Kobelt Accu-Steer HPU100 Series Instruction Manual

Kobelt Manufacturing Co. Ltd.
HPU100
Accu-Steer Hydraulic Power Unit
Owner’s Operation, Installation &
Maintenance Manual
August 2019

HPU100 Hydraulic Power Units Kobelt Manufacturing Co. Ltd.
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NOTES:
RECORD DATA BEFORE INSTALLATION FOR FUTURE REFERENCE
Model #:
Serial #:
Date of Purchase:
Date of Installation:

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TABLE OF CONTENTS
1Introduction ............................................................................................................ 4
1.1 Contact .................................................................................................................... 4
1.2 Safety....................................................................................................................... 4
2Product Description ................................................................................................. 6
2.1 Components ............................................................................................................ 7
2.2 Technical Specifications ........................................................................................... 7
3Installation ............................................................................................................ 10
3.1 Mechanical ............................................................................................................ 10
3.2 Hydraulic................................................................................................................ 10
3.3 Electrical ................................................................................................................ 11
4Commissioning ...................................................................................................... 17
4.1 Hydraulic Fill & Bleed............................................................................................. 17
4.2 Electrical Check...................................................................................................... 17
4.3 Functional Test ...................................................................................................... 18
5Operation.............................................................................................................. 19
6Maintenance ......................................................................................................... 20
6.1 Preventative Maintenance..................................................................................... 20
6.2 Recommended Spare Parts.................................................................................... 21
7Troubleshooting .................................................................................................... 22
8Warranty............................................................................................................... 23
9Appendix A: Installation Dimensions...................................................................... 24
10 Appendix B: Parts List ............................................................................................ 25
11 Appendix C: Manifold Assembly Parts.................................................................... 26
12 Appendix D: Typical System Arrangement.............................................................. 29
13 Appendix E: Brush Replacement ............................................................................ 30
14 Appendix F: Shaft Seal Replacement ...................................................................... 31

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1INTRODUCTION
1.1 CONTACT
Kobelt Manufacturing Co. Ltd.
8238-129th Street
Surrey, British Columbia
Canada, V3W 0A6
Sales Tel:
Fax:
Email:
Website:
[phone]
[phone]
[e-mail]
www.kobelt.com
This document is intended to clearly present comprehensive product data and provide
technical information to assist the end user in design applications. Kobelt reserves the right,
without notice, to change the design, or construction, of any products and to discontinue or
limit distribution of any products. Kobelt also reserves the right to change, or update, without
notice, any technical information contained within this document.
Kobelt recommends that customers visit our website to check for updates to this Manual.
Once a product has been selected for use, it should be tested by the user to ensure proper
function in all possible applications. For further instructions, please contact our distributors or
visit our website.
1.2 SAFETY
1.2.1 Safety Alerts
Throughout this manual, the following symbols, and their accompanying explanation, are
used to alert the user to special instructions concerning a service or operation that may be
hazardous if performed incorrectly or carelessly. The associated risk levels are stated below.
This symbol indicates an imminently hazardous situation which, if
not avoided, will result in death or serious injury.
This symbol indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
This symbol indicates a hazardous situation, which if not avoided,
could result in minor or moderate injury.
This symbol informs the reader of events not related to personal
injury but which there is a risk of damage to property or equipment.
This symbol informs the reader of safety-related instructions or
procedures.

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1.2.2 Notice to Installer
Disregarding the following safety measures can result in an accident causing severe injury to
personnel and damage to material assets.
•Only use the product as directed in this manual.
•Never put the product into service if there is evidence of visible damage.
•Never put the product into service before fully completing installation and
commissioning.
•Do not carry out any modifications to the product.
•Only use authentic Kobelt spare parts.
•Observe all local regulations, directives and laws during the installation of this product.
•All installation, commissioning, and maintenance work must only be conducted by
qualified personnel. (For the purpose of this manual, qualified personnel are persons
who are familiar with the assembly, installation, commissioning, and operation of the
product and who have the qualifications necessary for their occupation.)
•Observe all specifications in this manual. If these guidelines are not followed and
damage occurs, the warranty will be voided.
1.2.3 Product Hazards
High Pressure Operation: This HPU unit generates high pressure
hydraulics. Ensure all power sources are locked out prior to
performing work.
Equipment Starts Automatically: HPU units are controlled remotely
and may activate suddenly causing bodily harm. Ensure all power
sources are locked out prior to performing work.
Disconnect Power: Turn off power at distribution panel before
beginning installation to protect installer from electrical hazards.
Voltage and Current Compatibility: Confirm that the power source
is compatible with the maximum voltage and current ratings of is
product variant. Failure to do so could result in damage or fire.

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2PRODUCT DESCRIPTION
The Accu-Steer HPU100 pumpset is a continuous running pumpset designed to interface
hydraulic steering systems with electric or autopilot control. As described, the motor runs
continuously when started and the output oil is directed to the port or starboard line by
operating the four-way solenoid valve mounted on the pumpset. Its compact and rugged
construction provides ease of installation along with long life operation. This unit is available
in both 12 VDC and 24 VDC configurations.
This pumpset is suitable for vessels with steering actuators up to 40 cu in (820 cc) or vessels
up to 50 ft (15 m) in length. Proper pump selection and application is very important to
optimize steering performance and pump longevity.
Figure 1: HPU100 Overview Diagram

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2.1 COMPONENTS
The Accu-Steer HPU100 is a complete pump assembly consisting of a gerotor style pump,
adjustable flow control, adjustable pressure release valve and an electric permanent magnet
motor terminated in an electrical junction box. As the pump set is self-contained, installation
involves connecting the unit to the steering lines and the electric control and adjusting the
unit to the requirements of the steering system.
2.1.1 Electric Motor
The electric motor is a permanent magnet style D.C. motor featuring ball bearing supports
and replaceable brush gear. The motor is directly coupled to the pump unit by a machined
face. The electric motors are available in both 12 VDC and 24 VDC voltages.
2.1.2 Pump
The pump is a gerotor style gear unit with extremely quiet operation. Hydraulic flow control
and pressure relief are adjustable. The pressure relief valves are factory set for 500 psi.
and should not be altered in the field as it will change the electric motor current draw.
2.1.3 Hydraulic Manifold
The hydraulic manifold includes directional valve, flow control, pressure relief and by-pass
valve. it also acts as a base to hold motor and pump. All adjustment and hydraulics line
connected to manifold.
2.2 TECHNICAL SPECIFICATIONS
Table 1: HPU100 Technical Specifications
MODEL
HPU100-12
HPU100-24
HPU100S-24
KOBELT P/N:
600-031
600-032
600-032SS
NOMINAL VOLTAGE
12 VDC
24 VDC
MOTOR CURRENT
No Load: 10 A
Full Load: 30 A
No Load: 5 A
Full Load: 15 A
SOLENOID MAX. CURRENT
Direction: 2.5 A
Speed: 1.7 A
Direction: 1.3 A
Speed: 0.9 A
MAX. OUTPUT
1.0 GPM [3.7 Lit. /min.]
MAXIMUM ALLOWABLE PRESSURE
•A & B PORTS
•T PORT
1000 PSI [70 bar]
50 PSI [3.4 bar]
RELIEF PRESSURE
500 PSI [34 bar]
VALVE WITH SOFT SHIFT
NO
YES
SERVICE DUTY
Intermittent: 20% ON / 80% OFF
RECOMMENDED FLUID
ISO VG 32, VI 60 Hydraulic Oil
PORT SIZE AT MANIFOLD BODY
-06 SAE ORB
PORT ADAPTERS
-06 SAE ORB TO 1/4” NPT
OPERATING TEMPERATURE
14… 122oF [-10… 50oC]
PRODUCT WEIGHT
22 lbs [10 kg]

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2.2.1 Temperature Limits
The motor temperature has a maximum limit of 248oF [120oC]. Allowing the temperature to
exceed this limit will permanently damage the motor windings. The maximum oil
temperature limit is 149oF [65oC].
Observe the operating temperature range limits as presented in Table 1. Do not operate the
unit if the ambient temperature where the unit is located exceeds these limits.
Exceeding these temperatures may result in reduced operational life
or damage to the product.
2.2.2 Pressure Range
The normal operating pressure of the unit is 0 to 500 psi. Avoid operating the unit against the
rudder stops for prolonged periods of time.
2.2.3 Duty Cycle
The HPU100 is designed as an intermittently operated unit for normal steering applications.
High demand applications will over work the motor and cause over heating.

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Figure 2: Hydraulic Schematic
FLOW ADJ.
LOW SPEED
DUMP
BYPASS
VALVE
FROM
PUMP PUMP
TO
OUT
PORT OUT STARBOARD
PRESSURE
RELIEF
VALVE
4-WAY
SOLENOID
VALVE
TANK

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3INSTALLATION
3.1 MECHANICAL
The pumpset must be placed on a horizontal bracket with a solid foundation. It should be
close to and below the steering lines for ease of connections and bleeding.
The HPU is equipped with (4) four holes for 1/4” bolts through the mounting feet. Ensure
that the unit is securely fastened to a suitable foundation.
3.2 HYDRAULIC
Before connecting the hydraulic lines to the pumpset ensure all the hydraulic lines in the
steering system have been flushed and that the hydraulic oil is free of any contamination,
which may enter the pumpset and cause it to fail.
Most steering manufacturers have recommended hydraulic oils to be used in their systems.
The HPU100 is compatible with these oils. Most manufacturers use an ISO #32 oil.
Three hydraulic connections are required to the pumpset. Two lines connect the main
steering lines. The third line, which is the interconnect/fill line, connects the pumpset to the
header tank or helm pump. This third line is critical as it provides make up oil and allows the
pumpset to vent any air, which may enter the pumpset from the steering lines. It is
recommended that flexible hose be used for all three lines to prevent any pump noise from
being transmitted to the steering system. The two steering lines should have pressure rating
of 1000 psi, where the third interconnection line is a non-pressure line. Shut off or isolation
valves for all three lines are recommended. If the pumpset failed, the isolation valves can be
shut, and manual steering regained.
Ensure the plugs remain in place until the unit is ready for
connection.
All piping and hoses must be flushed prior to connection. Failure to
do so can result in damaged components and seals.
The three hydraulic connections 9/16-18 UNF (-06) ORB with optional 1/4” NPT (National Pipe
Thread) adaptor. If NPT adaptor is being used, a pipe thread sealant such as Teflon paste must
be applied. When installing the hydraulic fittings, a pipe thread sealant such as Teflon paste
must be used.
All hoses and piping must also be plugged or capped until ready for
connection.

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The piping to the steering cylinder should be minimum 1/4” nominal size with a suitable wall
thickness to safely withstand the operating pressure. The Port and Starboard steering lines
should have a pressure rating of 1000 psi minimum. Secure the piping against vibration with
pipe clamps spaced every 3 feet [1 m].
The connections to the hydraulic manifold must be made by hoses of suitable rating to
accommodate any movements, vibration or thermal strain.
Figure 3: Connections in Top Face of Hydraulic Manifold
Three (3) hydraulic connections are required:
•Connect two “Cylinder ports”to the two steering cylinders. It is not critical to identify
which of the steering lines is Port or Starboard as most new autopilots will determine
the pump direction and program the drive outputs to suit.
•Connect the the third port to Header tank or helm pump case port.
3.3 ELECTRICAL
The pumpset units are manufactured for operation from either 12 VDC or 24 VDC dependent
on the model number ordered. The Electrical Junction Box contains a remote start relay
(voltage dependent), a thermal overload breaker, and a terminal strip for external
connections. The DC start relay can be activated with a positive or negative switched signal.

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Ensure that the electrical cable used to feed the main power to the motor of the HPU150 is
sized properly to prevent voltage drop. Refer to ABYC or local boat electrical standards for
applicable rating recommendations.
The solenoids use a common connection (Terminal 5) on the terminal strip and can be
activated by a positive or a negative control signal. The Port and Starboard solenoid coils are
connected to Terminals 6 and 7 respectively.
Some autopilots have a switched output or clutch/relay output that may be optionally used to
operate the start relay.
DO NOT energize these solenoid coils detached from the valve.
Figure 4: HPU100 Electrical Junction Box Internal Wiring
HPU100-12 contains a 30A Thermal Breaker.
HPU100-24 contains a 15A Thermal Breaker.

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Table 2: HPU100 Terminal Block Wiring Connections
HPU100 Series
Terminal
#
Wire
Name
Wire
Colour
Function
1
MOTOR POS (+)
Red
Positive power supply to motor
2
MOTOR NEG (-)
Yellow
(or Black)
Negative power supply to motor.
3
START POS (+)
Red
Positive control signal to starter relay to
active motor and pump.
4
START NEG (-)
Yellow
(or Black)
Control signal common (negative) to start
relay to active motor and pump.
5
COIL COM
Green
Common Positive or Negative signal for
solenoids coil control.
6
COIL PORT
Red
Positive or Negative signal for PORT
direction solenoid coil.
7
COIL STBD
Black
Positive or Negative signal for STBD direction
solenoid coil.
8
N/C
--
No Connection (N/C)
Figure 5: HPU100 Terminal Block Diagram

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3.3.1 Example Connection Diagrams
The following section contains various example methods for connection of the HPU.
It is recommended that installation work is carried out by a Kobelt
Partner, authorized service representative, or trained installation
technician. Please contact the nearest Kobelt authorized distributor
for assistance.
Figure 6: HPU100 Jog Control Diagram, Common Negative

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Figure 7: HPU100 Autopilot Wiring Diagram, Common Positive

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Figure 8: HPU100 Autopilot Connection Option with Starter Connections

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4COMMISSIONING
4.1 HYDRAULIC FILL &BLEED
After the hydraulic and the electrical connections have been completed, open all isolating
valves and allow enough time for the pump and lines to fill with oil. Start the pump and
operate the 4-way solenoid valve to check that the port and starboard directions are correct.
If they are wrong, reverse connections to Terminals 6 and 7. Check the hard over to hard
over speed of the rudder and adjust the flow for the appropriate speed. Clockwise to
decrease and counter clockwise to increase.
The pressure relief is factory set at 500 psi and should not require
adjustment.
4.2 ELECTRICAL CHECK
Ensure that the cover is installed and secured on the value junction
enclosure and all pigtail connections have been properly terminated
and enclosed before powering on the HPU100.
Confirm that the electrical connections to the HPU100 have been made correctly and
correspond to the requirements of your system installation.

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4.3 FUNCTIONAL TEST
The Functional Test should be carried out while the vessel is still at
dock and before it is taken out to sea, after installation has been
completed.
After installation and filling, perform the following function tests:
1. Power ON the autopilot (or electronic jog lever).
2. Activate the autopilot (or electronic jog lever) to command motion.
3. Verify that the rudder position changed.
4. Set the autopilot to the manual mode and operate the pump-set to determine if
the Port and Starboard directions are correct.
5. If the rudder goes the opposite way than expected.
a. Reverse the two electrical leads between the coils and the autopilot.
Most new autopilot systems will perform this test during their
dockside set-up procedures.
6. Operate the pump-set and note the “hard-over” to “hard-over” (HO to HO) time.
7. Verify that it is in the range of 10 to 16 seconds. Times outside of this range
indicate a mismatched pump-set for the steering system.

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5OPERATION
The HPU100 operates as follows:
•Manifold receives oil from pump, and outputs to steering lines. Output flow determining
the speed of the rudder.
•Output flow is controlled by flow control valves.
•Pressure relief valve is factory set to approximately 500 psi.
•Excess flow is returned to tank via bypass valve.
•By energizing related solenoid on directional valve, flow will be sent to port or
starboard.

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6MAINTENANCE
6.1 PREVENTATIVE MAINTENANCE
The brushes on the electric DC motor can be easily checked by removing the caps and visually
inspecting the brushes. Replace the carbon brushes as required and check the internal
condition of the motor. (see appendix E)
•Monthly (12 times per year)
oInspect connections for leaks.
•Quarterly (4 times per year)
oVerify adequate oil level.
oVisually inspect wire and cable insulation for splits or damage.
•Every (2) two years
oSample and analyze the oil in the steering lines.
oDrain reservoir and clean out.