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.

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Figure 3: Connections in Top Face of Hydraulic Manifold
Three hydraulic connections are required to the pump-set:
•Connect ports ‘A’ & ‘B’ to the steering cylinder ports. 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 ‘T’ port to the header tank or helm pump case. This third line is critical, as it
provides make up oil and allows the pump-set to vent any air, which may enter the
pump-set from the steering lines.
Shut-off or isolation valves for all three lines are recommended. If the pump-set fails, the
isolation valves can be shut off and manual steering maintained.
If more the one helm pump is used, a return/fill line must be installed to connect the cases of
all the helm pumps together.
With steering systems where the fill/interconnect line is pressurized (e.g. - Hynautics or
Teleflex) the recommended operating pressure is approximately 20 to 25 psi. The plumbing is
connected as noted by the port names on the top of the unit shown in Figure 3.
The shaft seal on the HRP pump-sets are rated to 50 psi. Exceeding
this pressure with cause a shaft seal failure and void the warranty.
Do not connect the output lines (Cylinder) to the tank (T) port.
Failure to observe this caution will cause a shaft seal failure and void
the warranty.

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4.3 ELECTRICAL
The motor has two 5 foot [1.5 m] long 14 AWG wire leads (1 Red and 1 Black). Connect them
to an autopilot pump driver junction box or electrical steering interface.
Kobelt recommends the use of a dedicated circuit breaker to provide power to the HRP. Size
the breaker to trip the maximum current as required by the current outlined in the product
specifications table. The breaker should trip after no more than 600 seconds.
The motor power source must have proper short circuit and overload protection. Ensure that
electrical cable used is sized property to prevent excessive voltage drop. Refer to your local
marine standards or other local governing wiring codes for guidance.
Figure 4: HRP05/11/17 Wiring Diagram
4.3.1 Autopilot Connection
The HRP can be directly connected to autopilots that support the current required of the HRP
motor. The voltage supported is either 12VDC or 24VDC respective of the model variant being
installed.

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Example autopilot wiring diagrams are provided for reference below in Figure 5 thru Figure 7.
Remember to always follow the installation guidelines as provided
by your autopilot manufacturers’ manual.
Figure 5: Example Autopilot Connection - Raymarine ACU-100, -150, -200, -400
Figure 6: Example Autopilot Connection - SimRad AC12/AC42
Figure 7: Example Autopilot Connection - Furuno FAP-7002

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4.3.2 Jog Lever Connection
Alternatively, the HRP can be controlled from a Jog Lever, such as the Kobelt 7170. The
control voltages supported depend on the power relays selected and HRP variant used. A
sample configuration for wiring of an HRP and Kobelt 7170 Jog Lever is shown in Figure 8.
It is recommended that any design and implementation of such a
system be performed by a Certified Marine Installer, Kobelt
Distributor, or individual with appropriate training and knowledge.
Figure 8: HRP Jog Lever Control Wiring Diagram
Power supply to Jog and HRP should be protected with appropriate circuit breakers as per
local codes. If only a single battery power source if available, then they can be tied together at
the supply source.
Diodes are required to isolate control signals to the power control relay. It is also
recommended that protection diodes be applied across the relay coils if they are not
integrated into the relays selected for this application.

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5COMMISSIONING
5.1 HYDRAULIC FILL &BLEED
•Open all vales, if installed, after the hydraulic connections have been made.
•Fill the steering system with an anti-wear petroleum-based fluid appropriate for the
service conditions as recommended.
•Allow sufficient time for the pump and lines to fill with oil.
5.2 ELECTRICAL CHECK
•Confirm that the electrical connections to the Autopilot have been made.
•Confirm that a breaker has been installed correctly and is turned ON.
5.3 FUNCTIONAL TEST
The Function 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. Active 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 motor 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.
8. Confirm the unit develops rated pressure during operation.

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6MAINTENANCE
6.1 PREVENTATIVE MAINTENANCE
•Monthly (12 times per year)
oInspect connections for leaks.
•Quarterly (4 times per year)
oVerify adequate oil level.
oInspect the motor brushes.
oVisually inspect wire and cable insulation for splits or damage.
•Every two years
oSample and analyze the oil in the steering lines.
oDrain reservoir and clean out.
oVerify pump develops rated pressure.
oVerify insulation integrity of motor windings.
6.2 RECOMMENDED SPARE PARTS
As a minimum Kobelt recommends the following spare parts are on-hand:
Table 2: Recommended Spares
RECOMMENDED SPARES
QTY
ITEM
KOBELT PART #
1
HRP05/HRP11/HRP17 REPAIR KIT (12 VDC/24 VDC)
600-071-RK
Repair kit contains O-ring, shaft seal and brushes.
When purchasing spare parts refer to Appendix B: Pump Parts List at the back of this manual
for Kobelt component Part Numbers. See instructions at the end of this manual for shaft seal
and motor brush replacement.
It is recommended that any required service work on an Accu-Steer
unit be performed by a factory authorized service representative.
Please contact the nearest Kobelt authorized distributor for
assistance.

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7TROUBLESHOOTING
If you encounter problems with the operation of your product, please refer to the trouble-
shooting suggestions before contacting Kobelt for assistance. If the steps below do not
resolve your issue, please reach out either Kobelt directly or our Dealers in your area.
Table 3: Common Solutions
Problem
(Issue encountered)
Cause
(What it means)
Corrective Action
(What to do)
HRP does not turn ON
No power to unit.
1. Check that the breaker is ON and has
not tripped.
2. Check that power is being output by
the Autopilot.
3. Use a Mutli-meter to confirm if
power is present between the motor
leads when the Autopilot is
commanding motion.
Wheel feels soft
Air present in
Hydraulic System
1. Bleed hydraulic system to remove
trapped air.
2. Check for proper operation.
HRP turns in opposite
direction then
expected
Motor connection
leads are
backwards, OR, the
autopilot is
expecting the
reversed wiring
configuration.
1. Shut off power to the unit.
2. Disconnect the Red and Black wire
leads.
3. Swap the lead connections and re-
connect.
4. Check for proper operating direction.

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8WARRANTY
Kobelt Manufacturing Co. Ltd. (“Kobelt”) warrants the Products and Parts manufactured by
Kobelt to be free from defects in workmanship or material and that said products are
designed mechanically and functionally to perform to specifications.
This warranty is effective providing:
•The equipment is used within the intended operating conditions and in accordance
with Kobelt recommendations
•The equipment is installed according to equipment diagrams, specifications and
recommendations which Kobelt has provided
This warranty becomes invalid if the factory supplied serial number has been removed or
altered on the product. This warranty does not cover cosmetic damage or damage caused by
an act of God, accident, misuse, abuse, negligence or modification of any part of the product.
This warranty does not cover damage due to improper operation or maintenance, connection
to inappropriate equipment or attempted repair by anyone other than an authorized Kobelt
representative.
Upon identification of a potential issue or defect with a Kobelt Product or Part, the Warranty
Applicant (“Applicant”) must immediately contact Kobelt and describe the issue in writing, by
letter, fax, email or other electronic conveyance. Kobelt will then assess the cause of the
defect and determine warranty applicability and appropriate remediation.
If any part is found to be defective, Kobelt will replace said part FOB the Kobelt factory
provided that any such defective part is returned by the Buyer with freight and applicable
forwarding charges prepaid by the Buyer. Kobalt’s sole obligation to the Applicant will be to
repair or replace the defective part with same or similar product, to a maximum value of the
list price of the product or part. The Kobelt warranty does not cover labour charges, travel or
any other associated expenses.
All Products and Parts manufactured by Kobelt, are subject to a warranty against
manufacturer’s defects in materials or workmanship for a period of two (2) years from the
date of purchase.
Kobelt will be responsible for all Products or Parts sold by Kobelt but manufactured by 3rd
party manufacturing companies. However, these products and parts are subject to applicable
3rd party warranties and may not be the same as the Kobelt warranty.

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9APPENDIX A: INSTALLATION DIMENSIONS
Figure 9: HRP05/HRP11/HRP17 Installation Dimensions

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10 APPENDIX B: PUMP PARTS LIST
Figure 10: HRP05/HRP11/HRP17 Parts Diagram