Garmin | Reactor™ 40 Hydraulic Corepack with SmartPump v2 without GHC™ 20 | Installation instructions | Garmin Reactor™ 40 Hydraulic Corepack with SmartPump v2 and GHC™ 20 SmartPump Installation Instructions

Garmin Reactor™ 40 Hydraulic Corepack with SmartPump v2 and GHC™ 20 SmartPump Installation Instructions
SMARTPUMP
INSTALLATION
INSTRUCTIONS
Important Safety Information
WARNING
See the Important Safety and Product Information guide in the
product box for product warnings and other important
information.
You are responsible for the safe and prudent operation of your
vessel. The autopilot is a tool that enhances your capability to
operate your boat. It does not relieve you of the responsibility of
safely operating your boat. Avoid navigational hazards and
never leave the helm unattended.
Always be prepared to promptly regain manual control of your
boat.
CAUTION
Always wear safety goggles, ear protection, and a dust mask
when drilling, cutting, or sanding.
NOTICE
To avoid damage to your boat, the autopilot system should be
installed by a qualified marine installer. Specific knowledge of
hydraulic steering componentry and marine electrical systems is
required for proper installation.
When drilling or cutting, always check what is on the opposite
side of the surface.
This pump is only for use with Garmin autopilot systems.
Attempting to use this pump with any other system may damage
the system, the pump, or the vessel.
®
Registering Your Device
The SmartPump steers your boat by interacting with the
hydraulic steering system, based on commands from the
autopilot system.
Help us better support you by completing our online registration
today. Keep the original sales receipt, or a photocopy, in a safe
place.
1 Go to my.garmin.com/registration.
2 Sign in to your Garmin account.
Autopilot Software Updates
Tools Needed
After completing the autopilot installation, you should update the
software before performing the configuration process.
If you connected the autopilot system to a NMEA 2000 network
with a Garmin chartplotter, you can update the software using
the chartplotter.
If you did not connect the autopilot system to a NMEA 2000
network with a Garmin chartplotter, you must use a NMEA 2000
Network Updater (sold separately). Go to support.garmin.com
for update information.
®
SmartPump Type Identification
The autopilot system comes with one of two SmartPump
designs. Both designs are functionally identical, but have some
slight differences in appearance and port locations. When
referring to the two designs in these instructions, the terms
SmartPump À and SmartPump v2 Á are used to differentiate
between the two types. You can refer to the label on your
SmartPump package and consult these diagrams to determine
your SmartPump type.
•
•
•
•
•
•
•
•
•
•
Safety glasses
Drill and drill bits
Wrenches
Torque wrench (if configuring the pump for an unbalanced
steering cylinder)
Wire cutter/stripper
Screwdrivers: Phillips and flat
Cable ties
Marine corrosion inhibitor spray
Mounting screws: the pump kit includes mounting screws, but
if the included screws are not appropriate for the mounting
surface, you must provide the correct types of screws
Hydraulic system hardware (Hydraulic Considerations,
page 2):
◦ Hydraulic hose with machine-crimped or field-replaceable
fittings that have a minimum rating of 1000 psi
◦ Hydraulic T-connectors
◦ Hydraulic shut-off valves
◦ Thread sealant, such as Loctite 567
◦ Hydraulic bleeding equipment
◦ Hydraulic fluid
®
August 2018
190-02369-02_0B
Mounting Considerations
• Before you start the pump installation, you must identify the
type of hydraulic steering system in your boat and consult the
hydraulic diagrams. Each boat is different, and you must
consider the existing hydraulic layout before deciding where
to mount the pump (Hydraulic Considerations, page 2).
• You should mount the pump horizontally, if possible.
• If you cannot mount the pump horizontally, you must mount it
vertically with the pump head connectors facing up.
• You must mount the pump in a location to which you can
extend the hydraulic steering lines of the boat.
• The pump has five hydraulic-connector fittings, although only
three are used when installing the pump as recommended.
The pump-valve illustration provided in these instructions
may be helpful when determining the fitting layout that is best
for your installation location (Pump Ports and Valves,
page 2).
Mounting the Pump
Before you mount the pump, if your boat has an unbalanced
cylinder steering system, you must re-configure the pump to
work properly with the unbalanced cylinder (Configuring the
Pump for an Unbalanced Cylinder, page 5).
Before you can mount the pump, you must select a location
(Mounting Considerations, page 2) and determine the correct
mounting hardware (Tools Needed, page 1).
1 Hold the pump in the intended mounting location and mark
the locations of the mounting holes on the mounting surface,
using the pump as a template.
2 Using a drill bit appropriate for the mounting surface and
selected mounting hardware, drill the four holes through the
mounting surface.
3 Secure the pump to the mounting surface using the selected
mounting hardware.
from Teflon tape can enter the hydraulic system, become
stuck in valves, and render the autopilot or steering system
inoperable.
• When using liquid thread sealant, you must follow the
instructions regarding the cure time, for example, Loctite 567
cures after four hours. If the thread sealant is not properly
cured per the manufacturer's instructions, the high pressure
in the hydraulic lines may push the sealant out of the threads
and create a leak.
• If you use Teflon tape on any fittings, you must use extreme
care to avoid introducing debris into the hydraulic lines:
◦ You should not apply the tape near the last two threads of
the connector (the threads deepest inside the connection).
◦ You must apply the tape tightly on the threads, because
making a connection with loose tape may result in debris
entering the hydraulic system.
• When disconnecting a connector sealed with liquid sealant or
Teflon tape, you must take care to keep any slivers or other
debris from the cured sealant or tape from entering the
hydraulic system.
Pump Ports and Valves
The two styles of pump that may be included as part of your
autopilot kit use similar port configurations. Use the diagrams
and table below when planning your pump hydraulic
connections.
Hydraulic Considerations
NOTICE
When adding hydraulic line to the system, use only hose with
machine-crimped or field-replaceable fittings that have a
minimum rating of 1000 lbf/in² (6,895 kPa).
Use caution when applying thread sealant to avoid damage to
the hydraulic system or to the autopilot system.
Do not attempt to use the autopilot to steer the boat until you
bleed all air from each part of the hydraulic system.
Consult the hydraulic-layout diagrams to help determine how to
best install the pump in the hydraulic system of the boat
(Hydraulic Layouts, page 3).
When planning the hydraulic layout and making all hydraulic
connections, consider the following:
• The pump must be reconfigured if the boat is equipped with
an unbalanced steering cylinder (Configuring the Pump for an
Unbalanced Cylinder, page 5).
• The size and thread types for the hydraulic ports on the pump
are listed in the specifications (Port and Fitting Specifications,
page 5).
• You should use T-connectors (not included) to connect the
hydraulic lines to the pump.
• You should install shut-off valves (not included) in the
hydraulic lines between the pump manifold and T-connectors
to allow for easy pump isolation and removal.
• For hydraulic fittings with an O-ring, such as ORB and ORFS
fittings, you should not use thread sealant.
• For hydraulic fittings without an O-ring, you should use a
liquid thread sealant, such as Loctite 567, instead of Teflon
tape on all pipe threads in the hydraulic system. Small debris
®
2
Item Description
À
Á
Ê
Ë
SmartPump
SmartPump v2
Bypass valve. Used for hydraulic bleeding only, and must remain
fully tightened during normal operation.
Check valves. Must be reconfigured if the boat is equipped with
an unbalanced cylinder (Configuring the Pump for an Unbalanced
Cylinder, page 5).
Item Description
Ì
Í
C1 and C2 ports. These ports may be used instead of the H1 and
H2 ports if they are more appropriate for your installation location.
Î
Return line port. Connects to the return port on the helm through
a shut-off valve (recommended).
NOTE: The recommended installation method uses shut-off
valves and T-connectors to connect the pump to the helm and
cylinder, so the pump can be removed for service while the boat
retains normal steering. You can install the pump using all five
ports (connecting H1 and H2 to the helm and C1 and C2 to the
cylinder), but this type of installation is not recommended
because it does not allow you to operate the steering system if
you must remove the pump for service.
Hydraulic Layouts
NOTICE
If the steering system in your boat does not match any of the
hydraulic layouts in this manual and you are unsure how to
install the pump, contact Garmin Product Support.
Before you start the pump installation, identify the type of
hydraulic steering system in your boat. Each boat is different,
and you must consider certain aspects of the existing hydraulic
layout before deciding where to mount the pump.
Before you start the pump installation, you should throughly
review the hydraulic considerations for important information on
hydraulic hose and fitting types, installation methods, and
thread-sealant information (Hydraulic Considerations, page 2).
Single-Helm Layout
À
Á
Â
Ã
Ä
Å
Æ
Ç
Dual-Helm Layout
H1 and H2 ports. These are the recommended ports for
connecting the pump to the helm and cylinder.
The recommended installation method uses a shut-off valve and
a T-connector to split each connector on the pump for the helm
and cylinder connections (Hydraulic Layouts, page 3).
À
Á
Â
Ã
Ä
Å
Æ
Ç
È
Return line
Shadow Drive valve
Starboard line
Port line
Shut-off valves
Pump
Upper helm
Lower helm
Steering cylinder
Single-Helm with Power Assist Layout
NOTICE
The pump must be installed between the cylinder and the
power-assist module to function correctly.
NOTE: Removal of the power assist-module may be necessary
to gain access to the fittings, hoses, and bleed-tee fitting.
Shadow Drive™ valve
Starboard line
Return line
Shut-off valves
Port line
Pump
Helm
Steering cylinder
À
Á
Â
Ã
Ä
Å
Æ
Ç
È
Shadow Drive
Starboard line
Return line
Port line
Power-assist module
Shut-off valves
Pump
Helm
Steering cylinder
3
Single-Helm with Uflex MasterDrive™ Layout
®
CAUTION
When installing the pump in a system with a Uflex MasterDrive,
do not cut the high-pressure line connecting the power unit to
the helm to avoid injury or property damage.
À
Á
Â
Ã
Ä
Å
Æ
Ç
È
É
Uflex MasterDrive power unit
Shadow Drive
High pressure line - DO NOT CUT
Starboard line
Shut-off valves
Return line
Helms
Port line
Pump
Steering cylinders
Connecting the Hydraulic Hoses to the Pump
PL TR
À
Á
Â
Ã
Ä
Å
Æ
Ç
È
É
Uflex MasterDrive power unit
Return line
High pressure line - DO NOT CUT
Shadow Drive
Shut-off valves
Port line
Starboard line
Pump
Helm
Steering cylinders
Dual-Helm with Uflex MasterDrive Layout
CAUTION
When installing the pump in a system with a Uflex MasterDrive,
do not cut the high-pressure line connecting the power unit to
the helm to avoid injury or property damage.
For assistance, see the layout diagrams (Hydraulic Layouts,
page 3).
1 Disconnect the necessary hoses from the hydraulic system.
2 Add a T-connector to the starboard and port hoses of the
hydraulic system between the helm and the steering cylinder.
NOTE: If the boat has a power-assist module, you must add
the T-connectors between the power-assist module and the
steering cylinder.
3 Complete an action:
• If the boat does not have a return hose connected to the
helm, add enough hydraulic hose to connect the return
fitting on the helm to the pump.
• If the boat has a return hose connected to the helm, add a
T-connector to the return hose.
NOTE: If the boat has a power-assist module, you must
add the T-connector to the return hose between the
power-assist module and the helm.
4 Add hydraulic hose to the unused fitting on each T-connector,
with enough hose to connect the T-connector to the pump
fittings.
5 Install a shut-off valve (not included) on each hydraulic hose
from the T-connector to the pump.
6 If you added hydraulic hose to the return fitting on the helm,
install a shut-off valve (not included) on the hydraulic hose
from the helm to the pump.
7 Connect the starboard hose from the T-connector, through a
shut-off valve, to a pump fitting labeled with a C1 or C2.
8 Connect the port hose from the T-connector, through a shutoff valve, to the other pump fitting labeled with a C1 or C2
that you did not use in the previous step.
9 Complete an action:
• If you added hydraulic hose to the return fitting on the
helm, connect the return hose from the helm, through a
shut-off valve, to the pump fitting labeled with a T.
• If you added a T-connector to an existing return hose,
connect the return hose from the T-connector, through a
shut-off valve, to the pump fitting labeled with a T.
10 Install the Shadow Drive valve in the port or starboard
hydraulic hose between the helm and the T-connector that
connects to the pump.
See the installation instructions provided in the autopilot
corepack when installing the Shadow Drive valve.
11 Insert, tighten, and seal the included plugs in the unused
pump fittings, if they are not already in place.
PL TR
PL TR
Connection Considerations
• You should mount the SmartPump and connect it to the
hydraulic system before connecting the SmartPump to power
and to the CCU.
• The ports on the SmartPump labeled POWER and CCU are
the only ports used in a typical installation.
4
• The port on the SmartPump labeled FEEDBACK is used only
when installing an optional rudder feedback sensor.
Specifications
Specification
Measurement
Completing the Installation
Dimensions (H x W x
D)
SmartPump: 197 x 190 x 244 mm (7.75 x 7.48 x
9.61 in.)
SmartPump v2: 186 x 190 x 264 mm (6.61 x
7.48 x 10.39 in.)
Weight
SmartPump: 7.5 kg (16.5 lb.)
SmartPump v2: MEASUREMENT PENDING
Temperature range
From -15° to 55°C (from 5° to 131°F )
Material
• Electronics control unit (ECU): Fully gasketed
aluminum alloy
• Bracket: Carbon steel
• Manifold: Aluminum alloy
• Motor: Aluminum alloy
Power cable length
2.7 m (9 ft.)
Input voltage
From 10 to 30 Vdc
Fuse
40 A, blade-type
Main power usage
•
•
•
•
1 Follow the instructions included in the autopilot corepack to
install the rest of the autopilot components.
2 Follow the instructions included in the autopilot corepack to
bleed the air from the hydraulic system.
Apply
a marine corrosion inhibitor spray to the SmartPump to
3
ensure corrosion resistance.
Garmin recommends that you re-apply the marine corrosion
inhibitor once each year to extend the life of the SmartPump.
Configuration and Service
Configuring the Pump for an Unbalanced Cylinder
NOTICE
To avoid damage to the pump, keep all parts clean and free of
dust and debris while configuring the pump for an unbalancedcylinder steering system.
If you remove the check valves after bleeding the hydraulic
system, you must bleed it again. Reconfiguring the check valves
may introduce air into the hydraulic system.
If the boat has an unbalanced cylinder steering system, you
must configure the pump to work properly with the steering
system.
1 Locate the check valves À on the pump manifold.
Depending on the model of pump, the check valves are
located on either the side or top of the manifold.
2 Remove the check valves and pull the pistons Á out of the
pump manifold.
Standby: Less than 1 A
Engaged: From 5 to 10 A
SmartPump peak threshold: 34 A
SmartPump v2 peak threshold: 30 A
Port and Fitting Specifications
Port, Fitting, or Plug
SmartPump
SmartPump v2
H1 and H2 ports (top
of manifold)
SAE ORB-6 (2)
SAE ORB-5 (2)
C1 and C2 ports (side
of manifold)
SAE ORB-6 (2)
SAE ORB-5 (2)
T ports (side of
manifold)
SAE ORB-4 (1)
SAE ORB-5 (2)
Included fittings for H
and C ports
SAE ORB-6 to 1/4 in.
NPT straight (2)
SAE ORB-5 to 1/4 in.
NPT straight (2)
Included fittings for T
ports
SAE ORB-4 to 1/4 in.
NPT elbow (1)
SAE ORB-5 to 1/4 in.
NPT elbow (1)
Included plugs for
unused ports
SAE ORB-6 (2)
SAE ORB-5 (3)
NOTE: Hose fittings must be purchased separately, if needed,
to adapt from NPT to the hose type for each installation. For
example, most SeaStar™ installations require SeaStar HF5528
or Parker 68C-6-4 fittings. Most Uflex and Verado installs
require Parker 4-4 FLO. Also, the included adapters can be
removed to adapt directly to SeaStar HF6009 or Verado 4-5
F5OLO hose fittings.
SM
®
© 2017–2018 Garmin Ltd. or its subsidiaries
Garmin and the Garmin logo are trademarks of Garmin Ltd. or its subsidiaries,
registered in the USA and other countries. Shadow Drive™ is a trademark of Garmin Ltd.
or its subsidiaries. These trademarks may not be used without the express permission of
Garmin.
®
Loctite is a trademark of Henkel Corporation in the U.S. and elsewhere. NMEA 2000 is
a trademark of the National Marine Electronics Association.Parker Parker is a service
mark of Parker Intangibles, LLC. SeaStar™ SeaStar is a trademark of the Marine
Acquisition Corp. Teflon is a trademark of DuPont™. Uflex and MasterDrive™ are
trademarks of the UltraFlex Group. Verado is a trademark of Brunswick Corporation.
®
®
SM
®
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®
The pump is configured from the factory with the pistons in
the balanced configuration Â, where the tip of the piston is
pointing into the pump manifold.
3 Remove the O-rings à from the pistons and discard them.
If you cannot easily pull the o-rings from the pistons, you may
need to cut them.
4 Re-insert the pistons into the pump manifold in the
unbalanced configuration Ä, where the tip of the piston is
pointing out of the manifold.
5 Insert the check valves into the pump manifold, and tighten
them to 25 lbf-ft (34 N-m).
5
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