Related Manuals for Kobelt Accu-Steer HPU100 Series
Summary of Contents for Kobelt Accu-Steer HPU100 Series
- Page 1 HPU100 Accu-Steer Hydraulic Power Unit Owner’s Operation, Installation & Maintenance Manual August 2019 Kobelt Manufacturing Co. Ltd.
- Page 2 HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. NOTES RECORD DATA BEFORE INSTALLATION FOR FUTURE REFERENCE Model #: Serial #: Date of Purchase: Date of Installation: Rev C MNL-HPU100 2 of 32...
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Page 3: Table Of Contents
HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. ABLE OF ONTENTS Introduction ......................4 Contact ........................4 Safety ........................4 Product Description ....................6 Components ......................7 Technical Specifications ................... 7 Installation ......................10 Mechanical ......................10 Hydraulic ........................ 10 Electrical ........................ -
Page 4: Introduction
Kobelt reserves the right, without notice, to change the design, or construction, of any products and to discontinue or limit distribution of any products. Kobelt also reserves the right to change, or update, without notice, any technical information contained within this document. - Page 5 • Do not carry out any modifications to the product. • Only use authentic Kobelt spare parts. • Observe all local regulations, directives and laws during the installation of this product. • All installation, commissioning, and maintenance work must only be conducted by qualified personnel.
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Page 6: Product Description
HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. RODUCT ESCRIPTION The Accu-Steer HPU100 pumpset is a continuous running pumpset designed to interface hydraulic steering systems with electric or autopilot control. As described, the motor runs continuously when started and the output oil is directed to the port or starboard line by operating the four-way solenoid valve mounted on the pumpset. -
Page 7: Components
HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. OMPONENTS The Accu-Steer HPU100 is a complete pump assembly consisting of a gerotor style pump, adjustable flow control, adjustable pressure release valve and an electric permanent magnet motor terminated in an electrical junction box. As the pump set is self-contained, installation involves connecting the unit to the steering lines and the electric control and adjusting the unit to the requirements of the steering system. - Page 8 HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. 2.2.1 Temperature Limits The motor temperature has a maximum limit of 248 F [120 C]. Allowing the temperature to exceed this limit will permanently damage the motor windings. The maximum oil temperature limit is 149 F [65 Observe the operating temperature range limits as presented in Table 1.
- Page 9 HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. PORT STARBOARD 4-WAY SOLENOID VALVE PRESSURE RELIEF VALVE LOW SPEED FLOW ADJ. BYPASS DUMP VALVE FROM PUMP PUMP TANK Figure 2: Hydraulic Schematic Rev C MNL-HPU100 9 of 32...
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Page 10: Installation
HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. NSTALLATION ECHANICAL The pumpset must be placed on a horizontal bracket with a solid foundation. It should be close to and below the steering lines for ease of connections and bleeding. The HPU is equipped with (4) four holes for 1/4” bolts through the mounting feet. Ensure that the unit is securely fastened to a suitable foundation. -
Page 11: Electrical
HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. The piping to the steering cylinder should be minimum 1/4” nominal size with a suitable wall thickness to safely withstand the operating pressure. The Port and Starboard steering lines should have a pressure rating of 1000 psi minimum. Secure the piping against vibration with pipe clamps spaced every 3 feet [1 m]. - Page 12 HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Ensure that the electrical cable used to feed the main power to the motor of the HPU150 is sized properly to prevent voltage drop. Refer to ABYC or local boat electrical standards for applicable rating recommendations.
- Page 13 HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Table 2: HPU100 Terminal Block Wiring Connections HPU100 Series Terminal Wire Wire Function Name Colour MOTOR POS (+) Positive power supply to motor Yellow MOTOR NEG (-) Negative power supply to motor.
- Page 14 Example Connection Diagrams The following section contains various example methods for connection of the HPU. It is recommended that installation work is carried out by a Kobelt Partner, authorized service representative, or trained installation technician. Please contact the nearest Kobelt authorized distributor for assistance.
- Page 15 HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Figure 7: HPU100 Autopilot Wiring Diagram, Common Positive Rev C MNL-HPU100 15 of 32...
- Page 16 HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Figure 8: HPU100 Autopilot Connection Option with Starter Connections Rev C MNL-HPU100 16 of 32...
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Page 17: Commissioning
HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. OMMISSIONING & B YDRAULIC LEED After the hydraulic and the electrical connections have been completed, open all isolating valves and allow enough time for the pump and lines to fill with oil. Start the pump and operate the 4-way solenoid valve to check that the port and starboard directions are correct. -
Page 18: Functional Test
HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. UNCTIONAL The Functional Test should be carried out while the vessel is still at dock and before it is taken out to sea, after installation has been completed. After installation and filling, perform the following function tests: Power ON the autopilot (or electronic jog lever). -
Page 19: Operation
HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. PERATION The HPU100 operates as follows: • Manifold receives oil from pump, and outputs to steering lines. Output flow determining the speed of the rudder. • Output flow is controlled by flow control valves. -
Page 20: Maintenance
HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. AINTENANCE REVENTATIVE AINTENANCE The brushes on the electric DC motor can be easily checked by removing the caps and visually inspecting the brushes. Replace the carbon brushes as required and check the internal condition of the motor. -
Page 21: Recommended Spare Parts
HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. ECOMMENDED PARE ARTS As a minimum Kobelt recommends the following spare parts are on-hand: Table 3: Recommended Spares RECOMMENDED SPARES DESCRIPTION KOBELT PART # HPU100 REPAIR KIT (12 VDC / 24 VDC) 600-031-RK •... -
Page 22: Troubleshooting
If you encounter problems with the operation of your product, please refer to the trouble- shooting suggestions before contacting Kobelt for assistance. If the steps below do not resolve your issue, please reach out either Kobelt directly or our Dealers in your area. Table 4: Common Solutions... -
Page 23: Warranty
If any part is found to be defective, Kobelt will replace said part FOB the Kobelt factory provided that any such defective part is returned by the Buyer with freight and applicable forwarding charges prepaid by the Buyer. -
Page 24: Appendix A: Installation Dimensions
HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. A: I PPENDIX NSTALLATION IMENSIONS Figure 9: HPU100 Installation Dimensions Rev C MNL-HPU100 24 of 32... -
Page 25: Appendix B: Parts List
HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. 10 A B: P PPENDIX ARTS Figure 10: HPU100 Parts Diagram Rev C MNL-HPU100 25 of 32... -
Page 26: Appendix C: Manifold Assembly Parts
HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Table 5: HPU100 Parts List Model No.: HPU100-12 HPU100-24 Part No.: 600-031 600-032 ITEM DESCRIPTION MANIFOLD 502-110 GEROTOR 7250-0004 PUMP HOUSING SUB ASSEMBLY 502-115 O-RING 600-031-RK* PUMP END COVER PLATE 7001-0042 SCREW CAP SKT HD, 1/4-20 X 1 1/2... - Page 27 HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. 11 A C: M PPENDIX ANIFOLD SSEMBLY ARTS Figure 11: 502-110 Manifold Parts Diagram Rev C MNL-HPU100 27 of 32...
- Page 28 HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. Table 6: HM100 Manifold Parts Table Part No.: 502-406 ITEM DESCRIPTION HPU100 BLOCK 220-335 FLOW CONTROL 7044-0012 SHAFT SEAL 600-031-RK* BALL 1301-0005 BLEEDER SCREW 7040-0011 EXPANSION PLUG 7039-3055 DIFFERENTIAL PRESSURE SENSE VALVE...
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Page 29: Appendix D: Typical System Arrangement
HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. 12 A D: T PPENDIX YPICAL YSTEM RRANGEMENT Figure 12: Typical System Arrangement Rev C MNL-HPU100 29 of 32... -
Page 30: Appendix E: Brush Replacement
HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. 13 A E: B PPENDIX RUSH EPLACEMENT Steps for Replacement of Motor Brushes: Remove the brush caps. (Replacement kit includes new caps for installation). Remove the brushes. Inspect the brushes for wear. -
Page 31: Appendix F: Shaft Seal Replacement
HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd. 14 A F: S PPENDIX HAFT EPLACEMENT Steps for Replacement of Motor Shaft Seal: Clean both the Bore and Seal thoroughly with Methyl Hydrate or Similar Degreaser Apply thin film of Loctite 567 (Liquid Teflon) to the Bore and Seal Using moderate force, drive Seal into bottom of Bore using seating tool. - Page 32 Kobelt 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 Keivan Digitally signed by Keivan Ashouei Ashouei Date: 2020.08.05 12:48:24 -07'00'...