Navtec System 50 User manual

Congratulations on the purchase
of your new System 50, by Navtec.
Navtec Hydraulic Systems are an industry standard and have
been for more than a decade. The System 50 you’ve
purchased represents the ongoing ergonomic and mechan-
ical design program Navtec has initiated to address the
changing needs of modern yachts and the people who
sail them.
System 50 is designed for improved functioning at all levels
– operational, mechanical, and ergonomic. It also is
designed to accommodate a two-speed auto-pump or
a hydraulic power pack. The end result is an advanced,
flexible, intelligently designed hydraulic control system for
yachts 35 to 70 feet long.
About your
new Navtec System 50
Hydraulic Control Panel.
www.navtec.net
[email protected]
351 New Whitfield Street • Guilford, CT 06437 USA • Tel [phone] • Fax [phone]

Installation Instructions
Locate the panel position keeping in mind normal position of crew members while pump-
ing. Use a high-quality marine sealant between panel and bulkhead to prevent leaks.
Mount the separate reservoir with the hose fittings at the bottom. Be sure to leave room
above the removable cap at the top of the reservoir for filling. See Table II for reservoir
capacity and dimensions. If possible, the bottom of the reservoir should be above the pump
as pump suction will be more positive, but this is not essential for satisfactory operation.
Place the reservoir as close to the pump as possible to minimize the effect of pitch and heel.
Installing plumbing.
Connect either hose barb at the bottom of the reservoir with the pump intake hose barb
(#1), using the low pressure hose supplied. Be sure there is a plastic oil filter in this line.
(part # H0-012)
Connect the other hose barb on the bottom of the reservoir with hose barb (#2) on the
back of the panel for the return, using a second low-pressure hose.
A single high-pressure reinforced hose or stainless steel tube (rated for at least 5,000 psi)
must be run from the valve on the central panel to each operating cylinder. High-pressure
hose, cylinders and boom vangs are available from your Navtec distributor.
If the panel is single function the hose or tube runs from fitting (#3).
If multiple function, the hose runs from 1 of 4 ports on 4-way selector valve (#4).
For push-pull cylinders, when a 4-way valve is used (this is different than the 4-way selector
valve), consult your Navtec distributor or Navtec Inc. for plumbing instructions.
For the System 50 with a two speed pump you have two returns to the reservoir. One from
the manifold #2, the second from the pump #6. You will need a “t” fitting. (not included)
Information and advice on
oil and filter.
Navtec recommends the following oils: Shell Tellus T15® , Mobil DTE 11M® , Texaco Rando
HD215® , Royal Purple Syndraulic 15® . Never use brake fluid because it will attack the seals.
Oil should be checked periodically for cleanliness. Any particulate matter in the oil will
decrease the life of the moving parts and may also cause malfunctions. The oil filter should
be changed if there is any indication of pump skipping due to oil starvation. If using a
system in cold climates contact Navtec.
1
5
2
4
6
Multi-function/two speed pump
Single function/single speed pump
1
3
5
2

Pressurizing the cylinder.
Standard Navtec cylinders are equipped with an air pressure return. This return is pressurized
through the ‘tire’ valve at the clevis end of the cylinder. A bicycle pump or service
station air hose can be used to charge the return up to 100 psi. The air pressure should be
adjusted to give the desired rate of return.
WARNING: Once charged, do not attempt to disassemble the cylinder. Only an
authorized Navtec Hydraulic Service Center or Navtec Inc should do this.
How and when to bleed
the system.
After installing the panel, cylinders, and plumbing, oil should be added to the reservoir and the
system bled of all air. Each cylinder and line must be bled separately.
Step 1. Open release valve fully. If system is multi functioning, select function to be bled first.
Step 2. With hose attached to cylinder, extend cylinder fully. If there is air pressure in lower
chamber the cylinder will extend automatically.
Step 3. Disconnect hose at cylinder. Note: Always disconnect slowly to allow remaining pressure
to decrease slowly. Be prepared for possible oil drips.
Step 4. Close release valve and pump, holding the hose end in a can to collect oil. When oil is
bubble-free, reconnect hose to cylinder.
Step 5. Pump cylinder all the way down (with cylinder detached from rigging). Then open release
valve and allow cylinder to return fully. Check to be sure there is sufficient oil in the
reservoir so that it won’t run dry.
Step 6. Repeat above procedure for each cylinder and line.
Step 7. Check oil level / do not overfill.
Adjusting the relief valve.
The relief valve (#5) is factory-set to approximately 4000 psi. Adjustment is provided by the 1"
(25mm) round threaded cap in the aluminum valve block at the back of the panel. Maximum
relief setting is 5000 psi. Turning the cap counter-clockwise will lower the setting. Clockwise
will raise it. The adjustment is about 1000 psi per complete turn. To determine the setting with-
out tensioning the rig, disconnect any cylinder from the rigging and pump that cylinder until
it bottoms and the relief valve engages, which will be evident when continuous pumping fails
to raise the gauge pressure. The maximum pressure observed is the relief valve setting.
Operating Instructions
For Single Function System
(Without Selector Valve)
To increase tension in the cylinder, make sure that the release valve is closed. Do not over
tighten. Doing so will shorten the life of the valve. Then pump. The valve body has a special
zero-leakage check valve so no manual-locking valve is necessary. To reduce tension, open
the release valve. Remember that it is not necessary to turn very hard to close the valve.
continued on back...
(in3) (cm3) (in) (mm) (in) (mm) (in) (mm)
2 Qt. 60 983 6.88 174.8 8 203.2 4.88 124
4 Qt. 120 1967 7.75 196.9 10.88 276.4 5.75 146.1
Table II RESERVOIR CAPACITY & DIMENSIONS
SIZE USABLE VOL X Y DEPTH
X
Y

NAVTEC LIMITED WARRANTY
1. WARRANTY: Navtec warrants its products, in normal usage, to be free of defects in materials and workmanship for a period of one year from date of original purchase by the user, subject to the conditions and
limitations below. Any part that proves to be defective in normal usage during that one year period will be repaired or replaced Navtec. This warranty is subject to the following conditions and limitations:
A. Navtec’s liability shall be limited to repair or replacement (choice of remedy at Navtec’s option) of goods or parts defective in materials or workmanship. This shall be the buyer’s exclusive remedy in contract, tort
or otherwise. B. Except as otherwise provided, quality shall be in accordance with Navtec’s specifications. C. Determination of the suitability of the material for the use contemplated by the buyer is the sole
responsibility of the buyer, and Navtec shall have no responsibility in connection with such suitability. D Navtec shall not be liable for any harm resulting from: (1) failures due to use of products in applications for which
they are not intended. (2) failures due to corrosion, wear and tear, or improper installation. In the case of rod rigging products, improper installation includes, but is not limited to, the use of rod rigging end fittings
other than those manufactured by Navtec or meeting Navtec specifications. Improper installation also includes, but is not limited to, the use of dies other than those leased by Navtec to Authorized Navtec Representatives,
to form the head which is part of the patented Navtec Headed Rod Rigging System. E. Navtec shall not be responsible for shipping charges or installation labor associated with any warranty claims. F. Service by
anyone other than Authorized Navtec Representatives shall void this warranty unless in accordance with Navtec guidelines and standards of workmanship.
2. DISCLAIMER OF IMPLIED WARRANTIES. There are no warranties of merchantability, fitness for purpose, or any other kind, express or implied, and none shall be implied by law. The duration of any such warranties
that are nonetheless implied by law for the benefit of a consumer shall be limited to a period of one year from original purchase by the user. Some states do not allow limitations on how long an implied warranty lasts
so the above limitations may not apply to you.
3. LIMITATIONS OF CONSEQUENTIAL DAMAGES. Navtec shall not be liable for consequential damages to yachts, equipment or other property, or persons due to any failure of Navtec equipment. Some states do not
allow the exclusion or limitation of incidental or consequential damages, so the above limitation or inclusion may not apply to you.
4. This warranty gives you specific legal rights and you may also have other rights which vary from state to state.
{Operating Instructions cont.)
For Multi-Function System
(With Selector Valve)
This system operates the same way that the single function system operates (see previous page), except that the selector valve must
be positioned before pumping or releasing tension. To position, turn the selector valve handle in either direction to the desired
function (at rear of valve) to which the appropriate hose is attached until you feel the knob click. Function labels are available from
Navtec at no charge.
Note: The single-function panel can be converted to the multi-function panel at a later date. The conversion part number is A320-SMC-01.
Two-speed pump version
The two-speed pump will automatically shift down from the low(high flow) gear when the internal pressure shift point is reached.
The shifting point is adjustable to suit the desired level of pumping pressure needed to physically operate the pump. To adjust the
shifting point turn the set screw on the back of the pump counter clockwise to lower and clockwise to raise (#7). To check what
pressure point the auto shift valve is set at, disconnect a cylinder from the rigging and pump it down until the pressure builds. Upon
reaching the set pressure, the 2 larger pump pistons will close and the pump will suddenly become easier to operate. The shift
pressure point can be noted by reading the gauge when it shifts. The standard pressure setting as set at the factory is 1800 lbs.
Reading the gauge.
The Navtec gauge has a double-ended needle so that two scales can be used. The top scale, which reads in thousands of pounds per
square inch, is always included and indicates the pressure within the cylinder and the connecting plumbing. A lower scale, which reads
in thousands of pounds of force, can be overlaid on the gauge face if the cylinder size is known. These gauge face overlays are
available from Navtec. Please specify cylinder size when ordering. The pressure within the system can be converted to actual force
exerted by the cylinder, using Table IV or the formula below:
Pressure (lbs/inch2) X Cylinder area (inch2) = Force (lbs)
Gauges have a backing card that is specially treated to provide night illumination. If backing card does not
provide enough light, recharge by passing a flashlight beam slowly over the gauge.
1000 3000 5000
SIZE (in) (mm) (in2) (cm2) (lbs) (kg) (lbs) (kg) (lbs) (kg)
6 cyl. 0.437 11.1 0.639 4.12 640 290 1920 870 3190 1450
6 vang 0.625 15.9 0.482 3.11 480 220 1450 656 2410 1090
10 cyl. 0.5 12.7 1.16 7.48 1180 530 3480 1580 5800 2630
10 vang 0.75 19.1 0.914 5.89 910 410 2740 1240 4570 2070
12 cyl. 0.625 15.9 1.525 9.63 1525 690 4580 2080 7620 3460
12 vang 0.875 22.2 1.28 7.93 1230 560 3690 1670 6150 2790
17 cyl. 0.625 15.9 2.173 14.02 2170 990 6520 2960 10860 4930
17 vang 1 25.4 1.695 10.93 1690 770 5080 2300 8470 3840
22 cyl. 0.75 19.1 2.785 17.96 2780 1260 8350 2306 13920 6310
22 vang 1 25.4 2.442 15.75 2440 1110 7330 3320 12210 5540
30 cyl. 0.875 22.2 4.414 28.47 4410 2000 13240 6000 22070 10000
30 vang 1.25 31.8 3.778 24.37 3780 1710 11330 5140 18890 8570
40 cyl. 1 25.4 6.435 41.51 6430 2920 19300 8750 32170 14580
40 vang 1.25 31.8 5.993 38.66 5990 2720 17980 8150 29960 13590
60 cyl. 1.25 31.8 8.571 55.3 8570 3890 25710 11660 42850 19430
60 vang 1.5 38.1 8.031 51.81 8030 3640 24090 10930 40150 18210
Table III Cylinder Force vs. Pressure
CYL/VANG ROD DIAM CYL. AREA “OBSERVED PRESSURE (from gauge, in psi)”