hydraulic steering kits come complete with all of the necessary components, including the helm pump, steering cylinder, hydraulic hoses, fittings, fluid reservoir, and mounting hardware. The kits are available in a variety of sizes to fit different boat types and engine sizes.
BayStar hydraulic steering is a two-line system. One line carries fluid from the helm pump to the steering cylinder, and the other line carries fluid back to the helm pump. When the steering wheel is turned, the helm pump forces fluid into the corresponding line, which causes the steering cylinder to move. The steering cylinder is connected to the boat’s rudder or drive unit, so when the cylinder moves, it turns the boat.
BayStar Hydraulic Steering Components
The following are the main components of a BayStar hydraulic steering system:
Helm pump: The helm pump is mounted on the boat’s console and is connected to the steering wheel. It is responsible for pumping fluid to and from the steering cylinder.
Steering cylinder: The steering cylinder is mounted on the boat’s transom and is connected to the rudder or drive unit. It is responsible for turning the boat.
Hydraulic hoses: The hydraulic hoses connect the helm pump to the steering cylinder. They carry the hydraulic fluid that powers the system.
Fittings: The fittings connect the hydraulic hoses to the helm pump, steering cylinder, and other components.
Fluid reservoir: The fluid reservoir stores the hydraulic fluid that circulates through the system.
Installing BayStar Hydraulic Steering
Installing BayStar hydraulic steering is a relatively straightforward process, but it is important to follow the manufacturer’s instructions carefully.
MOUNTING THE HELM
Step 1:
Determine desired mounting position. Ensure that the steering wheel will not interfere with other functional equipment. Check for adequate space behind the dash for fitting and line connections.
Step 2:
Tape the mounting template (found on page 3 of this manual) to the dash and use a center punch to mark the locations of the hole.
Step 3:
Confirm that you will not be drilling into any other equipment then; drill the 3” diameter center hole and the four 5/16″ diameter mounting holes as shown on the template.
Step 4:
Ensuring that the fill port is in the upper position, install the four washers and four nuts onto the mounting studs of the helm pump. Torque nuts to 110 in-lb.
Step 5:
Lightly grease taper of the helm shaft and mount steering wheel to helm.
Step 6:
Install ORB helm fittings into rear of helm, see page 9 for ORB fitting installation.
CYLINDER INSTALLATION
Step 1:
Using a good quality marine grease (such as Evinrude Triple Guard, Quicksilver anti-corrosion, Yamaha marine grease, or equivalent), liberally lubricate the tilt tube, support rods (Item 5) and mount nut (item 7) and then slide the support rods (item 5) into engine tilt tube.
Step 2:
Lightly grease the tiller bolt (Item 2) & partially screw into the appropriate hole in the tiller arm to assure a proper fit. Remove and go to Step 3.
Step 3:
Select appropriate insert diagram from Figure 11 through 15 to determine proper orientation of the cylinder assembly, the tiller bolt and the self-locking nut (Items 8, 2 and 1). Grease and install as indicated.
Step 4:
Screw lubricated mounting nut (item 7) onto tilt tube of the engine. Torque nut 20–25 ft-lb.
Step 5:
Lightly grease the ends of the cylinder shaft and holes of the support rods (item 5). Attach and secure support rods (Item 5) to the cylinder shaft. Tighten using the nuts and washers (Items 4 & 3) as illustrated in Figure 11 through 17.
REVERSING COMPACT CYLINDER ENGINE PLATE
1. DO NOT attempt to reverse the pivot plate with the cylinder installed on the engine. (This may damage the steering shaft, causing irreparable damage.)
2. Remove the two cap screws from one end of the steering cylinder using the 5/32″ Allen head wrench, or socket.
DO NOT pull the gland off the end of the shaft, doing so may damage the seals when you try to reassemble it.
3. Remove the pivot plate and flip over end for end, placing the end hole over the shaft stub on the fixed gland.
4. After removing the cap screws there will be small amounts of debris on the screw. Ensure that any loose debris is removed from inside and the face of the cylinder body.
5. Carefully slide the loose gland back into place so that the gland stub fits into the hole on the pivot plate. Some SeaStar steering fluid applied to the O-ring on the gland may ease reinsertion into the barrel.
6. Align the screw holes on the gland with the threaded holes on the barrel, ensure that the gland face is butted tightly against the end of the barrel, with no debris in between, and fasten using the cap screws removed earlier. Tighten to torque spec 60 in-lb (5 ft-lb).
Cost
The price of BayStar hydraulic steering on eBay varies depending on the specific system you are looking for, but you can expect to pay between $900 and $1,500 for a complete system. Here are some examples of BayStar hydraulic steering systems currently available on eBay:
- Teleflex Hk4200a Baystar Hydraulic Steering Kit 17893 – $959.99
- SeaStar HK4200A-3 BayStar Hydraulic Outboard Steering Kit – $999.99
- BayStar Outboard Steering System – $1,299.99
- BayStar Hydraulic Steering Kit for Single Outboard Boats – $1,499.99
Review
BayStar Hydraulic Steering Install on my Mako Boat!
Double-Pump Hydraulic System
Figure 1.5 shows an application for an unloading valve. It is a circuit that uses a high-pressure, low-flow pump in conjunction with a low-pressure, high-flow pump. A typical application is a sheet metal punch press in which the hydraulic cylinder must extend rapidly over a great distance with low-pressure but high-flow requirements. This occurs under no load. However during the punching operation for short motion, the pressure requirements are high, but the cylinder travel is small and thus the flowrequirementsare low. The circuit in Fig. 1.5 eliminates the necessity of having a very expensive high-pressure, high-flow pump.
When the punching operation begins, the increased pressure opens the unloading valve to unload the low-pressure pump. The purpose of relief valve is to protect the high-pressure pump from over pressure at the end of cylinder stroke and when the DCV is in its spring-centered mode. The check valve protects the low-pressure pump from high pressure, which occurs during punching operation, at the ends of the cylinder stroke and when the DCV is in its spring-centered mode.
Regenerative Cylinder Circuit
Figure 1.3 shows a regenerative circuit that is used to speed up the extending speed of a double-acting cylinder. The pipelines to both ends of the hydraulic cylinder are connected in parallel and one of the ports of the 4/3 valve is blockedby simply screwing a thread plug into the port opening. During retraction stroke, the 4/3 valve is configured to the right envelope. During this stroke, the pump flow bypasses the DCV and enters the rod end of the cylinder. Oil from the blank end then drains back to the tank through the DCV.
When the DCV is shifted in to its left-envelope configuration, the cylinder extends as shown in Fig. 1.3.The speed of extension is greater than that for a regular double-acting cylinder because the flow from the rod end regenerates with the pump flow Qp to provide a total flow rate Qt.
Pump-Unloading Circuit
Figure 1.4 shows a hydraulic circuit to unload a pump using an unloading valve.When the cylinder reaches the end of its extension stroke, the pressure of oil rises because the check valve keeps the high-pressure oil. Due to high-pressure oil in the pilot line of the unloading valve, it opens and unloads the pump pressure to the tank.
When the DCV is shifted to retract the cylinder, the motion of the piston reduces the pressure in the pilot line of the unloading valve. This resets the unloading valve until the cylinder is fully retracted. When this happens, the unloading valve unloads the pump due to high-pressure oil. Thus, the unloading valve unloads the pump at the ends of the extending and retraction strokes as well as in the spring-centered position of the DCV.
