Windpilot PACIFIC LIGHT User manual

PACIFIC LIGHT ManualPACIFIC LIGHT Manual
PACIFIC LIGHT Manual

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WELCOME …
… to the world of silent self-steering!
Prepare to be pleasantly surprised by your new windvane steering system: life aboard will never be
the same again!
Learn to trust your new live-aboard guest. Enjoy the moment you realise it can steer with the kind
of stamina and prolonged precision we can only dream of. Hand over to your tireless new mate
and make the most of all the time it leaves you for other things. Life aboard will become much
more relaxed; time at sea will be generally more restful. And those long trips that were once all but
inconceivable are now very much within your grasp.
We at WINDPILOT are almost as single-minded as our windvane gears. We have been continuously
developing and refining our systems for more than 40 years now - and all that experience comes free
with every system sold. You will notice the difference: we have left no stone unturned!
KISS (keep it simple, stupid) - that’s the motto we live by at WINDPILOT. We realise that manuals are
probably well down your list of reading priorities, but there are mistakes to be made and they can be
avoided. Good advice is particularly valuable at sea, especially if you have it there on board with you,
so take a deep breath and read on…
You expect good steering from your WINDPILOT and it, in turn, has certain expectations of you
:
... DON’T NEGLECT YOUR SAIL TRIM
Poor trim amplifies weather helm, which means more pressure on the rudder and less boat speed.
Don’t sail with the handbrake on! A well trimmed boat heels less and requires less pressure on the
rudder. That means it sails faster. Adjust the mast, trim the sails: try it, you have plenty of time!
... BE AWARE OF THE CONDITIONS
Some combinations of wind and sea conditions will be too much for your windvane gear: imagine
trying to steer around breaking waves with your eyes closed, for example.
... MAKE SURE YOUR WINDPILOT IS PROPERLY INSTALLED
Install it with care, treat it well and be prepared to give it a little attention now and again.
... TALK TO US, PREFERABLY RIGHT FROM THE START
If you would like confirmation that your system is properly installed and that the steering lines and so
on are just right, send us a few photos of your WINDPILOT set up and ready for action. Pictures tell it
like it is and make it easier for us to help you.
You have our word on it - lazy days at sea await… at least as far as steering is concerned…
Peter Förthmann

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Contents
1.0 INSTALLATION 6
1.1 TOOLS 6
1.2 INSTALLATION OPTIONS 6
1.3 POINTS TO CONSIDER BEFORE INSTALLATION 7
1.3.1 POSITIONING THE SYSTEM 7
1.3.2 BAD AIR AND THE WINDVANE 8
1.3.3 PENDULUM RUDDER AND MAIN RUDDER 8
1.3.4 ON LAND OR IN THE WATER? 8
1.4 INSTALLATION: QUICK GUIDE 8
1.4.1 THE FIVE CRITERIA 8
1.5 INSTALLATION: COMPREHENSIVE GUIDE 9
1.5.1 HEIGHT ABOVE THE WATERLINE 9
1.5.2 DO I NEED TO REINFORCE THE TRANSOM? 9
1.5.3 WHAT IF THE BRACKET IS ALIGNED INCORRECTLY? 10
1.5.4 MOUNTING THE SYSTEM ON THE MOUNTING BRACKET 10
1.5.5 ALIGNMENT 10
1.5.6 PENDULUM RUDDER LIFT-UP 10
1.6 THE STEERING LINES 10
1.6.1 GENERAL 10
1.6.2 THE BASICS 11
1.6.3 WINDPILOT SYSTEM REQUIREMENTS 11
1.6.4 CROSSBAR 11
1.6.5 DEDICATED BREAK POINT FOR STEERING LINES 11
1.6.6 SHOULD I SPLICE THE STEERING LINES? 11
1.6.7 STEERING LINES AND TILLER STEERING 12
1.6.7.1 POSITIONING THE TILLER FITTING 12
1.6.7.2 POSITIONING THE RING ON THE PENDULUM ARM 12
1.6.7.3 STEERING LINE BLOCKS 12
1.6.7.4 LINE TENSION 12
1.6.7.5 CENTRING THE TILLER AND THE CHAIN 12
PACIFIC LIGHT Manual

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1.6.8 STEERING LINES AND WHEEL STEERING 13
1.6.8.1 FITTING THE WHEEL ADAPTOR 13
1.6.8.2 RIGGING THE STEERING LINES 13
1.6.8.3 CONNECTION POINT 13
1.6.8.4 LINE TENSION 13
1.6.8.5 TRANSMISSION RATIO 14
1.6.8.6 VARIABLE FORCE TRANSMISSION 14
1.6.8.7 FORCE TRANSMISSION WITH WHEEL STEERING: EXAMPLES 14
1.6.9 STEERING LINES AND THE EMERGENCY TILLER 14
1.6.9.1 MECHANICAL WHEEL STEERING 14
1.6.9.2 HYDRAULIC WHEEL STEERING 15
1.7 THE PENDULUM RUDDER 15
1.7.1 MOUNTING THE RUDDER BLADE 15
1.7.2 POSITIONING THE RUDDER BLADE 15
1.7.3 OVERLOAD PROTECTION 15
1.7.4 PENDULUM RUDDER LIFT-UP 15
1.8 WINDPILOT AND AUTOPILOT 16
2.0 SAILING WITH YOUR WINDPILOT 16
2.1 SAILING WITH YOUR WINDPILOT: QUICK GUIDE 16
2.2 SAILING WITH YOUR WINDPILOT: COMPREHENSIVE GUIDE 16
2.2.1 SYSTEM NOT IN USE 16
2.2.2 PREPARING FOR USE 16
2.2.3 CONNECTING THE STEERING LINES 16
2.2.3.1 TILLER STEERING 16
2.2.3.2 WHEEL STEERING 16
2.2.4 ALTERING COURSE/TURNING 17
2.2.5 FINE TRIM - TILLER STEERING 17
2.2.6 FINE TRIM - WHEEL STEERING 17
2.2.6.1 IS THE VARIABLE FORCE TRANSMISSION SET CORRECTLY? 17
2.2.6.2 DETERMINING THE IDEAL SETTINGS 17
2.2.7 SETTING THE WINDVANE FOR DIFFERENT WIND STRENGTHS 18
2.2.7.1 LIGHT WINDS 18
2.2.7.2 MODERATE WINDS 18
2.2.7.3 STRONG WINDS 18
2.2.7.4 THE IDEAL WINDVANE POSITION 18
2.2.8 SWITCHING BACK TO MANUAL STEERING 19
2.2.8.1 EMERGENCY 19
2.2.8.2 NORMAL USE 19
2.2.9 REMOVING THE SYSTEM IN HARBOUR/FOR WINTER STORAGE 19
3.0 CAUTION 20
4.0 MAINTENANCE 20
4.1 BEARINGS 20
4.2 CLEANING 21
4.3 BEVEL GEAR LINKAGE 21
4.4 PUSH ROD 21
4.5 CAST AND TUBULAR COMPONENTS 22
4.6 LANOLIN 22
4.7 ANTIFOULING 22
4.8 WINDVANE 22
4.9 WINDVANE TELLTALE 22
5.0 TROUBLESHOOTING 23
5.1 SYSTEM IS TURNING THE WRONG WAY 23

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5.2 SYSTEM PERFORMANCE IS NOT SATISFACTORY 23
5.2.1 POSITION OF PENDULUM RUDDER BLADE 23
5.2.2 STEERING LINES RIGGED INCORRECTLY 23
5.2.3 THE PENDULUM RUDDER IS NOT MOVING 25 DEGREES TO EACH SIDE 23
5.3 SYSTEM IS STICKING 23
5.3.1 AT THE WINDVANE 23
5.3.2 AT THE WINDVANE SHAFT 24
5.3.3 AT THE RUDDER AXLE 24
5.3.3.1 DISASSEMBLY PROCEDURE 24
5.3.3.2 ASSEMBLY PROCEDURE 24
5.3.4 AT THE STEERING LINES 24
5.4 THE PUSH ROD IS BENT 24
5.5 THE WINDVANE SHAFT IS LOOSE 24
5.6 THE RUDDER BLADE IS VIBRATING 25
6.0 REPAIRS 25
Overview of the part numbers in the parts lists 26
Parts list Accessories 26
MOUNTING OPTIONS F 0 - 1 35
WRONG PERFECT 37
LINE TRANSFER 38
CATAMARANS 42
STERN LADDER 43

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PACIFIC LIGHT
1.0 INSTALLATION
1.1 TOOLS
 • rule
 • pencil
 • 2.5mmand5mmAllenkeys(includedindelivery
package)
 • 9mmand10.5mmdrillbits
 • 10mm,17mmand19mmring/forkwrench/
spanner
 • Sikaflexsealingcompound
 • rubbermallet
 • drill
1.2 INSTALLATION OPTIONS
F 0 standard mounting bracket for moderately
raked sterns
F 1 mounting bracket with extension for extreme
sterns
CB crossbar for steering lines on extreme sterns
WH wheel adaptor for boats with wheel steering

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1.3 POINTS TO CONSIDER BEFORE
INSTALLATION
 • ThePACIFICLIGHTwasfullyassembledbefore
leaving our premises.
1.3.1 POSITIONING THE SYSTEM
 • YourWINDPILOTshouldbeinstalledatthecentre
of the transom approximately 10 cm/4 in below
deck level.
 • Off-centreinstallationispossible(max.10cm/4in)
but not ideal.
 • Ifyourboathasacentrallymountedbathingladder,
it should be relocated to the port side.
 • CAUTION:thinktwicebeforemovingtheladderto
the starboard side. When the pendulum rudder is
raised, the pendulum arm 300 swings down very
close to the bottom of the transom on the starboard
side - check for clearance.
 • TIP: install the PACIFIC LIGHT first, then sort out
the bathing ladder.
 • Tiesafetylinestoallcomponentsbeforeyoustart.
 • Secureclamps860onthemountingbracketwith
tape.
 • CoatthemountingboltswithlanolinorDuralac.
 • ShouldIuseaspiritlevel?No,boatsarenever
perfectly level; it is better to trust your eye.

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1.3.2 BAD AIR AND THE WINDVANE
 • Thewindvaneshouldnotsubjecttodisturbed
airflows in its working position.
NO PROBLEM
 • Badairfromasprayhood:thesprayhoodis
normally far enough from the stern not to be a
problem.
 • Badairarounddavits
 • Badairfromthesuperstructure
 • Badairoffthemainsail(sloop/cutter)
 • Badaircausedbypeopleinthecockpit
PROBLEM
 • Badairoffthemizzensail
 • Badaircausedbyanoutboardmotoronthe
pushpit
 • Badaircausedbyfenders/liferaftonthepushpit
1.3.3 PENDULUM RUDDER AND MAIN RUDDER
 • Thependulumrudderisusedsimplytogenerate
hydrodynamic force; since it does not steer the boat
directly, is ok for it to be close behind the trailing
edge of the main rudder.
 • Thependulumruddermoveslaterallyinoperation.
 • Turbulencecausedbythemainrudderdoesnot
interfere with the operation of the pendulum rudder.
1.3.4 ON LAND OR IN THE WATER?
 • YoucanfityourWINDPILOTwiththeboatashore
or afloat: it doesn’t really matter, as all the holes are
above the waterline.
 • Buttheheightabovethewaterlineforinstallationis
easier to find with the boat in the water.
1.4 INSTALLATION: QUICK GUIDE
1.4.1 THE FIVE CRITERIA
1 Installation height: mounting bolt 430 for the
pendulum rudder blade 440 should be 5-10 cm/2-4
in above the water (static waterline).
2 Overhanging/traditional sterns: does ring 315 on
the pendulum arm 300 swing clear of the top of
the transom/pushpit when the pendulum rudder is
raised?
3 Forward-raked/sugar-scoop sterns: does pendulum
rudder shaft 400 swing clear of the bottom/
aftermost edge of the transom?
4 Start by fastening the mounting bracket in place
with just one bolt. Then align the bracket, mark
where the remaining holes should be and predrill
them with the 9 mm bit. Now drill out the holes with
the 10.5 mm bit and complete installation of the
mounting bracket.
5 Align the system. Windvane shaft 140 must be
vertical!
Nr.140
VERTIKAL!
CAUTION!
Fig used here
the PACIFIC!!

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1.5 INSTALLATION: COMPREHENSIVE GUIDE
 • Rememberthefivecriteria.
1.5.1 HEIGHT ABOVE THE WATERLINE
 • Theruddershafthasbeenmanufacturedtothe
correct length for your boat.
 • Thedynamicwaterlineshouldcovertherudder
blade.
 • Therudderwillprojectsomedistanceabovethe
static waterline.
 • Ideal installation height: bolt 435 should be about
5-10 cm/2-4 in above the static waterline.
 • Locatethemountingbracketonthetransomatthe
appropriate installation height.
 • Usethemallettorotatethefourclamps860into
place against the transom.
 • Drillonehole(predrillwiththe9mmbitthen
complete with the 10.5 mm bit).
 • Passaboltthroughtheholejustdrilledtoholdthe
bracket in place.
 • Alignthebracket(level).
 • Predrilltheremainingthreeholesthroughthe
clamps (9 mm bit).
 • Removethebracket.
 • Drill out all the holes with the 10.5 mm bit.
 • Placesealingcompound(Sikaflex)aroundeach
hole.
 • Setthe60mmdiameterplasticdiscsonthe
Sikaflex compound.
 • Fastenthebracketwithallfourbolts.
 • Workinginsidethehull,setthewashersonthebolt
ends and tighten the nuts/locknuts.
 • SEQUENCE:bolthead/stainlesswasher/plastic
washer/clamp/60 mm plastic disc/Sikaflex/transom/
stainless washer/nut/nut
 • CAUTION:Theboltsmustbeproperly seated and
tightened - check them regularly!
 • Iftheboltsworkloose,thewholesystemcouldbe
lost.
 • AttachasafetylinetoyourPACIFICLIGHTjustin
case.
1.5.2 DO I NEED TO REINFORCE THE TRANSOM?
 • No.Theforcesonthetransomarerelativelylow
and should never exceed the steering force exerted
on the tiller plus the weight of the system itself.

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1.5.3 WHAT IF THE BRACKET IS ALIGNED
INCORRECTLY?
 • Noproblem:loosenmountingbolts901andusethe
rubber mallet to move the clamps along the cheeks
900/910 until the alignment is satisfactory.
1.5.4 MOUNTING THE SYSTEM ON THE
MOUNTING BRACKET
 • Slidethesystemintothebracketwiththependulum
axle 310 at the front and fasten in place with
mounting bolt 901.
1.5.5 ALIGNMENT
WINDVANE SHAFT 140
 • Thewindvaneshaft140mustbevertical.
 • Side-to-sideadjustment:releasebolt701
 • Fore-and-aftadjustment:releasebolt201
 • Don’tforgettoretightentheboltsoncethe
windvane is properly aligned!
 • Ifyoustillcan’tmakethewindvanevertical,see
1.5.4 What if the Bracket is Aligned Incorrectly?
1.5.6 PENDULUM RUDDER LIFT-UP
 • Tieoneendoftheredlift-uplinethroughring431
and secure the other end to the pushpit. Raise the
pendulum rudder, take the red line once around
windvane shaft 140 and rudder shaft 400 and tie it
back to the pushpit.
1.6 THE STEERING LINES
1.6.1 GENERAL
 • ThesteeringperformanceofyourPACIFICLIGHT
will be strongly influenced by the quality of the
force transmission from the pendulum rudder to
the main rudder; in other words, you can’t have
good steering unless the steering lines are working
smoothly.
 • Dependingonthesettingofthevariable
transmission, the PACIFIC LIGHT provides
maximum steering line travel of between 20 and
25 cm/8 and 10 in (a feature it shares with other
popular systems like the Aries and Monitor).
 • Anythingthatimpairstheforcetransmissionwill
have an immediate impact on steering quality.
Slack, stretch or play in the steering lines or
stiffness in the main rudder bearings all detract
from the performance of your system. Errors and
compromises at this point add up to poor steering,
plain and simple. All servo-pendulum gears that use
the 2:1 bevel gear linkage (Aries, Fleming, Monitor)
work in exactly the same way. The differences lie in
the operating conditions on different boats!
 • NOTE:whatuseis20-25cm/8-10inoftravelatthe
pendulum arm if only a fraction of that reaches the
main rudder?