Kobelt HPU400 Series Owner'S Operation, Installation & Maintenance Manual Download

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Kobelt Manufacturing Co. Ltd.

HPU400

Accu-Steer Hydraulic Power Unit

Owner’s Operation, Installation &

Maintenance Manual

June 2019

Summary of Contents for HPU400 Series

Page 1: ...Kobelt Manufacturing Co Ltd HPU400 Accu Steer Hydraulic Power Unit Owner s Operation Installation Maintenance Manual June 2019...

Page 2: ...HPU400 Hydraulic Power Units Kobelt Manufacturing Co Ltd Rev A MNL_HPU400 2 of 33 NOTES RECORD DATA BEFORE INSTALLATION FOR FUTURE REFERENCE Model Serial Date of Purchase Date of Installation...

Page 3: ...1 3 1 Mechanical 11 3 2 Hydraulic 11 3 3 Electrical 13 4 Commissioning 16 4 1 Hydraulic Fill Bleed 16 4 2 Electrical Check 16 4 3 Functional Test 17 5 Operation 18 6 Maintenance 19 6 1 Preventative Ma...

Page 4: ...ted for use it should be tested by the user to ensure proper function in all possible applications For further instructions please contact our distributors or visit our website 1 2 SAFETY 1 2 1 Safety...

Page 5: ...ified personnel are persons who are familiar with the assembly installation commissioning and operation of the product and who have the qualifications necessary for their occupation Observe all specif...

Page 6: ...on This unit is available in a wide range of voltages and flows for both standard and custom requirements HPU series are suitable for vessels from 30 to 150 in length depending on the vessels steering...

Page 7: ...teel gears and a high pressure shaft seal The suction side of the gear pump is connected to a suction drop manifold This manifold has oversized porting for low velocity oil flow and air oil separation...

Page 8: ...06 SAE ORB TO 1 4 NPT OPERATING TEMPERATURE 14 122o F 10 50o C PRODUCT WEIGHT 85 lbs 39 kg Table 2 HPU400 Technical Specifications AC Configurations MODEL HPU400 115 230 12 HPU400S 115 230 12 HPU400...

Page 9: ...mum oil temperature limit is 149oF 65oC Observe the operating temperature range limits as presented in Table 1 Do not operate the unit if the ambient temperature where the unit is located exceeds thes...

Page 10: ...HPU400 Hydraulic Power Units Kobelt Manufacturing Co Ltd Rev A MNL_HPU400 10 of 33 Figure 2 Hydraulic Schematic...

Page 11: ...ULIC Three hydraulic connections are required to the pumpset Two lines connect the main steering lines and the third line to the header tank of interconnect line which compensates for thermal expansio...

Page 12: ...draulic fitting in the 3 8 NPT port a pipe thread sealant such as Teflon paste must be used All hoses and piping must also be plugged or capped until ready for connection The piping to the steering cy...

Page 13: ...t or Starboard as most new autopilots will determine the pump direction and program the drive outputs to suit Connect the TANK port to the to pump suction line with recommended in line filter Connect...

Page 14: ...their motor protection and starting circuits conform to ABYC recommendations or other applicable local electrical codes Ensure that the electrical cable used to supply the motor and control connectio...

Page 15: ...1 HS A White 18AWG High Speed Coil connection A 1 HS B White 18AWG High Speed Coil connection B 2 CYL1 A Black 18AWG Cylinder Port 1 Coil connection A 2 CYL1 B Black 18AWG Cylinder Port 1 Coil connec...

Page 16: ...s to Terminals 6 and 7 Check the hard over to hard over speed of the rudder and adjust the low speed adjustment for the appropriate speed Clockwise to decrease and counter clockwise to increase Once t...

Page 17: ...Verify that the rudder position has changed 5 Set the autopilot to manual mode and operate the pump set to determine if the Port and Starboard directions are correct 6 If the rudder goes the opposite...

Page 18: ...open the opposite side check valve and allows flow comeback When there is no pressure in lines directional valve is in center both check valves are close and holding the load in position By energizing...

Page 19: ...the filter cap and change or clean the filter Return the pump to normal operation If the filter becomes plugged on a regular basis the steering system should be flushed out and the hydraulic oil repl...

Page 20: ...Repair Kit Manifold Repair Kit 600 160 RK 7070 0023 RK 7061 0005 RK 600 013 RK 1 HPU200 300 400 REPAIR KIT 115 230 VAC Pump Repair Kit Manifold Repair Kit 600 142 RK 7061 0005 RK 600 013 RK When purc...

Page 21: ...ar goes hard over Short circuit in electrical wiring to solenoid Test wiring and solenoid valve coils Solenoid valve contaminated Isolate lines clean and or repair the solenoid valve as required Steer...

Page 22: ...entification of a potential issue or defect with a Kobelt Product or Part the Warranty Applicant Applicant must immediately contact Kobelt and describe the issue in writing by letter fax email or othe...

Page 23: ...HPU400 Hydraulic Power Units Kobelt Manufacturing Co Ltd Rev A MNL_HPU400 23 of 33 9 APPENDIX A INSTALLATION DIMENSIONS Figure 7 HPU400 Installation Dimensions...

Page 24: ...HPU400 Hydraulic Power Units Kobelt Manufacturing Co Ltd Rev A MNL_HPU400 24 of 33 10 APPENDIX B PARTS LIST Figure 8 HPU400 Parts Diagram...

Page 25: ...LOCK WASHER 1023 0311 11 SCREW HEX HEAD 5 16 18 x 2 1 2 1001 1140 12 SOCKET HEAD CAP SCREW 10 12x 1 1 4 1002 0820 13 LOCK WASHER 1023 408 14 DIRECTIONAL VALVE 7036 0013 15 CABLE GLAND 1 2 NPT 6009 784...

Page 26: ...2 1015 0808 30 PLUG HEX HEAD 16 ORB 7039 0679 31 ADAPTER STR 10 MORB X 10 FJIC 7039 0157 32 HPU FOOT MOUNT PLATE 7057 0011 33 SCREW FLAT SKT HD 5 16 18 UNC X 3 4 1015 1112 34 LOCK WASHER 3 8 1023 0412...

Page 27: ...8 NPT 7039 3043 10 LOCK WASHER 1023 0311 11 SCREW HEX HEAD 5 16 18 x 2 1 2 1001 1140 12 SOCKET HEAD CAP SCREW 10 12x 1 1 4 1002 0820 13 LOCK WASHER 1023 408 14 DIRECTIONAL VALVE 7036 0012 7036 0013 1...

Page 28: ...2 1015 0808 30 PLUG HEX HEAD 16 ORB 7039 0679 31 ADAPTER STR 10 MORB X 10 FJIC 7039 0157 32 HPU FOOT MOUNT PLATE 7057 0011 33 SCREW FLAT SKT HD 5 16 18 UNC X 3 4 1015 1112 34 LOCK WASHER 3 8 1023 0412...

Page 29: ...HPU400 Hydraulic Power Units Kobelt Manufacturing Co Ltd Rev A MNL_HPU400 29 of 33 11 APPENDIX C MANIFOLD ASSEMBLY PARTS Figure 9 502 406 Manifold Parts Diagram...

Page 30: ...25 4 1 PLUG HEX SKT 04 ORB PLATED STEEL 7039 0661 5 1 EXPANSION PLUG CV173 218S 7039 3054 6 1 RELIEF VALVE 7043 0008 7 1 DIFFERENTIAL PRESSURE SENSE VALVE 80 PSI 7046 0001 8 1 PLUG HEX SKT 02 ORB PLAT...

Page 31: ...HPU400 Hydraulic Power Units Kobelt Manufacturing Co Ltd Rev A MNL_HPU400 31 of 33 12 APPENDIX D TYPICAL SYSTEM ARRANGEMENT Figure 10 Typical System Arrangement Closed Loop...

Page 32: ...HPU400 Hydraulic Power Units Kobelt Manufacturing Co Ltd Rev A MNL_HPU400 32 of 33 Figure 11 Typical System Arrangement Open Loop In this arrangement suction block must be removed...

Page 33: ...lt Manufacturing Co Ltd 8238 129th Street Surrey British Columbia Canada V3W 0A6 Sales Tel 1 604 572 3935 Fax 1 604 590 8313 Email sales kobelt com Website www kobelt com Made in Canada Printed in Can...

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