Raymarine autopilot ST4000+ User manual

ST4000+ Autopilots
ST4000+ Autopilots Service Manual 83115-1
Warning
CE Marking of Equipment/Replacement Parts
IftheAutohelmequipmentunderrepair,test,calibration,installationorsettingtoworkcarriestheEuropeanCEmark,
onlypartsandcomponentssuppliedorapprovedforsuchusebyRaytheonshouldbeusedinordertomaintain
compliancewiththerelevantCErequirements.
Incorporation,useorattachment,byanymeans,ofpartsorcomponentsnotsuppliedforornotapprovedforsuchuseby
Raytheonor,ifsuppliedorapprovedforusebyRaytheon,notproperlyfittedinaccordancewithinstructionspublished,
providedorrecommendedbyRaytheon,maycausetheequipmenttomalfunctionand,inparticular,tobecomeunsafeor
tonolongermeettherelevantCErequirements.Inthesecircumstances,RaytheonMarineEuropeLtdexcludesliability
tothefullestextentpermissibleinlawforanylossordamageincludinganyliabilityforitscontributiontosuchlossor
damagebyitsnegligentactsoromissions.
ST4000+ Autopilots Service Manual
Foruseon
Z326,WheelAutopilot
Z327,TillerAutopilot
Z332,TillerGPAutopilot
D3730-1

ST4000+ Autopilots
ST4000+ Autopilots Service Manual 83115-1

Contents
ST4000+AutopilotsService Manual 83115-1
Contents
Chapter 1. ST4000+ Control Head ......................................................................................... 1
1.1PCBChanges ................................................................................................. 1
1.2 Disassembly/Assembly.................................................................................... 2
ST4000+ControlHead spare partslist ........................................................... 3
1.3 PCBDetails .................................................................................................... 4
Input/OutputSignals (referto Figure 2.Circuit Diagram) ................................... 4
CircuitDiagram..................................................................................... 5
PCB Layout .................................................................................................. 6
PCBComponent list ............................................................................. 7
Chapter 2. Fluxgate CompassTransducer ............................................................................ 9
2.1Functional test ................................................................................................. 9
2.2 Magneticdeviation .......................................................................................... 9
2.3 Disassembly/assembly................................................................................... 10
FluxgateCompassspare partslist................................................................ 10
Chapter3. Wheel DriveActuator ......................................................................................... 11
3.1Wheel DriveActuator test................................................................................ 11
3.2 Disassembly/assembly................................................................................... 12
WheelDriveActuator spare partslist ............................................................ 13
Disassembly............................................................................................... 14
Beltremoval ....................................................................................... 14
Pinionsprocket removal ...................................................................... 14
Drive leverandeccentricremoval......................................................... 14
Motorremoval .................................................................................... 14
Gearbox removal ................................................................................ 15
Gearbox disassembly................................................................. 15
Assembly ................................................................................................... 16
Gearbox assembly.............................................................................. 16
Motorassembly.................................................................................. 16
Adjustmenteccentric assembly ........................................................... 16
Drive lever and eccentricassembly ...................................................... 17
Pinionsprocket and beltassembly ....................................................... 17
Drive ringclosure................................................................................ 17
3.3Setting BeltTension........................................................................................ 18
Toolsrequired: ............................................................................................ 18
Motordrive box ........................................................................................... 18
Motordrive boxparts .......................................................................... 19
Procedure ................................................................................................. 19

ST4000+ Autopilots
ST4000+ Autopilots Service Manual 83115-1
Chapter 4.Tiller Drive Actuator ............................................................................................ 21
4.1TillerDriveActuator test .................................................................................. 21
4.2 Disassembly/assembly................................................................................... 22
TillerDriveActuatorsparepartslist............................................................... 23
TillerDriveActuatorGPconversionkit(W003)............................................... 23
Chapter 5.Tiller Drive Actuator GP ...................................................................................... 25
5.1TillerDriveActuator GP test ............................................................................ 25
5.2 Disassembly/assembly................................................................................... 26
TillerDriveActuatorGPsparepartslist ......................................................... 27

Chapter1.ST4000+ ControlHead
ST4000+ Autopilots Service Manual 83115-1 1
Chapter 1. ST4000+ Control Head
1.1 PCB Changes
WhenaPCB is changed, itmay benecessarytoset the newPCBto the
requiredpilottype,ST4000+Wheel, ST4000+Tilleror ST4000+TillerGP
1. Iftheinstrument is disassembled,fitthereflector,diffuser, elastomers,
LCDandsurround to thePCB
2. Apply12V powertothe instrument/PCB assembly
3. Press and holdSTDBYfor14 seconds untilCAL ?is displayed
4. Momentarily press+1and -1 togetherto gain access toextended
calibration(dealerset - up)
5. Advancefrom the CALLOCK page to thepilot type pageby pressing
DISP
6. Usethe+1 and -1 buttonsto setthepilottype as required, 4000WHL
(wheel)or4000TILL(tiller)
7. PressSTDBY to exitextendedcalibration
8. Switchoff the power supply.Donotdisconnect
9. Whenthepilot is fullypowereddown, switchthe poweron again
10.Checkthat the requiredpilot type is momentarily displayedbefore
STANDBYisentered.If not, repeattheset- up procedure.Inthecaseof
asecond failure, change thePCB.

ST4000+ Autopilots
2ST4000+AutopilotsService Manual 83115-1
1.2 Disassembly/Assembly
1. Facia 2. Keypad 3. Label 4. Window insert 5. LCD surround 6. LCD 7. Elastomer strip (x2) 8. Diffuser 9. Reflector
D3721-1
2 17 (Note A)
1345
6 7 (x2) 8 (Note B) 9 10 12 (Note C)
11 (x3) 14 13 11 (x8)
10. PCB 11. Retaining screw (x11) 12. Case seal 13. Rear cover 14. Buzzer connector 15. Label 16. Bulkhead gasket 17. Keypad shim (earlier units only)
Notes: A. Earlier production units have a shim (17) fitted to aid keypad compression. B. The castellated top edge of the diffuser (8) fits under the legs of the LEDs on the top edge of the PCB (10). C. It is recommended that a new case seal (12) is fitted on assembly.
15
16
Figure1: ST4000+ControlHeadexplodedview

Chapter1.ST4000+ ControlHead
ST4000+ Autopilots Service Manual 83115-1 3
ST4000+ Control Head spare parts list
Theitem numbersrefertoFigure 1:ST4000+ControlHead explodedview
Item SpareDescription PartNo. Comments
1 Facia W115
2 Keypad Q219
Displaykit, including Q220
3 Label(selection) FitST4000+label
4 Windowinsert
5 LCDsurround
6 LCD
7 Elastomer(x2)
Diffuserkit, including W117
8 Diffuser
9 Reflector
10 PCB Q221 ST4000+/ST5000+PCB
Fixingkit, including W120
11 Screw(x11)
12 Caseseal W118
Backcoverassembly, including W119
13 Back cover Comesfittedwith,
Gortexfilter,
Sleeving,
Buzzerand
14 Buzzerconnecter
15 Label(selection) FitST4000+ label
16 Bulkheadgasket W125
Suncover D340 Notillustrated

ST4000+ Autopilots
4ST4000+AutopilotsService Manual 83115-1
1.3 PCB Details
Input/Output Signals (refer to Figure 2.Circuit Diagram)
PinNo. Signal Description
PL1/1 +12V Nominal12Vdc
PL1/2 0Vin 0V
PL1/3 SeaTalk Intermittentstreamsof(nominal)12Vpulses
PL2/1 +12V Nominal12Vdc
PL2/2 0Vin 0V
PL2/3 SeaTalk Intermittentstreamsof(nominal)12Vpulses
P1 +12V Nominal12Vdc
P2 0Vin 0V
P3 SCRN 0V
P4 Bias Nominal2.5Vdc(VRESET)
P5 F/GA +2.5Vdc
P6 F/GB +2.5Vdc
P7 Coildrive ACsignal,17cyclesat7.9kHz,driventwice
every1/16second
P8 Rudderreference Nominal5Vsupplytorudderreference
supply
P9 Rudderreference 0to5Vdc(nominal)rudderreferenceoutput
P10 Rudderreference0V 0V
P11 SCRN 0V
C+ Clutch +12VifAutopilotengaged;otherwise0V
C– Clutch0V 0V
MD1 MD1 WhenAutopilotengagedanddependingon
directionofdrive,intermittentvariablelength
pulses,nominal12V;otherwise0V
MD2 MD2 WhenAutopilotengagedanddependingon
directionofdrive,intermittentvariablelength
pulses,nominal12V;otherwise0V
NMEAin+ NMEA+ Intermittentstreamsof(nominal)12Vpulses
NMEAin– NMEA– 0V

Chapter1.ST4000+ ControlHead
ST4000+ Autopilots Service Manual 83115-1 5
Circuit Diagram
D3723-1
Figure2: CircuitDiagram

ST4000+ Autopilots
6ST4000+AutopilotsService Manual 83115-1
PCB Layout
D3722-1
Taken from Drawing No: 4376-001 Issue: P Date: 03.10.97
Figure3: PCBComponentLayout

Chapter1.ST4000+ ControlHead
ST4000+ Autopilots Service Manual 83115-1 7
PCB Component list
D3724-1
Taken from Drawing No: 4376-001 Issue: P Date: 03.10.97

ST4000+ Autopilots
8ST4000+AutopilotsService Manual 83115-1

Chapter2. FluxgateCompassTransducer
ST4000+ Autopilots Service Manual 83115-1 9
Chapter 2. Fluxgate Compass Transducer
2.1 Functional test
Disconnectthe Fluxgate fromthe Autopilotand checkcontinuity as follows:
Cablecolour Connectorpinnumber Resistance
Screentoblue 2/4 <10ohms
Redtogreen 3/5 <5ohms
Redtoyellow 3/6 <5ohms
Redtoscreen 3/2 Opencircuit
2.2 Magnetic deviation
TheFluxgateCompass requires carefulsiting if optimum Autopilot
performance is to beacheived.The SeaTalkelectronicsisabletocorrect the
compassformost deviatingmagneticfields present whenthe linearisation
procedureis carried out.Any furtherdeviation,introduced after linearisation,
willintroducean error between the Fluxgate andthe ship’s compass.This
canbe removedbycarrying outthelinearisation again.If the displayed
deviation isgreaterthan+/– 15 degreesthe Fluxgate shouldbe resited.
Note:Thelinearisationprocedure should always be carriedoutifthe
Fluxgatehas been exchanged, removed or moved fromits original mounting
position.

ST4000+ Autopilots
10 ST4000+ Autopilots Service Manual 83115-1
2.3 Disassembly/assembly
D3726-1
1274
365
8
9
1. Cover
2. Seal
3. Pivot retaining screw (x2)
4. Bracket
5. Pivot sub-assembly
6. Fluxgate sub-assembly
7. Body
8. Body screw (x4)
9. Cable
Figure4.FluxgateCompassexplodedview
Fluxgate Compass spare parts list
Theitem numbersrefer to Figure4: FluxgateCompass explodedview
Item SpareDescription Part No. Comments
Compassbasekit, including M096
3 Pivotretainingscrew(x2)
4 Bracket
Fluxgatesub-assembly, including M022
5 Pivotsub-assembly(x2)
6 Fluxgatesub-assembly

Chapter3. WheelDriveActuator
ST4000+ Autopilots Service Manual 83115-1 11
Chapter 3. Wheel Drive Actuator
3.1 Wheel Drive Actuator test
Carry outthepassiveandactive tests detailedinFigure 6.
D2386-1
PSU
12V 15A
Switch
Fuse/CB
12A
Figure5.WheelDriveActuatortestconnections
Change damaged
components
Check gears,
belt, rollers,
belt tension,
eccentric, drive
lever, motor
Start
No
Yes
Visually inspect unit
Rotate drive ring by hand
with clutch disengaged
No
Yes
OK
OK
Check resistance across
motor connector pins 2 and 3
is approximately 1 to 2 ohms
Change/adjust
as necessary
No
Yes
Check wiring
and connector
OK
Check motor
Change as
necessary
OK
D2390-1
No
Yes
Connect power supply
as in Figure 5
OK No
Yes
Change/adjust
as necessary
Switch on.Check drive ring
moves in opposite direction
to that of first test and
current is less than 2A
No
Yes
OK
Actuator OK.
End of test
Switch on, and with clutch
engaged, check drive ring
moves and current is less
than 2A
Restrain drive ring rotation
until 6.5A is obtained. Check
that belt does not slip.
OK No
Yes
Reverse polarity of supply
Restrain drive ring rotation
until 6.5A is obtained. Check
that belt does not slip.
No
Yes
OK
Check gears, belt,
rollers, belt
tension, eccentric,
drive lever, motor
Change/adjust
as necessary
Check gears, belt,
rollers, belt
tension, eccentric,
drive lever, motor
Figure6.WheelDriveActuatortestflowchart

ST4000+ Autopilots
12 ST4000+ Autopilots Service Manual 83115-1
3.2 Disassembly/assembly
98
D3727-1
10
18
17
16
11
521
1. Drive ring 2. Back mounting plate assembly 3. Screw (x5) 4. Support plate 5. Belt 6. Bearing 7. Pinion sprocket 8. Roll pin 9. Drive lever 10. Drive wheel assembly 11. Drive eccentric assembly 12. Adjustment eccentric assembly
1 3(x5) 4 6 7 12 13 22(x4) 2
14 15
14 15
Large chamfer of adjustment locking nut to face protective cap
23 24 25 26 28 29 30 3127
20(x2) 19 32 33 34 35 36
13. Adjustment wheel assembly 14. Adjustment locking nut 15. Protection cap 16. Roller screw (x7) 17. Washer (x7) 18. Roller (x7) 19. Pin 20. Shim (x2) 21. Gearbox drive shaft/ gear carrier 'C' 22. Gearbox retaining screw (x4) 23. Gearbox 24. Red motor seal
25. Flux ring 26. Motor location peg 27. Motor 28. Motor clamp 29. Motor clamp 'O' ring 30. Connector 31. Connector seal 32. Sleeve 33. End cap 'O' ring 34. End cap 35. Sealing cap 36. Connector nut 37. Cable assembly
37
Figure7. WheelDriveActuatorexplodedview

Chapter3. WheelDriveActuator
ST4000+ Autopilots Service Manual 83115-1 13
Wheel Drive Actuator spare parts list
Theitem numbersrefertoFigure7: Wheel DriveA ctuator explodedview
Item SpareDescription PartNo. Comments
1 Drivering N031
2 Backmountingplateassembly N013 Comesfittedwith,
pre-assembled
gearbox,item23
5 Belt D169
Pinionkit, including N014
7 Pinionsprocket
15 Protectioncap
19 Pin
20 Shim(x2)
Driveleverkit, including N011
8 Rollpin
9 Drivelever
11 Driveeccentricassembly N024
Gearboxdriveshaft/gear N026
carrier‘C’kit, including
21 Gearboxdriveshaft/
gearcarrier‘C’ SeeFigure8,item3
– Planetgear(x12) SeeFigure8,item4
– Shim SeeFigure8,item2
– ‘O’ring SeeFigure8,item1
27 Motor N012
Wiringkit, including Q106
28 Motorclamp
29 Motorclamp‘O’ring
30 Connector
31 Connectorseal
33 Endcap‘O’ring
34 Endcap
35 Sealingcap
36 Connectornut
37 Cableassembly

ST4000+ Autopilots
14 ST4000+ Autopilots Service Manual 83115-1
Disassembly
Belt removal
Referto Figure 7. Wheel DriveActuatorexplodedview.
1. Insert awide flat, non-metalicbladeinto the gapbetween the drivering
(1)andthe backmountingplate(2).Gently lever thebladeto force the
drivering (1)offthe rollers (18) ofthebackmounting plate(2).Repeat
thisactionin three to four places aroundthedrivering(1) in order to
remove.
2. Unscrewandremovethe fivescrews(3).Detachthesupport plate(4)
fromthebackmountingplate(2).
3. Removethebelt (5).
Pinion sprocket removal
Referto Figure 7. Wheel DriveActuatorexplodedview.
1. Perform actionsasdescribedin Beltremoval .
2. Liftthepinion sprocket (7)offthe gearboxdriveshaft/gearcarrier‘C’(21).
Drive lever and eccentric removal
Referto Figure 7. Wheel drive actuatorexplodedview.
1. Perform actionsasdescribedin Pinionsprocket removal .
2. Placea blockwith a suitable clearance holeunderthe drivelever/shaft
(9)toprovidesupport andpreventtheshaft bending whenthe roll pin is
driven out.
3. Driveout the rollpin(8).
4. Pullthedrive lever (9) off the driveeccentricshaft(11).
5. Liftthedrive eccentric assembly(11) and drivewheel assembly(10)off
thebackmountingplate(2).
Motor removal
Referto Figure 7. Wheel DriveActuatorexplodedview.
1. Unscrewandremovethe connector nut(36).
2. Remove the sealingcap(35).
3. Grip the gearbox(23), unscrewandremove thesleeve(32) ensuring the
connectordoes notrotate.
4. Withdraw motor(27)/location peg (26)disengagingit from thegearbox
(23).Slideoffthefluxring(25).
Note:Althoughgivenseparate itemnumbers,thegearbox(23) is an
integralpart of the backmounting plate assembly(2) and thelocation
peg(26)ispart of the motor (27).

Chapter3. WheelDriveActuator
ST4000+ Autopilots Service Manual 83115-1 15
5. Desolderconnectorwiresfrom the motor tags.
Gearbox removal
Refer toFigure7. WheelDriveActuator explodedview.
1. Perform actionsasdescribedin Pinionsprocket removal ,
and1,2,3 and 4 in Motorremoval .
2. Unscrewandremove the fourgearboxretainingscrews(22).
3. Separatethegearbox( 23) fromthebackmountingplate assembly(2)
leavingthegearbox driveshaft/gearcarrier‘C’(21)inplace.
4. Supportthegearboxdriveshaft/gearcarrier‘C’(21)anddriveoutthepin(19).
5 Withdrawthe gearbox driveshaft/gear carrier‘C’ (21)fromtheback
mountingplate assembly (2).
Gearbox disassembly
5
4
7
5
4
7
5
5
5
4
6
5
4
5
3
1
4
2
1. 'O' ring
2. Small shim spacer
3. Drive shaft/carrier assembly 'C'
4. Planet gear (x22)
5. Large shim spacer (x7)
6. Carrier assembly 'B'
7. Carrier assembly 'A' (x2)
8. Gear housing
8
D3725-1
Figure8. Gearboxexplodedview

ST4000+ Autopilots
16 ST4000+ Autopilots Service Manual 83115-1
Assembly
Inallcases,assemblyisastraightreversal of thestepsdescribedin
Disassembly .
Gearbox assembly
Referto Figure 7. Wheel DriveActuatorexplodedview.
1. Rebuild gearbox. RefertoFigure 8. Gearboxexplodedview
2. Fixthegearbox(23) to thebackmounting plateassembly(2) using the
four gearbox retainingscrews(22).
3. Slidethetwoshims(20)over the gearbox driveshaft/gear carrier‘C’(21)
andhard up againstthe backmounting plate assembly (2).
4. Support the gearboxdriveshaft/gearcarrier‘C’(21) and refit thepin(19).
Note:Iftheoriginal pin (19) isbentordamagedareplacementpincanbe
obtainedfrom pinionkit, partno.N014.
Motor assembly
Referto Figure 7. Wheel DriveActuatorexplodedview.
1. Fitthered motor seal (24)over the threadedendof the gearbox(23).
2. Insert the connector wiresthroughthe motor clamp(28),and solder the
connectorwirestothe motor tags – redleadtothe tag with a redspot,
black lead to theothermotor tag.
3. Slidefluxring(25)on the motor (27)andfitonto the gearbox(23)
ensuring thatthemotor drivegear isfullyengaged with thegeartrain and
themotorlocation peg (26) isengaged correctly into thegearbox(23).
4. Fitthe‘O’ring(29)ontothemotorclamp (28).
5. Placetheconnector seal (31)over the connector(30).
6. Screw the sleeve (32)withfitted‘O’ring(33) and end cap(34)ontothe
gearbox (23).
7. Placethesealing cap (35) over the connector (36)andsecure with the
connectornut(37).
Adjustment eccentric assembly
Referto Figure 7. Wheel DriveActuatorexplodedview.
1. Assemblethe adjustmentwheel assembly(13),adjustment eccentric
assembly(12), adjustment locknut (14) with itschamferededgefacing
outwards,andprotectioncap(15)tothebackmountingplateassembly(2).
Note:Ensurethatthedrivelever(9) is in theslack(declutched) position
andtheadjustment eccentricassembly(12)isin its lowest position,so
thatthebelt(5)isatitsslackest.