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Autohelm St4000 Manual



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ST4000+ Autopilots




                                                                                                 D3730-1




                           ST4000+ Autopilots Service Manual
                                      For use on
                                 Z326, Wheel Autopilot
                                  Z327, Tiller Autopilot
                                Z332, Tiller GP Autopilot



                                                       Warning

                         CE Marking of Equipment/Replacement Parts
  If the Autohelm equipment under repair, test, calibration, installation or setting to work carries the European CE mark,
      only parts and components supplied or approved for such use by Raytheon should be used in order to maintain
                                    compliance with the relevant CE requirements.

Incorporation, use or attachment, by any means, of parts or components not supplied for or not approved for such use by
  Raytheon or, if supplied or approved for use by Raytheon, not properly fitted in accordance with instructions published,
provided or recommended by Raytheon, may cause the equipment to malfunction and, in particular, to become unsafe or
 to no longer meet the relevant CE requirements. In these circumstances, Raytheon Marine Europe Ltd excludes liability
    to the fullest extent permissible in law for any loss or damage including any liability for its contribution to such loss or
                                           damage by its negligent acts or omissions .

                                                                                        ST4000+ Autopilots Service Manual 83115-1
                                            ST4000+ Autopilots




ST4000+ Autopilots Service Manual 83115-1
Contents



Contents
Chapter 1. ST4000+ Control Head ......................................................................................... 1
           1.1 PCB Changes ................................................................................................. 1
           1.2 Disassembly/Assembly.................................................................................... 2
                ST4000+ Control Head spare parts list ........................................................... 3
           1.3 PCB Details .................................................................................................... 4
                Input/Output Signals (refer to Figure 2. Circuit Diagram) ................................... 4
                      Circuit Diagram..................................................................................... 5
                PCB Layout .................................................................................................. 6
                      PCB Component list ............................................................................. 7
Chapter 2. Fluxgate Compass Transducer ............................................................................ 9
           2.1 Functional test ................................................................................................. 9
           2.2 Magnetic deviation .......................................................................................... 9
           2.3 Disassembly/assembly ................................................................................... 10
                 Fluxgate Compass spare parts list................................................................ 10
Chapter 3. Wheel Drive Actuator ......................................................................................... 11
           3.1 Wheel 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 eccentric assembly ........................................................... 16
                       Drive lever and eccentric assembly ...................................................... 17
                       Pinion sprocket and belt assembly ....................................................... 17
                       Drive ring closure ................................................................................ 17
           3.3 Setting Belt Tension ........................................................................................ 18
                 Tools required: ............................................................................................ 18
                 Motor drive box ........................................................................................... 18
                       Motor drive box parts .......................................................................... 19
                 Procedure ................................................................................................. 19


                                                                                         ST4000+ Autopilots Service Manual 83115-1
                                                                                                     ST4000+ Autopilots


Chapter 4.Tiller Drive Actuator ............................................................................................ 21
           4.1 Tiller 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
           5.1 Tiller Drive Actuator GP test ............................................................................ 25
           5.2 Disassembly/assembly ................................................................................... 26
                  Tiller Drive Actuator GP spare parts list ......................................................... 27




ST4000+ Autopilots Service Manual 83115-1
Chapter 1. ST4000+ Control Head



Chapter 1. ST4000+ Control Head

           1.1 PCB Changes
                    When a PCB is changed, it may be necessary to set the new PCB to the
                    required pilot type, ST4000+ Wheel, ST4000+ Tiller or ST4000+ Tiller GP
                    1. If the instrument is disassembled, fit the reflector, diffuser, elastomers,
                       LCD and surround to the PCB
                    2. Apply 12V power to the instrument/PCB assembly
                    3. Press and hold STDBY 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, 4000 WHL
                       (wheel) or 4000 TILL (tiller)
                    7. Press STDBY to exit extended calibration
                    8. Switch off the power supply. Do not disconnect
                    9. When the pilot is fully powered down, switch the power on again
                    10.Check that the required pilot type is momentarily displayed before
                       STANDBY is entered. If not, repeat the set - up procedure. In the case of
                       a second failure, change the PCB.




                                                                ST4000+ Autopilots Service Manual 83115-1 1
                                                                                             1   3   4        5            6   7 (x2)        8 (Note B)          9           10         12 (Note C)                            16          15




2 ST4000+ Autopilots Service Manual 83115-1
                                              Figure 1: ST4000+ Control Head exploded view
                                                                                                                                                                                                                                                                   1.2 Disassembly/Assembly




                                                                                                                                                                                                        11 (x3)           14        13   11 (x8)




                                                                                                                               Notes:                                                 1. Facia                    10. PCB
                                                                                                                               A. Earlier production units have a shim (17) fitted    2. Keypad                   11. Retaining screw (x11)
                                                                                                                                  to aid keypad compression.                          3. Label                    12. Case seal
                                                                                                                               B. The castellated top edge of the diffuser (8) fits   4. Window insert            13. Rear cover
                                                                                                                                  under the legs of the LEDs on the top edge of       5. LCD surround             14. Buzzer connector
                                                                                                                                  the PCB (10).                                       6. LCD                      15. Label
                                                                                                         2   17 (Note A)
                                                                                                                               C. It is recommended that a new case seal (12) is      7. Elastomer strip (x2)     16. Bulkhead gasket
                                                                                                                                  fitted on assembly.                                 8. Diffuser                 17. Keypad shim (earlier units only)
                                                                                                                                                                                      9. Reflector

                                                                                                                                                                                                                                                         D3721-1
                                                                                                                                                                                                                                                                                              ST4000+ Autopilots
Chapter 1. ST4000+ Control Head


                    ST4000+ Control Head spare parts list
                    The item numbers refer to Figure 1: ST4000+ Control Head exploded view

                    Item      Spare Description                  Part No.      Comments
                    1         Facia                              W115
                    2         Keypad                             Q219
                              Display kit, including             Q220
                    3            Label (selection)                             Fit ST4000+ label
                    4            Window insert
                    5            LCD surround
                    6            LCD
                    7            Elastomer (x2)
                              Diffuser kit, including            W117
                    8             Diffuser
                    9             Reflector
                    10        PCB                                Q221          ST4000+/ST5000+ PCB
                              Fixing kit, including              W120
                    11            Screw (x11)
                    12        Case seal                          W118
                              Back cover assembly, including     W119
                    13           Back cover                                    Comes fitted with,
                                                                               Gortex filter,
                                                                               Sleeving,
                                                                               Buzzer and
                    14                                                         Buzzer connecter
                    15            Label (selection)                            Fit ST4000+ label
                    16        Bulkhead gasket                    W125
                              Sun cover                          D340          Not illustrated




                                                               ST4000+ Autopilots Service Manual 83115-1 3
                                                                                            ST4000+ Autopilots


                 1.3 PCB Details

                              Input/Output Signals (refer to Figure 2. Circuit Diagram)

                              Pin No.         Signal                Description
                              PL1/1           +12V                  Nominal 12V dc
                              PL1/2           0V in                 0V
                              PL1/3           SeaTalk               Intermittent streams of (nominal) 12V pulses
                              PL2/1           +12V                  Nominal 12V dc
                              PL2/2           0V in                 0V
                              PL2/3           SeaTalk               Intermittent streams of (nominal) 12V pulses
                              P1              +12V                  Nominal 12V dc
                              P2              0V in                 0V
                              P3              SCRN                  0V
                              P4              Bias                  Nominal 2.5V dc (VRESET)
                              P5              F/GA                  +2.5V dc
                              P6              F/GB                  +2.5V dc
                              P7              Coil drive            AC signal, 17 cycles at 7.9kHz, driven twice
                                                                    every 1/16 second
                              P8              Rudder reference      Nominal 5V supply to rudder reference
                                              supply
                              P9              Rudder reference      0 to 5V dc (nominal) rudder reference output
                              P10             Rudder reference 0V   0V
                              P11             SCRN                  0V
                              C+              Clutch                +12V if Autopilot engaged; otherwise 0V
                              C­              Clutch 0V             0V
                              MD1             MD1                   When Autopilot engaged and depending on
                                                                    direction of drive, intermittent variable length
                                                                    pulses, nominal 12V; otherwise 0V
                              MD2             MD2                   When Autopilot engaged and depending on
                                                                    direction of drive, intermittent variable length
                                                                    pulses, nominal 12V; otherwise 0V
                              NMEA in+        NMEA+                 Intermittent streams of (nominal) 12V pulses
                              NMEA in­        NMEA­                 0V




4 ST4000+ Autopilots Service Manual 83115-1
Chapter 1. ST4000+ Control Head


Circuit Diagram




                                                                         D3723-1




Figure 2: Circuit Diagram

                                  ST4000+ Autopilots Service Manual 83115-1 5
                                                                                           ST4000+ Autopilots


                              PCB Layout




                               Taken from Drawing No: 4376-001 Issue: P   Date: 03.10.97                 D3722-1



                              Figure 3: PCB Component Layout

6 ST4000+ Autopilots Service Manual 83115-1
Chapter 1. ST4000+ Control Head


                    PCB Component list




                    Taken from Drawing No: 4376-001 Issue: P   Date: 03.10.97                                         D3724-1




                                                                                ST4000+ Autopilots Service Manual 83115-1 7
                                              ST4000+ Autopilots




8 ST4000+ Autopilots Service Manual 83115-1
Chapter 2. Fluxgate Compass Transducer



Chapter 2. Fluxgate Compass Transducer

           2.1 Functional test
                    Disconnect the Fluxgate from the Autopilot and check continuity as follows:

                    Cable colour         Connector pin number            Resistance
                    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


           2.2 Magnetic deviation
                    The Fluxgate Compass requires careful siting 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
                    deviation is greater than +/­ 15 degrees the Fluxgate should be resited.
                    Note: The linearisation procedure should always be carried out if the
                    Fluxgate has been exchanged, removed or moved from its original mounting
                    position.




                                                                ST4000+ Autopilots Service Manual 83115-1 9
                                                                                                                ST4000+ Autopilots


2.3 Disassembly/assembly

                  1           2                4                                7




                                                                                                                          8




                                                         3                 6              5                               9
                                                1. Cover
                                                2. Seal                             6. Fluxgate sub-assembly
                                                3. Pivot retaining screw (x2)       7. Body
                                                4. Bracket                          8. Body screw (x4)
                                                5. Pivot sub-assembly               9. Cable
                                                                                                                               D3726-1



Figure 4. Fluxgate Compass exploded view


                             Fluxgate Compass spare parts list
                             The item numbers refer to Figure 4: Fluxgate Compass exploded view

                             Item              Spare Description                                Part No.       Comments
                                               Compass base kit, including                      M096
                             3                   Pivot retaining screw (x2)
                             4                   Bracket
                                               Fluxgate sub-assembly, including                 M022
                             5                    Pivot sub-assembly (x2)
                             6                    Fluxgate sub-assembly




10 ST4000+ Autopilots Service Manual 83115-1
Chapter 3. Wheel Drive Actuator



Chapter 3. Wheel Drive Actuator

            3.1 Wheel Drive Actuator test
                     Carry out the passive and active tests detailed in Figure 6.



                                                                                    Fuse/CB
                                                                                      12A

                                                                                     Switch



                                                                                                      PSU
                                                                                                    12V 15A

                                                                                                                                D2386-1



                     Figure 5. Wheel Drive Actuator test connections

                                   Start
                                                                             Connect power supply
                                                                                as in Figure 5
                            Visually inspect unit
                                                                           Switch on, and with clutch
                                           No          Change damaged      engaged, check drive ring
                                    OK
                                                         components        moves and current is less
                                       Yes                                         than 2A

                                                                                                          Check gears, belt,
                         Rotate drive ring by hand                                          No                 rollers, belt
                                                                                      OK
                          with clutch disengaged                                                          tension, eccentric,
                                                                                         Yes               drive lever, motor

                                                        Check gears,                                       Change/adjust
                                           No            belt, rollers,                                     as necessary
                                    OK                  belt tension,
                                                       eccentric, drive
                                       Yes              lever, motor
                                                                           Restrain drive ring rotation
                                                                          until 6.5A is obtained. Check
                                                        Change/adjust        that belt does not slip.
                                                         as necessary

                                                                                            No
                                                                                      OK
                          Check resistance across                                        Yes
                        motor connector pins 2 and 3
                                                                           Reverse polarity of supply
                        is approximately 1 to 2 ohms
                                                                          Switch on.Check drive ring
                                           No            Check wiring     moves in opposite direction
                                    OK                  and connector       to that of first test and
                                                                            current is less than 2A
                                       Yes
                                                                  No                                      Check gears, belt,
                                                             OK
                                                                                            No                 rollers, belt
                                                                                      OK
                                                               Yes                                        tension, eccentric,
                                                                                         Yes               drive lever, motor
                                                        Check motor
                                                                                                           Change/adjust
                                                                                                            as necessary

                                                         Change as
                                                         necessary
                                                                           Restrain drive ring rotation
                                                                          until 6.5A is obtained. Check
                                                                             that belt does not slip.


                                                                                            No
                                                                                      OK

                                                                                         Yes
                                                                                  Actuator OK.
                                                                                   End of test
                                                                                                                                D2390-1


                     Figure 6. Wheel Drive Actuator test flowchart
                                                                          ST4000+ Autopilots Service Manual 83115-1 11
                                                                                                  5      11       16   17    18 10 20(x2) 19   21        9    8                  32             33      34    35 36               37




12 ST4000+ Autopilots Service Manual 83115-1
                                               Figure 7. Wheel Drive Actuator exploded view
                                                                                                                                                                                                                                                           3.2 Disassembly/assembly




                                                                                                                                                              23          24             25             26        27         28 29       30     31

                                                                                                                                                      14 15
                                                                                                                                                                   Large chamfer of
                                                                                                                                                                   adjustment locking
                                                                                                                                                                   nut to face
                                                                                                                                                                   protective cap
                                                                                                                                                                                        14 15


                                                                                                                                                     1. Drive ring                        13. Adjustment wheel assembly      25. Flux ring
                                                                                                                                                     2. Back mounting plate               14. Adjustment locking nut         26. Motor location peg
                                                                                                                                                        assembly                          15. Protection cap                 27. Motor
                                                                                                                                                     3. Screw (x5)                        16. Roller screw (x7)              28. Motor clamp
                                                                                                                                                     4. Support plate                     17. Washer (x7)                    29. Motor clamp 'O' ring
                                                                                                                                                     5. Belt                              18. Roller (x7)                    30. Connector
                                                                                                                                                     6. Bearing                           19. Pin                            31. Connector seal
                                                                                                                                                     7. Pinion sprocket                   20. Shim (x2)                      32. Sleeve
                                                                                                                                                     8. Roll pin                          21. Gearbox drive shaft/           33. End cap 'O' ring
                                                                                                                                                     9. Drive lever                           gear carrier 'C'               34. End cap
                                                                                                                                                    10. Drive wheel assembly              22. Gearbox retaining screw (x4)   35. Sealing cap
                                                                                                                                                    11. Drive eccentric assembly          23. Gearbox                        36. Connector nut
                                                                                              1       3(x5)   4        6 7   12   13 22(x4)    2    12. Adjustment eccentric assembly     24. Red motor seal                 37. Cable assembly

                                                                                                                                                                                                                                                 D3727-1
                                                                                                                                                                                                                                                                                      ST4000+ Autopilots
Chapter 3. Wheel Drive Actuator


                     Wheel Drive Actuator spare parts list
                     The item numbers refer to Figure 7: Wheel Drive A ctuator exploded view

                     Item         Spare Description                 Part No.      Comments
                     1            Drive ring                        N031
                     2            Back mounting plate assembly      N013          Comes fitted with,
                                                                                  pre-assembled
                                                                                  gearbox, item 23
                     5            Belt                              D169
                                  Pinion kit, including             N014
                     7               Pinion sprocket
                     15              Protection cap
                     19              Pin
                     20              Shim (x2)
                                  Drive lever kit, including        N011
                     8               Roll pin
                     9               Drive lever
                     11           Drive eccentric assembly          N024
                                  Gearbox drive shaft/gear          N026
                                  carrier `C' kit, including
                     21              Gearbox drive shaft/
                                     gear carrier `C'                             See Figure 8, item 3
                     ­               Planet gear (x12)                            See Figure 8, item 4
                     ­               Shim                                         See Figure 8, item 2
                     ­               `O' ring                                     See Figure 8, item 1
                     27           Motor                             N012
                                  Wiring kit, including             Q106
                     28              Motor clamp
                     29              Motor clamp `O' ring
                     30              Connector
                     31              Connector seal
                     33              End cap `O' ring
                     34              End cap
                     35              Sealing cap
                     36              Connector nut
                     37              Cable assembly




                                                                 ST4000+ Autopilots Service Manual 83115-1 13
                                                                                          ST4000+ Autopilots


                             Disassembly

                             Belt removal
                             Refer to Figure 7. Wheel Drive Actuator exploded view.
                             1. Insert a wide flat, non-metalic blade into the gap between the drive ring
                                (1) and the back mounting plate (2). Gently lever the blade to force the
                                drive ring (1) off the rollers (18) of the back mounting plate (2). Repeat
                                this action in three to four places around the drive ring (1) in order to
                                remove.
                             2. Unscrew and remove the five screws (3). Detach the support plate (4)
                                from the back mounting plate (2).
                             3. Remove the belt (5).

                             Pinion sprocket removal
                             Refer to Figure 7. Wheel Drive Actuator exploded view.
                             1. Perform actions as described in Belt removal.
                             2. Lift the pinion sprocket (7) off the gearbox drive shaft/gear carrier `C' (21).

                             Drive lever and 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 assembly (11) and drive wheel assembly (10) off
                                the back mounting plate (2).

                             Motor removal
                             Refer to Figure 7. Wheel Drive Actuator exploded view.
                             1. Unscrew and remove the connector nut (36).
                             2. Remove the sealing cap (35).
                             3. Grip the gearbox (23), unscrew and remove the sleeve (32) ensuring the
                                connector does not rotate.
                             4. Withdraw motor (27)/location peg (26) disengaging it from the gearbox
                                (23). Slide off the flux ring (25).
                                  Note: Although given separate item numbers, the gearbox (23) is an
                                  integral part of the back mounting plate assembly (2) and the location
                                  peg (26) is part of the motor (27).
14 ST4000+ Autopilots Service Manual 83115-1
Chapter 3. Wheel Drive Actuator


                     5. Desolder connector wires from the motor tags.

                     Gearbox removal
                     Refer to Figure 7. Wheel Drive Actuator exploded view.
                     1. Perform actions as described in Pinion sprocket removal,
                        and 1, 2, 3 and 4 in Motor removal.
                     2. Unscrew and remove the four gearbox retaining screws (22).
                     3. Separate the gearbox ( 23) from the back mounting plate assembly (2)
                        leaving the gearbox drive shaft/gear carrier `C' (21) in place.
                     4. Support the gearbox drive shaft/gear carrier `C' (21) and drive out the pin(19).
                     5 Withdraw the gearbox drive shaft/gear carrier `C' (21) from the back
                       mounting plate assembly (2).

                     Gearbox disassembly


                                                   8
                                                                                  5                       5
                                                                                  5                       5

                                                                                  4                       4

                                                                                                          4
                                                                                  7

                                                                                                          3
                                                                                  5
                                                                                  5

                                                                                  4
                                                   5
                                                   4                                                      2
                                                                                  6
                                                                                                          1
                                                   7

                                                   1. 'O' ring                           5. Large shim spacer (x7)
                                                   2. Small shim spacer                  6. Carrier assembly 'B'
                                                   3. Drive shaft/carrier assembly 'C'   7. Carrier assembly 'A' (x2)
                                                   4. Planet gear (x22)                  8. Gear housing
                                                                                                                  D3725-1



                     Figure 8. Gearbox exploded view




                                                                      ST4000+ Autopilots Service Manual 83115-1 15
                                                                                         ST4000+ Autopilots


                             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.


16 ST4000+ Autopilots Service Manual 83115-1
Chapter 3. Wheel Drive Actuator


                     Drive lever and eccentric assembly
                     Refer to Figure 7. Wheel Drive Actuator exploded view.
                     1. Assemble the drive eccentric assembly (11) and drive wheel assembly
                        (10) to the back mounting plate assembly (2).
                     2. Slide the drive lever (9) onto the drive eccentric assembly (11). Support
                        the drive lever (9) and insert the roll pin (8).
                         Note: Always use a new roll pin (8) on refit.

                     Pinion sprocket and belt assembly
                     Refer to Figure 7. Wheel Drive Actuator exploded view.
                     1. Slot the pinion sprocket (7) over the gearbox drive shaft (21) and pin (19).
                     2. With the drive lever (9) in its slack (declutched) position and the
                        adjustment eccentric assembly (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 threads in the screw pillars when securing
                         the support plate (4).

                     Drive ring closure
                     Refer to Figure 7. Wheel Drive Actuator exploded view.
                     1. Rest the drive ring (1) over the rollers (18).
                     2. Locate the rollers (18) nearest the gearbox (23) into the groove of the
                        drive ring (1). Push down and around the drive ring (1) to progressively
                        snap the drive ring (1) over the remaining rollers (18).
                     3. Spin the drive ring (1) in both directions, two or three times, too ensure
                        the assembly is fully seated and free running.




                                                                ST4000+ Autopilots Service Manual 83115-1 17
                                                                                                            ST4000+ Autopilots


                 3.3 Setting Belt Tension
                             The purpose of the belt tensioning procedure is to ensure that:
                             1. The belt is sufficiently tight to transmit the normal maximum drive
                                torques.
                             2. The belt is not over-tightened, 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
                                                                                                                SW1
                                           FS1
                                                                                IC1
                                                                              LM396K
                                           15A

                                                                                           R1

                                                                                           121R                      Red (ZO78)
                                                                                                                    Brown (Z077)
                                      12V
                                    BATTERY                                                                         ACTUATOR

                                                                                                                        Blue
                                                 D1      + C1       + C2          R2     + C3     + C4         R3

                                                 MR752     4700uF     4.7uF       845R     22uF     4.7uF      1KO




                                                                                                                                   D2384-1



                             Figure 9. Motor drive box circuit diagram




18 ST4000+ Autopilots Service Manual 83115-1
Chapter 3. Wheel Drive Actuator


                     Motor drive box parts

                     Component         Description
                     R1                Resistor      121R 0.1% metal film
                     R2                Resistor      845R 0.1% metal film
                     R3                Resistor      1k0 0.5W
                     C1                Capacitor     4700uF 20% electrolytic 25V
                     C2                Capacitor     4.7uF 10% solid tantalum 35V
                     C3                Capacitor     22uF 10% solid tantalum 35V
                     C4                Capacitor     4.7uF 10% solid tantalum 35V
                     D1                Diode         MR 752
                     IC1               LM396K        High power 10A regulator
                     F1                Fuse       15A quick blow
                                       Fuseholder 1.1/4 inch
                     SW1               Switch      Single pole single throw
                                       TO3         Insulating kit
                                       Diecast box



                     Procedure
                     1. Screw the drive ring clamp to the front ring. Use the group of two holes on
                        their own, 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 and
                        allow the eccentric to move to the minimum tension position
                     6. Switch on the drive to the motor and, using a 1.5mm Allen key, rotate the
                        eccentric anticlockwise (as viewed from above) to increase belt tension
                        until the belt just stops slipping (motor stalled)
                     7. Check that the motor current is approximately 6.5 amps
                     8. Tighten the locking nut, apply Loctite to retain the setting and switch off
                        the motor drive.




                                                                 ST4000+ Autopilots Service Manual 83115-1 19
                                               ST4000+ Autopilots




20 ST4000+ Autopilots Service Manual 83115-1
Chapter 4. Tiller Drive Actuator



Chapter 4. Tiller Drive Actuator

             4.1 Tiller Drive Actuator test
                       Carry out the passive and active tests detailed in Figure 11.Tiller Drive Actuator
                       test flowchart.



                                       Blue
                                                     Fuse/CB                                         1
                                                       12A                                       2       3
                                     Brown

                                                     Switch                            Blue                  Brown

                                                                                          Actuator deck plug

                                      PSU
                                    12V 15A


                                                                                                                              D2394-1



                       Figure 10.Tiller Drive Actuator test connections


                                    Start
                                                                            Connect power supply
                             Visually inspect unit                            as in Figure 10.

                                            No          Change damaged
                                     OK
                                                          components
                                        Yes                                       Switch on,
                                                                          check thrust rod moves and
                                                                            current less than 2.5A
                             Extend and retract
                             thrust arm by hand                                                              Check gears,
                                                                                            No                 thrust rod,
                                                                                       OK
                                                                                                             actuator body,
                                                         Check gears,                     Yes                    motor
                                            No             thrust rod,
                                     OK                  actuator body,
                                                             motor                                             Change
                                        Yes                                                                  as necessary

                                                            Change
                                                          as necessary            Switch off.
                                                                          Reverse connections to PSU

                           Check resistance across
                         motor connector pins 2 and 3                              Switch on.
                         is approximately 1 to 2 ohms                       Check thrust rod moves
                                                                              in opposite direction
                                            No            Check wiring       to that of first test and
                                     OK                  and connector       current less than 2.5A

                                        Yes
                                                                   No
                                                              OK                                             Check gears,
                                                                                            No                 thrust rod,
                                                                                       OK
                                                                 Yes                                         actuator body,
                                                                                          Yes                    motor
                                                         Check motor


                                                                                                               Change
                                                          Change as                                          as necessary
                                                          necessary
                                                                                 Actuator OK.
                                                                                  End of test
                                                                                                                              D3728-1



                       Figure 11. Tiller Drive Actuator test flowchart

                                                                          ST4000+ Autopilots Service Manual 83115-1 21
                                                                                                1. Ram cap                     9. Flux ring                                       3
                                                                                                2. Thrust tube                10. Motor sleeve
                                                                                                3. Lead screw assembly        11. End cap assembly
                                                                                                4. Planet gear (x4)           12. Cable clamp
                                                                                                5. Shim                       13. Clamp seal
                                                                                                6. 'O' ring (x3)              14. Cable clamp nut
                                                                                                7. Gear annulus               15. SeaTalk deck plug
                                                                                                8. Motor (Q114)
                                                                                                                                                                2
                                                                                                                                                                                                                        6
                                                                                                Notes:
                                                                                                A. Ensure cable clamp nut (14) is unscrewed before                                                             7
                                                                                                   undoing the motor sleeve.                                                                              Notes B & C
                                                                                                B. The hole in the gear annulus (7) that accepts the                                                 6
                                                                                                   drive gear of the motor (8) is of a different diameter                                       5
                                                                                                   to that of the ST4000+ GP gear annulus.                                             4 (x4)
                                                                                                C. Care should be taken not to cross-thread the




22 ST4000+ Autopilots Service Manual 83115-1
                                                                                                   annulus (7) when screwing into the thrust tube (2).




                                               Figure 12. Tiller Drive Actuator exploded view
                                                                                                                                                                                                                                      4.2 Disassembly/assembly




                                                                                                1




                                                                                                                                                                                                          14
                                                                                                                                                                                                         Note A
                                                                                                                                                                                                13
                                                                                                                                                                                        12


                                                                                                                                                                                  11

                                                                                                                                                                              6
                                                                                                                                                                                             End view of Annulus (7)
                                                                                                                                                                         15

                                                                                                                                                                    10




                                                                                                                                                            9
                                                                                                                                                                                         ST4000+           ST4000+ GP
                                                                                                                                                                                       13mm diameter      16mm diameter
                                                                                                                                                       8


                                                                                                                                                                                                                            D2395-1
                                                                                                                                                                                                                                                                 ST4000+ Autopilots
Chapter 4. Tiller Drive Actuator


                       Tiller Drive Actuator spare parts list
                       The item numbers refer to Figure 12: Tiller Drive Actuator exploded view

                       Item            Spare Description                   Part No.      Comments
                                       Drive module                        Q047          Complete drive unit
                       8               Motor                               Q114
                       11              End cap assembly                    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.

                              1    2   3       4      3       5     6




                                                                               7




                              1. Planet gear (x4)
                              2. Shim
                              3. 'O' ring (x3)
                              4. Gear annulus
                              5. Motor
                              6. Motor spacer
                              7. Cable tie
                              8. Motor sleeve                                      8        3      9
                              9. End cap assembly
                                                                                                               D2397-1



                       Figure 13. Tiller Drive Actuator GP conversion kit (W003)




                                                                        ST4000+ Autopilots Service Manual 83115-1 23
                                               ST4000+ Autopilots




24 ST4000+ Autopilots Service Manual 83115-1
Chapter 5. Tiller Drive Actuator GP



Chapter 5. Tiller Drive Actuator GP

             5.1 Tiller Drive Actuator GP test
                       Carry out the passive and active tests detailed in Figure 15.Tiller Drive Actuator
                       GP test flowchart.



                                       Blue
                                                     Fuse/CB                                          1
                                                       12A                                        2       3
                                     Brown

                                                     Switch                             Blue                  Brown

                                                                                           Actuator deck plug

                                      PSU
                                    12V 15A


                                                                                                                               D2398-1



                       Figure 14.Tiller Drive Actuator GP test connections


                                    Start
                                                                             Connect power supply
                             Visually inspect unit                             as in Figure 10.

                                            No          Change damaged
                                     OK
                                                          components
                                        Yes                                        Switch on,
                                                                           check thrust rod moves and
                                                                              current less than 2A
                             Extend and retract
                             thrust arm by hand                                                               Check gears,
                                                                                             No                 thrust rod,
                                                                                        OK
                                                                                                              actuator body,
                                                         Check gears,                      Yes                    motor
                                            No             thrust rod,
                                     OK                  actuator body,
                                                             motor                                              Change
                                        Yes                                                                   as necessary

                                                            Change
                                                          as necessary             Switch off.
                                                                           Reverse connections to PSU

                           Check resistance across
                         motor connector pins 2 and 3                               Switch on.
                         is approximately 1 to 2 ohms                        Check thrust rod moves
                                                                               in opposite direction
                                            No            Check wiring        to that of first test and
                                     OK                  and connector         current less than 2A

                                        Yes
                                                                   No
                                                              OK                                              Check gears,
                                                                                             No                 thrust rod,
                                                                                        OK
                                                                 Yes                                          actuator body,
                                                                                           Yes                    motor
                                                         Check motor


                                                                                                                Change
                                                          Change as                                           as necessary
                                                          necessary
                                                                                  Actuator OK.
                                                                                   End of test
                                                                                                                               D3731-1



                       Figure 15.Tiller Drive Actuator GP test flowchart

                                                                           ST4000+ Autopilots Service Manual 83115-1 25
                                                                                                   1. Ram cap                     9. Cable tie                                             3
                                                                                                   2. Thrust tube                10. Motor spacer
                                                                                                   3. Lead screw assembly        11. Motor sleeve
                                                                                                   4. Planet gear (x4)           12. End cap assembly
                                                                                                   5. Shim                       13. Cable clamp
                                                                                                   6. 'O' ring (x3)              14. Clamp seal
                                                                                                   7. Gear annulus               15. Cable clamp nut
                                                                                                   8. Motor                      16. SeaTalk deck plug

                                                                                                   Notes:                                                                                                                           6
                                                                                                                                                                        2
                                                                                                   A. Ensure cable clamp nut (15) is unscrewed before
                                                                                                                                                                                                                           7
                                                                                                      undoing the motor sleeve.                                                                                       Notes B & C
                                                                                                   B. The hole in the gear annulus (7) that accepts the                                                           6
                                                                                                      drive gear of the motor (8) is of a different diameter                                             5
                                                                                                      to that of the ST4000+ gear annulus.                                                      4 (x4)




26 ST4000+ Autopilots Service Manual 83115-1
                                                                                                   C. Care should be taken not to cross-thread the
                                                                                                      annulus (7) when screwing into the thrust tube (2).




                                               Figure 16. Tiller Drive Actuator GP exploded view
                                                                                                                                                                                                                                                  5.2 Disassembly/assembly




                                                                                                   1




                                                                                                                                                                                                                         15
                                                                                                                                                                                                                        Note A
                                                                                                                                                                                                             14
                                                                                                                                                                                                    13



                                                                                                                                                                                          12
                                                                                                                                                                                      6
                                                                                                                                                                                                    End view of Annulus (7)
                                                                                                                                                                                 16

                                                                                                                                                                            11




                                                                                                                                                                   10                            ST4000+                ST4000+ GP
                                                                                                                                                                                               13mm diameter           16mm diameter
                                                                                                                                                               9
                                                                                                                                                         8

                                                                                                                                                                                                                                        D2396-1
                                                                                                                                                                                                                                                                             ST4000+ Autopilots
Chapter 5. Tiller Drive Actuator GP


                       Tiller Drive Actuator GP spare parts list
                       The item numbers refer to Figure 16: Tiller drive actuator GP exploded view

                       Item       Spare Description              Part No.      Comments
                                  Drive module                   Q086          Complete drive unit
                                  ST4000+ GP kit, incuding       W003          Serves as an upgrade
                       4            Planet gear (x4)                           conversion kit for the
                       5            Shim                                       ST4000+ tiller drive
                       6            `O' ring (x3)                              actuator.
                       7            Annulus
                       8            Motor
                       9            Cable tie
                       10           Motor spacer
                       11           Motor sleeve
                       12           End cap assembly




                                                              ST4000+ Autopilots Service Manual 83115-1 27
                                               ST4000+ Autopilots




28 ST4000+ Autopilots Service Manual 83115-1
ST4000+ Autopilots




                     ST4000+ Autopilots Service Manual 83115-1
                                                                       ST4000+ Autopilots




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

ST4000+ Autopilots Service Manual 83115-1


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