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?

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1.6.2 THE BASICS
 • Keepthesteeringlinesasshortaspossible.
 • Usethesmallestpossiblenumberofblocks.
 • Usenon-stretchlines.
 • Makesuretheangleformedbythelinesbetween
the system and the back of the boat (seen from
above) is no greater than 30 degrees.
 • Checkthetensionofthesteeringlines.
 • Watchtomakesurethatlinetravelisnotbeing
wasted between the pendulum arm and the main
rudder.
 • Checkthatthemainrudderbearingsrunsmoothly.
 • Checkwheelsteeringsystemsforplayand
stiffness.
1.6.3 WINDPILOT SYSTEM REQUIREMENTS
 • Ring315onthependulumarmmustbeatdeck
level.
 • Thiskeepsthesteeringlinesshort.
 • Therearenounnecessaryblocksonthesteering
lines.
 • Therearenoblocksfittedtothesystemitself.
 • Thependulumruddershaftislongenoughto
provide plenty of leverage for the pendulum rudder.
 • Thebevelgearlinkageisworkingproperlyto
provide automatic yaw damping.
 • Thesystemissensitiveinlightairsbutpowerfulin
stronger wind conditions.
CAUTION
 • Takecarewhensettingupthesteeringlines
between the WINDPILOT and the main rudder.
Poor force transmission will seriously impair
steering quality.
1.6.4 CROSSBAR
 • Iftheangleformedbythelinesbetweenthesystem
and the first set of turning blocks on the back of the
boat (seen from above) is greater than 30 degrees,
performance is likely to suffer. The blocks may be
moved to the ends of a crossbar fitted adjacent
to the top of the mounting bracket to improve the
angle and resolve the problem.
1.6.5 DEDICATED BREAK POINT FOR STEERING
LINES
 • Twooftheturningblocksforthesteeringlines
should be fastened to the boat only with thin cord
(e.g. 3 mm burgee halyard). If, for whatever reason,
the transmission system should be overloaded,
these lines will break and save the rest of the
setup.
1.6.6 SHOULD I SPLICE THE STEERING LINES?
 • No,itisbetterjusttouseknotsasyoucanthen
end-for-end the lines easily to spread the wear.

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1.6.7 STEERING LINES AND TILLER STEERING
1.6.7.1 POSITIONING THE TILLER FITTING
 • Tillerfitting010shouldbemountedabout65%of
the way along the tiller, measuring from the rear
(e.g. if your tiller is 100 cm/40 in long, the fitting
should be about 65 cm/26 in from the aft end).
 • Movingthetillerfittingfurtherforwardincreases
leverage but reduces the angle through which your
PACIFIC LIGHT can turn the rudder.
 • Movingthetillerfittingaftincreasesthisanglebut
reduces leverage.
 • NOTE:itisimpossibletohavemoreleverageAND
more movement at the same time!
 • Aservo-pendulumsystemwithautomaticyaw
damping like the PACIFIC LIGHT is designed
to operate with an average steering line travel
between the system and main rudder of 20-25
cm/8-10 in.
1.6.7.2 POSITIONING THE RING ON THE
PENDULUM ARM
 • Movingtheringupthearm(awayfromtheaxle)
increases travel but reduces transmission force.
 • Movingtheringdownthearm(towardstheaxle)
increases transmission force but reduces travel.
 • See2.2.6.2DeterminingtheIdealSettings.
1.6.7.3 STEERING LINE BLOCKS
 • Thefirstpairofblocksshouldbemountedonor
outside the pushpit as far aft as possible.
 • Theotherpairshouldbemountedonthecockpit
coaming slightly aft of the tiller fitting.
 • Tiethesteeringlinestothering315onthe
pendulum arm.
 • Leadthemforwardtothetillerthroughthetwosets
of blocks.
 • Attachthechainsectionwherethesteeringlines
approach the tiller fitting.
1.6.7.4 LINE TENSION
 • Thelinesmustbeneithertooslacknortootight;
either will impair steering.
 • Thesteeringlinesshouldberiggedsuchthat
engaging the chain in the tiller fitting sets them to
their ideal working tension.
 • IDEALTENSION:noslack,nostrain.
1.6.7.5 CENTRING THE TILLER AND THE CHAIN
 • Thesystemandtillercanbecentredwithrespectto
each other (e.g. to compensate for weather helm as
wind and sea conditions change) by adjusting the
chain at the tiller fitting.
 • Assemblysequence:line/shackle/chain/2snap
shackles/line.

13
1.6.8 STEERING LINES AND WHEEL STEERING
1.6.8.1 FITTING THE WHEEL ADAPTOR
 • Startbyfasteningtheadaptortoonespokeofthe
wheel.
 • Makesuretheadaptoriscentredandthenfasten
two more clamps to the wheel.
 • Removetheplasticretainingbolt.Theadaptormust
be able to rotate freely without fouling the spokes.
 • Thelinesshouldeachbeledaroundtheadaptor
one and a half times from the point where they
attach to it (friction/load distribution). They can then
be connected to the steering lines coming from the
side/aft (using snap shackles).
1.6.8.2 RIGGING THE STEERING LINES
 • Bothlinesshouldinitiallybeledfromthering315to
the corners of the pushpit.
 • Ifdesired,onelinemaynowbeledacrossthe
pushpit so that both lines are on the same side of
the boat.
 • NOTE:keepingbothlinesonthesamesideofthe
cockpit leaves the other side free for access.
 • Takethelinesforwarduntiltheyarelevelwiththe
wheel.
 • Passthemthroughapairofturningblocksand
across towards the binnacle.
BOTH LINES ON THE PORT SIDE
 • Thelinethatrunsfromthesystemtotheport side
of the boat should be led around the bottom of the
wheel adaptor.
BOTH LINES ON THE STARBOARD SIDE
 • Thelinethatrunsfromthesystemtothestarboard
side of the boat should be led around the bottom of
the wheel adaptor.
1.6.8.3 CONNECTION POINT
 • Eachlinefromthewheeladaptorshouldbe
connected to the appropriate steering line from
the system using two snap shackles (i.e. four
snap shackles in total). This helps when you
come to release or reconnect the lines (to engage
or disengage the PACIFIC LIGHT). Ideally the
connection should be half way between the
binnacle and the pair of turning blocks at the side
of the cockpit, but if there is insufficient space, the
snap shackles can also be connected between
the turning blocks in the cockpit and those on the
pushpit.
 • CAUTION:besuretomarkthesnapshacklesso
that you can tell which to connect to which!
1.6.8.4 LINE TENSION
 • Slackcanbecontrolledbyincludinganextra
block on the steering lines. This block is mounted
(e.g. on the pushpit) so that it can be tensioned
perpendicular to the lines using thin cord. The more

14
you tension the cord, the more the block pulls the
slack out of the steering lines.
 • Releasingthisblockprovidessufficientslackto
uncouple the snap shackles at the connection
point.
 • Theblockcanthenbeusedtore-tensionthe
steering lines once the snap shackles have been
reconnected prior to switching over to WINDPILOT
steering.
1.6.8.5 TRANSMISSION RATIO
 • Thewheeladaptorisdesignedformechanical
wheel steering systems with a range of around two
and a half revolutions from stop to stop and a wheel
diameter of approximately 60 cm/24 in. This means
in practical terms that the maximum line travel of 25
cm/10 in is sufficient to turn the wheel through half
a revolution given, perfect transmission.
1.6.8.6 VARIABLE FORCE TRANSMISSION
 • Theforcetransmissioncharacteristicscanbe
adjusted using the slot in the pendulum arm 300
(see 2.2.6.2 Determining the Ideal Settings).
1.6.8.7 FORCE TRANSMISSION WITH WHEEL
STEERING: EXAMPLES
Example 1:
 • Wheeldiameter=approx.60cm/24in
 • Revolutionsfromstoptostop=2.5
 • Positionofring315=approx.centred in the slot
Example 2:
 • Wheeldiameter=approx.100cm/40in
 • Revolutionsfromstoptostop=1.5
 • Positionofring315=towardsthebottom of the slot
Example 3:
 • Wheeldiameter=approx.55cm/22in
 • Revolutionsfromstoptostop=3-4
 • Positionofring315=towardsthetop of the slot
TEST
 • Itisactuallyquitestraightforwardtoworkout
the key parameters for your boat - see 2.2.6.2
Determining the Ideal Settings.
1.6.9 STEERING LINES AND THE EMERGENCY TILLER
1.6.9.1 MECHANICAL WHEEL STEERING
 • Connectingthesteeringlinestotheemergency
tiller of a mechanical wheel steering system will not
yield good steering because the tiller has to move
the whole of the steering mechanism from the
wrong end every time it tries to turn the rudder. It’s
like trying to turn the steering wheel of your car by
sitting in the road and tugging on the front wheels!
 • Goodsteeringcanonlybehadbythisrouteifthe
transmission components of the wheel steering
system are completely disconnected from the
quadrant (emergency).

15
1.6.9.2 HYDRAULIC WHEEL STEERING
 • Connectingthesteeringlinestotheemergency
tiller of a hydraulic steering system is pointless,
as the tiller cannot possible supply enough force
effectively to move the hydraulic cylinder. A bypass
valve will not help either.
 • Goodsteeringcanonlybehadbythisrouteifthe
transmission components of the wheel steering
system are completely disconnected from the
quadrant (emergency). A word of advice for
anybody still tempted to try connecting a servo-
pendulum system up to a hydraulically operated
main rudder: don’t do it - you’ll end up steering by
hand!
 • Hydraulicsteeringsystemsareinanycasevery
rare on smaller boats.
1.7 THE PENDULUM RUDDER
1.7.1 MOUNTING THE RUDDER BLADE
 • Thependulumrudderblade440shouldbe
mounted with the rounded edge facing forward and
the sharp edge facing aft.
1.7.2 POSITIONING THE RUDDER BLADE
 • Thependulumrudderblademustbeangled
down and aft exactly in line with the rudder shaft,
otherwise the balance will be off.
 • Adjustingtherudderbladeaftreducestheforce
generated (by reducing the balance proportion).
 • Adjustingtherudderbladeforwardincreasesthe
balance proportion excessively, with the result that
the rudder controls the windvane instead of the
other way around.
 • Both the adjustments described impair the
performance of the system and make steering
problems inevitable.
1.7.3 OVERLOAD PROTECTION
 • Mountingbolt435fortherudderblade440should
be tightened gently so that the rudder blade can still
swing up if it strikes something below the water.
 • Therudderbladeisretainedintheshaftforkby
friction only.
1.7.4 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 the windvane shaft 140 and rudder shaft
400 and tie it back to the pushpit.
 • Itisnotpossibletoraisethependulumrudder
out of the water while the boat is moving as the
resistance is generally too high. Lift-up under way
may be possible at speeds below two knots.
 • Thependulumruddermaybedroppedbackinto
the operating position at any time.

16
1.8 WINDPILOT AND AUTOPILOT
 • ThePACIFICLIGHTisusedexclusivelyonsmaller
boats, most of which will have tiller steering. If a
cockpit autopilot is used, it should be connected
as usual to the main steering and not to the
PACIFIC LIGHT. The autopilot is normally used
when motoring, so there should be no problem with
power consumption.
2.0 SAILING WITH YOUR WINDPILOT
2.1 SAILING WITH YOUR WINDPILOT: QUICK
GUIDE
 • Bringtheboatontocourse.
 • Lowerthependulumrudderbladeintothewater.
 • Fitthewindvane.
 • Setthewindvaneintothewind(itshouldnowbe
standing upright).
 • Connectthesteeringlinestotheboat’smain
steering.
 • Finetrimthesteeringatthesystemorthemain
rudder.
2.2 SAILING WITH YOUR WINDPILOT:
COMPREHENSIVE GUIDE
2.2.1 SYSTEM NOT IN USE
 • Keepthependulumrudderbladeinthelift-up
position.
 • Removethewindvane.
2.2.2 PREPARING FOR USE
 • Bring the boat onto course.
 • Lowerthependulumrudderbladeintothewater.
 • Fitthewindvaneandturnitintothewindmanually
(the windvane should now be standing upright).
 • NOTE:thecounterweightshouldnowbepointing
into the wind.
2.2.3 CONNECTING THE STEERING LINES
2.2.3.1 TILLER STEERING
 • Connectthetwosnapshackles.
 • Engagethechaininthetillerfitting.
 • Removeanyslackinthelines.
 • CAUTION:onlyremovetheslack.Donotpullthe
lines taught, as this increases friction and impairs
steering.
2.2.3.2 WHEEL STEERING
 • Connectthetwopairsofsnapshackles(makesure
the lines are not crossed!).
 • Removeanyslackinthelines.
 • CAUTION:onlyremovetheslack.Donotpullthe
lines taught, as this increases friction and impairs
steering.

17
2.2.4 ALTERING COURSE/TURNING
 • Turnthewindvaneshaft140manuallyandreferto
the degree scale on the windvane shaft.
2.2.5 FINE TRIM - TILLER STEERING
 • Ifwind/weatherhelmchange,adjusttherudder
position by changing the chain link in the tiller
fitting.
 • Thewindvaneshouldworkevenlyaroundthe
upright position most of the time. If it is permanently
off to one side, adjust your sail trim or reef down.
 • NOTE:yourPACIFICLIGHTcanexertupto200
kg/440 lbs of tensile force on the main steering,
but sailing with the rudder well over all the time is
highly undesirable (i.e. slow). Trim your boat and
your sails - it’s simpler and you’ll get there faster!
 • Youcantellifyourtrimcould/shouldbeimproved
just by looking at the tiller. If the tiller is constantly
off-centre, something needs to be done!
2.2.6 FINE TRIM - WHEEL STEERING
 • Releasetheleversonthewheeladaptor.
 • Adjustthemainwheeluntiltheboatisproperly
balanced.
 • Retightenthelevers.
 • CAUTION:donotovertightentheadaptorlevers.
The adaptor works like a disc brake: if the system
is overloaded, the drum slides on the disc to absorb
the excess force and prevent damage to itself or
the other transmission components.
 • TIP:itisnotnecessarytoreleasetheadaptor
levers completely to fine trim at the wheel. The
whole operation is easier if they are simply
loosened enough to allow the adaptor to slide. It is
normally sufficient on a small boat to tighten only
one of the levers. The second lever can then be
tightened if required in more difficult conditions.
2.2.6.1 IS THE VARIABLE FORCE TRANSMISSION
SET CORRECTLY?
 • Withtheboatmakinggoodspeed,manually turn
the windvane all the way to one side and hold it
there:
 • Ifthependulumruddermovesapprox.25degrees
to one side, the force transmission is set correctly.
 • Ifthependulumruddermovessignificantlyless
than 25 degrees, slide ring 315 a little further down
the pendulum arm (less travel but more force).
 • Ifyouhavetillersteering,youcouldalternatively
move the tiller fitting forward (never move the fitting
aft).
2.2.6.2 DETERMINING THE IDEAL SETTINGS
 • Thependulumarmshouldalwaysbeabletomake
use of its full 25 degrees of travel to each side. This
can be adjusted by moving the transmission point
(ring 315).
 • TIP:leavetheringinthecentreoftheslotuntilyou
have tested everything properly under sail.

18
 • Ifthependulumarmreaches25degreesoff-centre
too quickly and easily, move ring 315 up the slot
(longer lever).
 • Keeptestingthesettingsandmovingtheringup
until the lateral travel of the pendulum arm begins
to be limited to less than 25 degrees.
 • Nowgraduallymovetheringbackdowntheslot,
testing the different settings as you go, until the
pendulum arm is just able to reach the full 25
degrees of travel.
 • CAUTION:larger,heavierboatsmayneedtoreach
a relatively high boat speed to move the pendulum
arm through the full 25 degrees.
 • Theforcegeneratedbytheservosystemisalways
dependent on leverage, rudder area and speed.
These factors are the product of physical laws, the
consequences of which are inescapable!
2.2.7 SETTING THE WINDVANE FOR DIFFERENT
WIND STRENGTHS
2.2.7.1 LIGHT WINDS
 • Setthewindvaneabsolutelyverticalformaximum
sensitivity.
 • Theuprightsettingalsoprovidesmaximumsteering
force with the wind from astern.
 • Astripofspinnakercloth(‘windvanetelltale’)on
the upper trailing edge of the vane further improves
sensitivity.
 • CAUTION:youshouldnotneedtousealarger
windvane in light airs. If you do use a larger vane,
it must be exactly the same weight as the standard
vane.
 • Thissettingisparticularlysuitableforsailingwith
the wind aft of the beam, when the apparent wind
strength is always relatively low.
2.2.7.2 MODERATE WINDS
 • Setthewindvaneangledback20degreesaway
from the wind.
 • Thispositionisthegeneralsettingforsailing
with the wind forward of the beam (relatively high
apparent winds).
2.2.7.3 STRONG WINDS
 • Anglethewindvanefurtherbackfromthewind
(more damping).
 • Ifthewindvanebeginstovibrateinverystrong
winds, try angling it back even further. The vane
can go as far as about 70 degrees back, which
should improve damping and give smoother
steering impulses (and hence better steering).
 • Thispositionisthegeneralheavyairsetting.
2.2.7.4 THE IDEAL WINDVANE POSITION
 • Thewindvaneshouldalwaysbeworkingevenly
around the upright position.
 • Ifallthemovementisoccurringononeside,
i.e. between the upright position and one of the

19
end stops, adjust the tiller connection or wheel
adaptor position until the movement is more evenly
distributed.
 • Ifthewindvaneispermanentlywellovertoone
side, correct the course setting at the windvane
shaft.
 • Checkthedegreescale.
 • NOTE:thereadingonthescaleatthewindvane
shaft 140 may differ slightly from the reading
on your wind instrument. This is because wind
conditions at deck level tend to be different from
those at the top of the mast.
2.2.8 SWITCHING BACK TO MANUAL STEERING
2.2.8.1 EMERGENCY
 • Disconnectthesteeringlinesfromthemain
steering (tiller: disengage chain, wheel: release
wheel adaptor adjustment levers).
 • Thewindvanegearisnowcompletelyisolatedand
will not interfere with the steering in any way. You
may alter course as desired.
2.2.8.2 NORMAL USE
 • Removethewindvane.
 • Disconnectthesteeringlinesfromthemain
steering.
 • Liftupthependulumrudderusingtheredline.
 • CAUTION:slowdownbeforeattemptingtoliftup
the pendulum rudder. If the boat is moving too
fast, there will be too much resistance to raise the
pendulum rudder.
 • Thependulumruddermayactuallybeleftinthe
water without doing any harm, but don’t forget to
lift it up out of the way before entering harbour/
manoeuvring under engine.
2.2.9 REMOVING THE SYSTEM IN HARBOUR/FOR
WINTER STORAGE
 • Releasebolt…
 • Securethesystemwithasafetyline.
 • Removethesystem.
 • Thereisnoneedtoremovethemountingbracket.
 • CAUTION:Whenfitting/removingyourPACIFIC
LIGHT be sure never to handle/lift it by the
windvane shaft 140 alone. The shaft is retained
by just a single locking screw 207 (M4) and is not
designed to bear the weight of the whole unit.
 • Thesystemisbesthandled/liftedusingthe
pendulum arm and the casting 220 at the base of
the windvane shaft.

20
3.0 CAUTION
 • TheWINDPILOTPACIFICLIGHTisaservo-
dynamic system.
 • Keephandswellawayfromthependulumarm
when the system is in operation (trap hazard).
 • Takecarewhenadjustingthewindvaneshaft
manually (e.g. changing course) while the vane is
in operation: moving parts can be dangerous.
 • Thependulumruddercanonlyberaisedintothe
lift-up position at boat speeds of less than 2 knots.
 • Thependulumruddermaybedroppedbackinto
the operating position at any time.
 • Alwayssecurethesystemwithasafetylinebefore
attempting to fit or remove it.
 • Checkthemountingnutsandboltsonthetransom
regularly.
 • CAUTION:thesystemmaybelostifthemounting
bolts work loose. Never use the system if the bolts
are known to be loose.
 • Whenfittingorremovingthesystemhandle/liftit
only using the pendulum arm and the casting at the
bottom of the windvane shaft!
 • ThePACIFICLIGHTisdesignedforboatsnolarger
than 27 ft / 2.5 metric tons.
4.0 MAINTENANCE
 • Thesystemislargelymaintenancefree.Itis,
however, as susceptible to the effects of sun, salt
and dirt as anything else onboard and will reward
you for a little attention. Please take note of the
care guidelines below. Follow them, and your
WINDPILOT system should keep going indefinitely.
4.1 BEARINGS
 • ThebearingsaremadefromTeflon,POMand
Delrin. These materials must not be oiled or
greased.
 • Greaseoroilincontactwithseawaterquickly
solidifies, causing bearings to stick or seize.