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Autohelm

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Autohelm

Autohelm

SeaTalk Service Manual

21

7.1 Service Visit - Diagnostic Procedure

On arrival check for bad connections (corroded connector pins, loose connectors etc)
and for inadequate power supplies. If the system still exhibits a fault, then use the
diagnostic procedure outlined below. Once the faulty module has been detected refer
to the relevant Product Section for detailed service information.

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Summary of Contents for Autohelm ST6000

Page 1: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 1 Autohelm Inboard Autopilots ST6000 and ST7000 systems Service Manual Tom Green 11 02 ...

Page 2: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 2 ...

Page 3: ... Z123 1 Service Procedures 2 Technical Information Type CR Interface Box Z085 1 Service Procedures 2 Technical Information Rudder Reference Transducer Z131 Service Procedures Fluxgate Compass Transducers Z130 Service Procedures Fluxgate Compass Transducer Z105 Service Procedures Rudder Reference Transducer Z060 Service Procedures Masthead Pushpit Windvane Transducers Z080 Z087 Service Procedures L...

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Page 5: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 1 ST7000 Basic System 1 Service Procedures ...

Page 6: ...ls 10 3 4 Calibration 12 3 5 Fluxgate Compass Automatic Deviation Correction 15 4 Common System Problems 16 5 Track Control Interfacing 17 5 1 Inverted Data 17 5 2 Conversion of Units 17 5 3 Alarm Messages 17 5 4 N M E A Input Format 18 6 Special Functions 19 6 1 Display of Software Version 19 6 2 Permanent Watch Alarm Mode 19 6 3 Display Test Mode 19 6 4 LCD Contrast Ratio Adjustment 19 7 Service...

Page 7: ...k Instruments Early systems pre March 90 were supplied with Z060 Z105 Rudder Reference and Fluxgate transducers Later systems use the Z131 and Z130 transducers The ST7000 course computer can be used with all Seatalk compatible control units and will operate all of the following drive units Z039 Linear Drive Type 1 Z037 Rotary Drive Type 1 Z041 Hydraulic Pump Type 1 Z081 Hydraulic Pump Type 0 Z088 ...

Page 8: ... after 10 seconds Course Changes 1 1 10 10 New Automatic Heading Push to alter course to port and starboard in increments of 1 and 10 degrees Standby Current Heading Push to disengage the autopilot for manual steering The previous automatic heading is memorised Track see operating hints Automatic Heading Push to select track control from Auto Push again to return to automatic steering OR Push and ...

Page 9: ...ng Hints Rudder Gain Level Push and hold down for 1 second both Response keys together to display rudder gain level Rudder Gain Level Within 10 seconds push once to increase or decrease rudder gain Response and Rudder levels are displayed for 10 seconds only Illumination Illumination Level Push and hold down Display for 1 second to switch on illumination Within 10 seconds push Display to select il...

Page 10: ...g to Waypoint Distance to Waypoint The 4 minute timer is now running After 3 minutes Watch flashes on all control units After 4 minutes the alarm sounds on all control units Push Auto at any time to reset the timer to 4 minutes and silence the alarm To cancel the Watch alarm at any time push Display Watch Alarm not available in Standby Only displayed when waypoint information is transmitted to the...

Page 11: ...onds Sounds if the cross track error exceeds 0 30n m Note Push Standby to silence an alarm and select Standby mode Low Battery Alarm Sounds if the course computer supply voltage falls below 11 volts for over 20 seconds Track Mode Alarms Sounds if no waypoint data is received from the Radio Navigation System for over 20 seconds Sounds if the data has the incorrect format or if an invalid flag is se...

Page 12: ...ich change the apparent wind direction can produce large trim changes In these cases the autopilot will not immediately assume the new automatic heading and only settle onto course when the Automatic Trim has been fully established It is recommended the following procedure is adopted for large course changes Note required new heading Select Standby and steer manually Bring vessel onto new heading ...

Page 13: ...h This must always be avoided no matter how clear the sea may appear to be It is the responsibility of the skipper to ensure the safety of his vessel at all times by careful navigation and that all crew members are familiar with the procedures required to engage and disengage the autopilot When searoom is restricted a crew member must be close to a control unit at all times if under Autopilot cont...

Page 14: ...angle transducer is accurately aligned as the Autotack function mirrors standing helm and any offset will change the initial tack angle Wind Trim Wind Trim allows the autopilot to be supervised by apparent wind direction The wind direction is read either From the SeaTalk bus requires Autohelm ST50 wind OR Directly from a Masthead Transducer Z080 OR From an NMEA 0183 input on the control unit Autom...

Page 15: ...A 0183 input or SeaTalk bus the apparent wind angle and tack sense P S is added to the display menu and accessed via the Display button Apparent Wind Angle Using Wind Trim It is important to understand that Wind Trim prevents over reaction to gusts or sudden wind shifts One minute is required to change the heading in response to a permanent change in apparent wind angle Do not attempt to override ...

Page 16: ...ng and Exiting from Calibration Mode To select calibration mode Push Standby Push and hold down for 2 seconds Track and Display together Repeat push and hold down for 2 seconds Track and Display together to enter calibration mode Rudder Gain level 5 2 Rate Gain level 2 1 Rudder Angle Limit degrees 30 30 Turn Rate Limit degrees sec 20 5 Cruise Speed knots 8 25 Off Course Alarm degrees 20 20 Trim Le...

Page 17: ...s used to scroll through the menu The displayed value is adjusted using the Response buttons hold button down for fast scroll Rudder Gain levels 1 to 9 see 5 5 Rate Gain levels 1 to 9 see 5 6 Counter Rudder Rudder Angle Limit 15 to 40 see 3 6 Rate of Turn Limit 2 to 20 sec Cruise Speed for Track mode operation 4 to 60 knots ...

Page 18: ...1 Proportional Follow up 2 Bang Bang Drive left Drive right Off Course Alarm 15 to 40 angle Automatic Trim see 5 4 1 on 0 off Autopilot Drive Unit Type 1 Future Use 2 Future Use 3 Mechanical 4 Hydraulic Remote Control Identifier For Future Use Rudder Position Deadband levels 1 to 9 See 3 7 ...

Page 19: ...lete 360 Keep turning until the display changes to show the amount of deviation the autopilot has corrected Note lf the amount exceeds 15 it is recommended the fluxgate should be re sited Use the course change buttons to adjust the displayed heading until it agrees with the steering compass or a known transit bearing Note 000 is always followed by OFF This will suppress the display of compass and ...

Page 20: ... 10 and 10 degree course change keys together for 2 seconds System displays ST 7000 for 2 sec s followed by NO LINK Seatalk Bus non operational Cabling error between control units and Course Computer System displays GYRO mode instead of STANDBY on power up Wind Anemometer connected to pilot Remove yellow connection from AUX 1 System displays maximum rudder angle on power up regardless of rudder po...

Page 21: ...convert all units of distance to Nautical Miles Therefore any receivers displaying Cross Track Error or Distance To Waypoint in either Kilometres of Statute miles etc will have their data displayed on the Control Unit in Nautical Miles 5 3 Alarm Messages Track mode has 3 alarm messages 1 No Data If a standard N M E A sentence is not received by the ST7000 2 Data Error The ST7000 has recognised the...

Page 22: ...ier characters i e RA DE LC etc are ignored allowing interface with any type of equipment so long as the sentence type is one of the following Track Control Bearing to Waypoint Distance to Waypoint Apparent Wind Speed Direction XTE APB WDR VWR XTR BPI WDC APA BWR BPI APB BWC BWR RMB BER BWC BEC BER RMB BEC RMB Apparent Wind Speed and Angle can be received from any external equipment transmitting t...

Page 23: ...can only be reversed by returning the Course Computer to Nautech Permanent Watch Alarm is achieved by first entering the calibration menu Once in calibration regardless of display message press the Auto Standby and Track keys together for 1 second before releasing The display will now show SELECT WATCH The user now has 10 seconds to select permanent watch alarm mode by again pressing Auto Standby ...

Page 24: ...cedure is carried out When trying to locate a fault it should be remembered that most failures will occur in the Course Computer with the Control Units as the next most likely It should be noted that the calibration variables and auto deviation correction will require re setting if the Course Computer Course Computer Software or its PCB are exchanged A procedure for carrying out this operation is ...

Page 25: ...rival check for bad connections corroded connector pins loose connectors etc and for inadequate power supplies If the system still exhibits a fault then use the diagnostic procedure outlined below Once the faulty module has been detected refer to the relevant Product Section for detailed service information ...

Page 26: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 22 ...

Page 27: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 1 Z082 Control Unit 1 Service Procedures ...

Page 28: ... Contents Page 1 Description 3 2 Dismantling 3 3 Re assembly 3 4 Display Contrast Adjustment 4 5 Functional Test 7 6 Product History 9 7 Software History 9 8 Spares Numbers 9 Illustrations Fig 1 Z082 Control Unit General Assembly 5 Fig 2 LCD Diffuser Assembly 6 ...

Page 29: ...icon grease to outer sheath grease can be wiped off after reassembly If removing the PCB assembly it will be necessary to de solder the cables from the PCB Great care should be exercised when de soldering so as not to damage the pads on the PCB 2 Unscrew and remove the 10 screws which secure the PCB to the facia Note Do not at this stage remove the screws which secure the LCD assembly to the PCB f...

Page 30: ...ly viewed from significantly above or below or when a replacement LCD with different drive characteristics has been fitted 1 Remove power from the unit 2 Unscrew the mounting thumb nuts and ease the Control unit forward from its mounting position 3 Unscrew and remove the 6 case screws from the rear cover Push each cable loom back through its grommet so as to obtain working clearance to the PCB fig...

Page 31: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 5 Control Unit General Assembly Z082 Fig 1 ...

Page 32: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 6 LCD Display Assembly Fig 2 ...

Page 33: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 7 5 Functional Test ...

Page 34: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 8 ...

Page 35: ... 7 Software History Z082 Version Change Course Computer Compatibility B Initial release S No 290001 All versions C Track function added Rudder Angle display updates at a faster rate S No 690075 All versions but must be used with a track compatible Course Computer if the track function is required 8 Spares Numbers Control Unit Z082 Item Catalogue No Comments Double Skin mounting kit Q003 Allows Con...

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Page 37: ...2 1 1 Power Supply 2 1 2 Microprocessor and Program Memory 2 1 3 LCD and Display Driver 2 1 4 Negative Rail Generator 2 1 5 N M E A Interface 2 1 6 Seatalk Bus Transmit and Receive 2 1 7 Keypad Operation 3 1 8 Buzzer Operation 3 1 9 Illumination Drive 3 Illustrations Fig 1 Circuit Diagram 5 Fig 2 PCB Assembly Parts List 7 ...

Page 38: ...ng and resistor R44 the clock signal for lC3 1 4 Negative Rail Generator A negative voltage rail is required by the LCD display and is generated by a switching regulator formed by TR11 D10 and D21 A 4 8KHz waveform is generated from the microprocessor P3 4 pin no 16 This drives a charge pump via transistorTR11 pumping charge from C19 via D1O and C20 The negative rail is then stabilised by D21 and ...

Page 39: ...configured as an astable multivibrator with a nominal frequency of 2 7KHz TR4 is used to switch the buzzer with TR13 acting as an invertor to turn the buzzer off during a micro processor reset 1 9 Illumination Drive TR10 12 and 16 provide a constant current drive for lamps LP1 LP2 LP3 and LP4 The current is set by resistors R56 and R62 TR12 is an inverting buffer to turn off the lights during a mi...

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Page 41: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 5 Fig 1 Z082 Control Unit Circuit Diagram ISS C ...

Page 42: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 6 ...

Page 43: ...0 31 2 CAPACITOR SOLID TANT 10UF 20 6V3 SIZE C C19 C20 30 1 1206 CAPACITOR 1000pF 10 5OV X7R C11 29 2 1206 CAPACITOR 33pF 5 50V COG C7 C8 28 3 1206 CAPACITOR 22pF 5 50V X7R C2 C4 C5 27 1 1206 CAPACITOR 0 1µF 20 50V X7R 26 1 ELECTROLYTIC CAPACITOR 100uF 20 6 3V MIN 5 5 MAX C3 25 1 1206 RESISTOR 100K 5 0 125W R35 24 4 1206 RESISTOR 1K0 2 0 125W R24 R25R26R27 23 1 1206 RESISTOR 220R 5 0 125W R42 22 1...

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Page 45: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 1 Z084 Course Computer 24V Z083 Course Computer 12V 1 Service Procedures Z083 COURSE COMPUTER 12V Z084 COURSE COMPUTER 24V ...

Page 46: ... 3 2 Dismantling 3 3 Re assembly 4 4 Functional Test 7 4 1 Bench Test stage 1 8 4 2 Bench Test stage 2 14 4 3 Bench Test stage 3 15 5 Product History 16 6 Software History 16 7 Spares Numbers 16 Illustrations Fig 1 Course Computer General Assembly 5 Fig 2 Power Amplifier General Assembly 6 ...

Page 47: ...on Both of these procedures are outlined in the 7000 system section 2 Dismantling reference figures 1 2 1 Unscrew and remove 2 countersunk screws securing lid on terminal box section and lift off 2 Unscrew and remove 2 thumb nuts securing extrusion assembly to terminal box unit and pull extrusion assembly away from terminal box 3 Course Computer PCB If servicing course computer PCB unscrew and rem...

Page 48: ...cting to the computer PCB Ensure a loom clip is fitted to the ribbon cable connector 2 Ensure that insulating caps are all in place before sliding the power amp PCB back into the extrusion Ensure that the silpads are fitted between the transistors and the extrusion 3 Ensure that the correct transistor type is placed at each location Fig 2 4 Ensure that transistor PCB securing screws are not loose ...

Page 49: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 5 ST7000 Course Computer General Assembly Z083 12V and Z084 24V Fig 1 ...

Page 50: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 6 ST7000 Course Computer Z083 Z084 Power Amp PCB Assembly Fig 2 ...

Page 51: ... Z084 24V N003 Power Supply min rating 20A SeaTalk Cable D131 Procedure a Connect all units to course computer and terminal board PCB b Position the rudder reference transducer arm diametrically opposite the cable gland c Connect 12V Z083 24V Z084 electronic and heavy duty supplies do not switch on d Start at Bench Test Stage 1 The procedure will determine if the course computer is faulty or corre...

Page 52: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 8 4 1 Course Computer Bench Testing Stage 1 ...

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Page 58: ...eaTalk Service Manual 14 4 2 Course Computer Bench Testing Stage 2 1 Proceeding from stage 1 bench testing remove the four screws retaining the computer PCB cover assembly and slide the PCB clear of the extrusion Do not disconnect the loom ...

Page 59: ...lm SeaTalk Service Manual 15 4 3 Course Computer Bench Testing Stage 3 Proceeding from stage 1 bench testing remove 4 screws retaining the computer PCB cover assembly and slide the PCB clear of the extrusion Do not disconnect the loom ...

Page 60: ...y Z083 Z084 Version Change Control Unit Compatibility S No C Initial release All versions 290001 D Auto Seastate problem cured All versions 490081 E Track function added All versions If Track keeping algorithm is required then control unit must also be Track Compatible 590206 G Trim function Improved All versions 500256 7 Spares Numbers Course Computers Z083 Z084 Item Catalogue No Comments Connect...

Page 61: ... Supply Voltage Monitor 3 1 9 Alarm Drive 3 2 Circuit Description Power Amplifier PCB 3 2 1 Voltage Regulator 24V Systems only 3 2 2 Reverse Connection Protection 3 2 3 Bridge Amplifier 4 Illustrations Fig 1 Course Computer PCB Circuit Diagram 5 Fig 2 Course Computer PCB Assembly Parts List 7 Fig 3 Power Amplifier PCB Circuit Diagram 12V and 24V 9 Fig 4 Power Amplifier PCB Assembly Parts List Z083...

Page 62: ...capacitors C15 and C16 C14 18 and 17 provide decoupling 1 3 Analogue to Digital Converter IC3 4 5 and 9 form a software driven analogue to digital converter IC3 and IC9 are 8 channel multiplexed analogue switches routing all analogue signals see table below through to IC4 which is configured as an integrator C9 is discharged at a constant rate triggering the comparator IC5 as it reaches a level of...

Page 63: ...ws calibration values to be stored and recalled each time after power up Data is written to the e2 PROM on pin 3 and read back on pin 4 1 8 Supply Voltage Monitor R53 and R54 scale down the supply voltage and feed it through to the analogue to digital convertor This enables the microprocessor to transmit a warning on the SeaTalk bus if the supply voltage drops below 11 2V 12V system or 22 4V 24V s...

Page 64: ...e B both a logic 1 The motor is shorted via TR7 and TR9 This mode is used for stopping the motor quickly Mode 2 Drive A and drive B both at logic 0 The motor is open circuit and therefore may run as a generator allowing measurement of motor back emf R14 and R16 in combination with R25 and R28 on the computer PCB scale down the back emf Mode 3 Drive A is at logic 1 Drive B is at logic 0 The motor w...

Page 65: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 5 Fig 1 ST7000 Z083 and Z084 Course Computer Circuit Diagram ISS B ...

Page 66: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 6 ...

Page 67: ... 1000pF 2 COG 50v C1 C9 34 33 02031 1 DIODE MR751 MOTOROLA D6 32 9200BAS19 1 DIODE SOT23 BAS19 D12 31 9200BAS16 9 DIODE SOT23 BAS16 D2 3 4 5 7 8 9 10 11 30 29 91063R3 2 WCR 1206 3R3 5 125W R87 88 28 9106470K 1 WCR 1206 470K 5 125W R68 27 910382R 1 WCR 1206 82R 5 125W R62 26 91035K6 3 WCR 1206 5K6 5 125W R53 59 90 25 910368K 13 WCR 1206 68K 5 125W R33 34 35 36 41 42 44 45 46 47 48 63 89 24 9103270R...

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Page 69: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 9 Z083 Power Amplifier Circuit Diagram 12V Z084 Power Amplifier Circuit Diagram 24V Fig 3 ...

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Page 71: ...020 2 CAPACITOR CERAMIC 0 01µF 20 25vmin C2 4 02004 4 DIODE IN 4148 D2 3 5 6 11 02002 1 DIODE IN 4818 D8 10 01158 4 RESISTOR CTILM 1K5 25W 5 R7 9 20 22 9 01157 2 RESISTOR WIREWOUND 82R 2 5W 5 R12 18 8 01102 RESISTOR CTILM IK 25W 1 R14 16 7 01061 3 RESISTOR CTILM 6K8 25W 5 R5 6 24 6 01055 t RESISTOR CTILM 270R 5W 5 R15 5 01045 4 RESISTOR CTILM 220R 25W 5 R11 13 17 19 4 01032 4 RESISTOR CTILM ZK2 25...

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Page 73: ...4148 D2 3 5 6 14 02002 DIODE IN 4818 D8 13 01162 RESISTOR WIREWOUND 330R 2 5W 5 R12 18 12 01140 RESISTOR C FILM 120R 2 5W 10 R2 11 01139 RESISTOR C FILM 680R 5W 5 R26 10 0112 2 RESISTOR C FILM 6K8 25W 1 R14 16 9 01083 5 RESISTOR C FILM 3K9 25W 5 R3 7 9 20 22 8 01061 3 RESISTOR C FILM 6K8 25W 5 R5 6 24 7 01055 1 RESISTOR C FILM 270R 5W 5 R15 6 01045 4 RESISTOR C FILM 220R 25W 5 R11 13 17 19 5 01031...

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Page 75: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 15 Colour code Sc White R Red G Green Y Yellow B Blue Br Brown SK1 Fig 6 Connector PCB Circuit Diagram Z083f Z084 ISS A ...

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Page 77: ...helm Autohelm Autohelm Autohelm SeaTalk Service Manual 17 3 07163 4 TERMINAL BLOCK 2 07119 1 D CONNECTOR 1 3015 029 1 PCB DETAIL ITEMS DR G PART N QTY DESCRIPTION Fig 7 Connector PCB General Assembly ISS C ...

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Page 79: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 1 ST6000 System 1 Service Procedures ...

Page 80: ...15 3 4 1 Adjusting Calibration 16 3 4 2 Display Contrast Adjustment 17 3 5 Fluxgate Compass Automatic Deviation Correction 18 4 Common system problems 19 5 Track control interfacing 19 5 1 Inverted data 19 5 2 Conversion of units 19 5 3 Alarm messages 19 5 4 NMEA Data input format 20 6 Special functions 21 6 1 Display of software version 21 6 2 Permanent watch alarm mode 21 6 3 Display Test mode 2...

Page 81: ...iption The ST6000 is a modular Seatalk compatible autopilot system that can be built up to match the individual requirements of most vessels and steering systems The ST6000 course computer can be used with all Seatalk compatible control units and ST50 instruments and will operate the following drive units Z039 Linear drive type 1 Z037 Rotary drive type 1 Z041 Hydraulic pump type 1 Z081 Hydraulic p...

Page 82: ...Automatic Heading Course Changes 1 1 10 10 New Automatic Heading Push to alter course to port and starboard in increments of 1 and 10 degrees Standby Current Heading Push to disengage the autopilot for manual steering The previous automatic heading is memorised Track see operating hints Automatic Heading Push to select track control from Auto Push again to return to automatic steering OR Push and ...

Page 83: ...ng Hints Rudder Gain Level Rudder Gain Level Push and hold down for 1 second both Response keys together to display rudder gain level Within 10 seconds push once to increase or decrease ruddergain Response and Rudder levels are displayed for 10 seconds only Illumination Illumination Level 3 High 2 Medium 1 Low OFF 0ff Push and hold down Display for 1 second to switch on illumination Within 10 seco...

Page 84: ...n Displays See section on Navigation Displays The Display pushbutton is used to cycle through additional information menus These menus depend on the autopilot mode and if navigation information is available Standby Mode Main Display Compass Heading Rudder Angle Navigation Displays See section on Navigation Displays Watch Alarm ...

Page 85: ...ided that the Navigation Receiver transmits the appropriate information see Installation Handbook Cross Track Error The arrows show the direction to steer to rejoin the desired Track Starboard Port Bearing to Waypoint Magnetic True Track Mode Main Display Locked Course Rudder Angle Navigation Displays See section on Navigation Displays Watch Alarm Distance to Waypoint Waypoint Number ...

Page 86: ...eset the timer to 4 minutes and silence the alarm To cancel the Watch alarm at any time push Display Warning Messages Off Course Alarm Sounds if the vessel deviates from the automatic heading by more than the selected amount for over 20 seconds Low Battery Alarm Sounds if the course computer supply voltage falls below 11 volts for over 20 seconds Track Mode Alarms Sounds if no waypoint data is rec...

Page 87: ... the new waypoint bearing Push Track to silence the alarm and automatically steer onto the new bearing to waypoint Manual Override Alarm Installations with stern drive actuators only Sounds for 10 seconds when the autopilot is manually overridden at the steering wheel After 10 seconds the autopilot will return to Standby automatically Note Push Standby to silence an alarm and select Standby mode u...

Page 88: ...the rudder angle transducer is accurately aligned as the Autotack function mirrors standing helm and any offset will change the initial tack angle Wind Trim Windvane Operation Wind Trim allows the autopilot to be supervised by apparent wind direction The wind direction is read either From the SeaTalk bus requires Autohelm ST 50 unit OR From an NMEA 0183 input on the control unit Push both red keys...

Page 89: ...is added to the display menu and accessed via the Display button Apparent Wind Angle The apparent Wind Angle is 35 Starboard Tack Using Wind Trim It is important to understand that Wind Trim prevents over reaction to gusts or sudden wind shifts One minute is required to change the heading in response to a permanent change in apparent wind angle Do not attempt to override the automatic sequence wit...

Page 90: ...nt and when it is safe to turn onto it resume automatic track control by simply pushing Track This accepts the new target waypoint and will steer the vessel onto the new bearing to waypoint The tidal offset may be very different on the new bearing and it is good practise to check the cross track error after a couple of minutes If the cross track error continues to increase make a course adjustment...

Page 91: ...mode by entering the Latitude see Installation Handbook Calibration section on Auto Adapt When selected the ST6000 automatically adjusts the Rudder Gain depending on the compass heading removing the need for manual adjustment Rudder Gain Speed Adjustment Powercraft High speed planning craft exhibit very different steering characteristics when on and off the plane As a result it is generally necess...

Page 92: ...TUATOR CLUTCH CAN NORMALLY BE OVERRIDDEN BY TURNING THE STEERING WHEEL HARD It is emphasised that this fault is extremely unlikely and can be immediately corrected as described If preferred a separate Override switch can be fitted close to the steering position which will break the actuator clutch drive for Emergency Use Stern Drive Actuator Manual Override Option Manual override is selected durin...

Page 93: ... 1 Rudder Angle Limit degrees 30 30 Turn Rate Limit degrees sec 20 5 Cruise Speed knots 8 25 Off Course Alarm degrees 20 20 Trim Level 1 1 Auto Adapt OFF ON Autopilot Drive Unit Type Mechanical Stern Drive Hydraulic Factory preset Set to Set to Drive Type 3 3 4 Rudder Position Deadband level See 3 8 1 1 1 Auto Release OFF ON OFF Selecting and Exiting from Calibration Mode To select calibration mod...

Page 94: ...ed value is adjusted using the Response buttons hold button down for fast scroll Rudder Gain levels 1 to 9 see 5 6 Rate Gain levels 1 to 9 see 5 7 Counter Rudder Rudder Angle Limit 15 to 40 see 3 6 Rate of Turn Limit 5 to 20 sec Cruise Speed for Track mode operation 4 to 60 knots Off Course Alarm 15 to 40 angle Automatic Trim see 5 4 Remote Control Identifier For Future Use ...

Page 95: ...elease see 3 8 0 OFF 1 ON The Auto Release facility is designed to provide Emergency Manual Override when used with the Autohelm Stern Drive Actuator For all other Drive Systems Auto Release must be selected OFF 0 3 4 2 Display Contrast Adjustment The LCD Contrast can be adjusted to suit a wide range of control unit viewing angles Push display and track together momentarily Push response to increa...

Page 96: ... 360 Keep turning until control unit beeps and the display changes to show the amount of deviation the autopilot has corrected Note If the amount exceeds 15 it is recommended the fluxgate should be re sited Use the course change buttons to adjust the displayed heading until it agrees with the steering compass or a known transit bearing Note 000 is always followed by OFF This will suppress the disp...

Page 97: ...ormally available on the receiver terminal block and the blue wire connected to the data line 5 2 Conversion of Units All data containing units of distance will be converted to Nautical miles by the Control Unit Therefore any receivers displaying Cross Track Error or Distance To Waypoint in either Kilometres of Statute miles etc will have their data displayed on the control unit in Nautical miles ...

Page 98: ...cope with delays between characters and delays between sentences All Talker identifier characters ie RA DE LC etc are ignored allowing interface with any type of equipment so long as the sentence type is one of the following Apparent wind speed and angle can be received from any external equipment transmitting the N M E A VWR header The ST6000 will only display apparent wind angle but will convert...

Page 99: ...with a permanent watch alarm mode as required by the Sea Fish Industry authority SFIA It must be stressed that the selection of this mode is permanent and can only be reversed by returning the course computer to Nautech Permanent watch alarm is achieved by first entering the calibration menu Once in calibration regardless of display message press the Auto Standby and Track keys together for 1 seco...

Page 100: ...ault it should be remembered that most failures will occur in the Course Computer with the Control Units as the next most likely It should be noted that the calibration variables and auto deviation correction will require re setting if either the course computer its PCB or its Software are exchanged Similarly if the Control Unit PCB is exchanged the display contrast will require re setting Procedu...

Page 101: ...utohelm SeaTalk Service Manual 23 7 1 Service Visit Diagnostic Procedure On arrival check for bad connections and for inadequate power supplies If the system still exhibits a fault then use the diagnostic procedure outlined below ...

Page 102: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 24 ...

Page 103: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 1 ST6000 Control Unit Z124 1 Service Procedures 2 Technical Information ...

Page 104: ...rvice Manual 2 1 Service Procedures Contents Page 1 Description 3 2 Dismantling 3 3 Reassembly 3 4 Display Contrast Adjustment 4 5 Functional Test 6 6 Product History 8 7 Software History 8 8 Spares Numbers 8 Illustrations Fig 1 General assembly 5 ...

Page 105: ...e can be wiped off after reassembly If removing the PCB assembly it will be necessary to de solder the cables from the PCB Great care should be exercised when de soldering so as not to damage the pads on the PCB 2 Unscrew and remove the 9 screws which secure the PCB to the facia Note Do not at this stage remove the screws which secure the LCD assembly to the PCB Refer to figure 1 to clarify which ...

Page 106: ... LCD has not been damaged or looms incorrectly soldered Adjust LCD contrast if necessary 4 Display Contrast adjustment The LCD Contrast can be adjusted to suit a wide range of control unit viewing angles Push display and track together momentarily Push response to increase contrast suits viewing from below Push response to decrease contrast suits viewing from above Adjust the display for optimum v...

Page 107: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 5 Fig 1 ...

Page 108: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 6 4 Z124 Control Unit Functional Test ...

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Page 110: ... number Comments 030001 production start 6 Software History Control Unit Z124 Version Change Serial No 65E Product launch 030001 7 Spares numbers Control unit Z124 Item Catalogue no Comments Double skin mounting kit Q003 allows fixing to up to 4 thick bulk heads PCB assembly Q027 LCD Q028 Protective cover D123 ...

Page 111: ... 2 1 1 Power Supply 2 1 2 Microprocessor and Program Memory 2 1 3 LCD and Display Driver 2 1 4 Negative Rail Generator 2 1 5 N M E A Interface 2 1 6 Seatalk Bus Transmit and receive 2 1 7 Keypad Operation 2 1 8 Buzzer Operation 3 1 9 Illumination Drive Illustrations Fig 1 Circuit Diagram 4 Fig 2 PCB Assembly Parts List 5 ...

Page 112: ...nerator A negative voltage rail is required by the LCD display and is generated by a switching regulator formed by TR6 D5 and D6 A 4 8kHz waveform is generated from the microprocessor P3 4 pin no 16 This drives a charge pump via transistor TR16 pumping charge from C20 via D6 to C21 The negative rail is then stabilised by D5 and R49 1 5 N M E A Interface NMEA data is fed to the control unit via PL2...

Page 113: ...equency of 2 7kHz TR7 and 8 are used to switch the buzzer with TR7 acting as an inverter to turn the buzzer off during a microprocessor reset 1 9 Illumination Drive TR10 12 and 16 provide a constant current drive for lamps LP1 and LP2 The current is set by resistors R11 and R12 TR6 is an inverting buffer to turn off the lights during a microprocessor reset Illumination level s are given by pulse w...

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Page 115: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 5 ST6000 Z124 Control Unit Circuit Diagram ISS E ...

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Page 117: ...S19 D1 D2 D3 31 93041000P 1 0805CAPACITOR1000pF 10 50VX7R C14 30 930522N 3 1206CAPACITOR22µf5 50VX7R C2 C5 C6 29 93070U1 10 1206CAPACITOR0 1µF 20 50VX7R D1 7 8 10 17 18 19 22 23 24 28 9314470P 0 0805CAPACITOR470pF 20 50VX7R C9 C11 C12 C13 SEE NOTE 3 27 931110U 1 CAPACITORSOLIDTANT10µF 20 6V3 SIZE0 C21 26 03063 2 CAPACITORELECTROLYTIC100uF 20 25VMIN07 5MAXC3 C4 25 93091U 1 CAPACITORSOLIDTANT1µF 20 ...

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Page 119: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 1 ST6000 Course Computer Z123 1 Service Procedures ...

Page 120: ...ohelm Autohelm SeaTalk Service Manual 2 Contents Page 1 Description 3 2 Disassembly 3 3 Reassembly 3 4 Functional Test 5 5 Product History 10 6 Software History 10 7 Spares Numbers 10 Illustrations Fig 1 General Assembly 4 ...

Page 121: ...ble length from the main distribution panel to the course computer plus the length from the course computer to the drive unit Drive Unit and Power Supply Cable Size Cable length Cable type Copper area Cable gauge up to 7m 50 0 25 2 5mm2 12 awg up to 10m 56 0 3 4 0mm2 10 awg up to 16m 54 0 3 6 0mm2 8 awg 2 Disassembly 1 Unscrew and remove the 2 countersunk screws securing lid on terminal box sectio...

Page 122: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 4 Course Computers Z083 Z084 General Assembly ...

Page 123: ...it vane transducer Z087 Rudder Reference Transducer Z060 Terminal PCB Q030 Terminal Block Multimeter Motor small AH1000 type M080 Power Supply Min rating 10A SeaTalk Cable D131 Procedure 1 Connect all units to course computer and terminal PCB 2 Position the rudder reference transducer arm diametrically opposite the cable gland 3 Connect the 12v supply do not switch on and refer to the bench testin...

Page 124: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 6 4 1 Course Computer Bench Testing Stage 1 ...

Page 125: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 7 ...

Page 126: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 8 ...

Page 127: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 9 ...

Page 128: ...erial No Comments Production start 030001 6 Software History Course Computer ST6000 Version Change Serial No 66F Product launch 030001 66G Improved Trim function 500571 7 Spares numbers Course Computer ST6000 Item Catalogue No Comment PCB Assembly Q031 Main course computer PCB PCB Assembly Q030 Terminal box PCB ...

Page 129: ...tion Contents Page 1 Circuit Description 2 1 1 Power Supply 2 1 2 Microprocessor and program memory 2 1 3 Power Amplifier 2 1 4 Analogue to Digital converter 2 1 5 Clutch Drive 3 1 6 Seatalk Bus Transmit and Receive 3 1 7 Fluxgate Drive 3 1 8 E2 Prom 3 1 9 Supply Voltage Monitor 3 ...

Page 130: ...1 3 Power Amplifier TR23 24 25 and TR26 are configured to form a power amplifier capable of driving a motor in four modes 1 Drive right 2 Drive left 3 Short circuit motor Brakes Motor 4 Open circuit motor Mode 3 is used to stop the motor quickly by switching Tr23 and 25 On and TR24 and 26 Off Mode 4 allows the motor speed to be measured by switching off all of the power transistors All four modes ...

Page 131: ... start bit and line idling high TR1 and Tr2 provide high and low drive respectively whilst TR3 and R1 give overload protection to Tr2 in the event of misconnection Tr4 and Tr5 allow the microprocessor to monitor its own transmissions and also to receive data from other units on the bus 1 7 Fluxgate drive IC2 produces bursts of 8KHz pulses on pin 2 which are then fed through Tr6 7 and 8 and AC coup...

Page 132: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 4 ...

Page 133: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 5 ST6000 Z123 Course Computer Circuit Diagram ISS A ...

Page 134: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 6 ...

Page 135: ...PACITOR 1206 0 1µF 20 50v C2 7 8 10 11 12 13 14 17 18 27 28 36 1 CAPACITOR 120 100pF 20 COG 50v OR CAPACITOR POLYSTYRENE 1000pF 1 10v MIN 03053 C9 35 1 CAPACITOR 1206 1000pF 20 50v C1 34 2 DIODE SOT23 BAW56 D4 9 33 5 DIODE SOT23 BAS 19 D11 12 14 18 19 32 1 DIODE SOT23 BAV99 D2 31 01157 2 RESISTOR WIRE WOUND 82R 5 2 5W R106 114 30 29 2 WCR 1206 FUTURE USE R69 72 28 2 WCR 1206 33K 1 0 125W R30 43 27...

Page 136: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 8 ...

Page 137: ...ice Manual 9 5 07212 2 TERMINAL BLOCK 2 WAY TB5 6 4 07108 2 TERMINAL BLOCK 3 WAY TB2 4 3 07109 1 TERMINAL BLOCK 4 WAY TB1 3 2 07118 1 D CONNECTOR SK1 1 3015 041 1 PCB DETAIL ITEMS DR G PART N Q T Y DESCRIPTION ST6000 Z123 Terminal PCB Assembly ISS A1 ...

Page 138: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 10 ...

Page 139: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 1 Type CR Interface Box Z085 1 Service Procedures ...

Page 140: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 2 Contents Page 1 Description 3 2 Functional Test 3 3 Operation non Autohelm power packs 4 ...

Page 141: ...terfaces to a type CR interface box Z085 The same interface box is used for both 12V and 24V systems and can be functionally tested by using the following procedure 2 Functional Test Connect 12V to clutch and battery Connect 0V to clutch and battery Confirm with a multimeter that 12V is present across the bypass connections Remove the 12V from clutch and confirm that 0V is present across the bypas...

Page 142: ...Autohelm Power Packs If the Type CR Interface Box is to be used to drive non Autohelm power packs the following points should be noted 1 Solenoid pull in voltage 8V 16V for 24V systems 2 Solenoid drop out voltage 2V 3 Solenoid nominal operating voltage should be the same as the pilot ...

Page 143: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 1 2 Technical Information Contents 1 Circuit Description Page 2 Illustrations Fig 1 Circuit Diagram Fig 2 PCB Assembly Fig 3 Parts List 3 4 5 ...

Page 144: ...puter clutch signal activates RLY1 which in turn supplies current to a bypass valve if fitted D1 suppresses any inductive spikes produced when the valve is switched and D2 protects against supply misconnection Each solenoid drive is derived by connecting one side of the solenoid to a motor terminal and the other side to 0V ...

Page 145: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 3 Fig 1 Z085 Type CR Interface Box Circuit Diagram ISS B ...

Page 146: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 4 ...

Page 147: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 5 Fig 2 Z085 Type CR Interface Box PCB Assembly ISS B ...

Page 148: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 6 ...

Page 149: ...utohelm Autohelm SeaTalk Service Manual 7 7000 Type CR Parts List Item DR G Part No PCB detail 3015 038 Diode MR751 D1 02031 Diode Fast Recovery MR850 D1 02036 PCB Connector 07 212 Relay T9030A RL1 15057 Dust Cover 15111 ...

Page 150: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 8 ...

Page 151: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 1 Rudder Reference Transducer Z131 Service Procedures ...

Page 152: ...utohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 2 Contents Page 1 Description 3 2 Functional Test 3 Illustration Fig 1 Rudder Reference Body Assembly Fig 2 Rudder Reference General Assembly 4 5 ...

Page 153: ...re that the arm is opposite the cable entry when the rudder is amidships Failure to do this could result in damage to the Rudder Reference if the arm is driven into its end stops by the steering system Once detected as faulty the Rudder Reference unit should be replaced as a complete unit 2 Functional Test The Rudder Reference unit when disconnected from the autopilot can be functionally tested by...

Page 154: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 4 Z131 Rudder Reference Body Assembly ...

Page 155: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 5 Z131 Rudder Reference General Assembly ...

Page 156: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 6 ...

Page 157: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 1 Fluxgate Compass Transducer Z130 Service Procedures ...

Page 158: ...ervice Manual 2 Contents Page 1 Description 3 2 Functional Test 3 3 Magnetic Deviation 3 4 Gimble Support Bracket Installation 5 5 Fluxgate Sensor Replacement 5 6 Product History 6 7 Spares Numbers 6 Illustrations Fig 1 Fluxgate General Assembly 4 ...

Page 159: ...e Screen to Blue 2 4 10 ohms Red to Green 3 5 5 ohms Red to Yellow 3 6 5 ohms Red to Screen 3 2 Open circuit 3 Magnetic Deviation The Z130 Fluxgate Compass requires careful siting if optimum autopilot performance is to be achieved The SeaTalk Course Computers are able to correct the compass for any deviating magnetic fields present when the linearisation procedure is carried out Any further deviat...

Page 160: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 4 Z130 Fluxgate General Assembly ...

Page 161: ...6 Before installing the cover check the gimbal action of the new assembly by tilting the case in all directions and observing the fluxgate movement 7 Refit the front cover and seal again rotating the screws anticlockwise to locate and tightening with a hand screw driver 8 Functionally check the Fluxgate with a D V M as follows Cable Colour Connector Pin no Resistance Screen to Blue 2 4 10ohms Red ...

Page 162: ...ections and observing the fluxgate movement 7 Refit the front cover and seal again rotating the screws anticlockwise to locate and tightening with a hand screw driver 8 Functionally check the Fluxgate with a D V M as follows Cable Colour Connector Pin no Resistance Screen to Blue 2 4 10ohms Red to Green 3 5 5 ohms Red to yellow 3 6 5 ohms Red to Screen 3 2 Open circuit ...

Page 163: ...es risk of fluxgate assembly becoming dislodged during transit 7 Spares Numbers Fluxgate Compass Z130 Item Catalogue No Comments Fluxgate bobbin Gimbal Assembly M022 Includes inner gimbal sub assembly and 2 x pivot assemblies Support bracket M096 Includes back case cable assembly pivot blocks support bracket and pivot retaining screws fitted as standard to units built after Serial No 600001 ...

Page 164: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 8 ...

Page 165: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 1 Fluxgate Compass Z105 ...

Page 166: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 2 Contents Page 1 Description 3 2 Functional Test 3 3 Magnetic Deviation 3 ...

Page 167: ...105 Fluxgate Compass requires careful siting if optimum autopilot performance is to be achieved The SeaTalk Course Computers are able to correct the compass for any deviating magnetic fields present when the linearisation procedure is carried out Any further deviation introduced after linearisation will introduce an error be tween the Fluxgate and the ships compass This can be removed by carrying ...

Page 168: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 4 ...

Page 169: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 1 Rudder Reference Transducer Z060 ...

Page 170: ...tohelm SeaTalk Service Manual 2 Contents Page 1 Description and Functional Test 3 2 Resetting Centre Position 3 3 Product History 7 Illustrations Fig 1 Rudder Reference Unit Standard Installation 5 Fig 2 Adjusting Centre Position 6 ...

Page 171: ...at with the rudder amidships the arm is diametrically opposite the cable gland see figure 31 Should it be necessary to install the transducer with its arm in an alternative position to the cable gland the centre position of the potentiometer must be reset as follows see figure 32 1 When the rudder is amidships determine the orientation of the rudder reference transducer arm to the cable gland 2 Re...

Page 172: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 4 Fig 1 Rudder Reference Unit Standard Installation ...

Page 173: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 5 Fig 2 Adjusting Centre Position ...

Page 174: ...elm Autohelm SeaTalk Service Manual 6 3 Product History Rudder Reference Z060 Change Serial Number Slotted mounting holes introduced 980001 Stainless Steel fittings introduced 290001 Stainless Steel studding introduced K90001 ...

Page 175: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 1 Pushpit Windvane Transducer Z087 Masthead Windvane Transducer Z080 Service Procedures ...

Page 176: ...ce Manual 2 Contents Page 1 Description 3 2 Functional Test Z080 Masthead Transducer 3 3 Functional Test Z087 Pushpit Transducer 3 4 Product History 4 5 Spares Numbers 4 Illustrations Fig 1 Z080 Masthead General Assembly 5 Fig 2 Z080 Mount Assembly 6 ...

Page 177: ...ration of the Z080 masthead mounted windvane can be checked using the following procedure 1 Connect 8V dc to the red core and 0V to the screen 2 Connect a digital volt meter across the screen and the green core 3 Rotate vane head through 360 degrees and check that the meter reading oscillates sinusoidally The maximum reading must be between 6V and 5 5V The minimum reading must be between 2V and 2 ...

Page 178: ...located tighter onto mast socket Self cut grub screws replace brass inserts in vane and anemometer bosses L90000 Tighter location of vane and cups onto respective transducer shafts 5 Spares Numbers Z080 Masthead Transducer Item Catalogue No Comments Vane transducer pod Q001 Used on both Z080 and Z087 transducers Anemometer transducer pod Q002 Masthead transducer arm Q025 Mast arm and pod housing w...

Page 179: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 5 Z080 Masthead Transducer General Assembly ...

Page 180: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 6 Z050 Mount Assembly ...

Page 181: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 1 Linear Drive Units Service Procedures Linear Drive Unit Z029 Z032 Linear Drive Unit Z029 Z058 Z059 ...

Page 182: ...troduction 3 2 Inspection 3 3 Dismantling 3 4 Re assembly 4 5 Operation with non Autohelm Autopilots 24V systems 4 6 Functional Test 4 7 Product History Type 2 Long Stroke 8 8 Product History Type 1 8 9 Product History Type 2 Short Stroke 8 10 Spares Numbers 9 Illustrations Fig 1 General Assembly 7 ...

Page 183: ...he plastic dust cover to the main unit use M3 alien key Slide the dust cover off the girdle tube b Unscrew and remove the four M6 caphead screws with washers and the two long hexagonal studs at the centre sides of the master plate Separate the mounting cover assembly from the master plate assembly after feeding the cables through the grommet c If servicing the clutch rotor assembly remove it from ...

Page 184: ...erating correctly c When rebuilding from the drive module stage ensure that the driven pulley planet gears washers and carrier are all correctly located and turning freely before and after the roll pin securing the carrier to the leadscrew is refitted Note that extreme care must be taken to fully support the leadscrew journal when driving the roll pin back into the carrier This prevents the leadsc...

Page 185: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 5 Linear Drive Unit Functional Test Procedure Z029 Z032 Z039 Z085 Z059 ...

Page 186: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 6 No load current limits Minimum A Maximum A Type 1 Z039 2 0 3 0 Type 2 12V Z029 Z058 2 5 3 5 Type 2 24V Z032 Z059 1 0 2 5 ...

Page 187: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 7 Fig 1 Linear Drive Unit Z029 Z032 Z039 Z058 Z059 General Assembly ...

Page 188: ...tory Type 1 Linear Drive Actuators Z039 Change Serial Number Comments Introduction 470003 Fracmo Motors introduced 680086 Girdle Buffer Stop material changed 790068 Extended high temperature use caused rubber buffer to swell giving higher back drive Rockford Leadscrew introduced 100002 9 Product History Type 2 Linear Drive Actuators Short Stroke Z058 Z059 Change Serial No Comments Introduction 470...

Page 189: ...ual 9 10 Spares Numbers Linear Drive Unites Z029 Z032 Z039 Z058 Z059 Item Catalogue No Drive Motor Z039 N001 Drive Motor Z058 Z029 N002 Drive Motor Z032 Z059 N003 Short Stroke drive module N004 Long Stroke drive module N005 Drive Belt N006 Clutch Rotor N007 ...

Page 190: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 10 ...

Page 191: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 1 Rotary Drive Units Z028 Z031 Z037 ...

Page 192: ...elm SeaTalk Service Manual 2 Contents Page 1 Rotary Drive Unit Introduction 3 2 Dismantling 3 3 Re assembly 3 4 Operation with non Autohelm Autopilots 24V 4 5 Functional Test 4 6 Spares Numbers 7 Illustrations Fig 1 General Assembly 6 ...

Page 193: ...r as above then unscrew and remove the 4 x 6mm caphead screws with washers and also the two long hexagonal studs at the centre sides of the main assembly The mounting cover assembly can now be removed from the master plate Care must be taken when removing the cover assembly to ensure the drive gear disengages without damage This is best done with the mounting cover placed down on the bench and the...

Page 194: ... gears Ensure the drive train rotates freely before refitting and tightening all the screws d When refitting the dust cover ensure that all leads are either secured to the hexagonal pillars or pulled uptight through the grommet so that they are kept clear of any moving parts e Ensure that the correct drive motor and product label is fitted by a simple voltage and current test checked against the s...

Page 195: ...elm Autohelm Autohelm SeaTalk Service Manual 5 Rotary Drive Unit Functional Test Procedure Z028 Z031 Z038 No load current limits Minimum A Maximum A Type 1 Z037 2 0 3 0 Type 2 12V Z028 2 5 3 5 Type 2 24V Z031 1 0 2 5 ...

Page 196: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 6 ...

Page 197: ...elm Autohelm Autohelm SeaTalk Service Manual 7 6 Spares numbers Rotary Drive Units Z028 Z031 Z037 Item Catalogue No Drive Motor Z037 N001 Drive Motor Z028 N002 Drive Motor Z031 N003 Drive Belt N006 Clutch Rotor N007 ...

Page 198: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 8 ...

Page 199: ...ohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 1 Hydraulic Drive Units Service Procedures Type 0 Piston Pump Z081 Constant Running Power Pack Z064 Z065 Z066 Z067 Reversing Gear Pump Z030 Z033 Z041 ...

Page 200: ...ing Power Pack Z064 65 66 67 3 2 1 Dismantling and Re assembly 3 3 Reversing Gear Pumps Z030 33 41 6 4 Type 0 Piston Pump Z081 8 4 1 Type 0 Pump Re installation 8 4 2 Type 0 Pump Bleeding 8 Illustrations Fig 1 Constant Running Power Pack General Assembly 5 Fig 2 Reversing Gear Pump General Assembly 7 Fig 3 Type 0 Pump Bleeding 9 ...

Page 201: ... flow to the steering cylinder The servicing information allows replacement of the solenoid valve assembly inspection and cleaning of the check valve and relief valve assembly and seal replacement It is not possible to service the pump and filter assembly which are contained within the reservoir as the reservoir seal requires special assembly techniques 2 1 Dismantling and Reassembly a To remove t...

Page 202: ...vice Manual 4 c If the relief valve assembly is removed the relief valve setting should be checked after reassembly The factory pre set is 750 psi d Ensure all parts are reassembled in the current sequence and nothing is missed out during reassembly ...

Page 203: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 5 Fig 1 Z064 6 5 66 67 Constant Running Power Packs Pilot Check and Relief Valve General Assembly ...

Page 204: ... valve assemblies it is usually only necessary to remove the cap spring and ball The dirt will in most cases be washed out with oil from the reservoir If the seats and 0 ring seals are removed these are best replaced by using the cap without the spring to position them The cap may then be removed and reassembled with the spring in position Ensure all parts are reassembled in the correct sequence a...

Page 205: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 7 Fig 2 Z041 Z030 Z033 Reversing Gear Pump ...

Page 206: ...ng the following procedures 1 Fill pipe B with oil 2 Connect pump drive cable to a 12V dc supply via a 10 ohm 50W resistor This allows the pump to rotate slowly without cavitating 3 Continue adding oil to pipe B as the level drops Note If oil is expelled from pipe B then reverse the connections to the pump 4 Stop the pump when oil appears out of pipe A Reconnect A to the steering system and repeat...

Page 207: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 9 Fig 3 Type 0 Piston Pump Bleeding ...

Page 208: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 10 ...

Page 209: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 1 Inboard Outboard Drive Unit Z088 Service Procedures ...

Page 210: ...tohelm Autohelm SeaTalk Service Manual 2 Contents Page 1 I O Drive Unit Introduction 3 2 Motor Replacement 3 2 1 Dismantling 3 2 2 Re assembly 3 3 Functional Test 4 4 Spares Numbers 6 Illustrations Fig 1 General Assembly 5 ...

Page 211: ...Autohelm Autohelm Autohelm Autohelm SeaTalk Service Manual 3 Fig 1 I O Drive Unit Exploded View Z088 ...

Page 212: ... Autohelm Autohelm Autohelm SeaTalk Service Manual 4 4 Spares numbers I O Sterndrive Unit Z088 Item Catalogue No Drive Motor N017 Drive Assembly N018 Mercruiser Installation Kit D137 Volvo Installation Kit D129 ...

Page 213: ... the support plate is held square during removal to prevent damage to clutch shaft It is now possible to remove the clutch gear core sub assembly spring and plastic bearing from clutch shaft Undo the lock nut of the 4 pin connector and remove Unscrew 2 off front dust cover retaining screws and push connector out of front dust cover Slide dust cover along girdle tube sub assembly to provide access ...

Page 214: ...n under load Failure of the clutch to disengage is probably due to a damaged clutch tooth in which case the drive unit must be replaced The spur reduction gearbox is noisy compared to the epicyclic gearboxes on other drive units This is normal The no load motor running current with the clutch engaged should be less than 1 5A The clutch current at 10V should be between 0 7 and 10A Connect the drive...

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