Raymarine autopilot ST4000+, Service Manual

Page 1: ...ot supplied for or not approved for such use by Raytheonor ifsuppliedorapprovedforusebyRaytheon notproperlyfittedinaccordancewithinstructionspublished providedorrecommendedbyRaytheon maycausetheequipmenttomalfunctionand inparticular tobecomeunsafeor tonolongermeettherelevantCErequirements Inthesecircumstances RaytheonMarineEuropeLtdexcludesliability to the fullestextentpermissibleinlawforanyloss o...

Page 2: ...ST4000 Autopilots ST4000 Autopilots Service Manual 83115 1 ...

Page 3: ...y 10 Fluxgate Compass spare parts list 10 Chapter 3 Wheel Drive Actuator 11 3 1Wheel Drive Actuator test 11 3 2 Disassembly assembly 12 Wheel Drive Actuator spare parts list 13 Disassembly 14 Belt removal 14 Pinion sprocket removal 14 Drive lever and eccentric removal 14 Motor removal 14 Gearbox removal 15 Gearbox disassembly 15 Assembly 16 Gearbox assembly 16 Motor assembly 16 Adjustment eccentri...

Page 4: ... 1Tiller Drive Actuator test 21 4 2 Disassembly assembly 22 Tiller Drive Actuator spare parts list 23 Tiller Drive Actuator GP conversion kit W003 23 Chapter 5 Tiller Drive Actuator GP 25 5 1Tiller Drive Actuator GP test 25 5 2 Disassembly assembly 26 Tiller Drive Actuator GP spare parts list 27 ...

Page 5: ...TDBY for 14 seconds until CAL is displayed 4 Momentarily press 1 and 1 together to gain access to extended calibration dealer set up 5 Advance from the CAL LOCK page to the pilot type page by pressing DISP 6 Use the 1 and 1 buttons to set the pilot type as required 4000WHL wheel or 4000TILL tiller 7 Press STDBY to exit extended calibration 8 Switch off the power supply Do not disconnect 9 When the...

Page 6: ...1 x3 14 13 11 x8 10 PCB 11 Retaining screw x11 12 Case seal 13 Rear cover 14 Buzzer connector 15 Label 16 Bulkhead gasket 17 Keypad shim earlier units only Notes A Earlier production units have a shim 17 fitted to aid keypad compression B The castellated top edge of the diffuser 8 fits under the legs of the LEDs on the top edge of the PCB 10 C It is recommended that a new case seal 12 is fitted on...

Page 7: ...isplaykit including Q220 3 Label selection FitST4000 label 4 Windowinsert 5 LCDsurround 6 LCD 7 Elastomer x2 Diffuserkit including W117 8 Diffuser 9 Reflector 10 PCB Q221 ST4000 ST5000 PCB Fixingkit including W120 11 Screw x11 12 Caseseal W118 Back cover assembly including W119 13 Back cover Comesfittedwith Gortexfilter Sleeving Buzzerand 14 Buzzerconnecter 15 Label selection FitST4000 label 16 Bu...

Page 8: ...5 F GA 2 5Vdc P6 F GB 2 5Vdc P7 Coildrive AC signal 17 cycles at 7 9kHz driven twice every 1 16 second P8 Rudderreference Nominal5Vsupplytorudderreference supply P9 Rudderreference 0to5Vdc nominal rudderreferenceoutput P10 Rudderreference0V 0V P11 SCRN 0V C Clutch 12VifAutopilotengaged otherwise0V C Clutch0V 0V MD1 MD1 WhenAutopilotengagedanddependingon directionofdrive intermittentvariablelength ...

Page 9: ...Chapter 1 ST4000 Control Head ST4000 Autopilots Service Manual 83115 1 5 Circuit Diagram D3723 1 Figure2 CircuitDiagram ...

Page 10: ...ST4000 Autopilots 6 ST4000 Autopilots Service Manual 83115 1 PCB Layout D3722 1 Taken from Drawing No 4376 001 Issue P Date 03 10 97 Figure3 PCBComponentLayout ...

Page 11: ...Chapter 1 ST4000 Control Head ST4000 Autopilots Service Manual 83115 1 7 PCB Component list D3724 1 Taken from Drawing No 4376 001 Issue P Date 03 10 97 ...

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Page 13: ...ting if optimum Autopilot performance is to be acheived The SeaTalk electronics is able to correct the compass for most deviating magnetic fields present when the linearisation procedure is carried out Any further deviation introduced after linearisation will introduce an error between the Fluxgate and the ship s compass This can be removed by carrying out the linearisation again If the displayed ...

Page 14: ...embly 6 Fluxgate sub assembly 7 Body 8 Body screw x4 9 Cable Figure4 FluxgateCompassexplodedview Fluxgate Compass spare parts list The item numbers refer to Figure 4 Fluxgate Compass exploded view Item SpareDescription PartNo Comments Compassbasekit including M096 3 Pivotretainingscrew x2 4 Bracket Fluxgatesub assembly including M022 5 Pivot sub assembly x2 6 Fluxgatesub assembly ...

Page 15: ...heck wiring and connector OK Check motor Change as necessary OK D2390 1 No Yes Connect power supply as in Figure 5 OK No Yes Change adjust as necessary Switch on Check drive ring moves in opposite direction to that of first test and current is less than 2A No Yes OK Actuator OK End of test Switch on and with clutch engaged check drive ring moves and current is less than 2A Restrain drive ring rota...

Page 16: ...hamfer of adjustment locking nut to face protective cap 23 24 25 26 28 29 30 31 27 20 x2 19 32 33 34 35 36 13 Adjustment wheel assembly 14 Adjustment locking nut 15 Protection cap 16 Roller screw x7 17 Washer x7 18 Roller x7 19 Pin 20 Shim x2 21 Gearbox drive shaft gear carrier C 22 Gearbox retaining screw x4 23 Gearbox 24 Red motor seal 25 Flux ring 26 Motor location peg 27 Motor 28 Motor clamp 2...

Page 17: ...D169 Pinionkit including N014 7 Pinionsprocket 15 Protectioncap 19 Pin 20 Shim x2 Driveleverkit including N011 8 Rollpin 9 Drivelever 11 Drive eccentric assembly N024 Gearboxdriveshaft gear N026 carrier C kit including 21 Gearboxdriveshaft gearcarrier C SeeFigure8 item3 Planetgear x12 SeeFigure8 item4 Shim SeeFigure8 item2 O ring SeeFigure8 item1 27 Motor N012 Wiringkit including Q106 28 Motorclam...

Page 18: ...d eccentric removal Refer to Figure 7 Wheel drive actuator exploded view 1 Perform actions as described in Pinion sprocket removal 2 Place a block with a suitable clearance hole under the drive lever shaft 9 to provide support and prevent the shaft bending when the roll pin is driven out 3 Drive out the roll pin 8 4 Pull the drive lever 9 off the drive eccentric shaft 11 5 Lift the drive eccentric...

Page 19: ...3 Separate the gearbox 23 from the back mounting plate assembly 2 leaving the gearbox drive shaft gear carrier C 21 in place 4 Supportthegearboxdriveshaft gearcarrier C 21 anddriveoutthepin 19 5 Withdraw the gearbox drive shaft gear carrier C 21 from the back mounting plate assembly 2 Gearbox disassembly 5 4 7 5 4 7 5 5 5 4 6 5 4 5 3 1 4 2 1 O ring 2 Small shim spacer 3 Drive shaft carrier assembl...

Page 20: ...ough 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 Pla...

Page 21: ...mbly 12 is in its lowest position fit the belt 5 around the pinion sprocket 7 drive wheel assembly 10 and adjustment wheel assembly 13 3 Position the support plate 4 with fitted bearing 6 onto the gearbox drive shaft 21 drive eccentric assembly 11 adjustment eccentric assembly 12 and over the screw pillars Insert the five screws 3 and secure the support plate 4 Note Take care not to cut new thread...

Page 22: ...ghtened as this will increase the backdrive load to a level where it can be felt on the vessel s wheel Tools required 4000 Drive unit torque fixture Service tool number T033 4000 Drive unit torque adjuster Service tool number T032 Motor drive box and ammeter Motor drive box FS1 12V BATTERY Red ZO78 Brown Z077 Blue ACTUATOR 15A IC1 LM396K D1 SW1 R1 121R MR752 C1 4700uF C2 4 7uF R2 845R C3 22uF C4 4...

Page 23: ...not two holes in a group of four Screw the torque restraint pin into the back mounting plate 2 Connect the motor to the motor drive box using an in line ammeter 0 10 amps to measure current 3 Connect the motor drive box to a 12V battery The drive box provides a regulated 10 5V supply to the motor 4 Engage the drive unit clutch 5 Use the eccentric adjuster to loosen anti clockwise the locking nut a...

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Page 25: ...act thrust arm by hand No Yes OK OK Check resistance across motor connector pins 2 and 3 is approximately 1 to 2 ohms Change as necessary No Yes Check wiring and connector OK Check motor Change as necessary OK Switch on check thrust rod moves and current less than 2 5A Connect power supply as in Figure 10 OK No Yes Change as necessary Switch on Check thrust rod moves in opposite direction to that ...

Page 26: ...15 SeaTalk deck plug 1 Notes A Ensure cable clamp nut 14 is unscrewed before undoing the motor sleeve B The hole in the gear annulus 7 that accepts the drive gear of the motor 8 is of a different diameter to that of the ST4000 GP gear annulus C Care should be taken not to cross thread the annulus 7 when screwing into the thrust tube 2 3 4 x4 5 6 7 Notes B C 6 8 9 6 10 11 12 13 14 Note A 15 2 ST400...

Page 27: ...ssembly W014 Tiller Drive Actuator GP conversion kit W003 This GP conversion kit W003 gives the option of converting the ST4000 which has the power to helm boats of up to 6 500 kg 14 300 lbs displacement to the ST4000 GP which would push the limit up to 9 000 kg 20 000 lbs displacement 8 1 Planet gear x4 2 Shim 3 O ring x3 4 Gear annulus 5 Motor 6 Motor spacer 7 Cable tie 8 Motor sleeve 9 End cap ...

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Page 29: ...nd retract thrust arm by hand No Yes OK OK Check resistance across motor connector pins 2 and 3 is approximately 1 to 2 ohms Change as necessary No Yes Check wiring and connector OK Check motor Change as necessary OK Switch on check thrust rod moves and current less than 2A Connect power supply as in Figure 10 OK No Yes Change as necessary Switch on Check thrust rod moves in opposite direction to ...

Page 30: ... 14 Clamp seal 15 Cable clamp nut 16 SeaTalk deck plug D2396 1 15 Note A 7 Notes B C Notes A Ensure cable clamp nut 15 is unscrewed before undoing the motor sleeve B The hole in the gear annulus 7 that accepts the drive gear of the motor 8 is of a different diameter to that of the ST4000 gear annulus C Care should be taken not to cross thread the annulus 7 when screwing into the thrust tube 2 ST40...

Page 31: ...s refer to Figure 16 Tiller drive actuator GP exploded view Item SpareDescription PartNo Comments Drivemodule Q086 Completedriveunit ST4000 GPkit incuding W003 Servesasanupgrade 4 Planetgear x4 conversionkitfor the 5 Shim ST4000 tillerdrive 6 O ring x3 actuator 7 Annulus 8 Motor 9 Cabletie 10 Motorspacer 11 Motorsleeve 12 Endcapassembly ...

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Page 33: ...ST4000 Autopilots ST4000 Autopilots Service Manual 83115 1 ...

Page 34: ...5 1 Raytheon Marine Company 676 Island Pond Road Manchester New Hampshire 03109 5420 Tel 001 603 647 7530 Fax 001 603 634 4756 Raytheon Marine Europe Limited Anchorage Park Portsmouth Hampshire PO3 5TD Tel 01705 693611 Fax 01705 694642 http www raytheon com ...