Kobelt HRP05 Series User manual

Kobelt Manufacturing Co. Ltd.
HRP05/HRP11/HRP17 Accu-Steer
Hydraulic Reversing Pump-Set
Owner’s Operation, Installation &
Maintenance Manual
November 2018

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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 Technical Data ......................................................................................................... 6
3Operation................................................................................................................ 8
4Installation ............................................................................................................ 10
4.1 Mechanical ............................................................................................................ 10
4.2 Hydraulic................................................................................................................ 10
4.3 Electrical ................................................................................................................ 12
5Commissioning ...................................................................................................... 15
5.1 Hydraulic Fill & Bleed............................................................................................. 15
5.2Electrical Check...................................................................................................... 15
5.3 Functional Test ...................................................................................................... 15
6Maintenance ......................................................................................................... 16
6.1 Preventative Maintenance..................................................................................... 16
6.2 Recommended Spare Parts.................................................................................... 16
7Troubleshooting .................................................................................................... 17
8Warranty............................................................................................................... 18
9Appendix A: Installation Dimensions...................................................................... 19
10 Appendix B: Pump Parts List .................................................................................. 20
11 Appendix D: Manifold Assembly Parts ................................................................... 22
12 Appendix D: Typical System Arrangement.............................................................. 24
13 Appendix E: Brush Replacement ............................................................................ 25
14 Appendix F: Shaft Seal Replacement ...................................................................... 26

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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 HRP unit generates high pressure
hydraulics. Ensure all power sources are locked out prior to
performing work.
Equipment Starts Automatically: HRP 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 HRP05, HRP11, and HRP17 are complete pump assemblies each consisting of a reversing
gerotor gear pump, hydraulic lock valves, suction, make-up check valves, a valve housing
manifold and an electric permanent magnet motor.
Figure 1: HRP Overview Diagram
2.1 TECHNICAL DATA
Table 1: HRP05/HRP11/HRP17 Technical Data
MODEL
HRP05-12/24
HRP11-12/24
HRP17-12/24
KOBELT PART #
600-071
600-072
600-081
600-082
600-091
600-092
NOMINAL VOLTAGE
12 VDC
24 VDC
12 VDC
24 VDC
12 VDC
24 VDC
MAXIMUM CURRENT
20 A
10 A
30 A
15 A
40 A
20 A
OUTPUT FLOW RATE
0.5 in3/sec
[8 cc/sec]
1.0 in3/sec
[16 cc/sec]
1.6 in3/sec
[26 cc/sec]
MAXIMUM ALLOWABLE
PRESSURE
•A & B PORTS
•T PORT
1000 PSI [70 bar]
50 PSI [3.4 bar]
CYLINDER CAPACITY
5 - 9 in3
[82 - 147 cc]
10 - 16 in3
[164 - 262 cc]
16 - 30 in3
[262 - 492 cc]
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
10 lbs [4.5 kg]
MOTOR WIRE LEADS
14 AWG: 5 feet [1.5 m]
MOTOR APPROVALS
Ignition Protected: UL-1500, SAE-1171

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2.1.1 Cylinder Compatibility
The HRP05/11/17 works with both balanced and unbalanced cylinders. When unbalanced
cylinders are used it is recommended that a vented header tank is used to allow for the
expansion and contraction from the unbalanced cylinder.
2.1.2 Duty Cycle
The HRP pump-sets are designed as an intermittently operated unit for normal steering
applications. High demand applications will over work the motor and cause over heating.
2.1.3 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 of the unit (Table 1: HRP05/HRP11/HRP17
Technical Data). Do not operate the unit if the ambient temperature where the unit is
located exceeds this limit.
2.1.4 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.

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3OPERATION
The Kobelt HRP Hydraulic Reversing Pump-sets are designed to interface a hydraulic steering
system with electric or autopilot control. The output flow rate of the pump-set determines
the actuation speed of the steering cylinder.
The HRP (Hydraulic Reversing Pump-set) operates as follows (reference numbers below refer
to Figure 2):
•As the motor (1) rotates CCW, oil from the gear pump (2) is pumped towards output
“A”.
•This oil passes through the check valve (5) and goes to the output line (7).
•The pressure at output “A” ensures the check valve (3) stays closed and manually opens
check valve (6).
•Opening check valve (6) allows the returning oil from the steering cylinder to flow back
to the pump.
•If the pressure at the pump suction “B” is less than the pressure in the make-up line, oil
from the make up line will pass by the check valve (4). This prevents cavitation due to
any air that may be in the steering line.
•When the pump stops turning all spring-loaded check valves return to the normally
closed position.
•When the motor (1) rotates (CW) the reverse movement of the oil and valves takes
place.

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Figure 2: Internal Hydraulic Schematic

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4INSTALLATION
4.1 MECHANICAL
Ideally, the location of the pump-set should satisfy the following conditions:
•Within 6 feet [1.8 m] of the steering cylinder.
•Below the steering cylinder for ease of connections and bleeding.
•Placed on a horizontal shelf or bracket.
•Not exposed to direct sunlight or any source of heat.
•Provide a foundation sturdy enough to prevent the transmission of excessive vibrations.
The HRP is equipped with (4) four clearance holes for #10 (M5) bolts through the mounting
feet. Ensure that the unit is securely fastened to a suitable foundation.
4.2 HYDRAULIC
The HRP pump-sets are equipped with a fitting with a 1/4" NPT port that are plugged for
shipping.
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 ports on the valve block are fitted with 1/4" NPT (National Pipe Thread)
adapters. If preferred, the adapters can be removed, and connections can be made directly
to the valve blocks -06 SAE ORB ports. When installing the hydraulic fitting in the 1/4" NPT
port 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.
The piping to the steering cylinder should be 3/8” nominal size and no less than 1/4” 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 pump-set must be made by hoses of suitable rating to accommodate
any movements, vibration or thermal strain. Hoses are also required to prevent any pump
noise from being transmitted to the steering system.