ST4000 Autopilots Service Manual For Use On Z326, Wheel .
ST4000 AutopilotsD3730-1ST4000 Autopilots Service ManualFor use onZ326, Wheel AutopilotZ327, Tiller AutopilotZ332, Tiller GP AutopilotWarningCE Marking of Equipment/Replacement PartsIf 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 maintaincompliance 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 byRaytheon 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 orto no longer meet the relevant CE requirements. In these circumstances, Raytheon Marine Europe Ltd excludes liabilityto the fullest extent permissible in law for any loss or damage including any liability for its contribution to such loss ordamage by its negligent acts or omissions .ST4000 Autopilots Service Manual 83115-1
ST4000 AutopilotsST4000 Autopilots Service Manual 83115-1
ContentsContentsChapter 1. ST4000 Control Head . 11.1 PCB Changes . 11.2 Disassembly/Assembly. 2ST4000 Control Head spare parts list . 31.3 PCB Details . 4Input/Output Signals (refer to Figure 2. Circuit Diagram) . 4Circuit Diagram. 5PCB Layout . 6PCB Component list . 7Chapter 2. Fluxgate Compass Transducer . 92.1 Functional test . 92.2 Magnetic deviation . 92.3 Disassembly/assembly . 10Fluxgate Compass spare parts list. 10Chapter 3. Wheel Drive Actuator . 113.1 Wheel Drive Actuator test. 113.2 Disassembly/assembly . 12Wheel Drive Actuator spare parts list . 13Disassembly . 14Belt removal . 14Pinion sprocket removal . 14Drive lever and eccentric removal . 14Motor removal . 14Gearbox removal . 15Gearbox disassembly . 15Assembly . 16Gearbox assembly. 16Motor assembly . 16Adjustment eccentric assembly . 16Drive lever and eccentric assembly . 17Pinion sprocket and belt assembly . 17Drive ring closure . 173.3 Setting Belt Tension . 18Tools required: . 18Motor drive box . 18Motor drive box parts . 19Procedure . 19ST4000 Autopilots Service Manual 83115-1
ST4000 AutopilotsChapter 4.Tiller Drive Actuator . 214.1 Tiller Drive Actuator test . 214.2 Disassembly/assembly . 22Tiller Drive Actuator spare parts list . 23Tiller Drive Actuator GP conversion kit (W003) . 23Chapter 5.Tiller Drive Actuator GP . 255.1 Tiller Drive Actuator GP test . 255.2 Disassembly/assembly . 26Tiller Drive Actuator GP spare parts list . 27ST4000 Autopilots Service Manual 83115-1
Chapter 1. ST4000 Control HeadChapter 1. ST4000 Control Head1.1 PCB ChangesWhen a PCB is changed, it may be necessary to set the new PCB to therequired pilot type, ST4000 Wheel, ST4000 Tiller or ST4000 Tiller GP1. If the instrument is disassembled, fit the reflector, diffuser, elastomers,LCD and surround to the PCB2. Apply 12V power to the instrument/PCB assembly3. Press and hold STDBY for 14 seconds until CAL ? is displayed4. Momentarily press 1 and -1 together to gain access to extendedcalibration (dealer set - up)5. Advance from the CAL LOCK page to the pilot type page by pressingDISP6. 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 calibration8. Switch off the power supply. Do not disconnect9. When the pilot is fully powered down, switch the power on again10.Check that the required pilot type is momentarily displayed beforeSTANDBY is entered. If not, repeat the set - up procedure. In the case ofa second failure, change the PCB.ST4000 Autopilots Service Manual 83115-1 1
1342Figure 1: ST4000 Control Head exploded view2 ST4000 Autopilots Service Manual 83115-117 (Note A)568 (Note B)910Notes:A. Earlier production units have a shim (17) fittedto aid keypad compression.B. The castellated top edge of the diffuser (8) fitsunder the legs of the LEDs on the top edge ofthe PCB (10).C. It is recommended that a new case seal (12) isfitted on assembly.7 (x2)11 (x3)1. Facia2. Keypad3. Label4. Window insert5. LCD surround6. LCD7. Elastomer strip (x2)8. Diffuser9. Reflector12 (Note C)1311 (x8)1510. PCB11. Retaining screw (x11)12. Case seal13. Rear cover14. Buzzer connector15. Label16. Bulkhead gasket17. Keypad shim (earlier units only)1416D3721-1ST4000 Autopilots1.2 Disassembly/Assembly
Chapter 1. ST4000 Control HeadST4000 Control Head spare parts listThe item numbers refer to Figure 1: ST4000 Control Head exploded viewItemSpare DescriptionPart No.1FaciaW1152KeypadQ219Display kit, includingLabel (selection)Window insertLCD surroundLCDElastomer (x2)Q22034567Diffuser kit, includingDiffuserReflectorW1178910PCBQ221Fixing kit, includingScrew (x11)W1201112Case sealW118Back cover assembly, includingBack coverW11913141516CommentsFit ST4000 labelST4000 /ST5000 PCBComes fitted with,Gortex filter,Sleeving,Buzzer andBuzzer connecterFit ST4000 labelLabel (selection)Bulkhead gasketW125Sun coverD340Not illustratedST4000 Autopilots Service Manual 83115-1 3
ST4000 Autopilots1.3 PCB DetailsInput/Output Signals (refer to Figure 2. Circuit Diagram)Pin No.SignalDescriptionPL1/1 12VNominal 12V dcPL1/20V in0VPL1/3SeaTalkIntermittent streams of (nominal) 12V pulsesPL2/1 12VNominal 12V dcPL2/20V in0VPL2/3SeaTalkIntermittent streams of (nominal) 12V pulsesP1 12VNominal 12V dcP20V in0VP3SCRN0VP4BiasNominal 2.5V dc (VRESET)P5F/GA 2.5V dcP6F/GB 2.5V dcP7Coil driveAC signal, 17 cycles at 7.9kHz, driven twiceevery 1/16 secondP8Rudder referencesupplyNominal 5V supply to rudder referenceP9Rudder reference0 to 5V dc (nominal) rudder reference outputP10Rudder reference 0V0VP11SCRN0VC Clutch 12V if Autopilot engaged; otherwise 0VC–Clutch 0V0VMD1MD1When Autopilot engaged and depending ondirection of drive, intermittent variable lengthpulses, nominal 12V; otherwise 0VMD2MD2When Autopilot engaged and depending ondirection of drive, intermittent variable lengthpulses, nominal 12V; otherwise 0VNMEA in NMEA Intermittent streams of (nominal) 12V pulsesNMEA in–NMEA–0V4 ST4000 Autopilots Service Manual 83115-1
Chapter 1. ST4000 Control HeadD3723-1Circuit DiagramFigure 2: Circuit DiagramST4000 Autopilots Service Manual 83115-1 5
ST4000 AutopilotsPCB LayoutTaken from Drawing No: 4376-001 Issue: PDate: 03.10.97Figure 3: PCB Component Layout6 ST4000 Autopilots Service Manual 83115-1D3722-1
Chapter 1. ST4000 Control HeadPCB Component listTaken from Drawing No: 4376-001 Issue: PDate: 03.10.97D3724-1ST4000 Autopilots Service Manual 83115-1 7
ST4000 Autopilots8 ST4000 Autopilots Service Manual 83115-1
Chapter 2. Fluxgate Compass TransducerChapter 2. Fluxgate Compass Transducer2.1 Functional testDisconnect the Fluxgate from the Autopilot and check continuity as follows:Cable colourConnector pin numberResistanceScreen to blue2/4 10 ohmsRed to green3/5 5 ohmsRed to yellow3/6 5 ohmsRed to screen3/2Open circuit2.2 Magnetic deviationThe Fluxgate Compass requires careful siting if optimum Autopilotperformance is to be acheived. The SeaTalk electronics is able to correct thecompass for most deviating magnetic fields present when the linearisationprocedure is carried out. Any further deviation, introduced after linearisation,will introduce an error between the Fluxgate and the ship’s compass. Thiscan be removed by carrying out the linearisation again. If the displayeddeviation is greater than /– 15 degrees the Fluxgate should be resited.Note: The linearisation procedure should always be carried out if theFluxgate has been exchanged, removed or moved from its original mountingposition.ST4000 Autopilots Service Manual 83115-1 9
ST4000 Autopilots2.3 Disassembly/assembly12478361. Cover2. Seal3. Pivot retaining screw (x2)4. Bracket5. Pivot sub-assembly596. Fluxgate sub-assembly7. Body8. Body screw (x4)9. CableD3726-1Figure 4. Fluxgate Compass exploded viewFluxgate Compass spare parts listThe item numbers refer to Figure 4: Fluxgate Compass exploded viewItemSpare DescriptionPart No.Compass base kit, includingPivot retaining screw (x2)BracketM09634Fluxgate sub-assembly, includingPivot sub-assembly (x2)Fluxgate sub-assemblyM0225610 ST4000 Autopilots Service Manual 83115-1Comments
Chapter 3. Wheel Drive ActuatorChapter 3. Wheel Drive Actuator3.1 Wheel Drive Actuator testCarry out the passive and active tests detailed in Figure 6.Fuse/CB12ASwitchPSU12V 15AD2386-1Figure 5. Wheel Drive Actuator test connectionsStartConnect power supplyas in Figure 5Visually inspect unitOKNoChange damagedcomponentsYesRotate drive ring by handwith clutch disengagedSwitch on, and with clutchengaged, check drive ringmoves and current is lessthan 2AOKNoYesOKNoYesCheck gears,belt, rollers,belt tension,eccentric, drivelever, motorChange/adjustas necessaryChange/adjustas necessaryRestrain drive ring rotationuntil 6.5A is obtained. Checkthat belt does not slip.OKOKNoYesCheck resistance acrossmotor connector pins 2 and 3is approximately 1 to 2 ohmsNoCheck gears, belt,rollers, belttension, eccentric,drive lever, motorReverse polarity of supplyCheck wiringand connectorYesOKSwitch on.Check drive ringmoves in opposite directionto that of first test andcurrent is less than 2ANoYesCheck motorOKNoYesCheck gears, belt,rollers, belttension, eccentric,drive lever, motorChange/adjustas necessaryChange asnecessaryRestrain drive ring rotationuntil 6.5A is obtained. Checkthat belt does not slip.OKNoYesActuator OK.End of testD2390-1Figure 6. Wheel Drive Actuator test flowchartST4000 Autopilots Service Manual 83115-1 11
15Figure 7. Wheel Drive Actuator exploded view12 ST4000 Autopilots Service Manual 83115-13(x5)114166 7171213 22(x4)18 10 20(x2) 19221238Large chamfer ofadjustment lockingnut to faceprotective cap2432253326342735 3613. Adjustment wheel assembly14. Adjustment locking nut15. Protection cap16. Roller screw (x7)17. Washer (x7)18. Roller (x7)19. Pin20. Shim (x2)21. Gearbox drive shaft/gear carrier 'C'22. Gearbox retaining screw (x4)23. Gearbox24. Red motor seal14 151. Drive ring2. Back mounting plateassembly3. Screw (x5)4. Support plate5. Belt6. Bearing7. Pinion sprocket8. Roll pin9. Drive lever10. Drive wheel assembly11. Drive eccentric assembly12. Adjustment eccentric assembly14 1593031D3727-125. Flux ring26. Motor location peg27. Motor28. Motor clamp29. Motor clamp 'O' ring30. Connector31. Connector seal32. Sleeve33. End cap 'O' ring34. End cap35. Sealing cap36. Connector nut37. Cable assembly28 2937ST4000 Autopilots3.2 Disassembly/assembly
Chapter 3. Wheel Drive ActuatorWheel Drive Actuator spare parts listThe item numbers refer to Figure 7: Wheel Drive A ctuator exploded viewItemSpare DescriptionPart No.1Drive ringN0312Back mounting plate assemblyN0135BeltD169Pinion kit, includingPinion sprocketProtection capPinShim (x2)N0147151920Drive lever kit, includingRoll pinDrive leverN0118911Drive eccentric assemblyN024N026–––Gearbox drive shaft/gearcarrier ‘C’ kit, includingGearbox drive shaft/gear carrier ‘C’Planet gear (x12)Shim‘O’ ring27MotorN012Wiring kit, includingMotor clampMotor clamp ‘O’ ringConnectorConnector sealEnd cap ‘O’ ringEnd capSealing capConnector nutCable assemblyQ10628293031333435363721CommentsComes fitted with,pre-assembledgearbox, item 23See Figure 8, item 3See Figure 8, item 4See Figure 8, item 2See Figure 8, item 1ST4000 Autopilots Service Manual 83115-1 13
ST4000 AutopilotsDisassemblyBelt removalRefer 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 thedrive ring (1) off the rollers (18) of the back mounting plate (2). Repeatthis action in three to four places around the drive ring (1) in order toremove.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 removalRefer 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 removalRefer 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 isdriven 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) offthe back mounting plate (2).Motor removalRefer 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 theconnector 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 anintegral part of the back mounting plate assembly (2) and the locationpeg (26) is part of the motor (27).14 ST4000 Autopilots Service Manual 83115-1
Chapter 3. Wheel Drive Actuator5. Desolder connector wires from the motor tags.Gearbox removalRefer 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 backmounting plate assembly (2).Gearbox disassembly85555444755345462171. 'O' ring2. Small shim spacer3. Drive shaft/carrier assembly 'C'4. Planet gear (x22)5. Large shim spacer (x7)6. Carrier assembly 'B'7. Carrier assembly 'A' (x2)8. Gear housingD3725-1Figure 8. Gearbox exploded viewST4000 Autopilots Service Manual 83115-1 15
ST4000 AutopilotsAssemblyIn all cases, assembly is a straight reversal of the steps described inDisassembly.Gearbox assemblyRefer to Figure 7. Wheel Drive Actuator exploded view.1. Rebuild gearbox. Refer to Figure 8. Gearbox exploded view2. Fix the gearbox (23) to the back mounting plate assembly (2) using thefour 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 beobtained from pinion kit, part no. N014.Motor assemblyRefer 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 theconnector 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 andthe 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 thegearbox (23).7. Place the sealing cap (35) over the connector (36) and secure with theconnector nut (37).Adjustment eccentric assemblyRefer to Figure 7. Wheel Drive Actuator exploded view.1. Assemble the adjustment wheel assembly (13), adjustment eccentricassembly (12), adjustment lock nut (14) with its chamfered edge facingoutwards, and protection cap (15) to the back mounting plate assembly (2).Note: Ensure that the drive lever (9) is in the slack (declutched) positionand the adjustment eccentric assembly (12) is in its lowest position, sothat the belt (5) is at its slackest.16 ST4000 Autopilots Service Manual 83115-1
Chapter 3. Wheel Drive ActuatorDrive lever and eccentric assemblyRefer to Figure 7. Wheel Drive Actuator exploded view.1. Assemble the drive eccentric assembly (11) and drive wheel assembly
ST4000 Autopilots ST4000 Autopilots Service Manual 83115-1 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,
4000 Mk2 Wheel Drive Service Manual 83158-1 5 4000 mk2 Wheel Drive Chapter 1: Introduction This manual explains the service and maintenance procedures for the Raymarine 4000 Mk2 wheel drive unit. Note: For information about servicing the ST4000 control unit and fluxgate compass, refer to the ST4000 Plus Autopilots Service Manual (83115-3). 1.1.
This manual explains the service and maintenance procedures for the Raymarine 4000 Mk2 wheel drive unit. 3.1 4000 MK2 wheel drive test Note: For information about servicing the ST4000 control unit and fluxgate compass, refer to the ST4000 Plus Autopilots Service Manual (83115-3) Change damaged components Check drive ring rotates freely
注：ST4000 �ートコンパスのサービスにつ いては、ST4000 Plus Autopilots Service Manual（83115-3）を参照して ください。 1.1 ホイールドライブ機能テスト 破損した部品を交換 ドライブリングが自由に回転し、
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