Kobelt HRP05 Series Maintenance Manual Download

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Kobelt Manufacturing Co. Ltd.

HRP05/HRP11/HRP17 Accu-Steer

Hydraulic Reversing Pump-Set

Owner’s Operation, Installation &

Maintenance Manual

November 2018

Summary of Contents for HRP05 Series

Page 1: ...Kobelt Manufacturing Co Ltd HRP05 HRP11 HRP17 Accu Steer Hydraulic Reversing Pump Set Owner s Operation Installation Maintenance Manual November 2018 ...

Page 2: ...HRP11 HRP17 Accu Steer Pump Set Kobelt Manufacturing Co Ltd Rev D HRP07 HRP11 HRP17_MANUAL 2 of 28 NOTES RECORD DATA BEFORE INSTALLATION FOR FUTURE REFERENCE Model Serial Date of Purchase Date of Installation ...

Page 3: ...draulic 10 4 3 Electrical 12 5 Commissioning 15 5 1 Hydraulic Fill Bleed 15 5 2 Electrical Check 15 5 3 Functional Test 15 6 Maintenance 16 6 1 Preventative Maintenance 16 6 2 Recommended Spare Parts 16 7 Troubleshooting 17 8 Warranty 18 9 Appendix A Installation Dimensions 19 10 Appendix B Pump Parts List 20 11 Appendix D Manifold Assembly Parts 22 12 Appendix D Typical System Arrangement 24 13 A...

Page 4: ...as been selected 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 Alerts Throughout this manual the following symbols and their accompanying explanation are used to alert the user to special instructions concerning a service or operation that may be ha...

Page 5: ...s manual qualified 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 specifications in this manual If these guidelines are not followed and damage occurs the warranty will be voided 1 2 3 Product Hazards High Pressure Operation This HRP unit generates high press...

Page 6: ... 600 072 600 081 600 082 600 091 600 092 NOMINAL VOLTAGE 12 VDC 24 VDC 12 VDC 24 VDC 12 VDC 24 VDC MAXIMUM CURRENT 20 A 10 A 30 A 15 A 40 A 20 A OUTPUT FLOW RATE 0 5 in3 sec 8 cc sec 1 0 in3 sec 16 cc sec 1 6 in3 sec 26 cc sec MAXIMUM ALLOWABLE PRESSURE A B PORTS T PORT 1000 PSI 70 bar 50 PSI 3 4 bar CYLINDER CAPACITY 5 9 in3 82 147 cc 10 16 in3 164 262 cc 16 30 in3 262 492 cc SERVICE DUTY Intermi...

Page 7: ...ring applications High demand applications will over work the motor and cause over heating 2 1 3 Temperature Limits The motor temperature has a maximum limit of 248o F 120o C Allowing the temperature to exceed this limit will permanently damage the motor windings The maximum oil temperature limit is 149oF 65oC Observe the operating temperature range of the unit Table 1 HRP05 HRP11 HRP17 Technical ...

Page 8: ...p 2 is pumped towards output A This oil passes through the check valve 5 and goes to the output line 7 The pressure at output A ensures the check valve 3 stays closed and manually opens check valve 6 Opening check valve 6 allows the returning oil from the steering cylinder to flow back to the pump If the pressure at the pump suction B is less than the pressure in the make up line oil from the make...

Page 9: ...HRP05 HRP11 HRP17 Accu Steer Pump Set Kobelt Manufacturing Co Ltd Rev D HRP07 HRP11 HRP17_MANUAL 9 of 28 Figure 2 Internal Hydraulic Schematic ...

Page 10: ... hoses must be flushed prior to connection Failure to do so can result in damaged components and seals The three hydraulic ports on the valve block are fitted with 1 4 NPT National Pipe Thread adapters If preferred the adapters can be removed and connections can be made directly to the valve blocks 06 SAE ORB ports When installing the hydraulic fitting in the 1 4 NPT port a pipe thread sealant suc...

Page 11: ...he steering lines Shut off or isolation valves for all three lines are recommended If the pump set fails the isolation valves can be shut off and manual steering maintained If more the one helm pump is used a return fill line must be installed to connect the cases of all the helm pumps together With steering systems where the fill interconnect line is pressurized e g Hynautics or Teleflex the reco...

Page 12: ...by the current outlined in the product specifications table The breaker should trip after no more than 600 seconds The motor power source must have proper short circuit and overload protection Ensure that electrical cable used is sized property to prevent excessive voltage drop Refer to your local marine standards or other local governing wiring codes for guidance Figure 4 HRP05 11 17 Wiring Diagr...

Page 13: ... are provided for reference below in Figure 5 thru Figure 7 Remember to always follow the installation guidelines as provided by your autopilot manufacturers manual Figure 5 Example Autopilot Connection Raymarine ACU 100 150 200 400 Figure 6 Example Autopilot Connection SimRad AC12 AC42 Figure 7 Example Autopilot Connection Furuno FAP 7002 ...

Page 14: ...nd implementation of such a system be performed by a Certified Marine Installer Kobelt Distributor or individual with appropriate training and knowledge Figure 8 HRP Jog Lever Control Wiring Diagram Power supply to Jog and HRP should be protected with appropriate circuit breakers as per local codes If only a single battery power source if available then they can be tied together at the supply sour...

Page 15: ...n out to sea after installation has been completed After installation and filling perform the following function tests 1 Power ON the autopilot or electronic jog lever 2 Active the autopilot or electronic jog lever to command motion 3 Verify that the rudder position changed 4 Set the autopilot to the manual mode and operate the pump set to determine if the Port and Starboard directions are correct...

Page 16: ...n integrity of motor windings 6 2 RECOMMENDED SPARE PARTS As a minimum Kobelt recommends the following spare parts are on hand Table 2 Recommended Spares RECOMMENDED SPARES QTY ITEM KOBELT PART 1 HRP05 HRP11 HRP17 REPAIR KIT 12 VDC 24 VDC 600 071 RK Repair kit contains O ring shaft seal and brushes When purchasing spare parts refer to Appendix B Pump Parts List at the back of this manual for Kobel...

Page 17: ... do HRP does not turn ON No power to unit 1 Check that the breaker is ON and has not tripped 2 Check that power is being output by the Autopilot 3 Use a Mutli meter to confirm if power is present between the motor leads when the Autopilot is commanding motion Wheel feels soft Air present in Hydraulic System 1 Bleed hydraulic system to remove trapped air 2 Check for proper operation HRP turns in op...

Page 18: ...ative Upon identification 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 other electronic conveyance Kobelt will then assess the cause of the defect and determine warranty applicability and appropriate remediation If any part is found to be defective Kobelt will r...

Page 19: ...HRP05 HRP11 HRP17 Accu Steer Pump Set Kobelt Manufacturing Co Ltd Rev D HRP07 HRP11 HRP17_MANUAL 19 of 28 9 APPENDIX A INSTALLATION DIMENSIONS Figure 9 HRP05 HRP11 HRP17 Installation Dimensions ...

Page 20: ...HRP05 HRP11 HRP17 Accu Steer Pump Set Kobelt Manufacturing Co Ltd Rev D HRP07 HRP11 HRP17_MANUAL 20 of 28 10 APPENDIX B PUMP PARTS LIST Figure 10 HRP05 HRP11 HRP17 Parts Diagram ...

Page 21: ...P05 12 HRP05 24 HRP11 12 HRP11 24 HRP17 12 HRP17 24 Part No 600 071 600 072 600 081 600 082 600 091 600 092 ITEM DESCRIPTION 1 SCREW 1002 1012 2 MOTOR 7070 0010 7070 0011 7070 0010 7070 0011 7070 0010 7070 0011 3 MANIFOLD 502 005 4 REPAIR KIT 600 071 RK 5 GEROTOR 7250 0001 7250 0002 7250 0003 6 PUMP HOUSING 502 011 502 011 502 012 7 SCREW 1002 1016 ...

Page 22: ...HRP05 HRP11 HRP17 Accu Steer Pump Set Kobelt Manufacturing Co Ltd Rev D HRP07 HRP11 HRP17_MANUAL 22 of 28 11 APPENDIX D MANIFOLD ASSEMBLY PARTS Figure 11 502 005 Manifold Parts Diagram ...

Page 23: ...17 MANIFOLD BODY 7001 0033 2 3 FITTING 06 ORB M x 1 4 NPT F 7039 0141 3 3 PLASTIC PLUG 1 4 NPT 7039 3042 4 5 EXPANSION PLUG CV173 218S 7039 3054 5 2 SPRING 1201 0261 6 2 PLUG HEX SKT 04 ORB PLATED STEEL 7039 0661 7 2 CHECK VALVE 7049 0017 8 2 BALL CHECK 1301 0108 9 1 REPAIR KIT 600 071 RK 10 1 RUBBER FOOT 7056 0052 11 1 SCREW PAN HD PHIL 6 32 x 1 2 18 8 1012 0608 12 1 HRP LOCKVALVE SPOOL 7006 0002...

Page 24: ...HRP05 HRP11 HRP17 Accu Steer Pump Set Kobelt Manufacturing Co Ltd Rev D HRP07 HRP11 HRP17_MANUAL 24 of 28 12 APPENDIX D TYPICAL SYSTEM ARRANGEMENT Figure 12 Typical System Arrangement ...

Page 25: ...Brushes 1 Remove the two nuts at the back of the motor 2 Remove the motor end cap 3 Inspect the brushes for wear 4 If replacement required a Remove them with consideration to the direction of brushes and springs b Install new brushes in proper orientation c Re assemble motor housing 5 If replacement not required a Re assemble motor housing Figure 13 Motor Brush Diagram ...

Page 26: ...Seal thoroughly with Methyl Hydrate or Similar Degreaser 2 Apply thin film of Loctite 567 Liquid Teflon to the Bore and Seal 3 Using moderate force drive Seal into bottom of Bore using seating tool Note Installation force is often provided solely by hand operated arbor presses or soft faced mallets used in conjunction with strike plates Figure 14 Motor Shaft Seal Diagram A Figure 15 Motor Shaft Se...

Page 27: ...HRP05 HRP11 HRP17 Accu Steer Pump Set Kobelt Manufacturing Co Ltd Rev D HRP07 HRP11 HRP17_MANUAL 27 of 28 This Page Intentionally Left Blank ...

Page 28: ...elt 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 Canada ...

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