ComNav 15CI User manual

ComNav Marine Autopilots
#15 -13511 Crestwood Place
Richmond, BC
Canada
V6V 2G1
Telephone: [phone]
Fax: [phone]
In Canda or the U.S.A:
Toll Free Phone: [phone]
Toll Free Fax [phone]
15CI and 25CI Reversing Motor Pumpset
Owner's Manual
Part Numbers: 20810009, 20810011, 20810026, 20810027
Manual Part Number: 29010015
29010015V1.0(15CI & 25CI Pumps).doc

***** IMPORTANT *****
The reversing motor pump you have purchased is a reliable, high quality product that will give
you many years of trouble-free service. To ensure that you get the most from your purchase,
read this installation and instruction manual carefully. By following the step-by-step procedure
and using only basic tools and materials, you will find the installation easy to do.
This Pump is not watertight and therefore is not warranteed against water damage.
If you are installing this pump on a Capilano or Syten steering system, you probably have
a 3 line steering system. Read the 3 line steering installation instructions carefully.
TOOLS AND MATERIAL REQUIRED TO INSTALL PUMP
1. Basic Tool Kit
2. Pipe Cutter
3. Funnel with Filter (a coffee filter will do)
4. 3/8" Electrical Drill
5. 2 Gallon Bucket (to catch excess oil)
6. Rags or Paper Towels
7. *Pipe Fittings (check with steering gear manufacturer for type and size)
8. *Tubing (check with steering gear manufacturer for type and size)
9. *Hydraulic Oil (check with steering gear manufacturer for type)
10. Teflon Based Thread Sealer (such as LOCKTITE P.S.T.)
11. Miscellaneous Hardware (for mounting pump and securing lines)
*Consult with your steering system manufacturer to get detailed information regarding
factory authorized installation materials. Failure to do so could void your warrantee.
29010015V1.0(15CI & 25CI Pumps).doc 1

PLANNING
Installation of the pump consists of:
• Finding a mounting location for the pump;
• Partially draining the steering system;
• Mounting and connecting the pump to the
existing steering lines
• Filling and bleeding the steering system.
A suitable mounting location for the pump
MUST:
• Be dry
• Be lower than at least one of the helm
pumps in the steering system
• Provide a solid mounting base
• Be at least 4 feet (3.1 M) from the vessel's
compass.
A mounting location for the pump SHOULD:
• Provide easy access to the pump
• Provide an easy connection point to the
steering system
• Minimize the length of the pump hoses
• Minimize the length of the wires to the m
motor.
A typical mounting location would be in the
engine compartment or the steering console.
The pump can be mounted in any orientation
except with Port C facing downward. If Port C
is facing downward then air will not be able to
rise out of the pump and the pump will not
have a supply of oil.
There are two ways to connect the pump to
the steering system. The first is to leave the
system completely filled and be careful not to
spill hydraulic fluid. The second is to drain
the system of fluid completely before cutting
or opening any lines.
If you follow the first method, remember that
when you disconnect or cut the steering
lines, there will be a constant slow discharge
of oil due to gravity draining the system.
Have a container ready to catch all excess
oil. Do not reuse any oil reclaimed from your
system.
Draining your System
If you wish to follow the second method and
drain the system, use the following simple
rocedure.p
1. Have a large container, about 2 gallons,
ready
2.Disconnect the delivery lines at a low point,
usually where the lines connect to the
steering cylinder
3 Turn the wheel of the highest helm pump in
both directions until no more fluid comes out
of the lines
4.Repeat the previous step on each lower
elm pump in turn.h
Types of Steering Systems
There are two general types of steering
systems, two line systems, and three line
systems. The pump connection to the
steering system is different for each type.
Separate instructions are supplied for both
types of steering systems.
29010015V1.0(15CI & 25CI Pumps).doc 2

You have a three line system if the helm pump is a Capilano Model 250 or 275 (Made by Teleflex),
or there is a Uniflow valve mounted close to the steering cylinder.
You have a two line system if you do not have the above components in your system.
CAUTION
CLEANLINESS must be maintained while making hydraulic connections. Contamination
introduced into the steering system fluid can cause steering components to malfunction,
possibly resulting in a loss of steering.
Before beginning to connect the pump to the steering system, review the following installation
hints:
• Cap or cover the ends of hoses with a
clean rag before pushing them between
bulkheads
• Do not blow copper filings off freshly cut
and reamed copper tube. Wipe the filings off,
instead
• Do not use a tape type thread sealer.
These can shred and enter the steering
system fluid. A teflon based thread sealer,
such as 'LOCTITE P.S.T.'must be used on all
male pipe threads. Do not place thread
sealer on the first two threads.
•Do not place thread sealer on female pipe
threads
•When tightening fittings into the pump
lockvalve, hold the lockvalve, not the motor.
That way, the lockvalve will not twist out of
alignment with the rest of the pump.
•Connection of the pump lines is most easily
made at existing breaks in the steering
system lines. For example: valves, t-joints
and other fittings.
Opening your hydraulic steering system will allow air to enter the pipes and pumps. This air must
be expelled when the steering system is bled after you refill your system and during the "Setup
Routine" when you can use the Autopilot to expel it.
29010015V1.0(15CI & 25CI Pumps).doc 3

HYDRAULIC CONNECTIONS FOR TWO LINE STEERING SYSTEMS
A simple schematic of the pump installation is shown in Figure 2.
2 Line Steering System Installation
Delivery Lines:
Ports A and B in the diagram above are
the input/output ports of the pump and
must be connected to the steering lines
coming from the steering cylinder. It does
not matter which pump port is connected
to which steering line.
Compensating Line:
In the above diagram Port C is the
compensating or bleed line, and must be
connected to the steering system's
reservoir. This connection can be made
at a helm pump, remote reservoir (if there
is one), the compensating line connecting
two helm pumps, or the compensating
line connecting a helm pump to the
remote reservoir. If the connection is
being made directly to the helm pump,
ensure that the bleed line is connected to
the LOWER helm bleed port.
The compensating line MUST have a gradual rise from the pump to the connection to the
steering system. This allows air to rise out of the pump, ensuring a constant supply of oil to the
pump.
29010015V1.0(15CI & 25CI Pumps).doc 4

3 Line Steering System Installation
HYDRAULIC CONNECTIONS FOR THREE LINE STEERING SYSTEMS
A simple schematic of the pump installation in shown in Figure 3.
Delivery Lines:
In the above diagram, Ports A and B are
the input/output ports of the pump and
must be connected to the steering lines
between the steering cylinder and the
Uniflow valve. The simplest method of
doing this is to install a tee in each of the
cylinder ports of the uniflow valve itself
and connect to these tees. It does not
matter which pump port is connected to
which steering line.
Compensating Line:
Port C is the compensating or bleed line
and must be connected to the steering
systems reservoir. This connection can
be made at: a helm pump, a remote
reservoir (if there is one); the return line
connecting two helm pumps; or the return
line between a pump and the Uniflow valve.
If the connection is being made directly to
the helm pump, ensure that the bleed line is
connected to the LOWER helm bleed port.
The connection MUST be at least six feet (2
M) from the Uniflow valve as shown above.
If the connection is too close to the Uniflow
valve, the manual steering system may not
work well.
The compensating line MUST have a
gradual rise from the pump to the
connection to the steering system. This
allows air to rise out of the pump, ensuring a
constant supply of oil to the pump.
29010015V1.0(15CI & 25CI Pumps).doc 5

REFILL AND BLEED
After you have installed your Pump, refill and bleed your manual steering system according to
the manufacturer's directions. Air which is in the Pump will be expelled in a seperate bleeding
routine after you connect the Pump to the autopilot.
SPECIFICATIONS
Part No. 20810009
Operating Voltage - 12 VDC
Displacement at 200 PSI - 60 Cubic Inches (982 cubic cm.) per Minute
Current at 200 PSI (13.8 kg/square cm.) - 6.5 Amps
Part No. 20810011
Operating Voltage - 12 VDC
Displacement at 200 PSI - 95 Cubic Inches (1556 cubic cm.) per Minute
Current at 200 PSI (13.8 kg/square cm.) - 9.0 Amps
Part No. 20810026
Operating Voltage - 24 VDC
Displacement at 200 PSI - 60 Cubic Inches (982 cubic cm.)
Current at 200 PSI (13.8 kg/square cm.) - 3.3 Amps
Part No. 20810027
Operating Voltage - 24 VDC
Displacement at 200 PSI - 95 Cubic Inches (1556 cubic cm.)
Current at 200 PSI (13.8 kg/square cm.) - 4.5 Amps
ALL PUMPS
Port Size - 1/4 Inch NPT, all ports
Max. Continuous Operating Pressure - 300 PSI (20.8 kg/square cm.)
Max. Continuous Current Draw - 12 Amps (12 VDC Models)
Minimum Stall Pressure (no flow) - 650 PSI (45.0 kg/square cm.)
Oil Type/Viscosity Range - Any approved hydraulic steering fluid
Operating Temperature Range - 0 to 50 Degrees Centigrade
Lockvalve Leakage - None
Unbalanced Cylinder Size - Up to 3/4 Inch (1.9 cm.) Diameter Rod
Weight - maximum 5 Pounds, (2.27 kg) including wire.
Size - 7.5 Inches Long x 5 Inches Wide x 4 Inches
High (19.1 cm. x 12.5 cm. x 10.16 cm.)
Shaft Seal - Long Life, Dual-Lip Spring Loaded Seal, Can
Hold Tank Pressures of 60 PSI. (4.1 kg/sq.cm.)
29010015V1.0(15CI & 25CI Pumps).doc 6

REVERSING PUMP ELECTRICAL CONNECTIONS
Reversing Pump connections to ComNav CT2T Motor Control Box
(Typically used on 1001,1101,1201 and 2001 Autopilots)
Reversing Pump connections to ComNav Processor type Autopilots
29010015V1.0(15CI & 25CI Pumps).doc 7

PUMP BLEEDING INSTRUCTIONS
1. Bleed your manual steering system
according to the manufacturer's
instructions. When you have completed
the bleeding, leave the equipment for
the bleeding procedure attached to your
hydraulic steering system.
2. Fill your highest reservoir completely.
Turn the steering wheel just past the
stop to press as much oil as is possible
into the system.
3. If you can, use a bottle of
recommended hydraulic oil and a piece
of plastic tubing to add extra capacity to
your highest reservoir.
The manufacturer of your system may
provide these items when you purchase
a bleeding kit for your system. If you
have a helper, have them watch the oil
level in the highest reservoir and refill it
when necessary.
4. Your hydraulic cylinder rod is now fully
extended in one direction. To bleed the
Reversing Pump you will be extending
the cylinder rod in the other direction.
Open one and close the other bleeding
screw just as you did when bleeding the
manual part of your system and you
were extending the cylinder arm in this
direction. Generally, you close the
bleeding screw or nipple closest to the
rod which is now retracted. Open the
bleeding screw closest to the now
extended rod. See diagram on following
page.
Adding Capacity
5. If possible, position yourself so that you
can see your hydraulic steering cylinder
while operating the steering controls of
the autopilot.
6. You will be able to move the steering
cylinder rod by pressing the Red Key or
the Green Key on the Autopilot. When
you press the key, the lights will stop
blinking and the red or green light will
turn on. Extend the rod as far as it will
travel in the other direction.
7. The Autopilot will stop driving the
Reversing Pump shortly after the rod
reaches the end of its travel.
29010015V1.0(15CI & 25CI Pumps).doc 8

Bleeding cylinder, rod moving left
Bleeding cylinder, rod moving right.
29010015V1.0(15CI & 25CI Pumps).doc 9

8. Refill your steering system from the
highest reservoir.
9. Adjust the bleeding screws so that the
cylinder will be bled when the rod is
extended in the original direction.
Generally, you close the bleeding screw
or nipple closest to the now retracted
rod. Open the bleeding screw closest to
the rod which is now extended.
10. Use the Autopilot to fully extend the
cylinder rod to the other side.
11. Refill the highest reservoir.
12. Repeat steps 6 to 10 at least 10 times.
13. Close all bleeding screw or nipples.
Clean up any spills of oil and wipe
fittings clean. Remove any buckets or
equipment a short distance from the
cylinders and fittings.
14. Use the Autopilot to extend the rod fully
in one direction and then the other.
15. Check for leaks by looking for spilled
hydraulic fluid near or on fittings and
cylinders.
**** IMPORTANT ****
DURING THE FIRST TWO TO THREE THE WEEKS AFTER YOU HAVE INSTALLED THE
PUMP AND BLED THE STEERING SYSTEM, THERE MAY STILL BE SOME RESIDUAL AIR
SUSPENDED IN THE OIL. TO PREVENT POOR STEERING PERFORMANCE, IT IS
IMPORTANT THAT YOU CHECK YOUR STEERING SYSTEM RESERVOIR SEVERAL TIMES
AFTER THE INITIAL INSTALLATION AND TOP IT UP AS NECESSARY. SHOULD THERE BE
NO RESERVOIR IN YOUR STEERING SYSTEM, PLEASE CHECK THE LEVEL OF THE
HIGHEST HELM PUMP AND TOP IT UP AS NECESSARY. CONSULT THE STEERING
MANUFACTURER FOR DETAILS.
29010015V1.0(15CI & 25CI Pumps).doc 10