PRETECH 7400 Series User manual

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MAN-0303 / Rev 20100601 http://www.pretechco.com
INSTALLATION INSTRUCTIONS
7400XX
7500XX
7100XX
7200XX
ZTS Mega Pinnacle Rotary Steering System
ZTS Mega Rotary Steering System
7000 Mega Pinnacle Rotary Steering System
7000 Mega Rotary Steering System
Manufactured by PRETECH CO Inc.
192, Bangdo-Ri, Docheock-Myeon,
Gwangju-Si, Gyeongki-Do (Korea)
E-mail: [e-mail]
Copyright 2010, PRETECH CO Inc. All Rights Reserved.
NOTICE : THIS INSTRUCTIONS CONTAIN IMPORTANT SAFETY INFORMATION AND MUST BE FORWARDED TO BOAT OWNER.
INTRO
These instructions show how to install the following products for Rotary
Steering Systems. See Fig 1.
P/N
DESCTIPTION
700040
700010
ZTS Rotary Helm (No Feedback)
7000 Rotary Helm (Feedback)
Please check the following components are prepared.
COMPONENT
DESCTIPTION
Installation Kit
Steering Cable
Steering Wheel
See Fig 2.
See Fig 3.
See Fig 4. ( Not included )
And following tools are required. See Fig 4.
TOOL
DESCTIPTION
Spanner
Hand Drill
Hand Saw
1/4”, 5/16”
φ 10mm[0.4”], φ 83mm[3.27”]
General
Safety Symbols , to alert
and indicate the level of risk
for the identified procedure.
1.
2.
3.
4.
Read this document thoroughly before installation.
Do not substitute parts without PRETECH’s confirmation.
Every condition in this document must be fulfilled.
Do not disassemble any part of the product.
Incorrect installation or using of foreign parts may cause operation
failure which can result damage or injury to boat or person.
PRETECH will not be responsibility for any cases that are
inconformity to the conditions of this instruction.
CHECK CLEARANCE
To avoid interference & difficulty in assembling, check the
clearance requirements. And check the clearance for Steering
wheel’s operation as Fig 5.
DRILL ON CONSOLE
After checking clearance, locate holes on dash.
Templates can be used to mark. See
Drawing A .
If necessary, enlarge the center hole to accommodate the steering
helm assembly.
ONE HOLE MUST BE TOP CENTER.
Fig 1. ZTS / 7000 Rotary Helm (700040 or 700010)
1
BRACKET, 1EA
6
NYLON NUT 5/16-18 UNC, 3EA
2
STAR WASHER 1/4”, 3EA
7
WOODRUFF KEY #9, 1EA
3
HEX BOLT 1/4-28 UNF, 3EA
8
FLAT WASHER 5/8”, 1EA
4
HEX BOLT 5/16-18 UNC, 3EA
9
NYLON NUT 5/8-18 UNF, 1EA
5
FLAT WASHER 5/16”, 3EA
Fig 2. Installation Kit
Fig 3. Steering Cable
Fig 4. Steering Wheel & Tools (Not included)

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MOUNT BRACKET
Use fasteners as next, and see Fig 6.
No.
FASTENER
DESCTIPTION
1
2
3
4
Bracket
Hex Head Screw
Flat Washer
Lock Nut
1EA
5/16-18 UNC, 3EA
5/16”, 3EA
5/16-18 UNC, 3EA
Nuts tightening torque
MIN. TORQUE
44.3 [lbf-in] (5.0 [N-m])
MAX.TORQUE
66.4 [lbf-in] (7.5 [N-m])
INSTALL ROTARY HELM
Place helm through the center hold and orientate the helm to give
the desire steering direction. There are multiple holes for mounting
the helm. Which ones you use will depend on your particular
installation location and cable routing.
If cable goes to the LEFT, hub cable openings should also go
left, etc.
Use fasteners as next, and see Fig 7.
No.
FASTENER
DESCTIPTION
1
2
3
Rotary Helm
Star Washer
Hex Head Screw
1EA
1/4”, 3EA
1/4-28 UNF, L 0.75”, 3EA
MOUNT TRIM BEZEL
Place the trim bezel over the shaft and snap into place over the
mounting bracket. Align Tilt Cap with the Bracket carefully. Fig8
No.
PART NAME
DESCTIPTION
1
TRIM BEZEL
1EA
INSTALL STEERING WHEEL
Fig9. Installing Steering Wheel
Turn steering wheel column until the keyway groove is top dead
center. (This will help to keep the keyway from falling out during
installation. Centering wheel adjustments will be made later while
attaching cable end to tiller.)
Place the woodruff key in the key slot on the shaft, then place
steering wheel on the shaft.
Use parts as next, and see Fig9.
(Shown steering wheel is just an example. It is not included.)
No.
FASTENER
DESCTIPTION
1
2
3
Woodruff Key #9
Flat Washer
Lock Nut
1EA
5/8”, 1EA
5/8-18 UNF, 1EA
Nuts tightening torque
MIN. TORQUE
44.3 [lbf-in] (5.0 [N-m])
MAX.TORQUE
66.4 [lbf-in] (7.5 [N-m])
Fig 5. Clearance Requirement (Top view)
Fig 6. Mounting Bracket
Fig 7. Installing ZTS Rotary Helm
Fig 8. Mounting Cap

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Place washer onto shaft then thread the nut onto the shaft.
Hold the steering wheel while tightening to avoid cable damage to
helm assembly
ROUTE CABLE
Assemble conduit fit by pulling locking knob. See Fig 10.
No.
FASTENER
DESCTIPTION
1
2
Spent Tube Core Cover
Steering Cable
1EA
1EA
Be sure locking knob is in fitting’s groove. See Fig 11.
Fig 11. Check Conduit fitting
After placing cable end(fitting) into helm unit, rotate steering as you
feed the cable end into the helm unit.
Keep minimum bending radius 8”(200mm) and clearance.
Fig 12 .
Feed cable through, turning wheel to pull cable end through rotary
assembly.
Check steering direction, making sure when wheel is turned to the
right, the boat should turn to the right as well.
Install spent tube cable cover by slipping it over the cable end, then
securing it in the same manner as cable jacket like you did.
See
Fig 10 one more time.
INSTALL CABLE ON TILLER
Route cable with as few turns as possible, keeping bends to an 8”
minimum radius.
Connect end of tiller using transom connection kit or stock steering
tube.
Adjust as required for steering wheel center with tiller center.
Check steering direction.
FINAL CHECKS-ALL CABLES
Before try to test operation, check following list especially.
No.
CHECK POINT
1
Cable radius NOT LESS than 8”minimum.
2
Turn wheel to determine that the direction of the
wheel matches the direction of the rudder action.
3
Brake (if used) is adjusted to proper feel.
4
Check that the rudder or drive stops coincide with
the cable travel.
5
All bolts and nuts are tightened to specifications.
Nuts tightening torque
MIN. TORQUE
44.3 [lbf-in] (5.0 [N-m])
MAX.TORQUE
66.4 [lbf-in] (7.5 [N-m])
Fig 10. Assembling Cable & Tube
Fig 12. Minimum Bending Radius of Cable
NOTE
Helm contains no internal field serviceable parts.
Any attempt at disassembly of these units will void warranty of
this product.
Instructions are for 90 degree mount helms only.
10 and 20 degree mounting and/or bezel kits are available.
Please contact your dealer or PRETECH for information on
purchase and installation.
Tilt helm assemblies are available.
Please contact your dealer or PRETECH for information.

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LIMITED WARRANTY
PRETECH warranty to the first retail (end user) purchaser of this
product, or a PRETECH product incorporated in another vendor’s
product that, for a period of one(1) year from the date of original
purchase, such product will be free from defects in materials and
workmanship.
PRETECH MAKES NO WARRANTY AS TO THE
MERCHANABILITY OR FITNESS OF ITS PRODUCTS FOR A
PARTICULAR PURPOSE.
The above warranty does not apply to a product that has not been
installed or maintained in accordance with PRETECH’s instructions,
been subjected to damage in an accident or abuse during
operation, or repaired or modified by persons other that PRETECH.
This warranty is also void when PRETECH Products are installed
on a boat or engine judged by PRETECH to be an inappropriate
application of its product or when PRETECH products are used
with other marine accessory products which in PRETECH’s
judgment are incompatible with the PRETECH product or adversely
affect its performance or durability.
If any PRETECH product is used commercially for such purposes
as rental or other income-producing activities then this warranty is
limited to 90 days from the date of the original retail purchase.
PRETECH’s responsibility in respect to warranty claims is limited
solely to repair or replacement of products found by PRETECH to
be defective. PRETECH DOES NOT PAY FOR LABOR
CHARGES connected with removal of a product deemed to be
defective or with installation of replacement or repaired product, or
for any other incidental or consequential damage.
To make a claim under this warranty, return believed to be defective
to your local marine dealer or PRETECH distributor, along with
proof of purchase. IF your dealer or distributor feels that a
warranty claim is justified, he/she should contact PRETECH giving
a description of the product and requesting authorization to return it
to the factory.
MERCHANDISE SHOULD NOT BE RETURNED TO
PRETECH UNTIL A RETURN GOODS AUTHORIZATION
FORM IS RECEIVED.
After receipt of an authorization form, he/she should return the
product, freight prepaid, to PRETECH. If found to be defective,
and if all return charges have been prepaid, PRETECH will repair
or replace the product and return the freight prepaid.
MAINTENANCE
It is recommended that the steering system be checked and
serviced at least every 30 days in salt water areas and at least
every 90 days in fresh water areas. Check and service the
following ;
No.
CHECK POINT
1
CABLE OUTPUT END :
Check all metal parts and the cable output end for
corrosion. Remove any old grease from the cable ram
and motor swivel connections using a mild solvent, such
as kerosene. Spray the cleaned areas with a moisture-
displacing lubricant such as WD-40 or equivalent and
apply a light coat of a good quality marine grease. Do
this with the cable ram fully extended.
2
CABLE :
Check the entire cable conduit for cracks or abrasion of
the plastic cover. Replace the cable if needed.
3
HELM :
Check all bolts, nuts, and fasteners for tightness.
4
WINTER STORAGE :
in winter storage or used infrequently, clean the cable
ram per the previously mentioned instructions. Cycle
the steering several times when applying lubricant. If at
any time the steering system becomes stiff, has an
excessive amount of freeplay or shows any change in its
operating characteristics, it is recommended to have the
system checked by authorized dealers.