INTRODUCTION
Nexus Pumpset PF-0,3 /S
Installation Manual
Thank you for choosing a Nexus Pumpset. Through this manual we will help you install
your new Nexus product. Please read through this manual carefully before starting your
installation.
1 Introduction
The Pumpset should be connected to the boat's hydraulic steering system according to
figure 1. The Pumpset motor only operates when carrying out a rudder command. When
the boat is on course, the Pumpset stops. A variable speed motor drive adjusts optimal
rudder speed and provides for minimum power consumption and maximum rudder posi-
tioning accuracy. Most existing multiple station steering systems have lock valves, which
automatically isolate stations from each other and from the autopilot Pumpset. A lock
valve should be installed so that the helm can be isolated.
2 Installation
Note! Because most installations differ, the following items are not supplied and need to
be sourced or made locally: Support bracket for Pumpset, 4 mounting screws and wash-
ers, hydraulic fittings and piping.
2.1 Installing the Pumpset
The Pumpset is splashproof and should be mounted in a cool dry location, which mini-
mises hydraulic piping and wiring runs. The enclosed figure indicates the piping required
for the different hydraulic steering systems. The Pumpset may be mounted horizontally
(Pumpset feet down) or vertically with the pump positioned above the motor. Be certain to
leave adequate space to access the bleed screw. Four screws and washers are required
to hold the Pumpset resilient feet to the mounting surface. In any case be sure, to mount
the pumpset itself or, if not possible, the pumpset-reservoir at the highest position of the
hydraulic system.
2.2 Installing hydraulic fittings and piping
It is recommended that all fittings to be installed are aligned with the Pumpset before it is
mounted. The type of hydraulic fittings required i.e., straight or 90° angle, will depend on
the mounting position of the Pumpset and the location of piping.
Recommended size for all connections are hydraulic hoses and fittings with an inner di-
ameter of 8 mm (0.32”) minimum to reduce the drag.
Use only hydraulic hoses, suitable for a working pressure of 1,000 PSI (70bar). The hy-
draulic fittings selected must be suitable for the hydraulic hoses size used.
Note! All ports on the Pumpset are 1/4" NPT.
Pipe sealant or teflon tape is required on all male pipe thread fittings. Be certain to keep
the sealant or tape at least two threads away from the starting threads to prevent threaded
tape or sealant from contaminating the system.
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INSTALLATION
2.3 Pumpset oil filling
If the Pumpset is used together with the Nexus Linear Drive, fill the Linear Drive first and
then connect the Linear Drive to the Pumpset before filling the Pumpset. See the Linear
Drive oil filling procedure in separate manual.
Use hydraulic oil viscosity grade ISO 20. About 110 ml is needed for the Pumpset only
without piping. Fill the Pumpset via the reservoir.
Once the boats main steering system has been filled, open the Pumpset bleed screw (on
top of the Pumpset), two complete turns. Wait until clear oil void of any air exits from the
bleed screw, then resecure the bleed screw. Then fill up the uppermost helm Pumpset or
reservoir of the main steering system, if necessary.
Pumpset PF-0,3S with solenoid and reservoir
Pumpset PF-0,3
2.4 Connec-
tion
Note! For correct
wire dimensions
see Nexus
Autopilot manual
”Wire Thick-
ness”.
Connect the Pumpset wires to the Nexus Servo Unit as follows:
·
·
Orange wire to Servo Unit terminal marked "MOTOR 1".
Black wire to Servo Unit terminal marked "MOTOR 2".
For Pumpset PF-0,3S with solenoid, connect also the two red wires as follows:
·
·
One solenoid red wire to terminal marked 16 ”+”.
One solenoid red wire to terminal marked 17 "GND".
It does not matter which wire red wire goes to which terminal.
3 Dockside testing
When the complete electrical installation is checked and the power is turned on, there are
further procedures to be carried out in order to completely remove any air in the system.
See 12 "Dockside Testing" of the Nexus Autopilot manual.
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INSTALLATION
4 Maintenance and inspection schedule
If the boat does not accumulate the hours indicated below within 3 months, the frequency
is every 3:rd month.
Warning !
Failure to rectify any faulty conditions discovered as a result of the inspection could cause
sudden loss of Autopilot control, with consequential danger. It is recommended that all
items referenced in the following table be inspected before commencing any cruise.
Type
Equipment:
Check for:
Remedy:
Inspection
Frequency:
200 hrs
Hydraulic
Oil reservoir level
Oil condition
Correct
Fill
Discoloration
Contamination
Damage
Leaks & Corrosion
Damage
Flush system and
replace the oil
Replace
1000 hrs
1000 hrs
1000 hrs
Hydraulic hoses
Hydraulic fittings
Replace
500 hrs
Leaks & Loosening Tighten
Piston rod seals
on pumpset
Linear drive
Tiller arm
Leaking
Replace
1000 hrs
Mechanical
Corrosion
Corrosion
Corrosion
Loosening
Corrosion
Loosening
Corrosion
Loosening
Replace or Repair
Replace
Replace
Tighten
Replace
Tighten
Replace
Tighten
2000 hrs
2000 hrs
2000 hrs
500 hrs
2000 hrs
500 hrs
Tiller bolts
Rod end bolt
on linear drive
Trunnion bolts
on linear drive
2000 hrs
500 hrs
5 Specifications
Type of Pumpset:
Dimensions:
Weight PF-0,3 (without oil):
Weight PF-0,3S (without oil):
Enclosure:
Reversible axial piston pump, 5-cylinder
Length 230 x width 105 x height 100 mm (91 x 41 x 40”)
3 kg (6.60 lb)
3,3 kg (7.27 lb)
Splash proof
Temperature range:
Power supply:
Peak pressure:
-5° to +50° C (+40° to 122° F)
Both Pumpsets available in 12 or 24 V DC
70 bar (1000PSI)
Ram capacity min - max:
Peak flow rate:
100 - 400 cc (6 - 24 in3) (no load)
1150 cc/min (70 in3/min) (no load)
Average power consumption: 2 - 4 A ca 36 Watts (at 12V)
Piping pressure:
Piping size:
Port dimensions:
Hydraulic oil viscosity:
Warranty period:
1000 PSI (70bar)
Min. 8 mm (0.32”) inner diameter
¼" NPT
ISO 20
2 years, see separate conditions
CE approval: The product conforms to the EMC requirements for immunity and emission
according to EN 5008-1 and EN 55022
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WARRANTY
6 Warranty
GENERAL
All our products are designed and built to comply to the highest class industry standards. If the products are correctly
installed, maintained and operated, as described in the installation and operation manual, they will provide long and
reliable service. Our international Network of distributors can provide you with the information and assistance you may
require virtually anywhere in the world.
Please read through and fill in this warranty card and send it to your national distributor for product registration.
LIMITED WARRANTY
The warranty covers repair of defective parts due to faulty Manufacturing and includes labour when repaired in the
country of purchase. The warranty period is stated in the product manual, and commences from the date of purchase.
The above warranty is the Manufacturer’s only warranty and no other terms, expressed or implied, will apply. The
Manufacturer specifically excludes the implied warranty of merchantability and fitness for a particular purpose.
CONDITIONS
·
The supplied warranty card and receipt with proof of purchase date, must be shown to validate any warranty
claim. Claims are to be made in accordance with the claims procedure outlined below.
The warranty is non-transferrable and extends only to the original purchaser.
The warranty does not apply to Products from which serial numbers have been removed, faulty installation or in-
correct fusing, to conditions resulting from improper use, external causes, including service or modifications not
performed by the Manufacturer or by its national distributors, or operation outside the environmental parameters
specified for the Product.
·
·
·
·
The Manufacturer will not compensate for consequential damage caused directly or indirectly by the malfunction
of its equipment. The Manufacturer is not liable for any personal damage caused as a consequence of using its
equipment.
The Manufacturer, its national distributors or dealers are not liable for charges arising from sea trials, installation
surveys or visits to the boat to attend to the equipment, whether under warranty or not. The right is reserved to
charge for such services at an appropriate rate.
·
·
The Manufacturer reserves the right to replace any products returned for repair, within the warranty period, with
the nearest equivalent, if repair within a reasonable time period should not be possible.
The terms and conditions of the warranty as described do not affect your statutory rights.
CLAIMS PROCEDURE
Equipment should be returned to the national distributor, or one of its appointed dealers, in the country where it was
originally purchased. Valid claims will then be serviced and returned to the sender free of charge.
Alternatively, if the equipment is being used away from the country of purchase, it may be returned to the national dis-
tributor, or one of its appointed dealers, in the country where it is being used. In this case valid claims will cover parts
only. Labour and return postage will be invoiced to the sender at an appropriate rate.
DISCLAIMER
Common sense must be used at all times when navigating and the Manufacturer’s navigation equipment should only
be considered as aids to navigation.
The Manufacturers policy of continuous improvement may result in changes to product specification without prior no-
tice.
Copyright ©:
Silva Sweden AB
Kuskvägen 4, 191 62 Sollentuna, Sweden
Tel: +46 -(0) 8 - 623 43 00. Fax: +46 -(0) 8 - 92 76 01
This manual is written for Nexus Pumpset (Art. No.):
12V PF-0,3 (21134), 24V PF-0,3 (21134-24)
12V PF-0,3S (21341), 24V PF-0,3S (21341-24)
Edition: August 1998
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