Raymarine autopilot ST4000+, Service Manual

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Autopilots
16 Autopilots Service Manual 83115-1
Assembly
In all cases, assembly is a straight reversal of the steps described in
Disassembly
.
Gearbox assembly
Refer to Figure 7. Wheel Drive Actuator exploded view.
1. Rebuild gearbox. Refer to Figure 8. Gearbox exploded view
2. Fix the gearbox (23) to the back mounting plate assembly (2) using the
four gearbox retaining screws (22).
3. Slide the two shims (20) over the gearbox drive shaft/gear carrier ‘C’ (21)
and hard up against the back mounting plate assembly (2).
4. Support the gearbox drive shaft/gear carrier ‘C’ (21) and refit the pin (19).
Note: If the original pin (19) is bent or damaged a replacement pin can be
obtained from pinion kit, part no. N014.
Motor assembly
Refer to Figure 7. Wheel Drive Actuator exploded view.
1. Fit the red motor seal (24) over the threaded end of the gearbox (23).
2. Insert the connector wires through the motor clamp (28), and solder the
connector wires to the motor tags – red lead to the tag with a red spot,
black lead to the other motor tag.
3. Slide flux ring (25) on the motor (27) and fit onto the gearbox (23)
ensuring that the motor drive gear is fully engaged with the gear train and
the motor location peg (26) is engaged correctly into the gearbox (23).
4. Fit the ‘O’ ring (29) onto the motor clamp (28).
5. Place the connector seal (31) over the connector (30).
6. Screw the sleeve (32) with fitted ‘O’ ring (33) and end cap (34) onto the
gearbox (23).
7. Place the sealing cap (35) over the connector (36) and secure with the
connector nut (37).
Adjustment eccentric assembly
Refer to Figure 7. Wheel Drive Actuator exploded view.
1. Assemble the adjustment wheel assembly (13), adjustment eccentric
assembly (12), adjustment lock nut (14) with its chamfered edge facing
outwards, and protection cap (15) to the back mounting plate assembly (2).
Note: Ensure that the drive lever (9) is in the slack (declutched) position
and the adjustment eccentric assembly (12) is in its lowest position, so
that the belt (5) is at its slackest.