4000 Mk2 Wheel Drive

Document Number: 83158-1 Date: October 2001
ST4000+ Wheel Pilot System (including compass and control unit) E12053, ST4000+ Wheel Pilot System 4000 Mk2 Wheel Drive only E12093, 4000 Mk2 Wheel Drive Unit
WARNING: CE Marking of Equipment/Replacement Parts
If the Raymarine equipment under repair, test, calibration, installation or setting to work carries the European CE mark, only parts and components supplied or approved for such use by Raymarine should be used in order to maintain compliance with the relevant CE requirements. Incorporation, use or attachment, by any means, of parts or components not supplied for or not approved for such use by Raymarine or, if supplied or approved for use by Raymarine, not properly fitted in accordance with instructions published, provided or recommended by Raymarine, may cause the equipment to malfunction and, in particular, to become unsafe or to no longer meet the relevant CE requirements. In these circumstances, Raymarine excludes liability to the fullest extent permissible in law for any loss or damage including any liability for its contribution to such loss or damage by its negligent acts or omissions.
4000 Mk2 Wheel Drive Service Manual 83158-1
4000 Mk2 Wheel Drive Service Manual
Service manual contents Raymarine Ltd, 2001

Contents

Chapter 1: Chapter 2: Introduction....5 1.1. Wheel drive functional test...5 Main Parts and Spares....6 2.1. Spares for 4000 Mk2 wheel drive...6 2.2. 4000 Mk2 wheel drive exploded view...7 Disassembly and Reassembly....8 3.1. Tools required....8 3.2. Disassembly....8 Support plate and drive belt...8 Clutch eccentrics, knob and lever...8 Bearing cage and drive ring...8 Motor and gearbox....9 3.3. Reassembly....9 Gearbox....9 Clutch eccentrics....9 Drive ring and bearing cage...9 Drive belt and support plate...10 Clutch lever and ratchet knob...10 Motor assembly....10 Front cover....10 3.4. Adjusting the clutch....11 3.5. Cleaning the wheel drive...11 3.6. Fitting spares and accessories...12 Clutch lever A18077....12 Clutch ratchet knob A18078....12 Support plate A18079....12 Clutch kit A18084...13 Drive belt kit A18083....13 Drive ring A18076 and Bearing kit A18085...14 Machined pulley A18087....14 Gearbox A18088....15 Motor A18086....15 Motor loom and seal kit A18092...15 Front cover A18074....16 Rear cover A18075...16 Wheel drive unit A18081....17 Torque restraint A18080...17 Single spoke clamp A18089....17

Chapter 3:

Chapter 1: Introduction
This manual explains the service and maintenance procedures for the Raymarine 4000 Mk2 wheel drive unit. Note: For information about servicing the ST4000+ control unit and fluxgate compass, refer to the ST4000 Plus Autopilots Service Manual (83115-3).
1.1. Wheel drive functional test
Switch on. With clutch engaged, check drive ring moves and current is less than 2 A
Remove front cover and visually inspect unit No

OK OK Yes

Rotate drive ring by hand with clutch disengaged Check drive ring rotates freely and belt does not drag

Check gears, belt tension, eccentrics, drive lever, motor Change/adjust as necessary
Change damaged components

OK Yes

Restrain drive ring rotation until 6.5 A is obtained. Check that belt does not slip.
Change/adjust as necessary
Reverse polarity of supply Check resistance across motor connector pins is approximately 1 to 2 ohms Switch on. Check drive ring moves in opposite direction to that of first test and current is less than 2 A Check wiring and connector Check gears, belt tension, eccentrics, drive lever, motor Change/adjust as necessary

Change as necessary

Check motor Restrain drive ring rotation until 6.5 A is obtained. Check that belt does not slip.
Connect power supply (see below)
Drive unit OK. End of test.

D5728-1

12 A Fuse/CB Switch

PSU 12 V 15 A

D5727-1

4000 mk2 Wheel Drive

Chapter 2: Main Parts and Spares
2.1. Spares for 4000 Mk2 wheel drive
Item 2 23 Spare/Accessory Front cover Front cover 6 mm drill bit Back cover Drive ring Clutch lever Clutch lever M5 x 30 mm screw Clutch ratchet knob Ratchet knob M5 x 30 mm screw Support plate Support plate M5 x 8 mm screw (x2) Torque restraint (pedestal bracket) Torque restraint No 10 x inch screw (x4) 4 mm drill bit Wheel drive unit Drive belt Clutch kit Clutch eccentric Clutch roller M5 x 30 mm screw Bearing kit Ball bearings (x21) Bearing cage (x3) Motor Machined pulley Gearbox Single spoke clamp Spoke clamp 16 mm spoke clamp insert 12 mm spoke clamp insert M5 x 16 mm screw 3 mm allen key Motor loom and seal kit Collar nut Rubber cap Motor clamp O-ring Loom plug assembly Gasket Power cable 4.5 m (15 ft) cable with plug at one end and connector spades at the other Part No. A18074 Not illustrated on exploded view A18075 A18076 A18077 Comments

A18078

A18079
A18080 Not illustrated on exploded view Not illustrated on exploded view Not illustrated on exploded view Entire wheel drive assembly

A18081 A18083 A18084

A18085
A18086 A18087 A18088 A18089 Not illustrated with exploded unit Not illustrated with exploded unit Not illustrated with exploded unit Not illustrated with exploded unit Not illustrated with exploded unit A18092

A18061

Not illustrated with exploded unit
2.2. 4000 Mk2 wheel drive exploded view
Front cover Support plate screw
(x2) Torque: 12 lb.in (1.4 Nm) 5 (x2) (x2)
Support plate Drive belt Clutch roller (x2) Screw M5 x 30 mm (x2) Clutch lever Clutch eccentric (x2) Clutch ratchet knob Bearing cage (x3) Drive ring Ball bearing (x21) Machined pulley Collar nut Rubber cap Motor tube Motor sleeve Motor Motor clamp O-ring Motor loom Seal Gearbox Back cover

10 (x3) 17

12 (x21)
6 (x2) Torque: 12 lb.in (1.4 Nm)

D5721-2

M5 x 8 mm (x2)
Chapter 3: Disassembly and Reassembly
Note: The numbered parts in the following instructions refer to the annotations on the exploded views.

3.1. Tools required

To assemble/disassemble the 4000 Mk2 wheel drive unit you will need a 3 mm allen key.

3.2. Disassembly

Remove the wheel drive from the wheel and release the clutch, then complete these steps:
Support plate and drive belt
1. 2. Remove the front cover (1) by pulling it away from the back cover. Remove the support plate: unscrew and remove the 2 support plate screws (2) lever the support plate (3) away from the back cover Remove the drive belt: lever the drive belt (4) up and over the machined pulley (13) remove the drive belt from the drive ring (11)
Clutch eccentrics, knob and lever
4. 5. Remove the 2 clutch rollers (5) from the clutch eccentrics. Note: the clutch rollers are identical. Remove the clutch lever: unscrew and remove the clutch lever screw (6) pull the clutch lever (7) off the back cover Remove the clutch lever eccentric (8). Remove the clutch ratchet knob: unscrew and remove the ratchet knob screw (6) pull the ratchet knob (9) off the back cover Remove the clutch knob eccentric (8). Note: the clutch lever eccentric and clutch knob eccentric are identical.
Bearing cage and drive ring
9. Remove the 3 parts of the bearing cage (10): insert one end of the allen key into the joint between 2 parts of bearing cage (10), then lever one part of the cage up so you can pull it out
10. Push all of the ball bearings together. The drive ring (11) will then be free to move. 11. Hold the drive unit horizontal, then lift off the drive ring (11).
Chapter 3: Disassembly and Reassembly 12. Remove the 21 ball bearings (12), taking care to retain them for reassembly (e.g. in the inside of upturned front cover). 13. Lift off the machined pulley (13).
14. Unscrew the plastic collar nut (14) by turning it anti-clockwise, then remove the rubber cap (15). 15. Unscrew the motor tube (16) by hand (turning it anti-clockwise) and then remove it. 16. Lift off the motor assembly, consisting of: motor sleeve (17), motor (18), motor clamp (19), O-ring (20), motor loom (21) and gasket (22). 17. Remove the gearbox (23) by pushing it out from the rear of the back cover (24).

3.3. Reassembly

CAUTION: Do NOT use mineral-based solvents (e.g. WD40) to lubricate or clean the wheel drive as they will damage the material. The wheel drive is designed to run without lubrication.

Gearbox

1. 2. Fit the gearbox (23) by inserting it from the inside of the back cover (24). Ensure that the locating slots on the gearbox are aligned with the lugs in the back cover. Place the machined pulley (13) onto the gearbox shaft, with the recessed face on top.

Clutch eccentrics

3. 4. Fit the 2 clutch eccentrics (8) with their flanges downwards, so that they are clear of the foul pins on the back cover. Note: the 2 clutch eccentrics are identical. Fit the 2 clutch rollers (5) over the clutch eccentrics. Note: the 2 clutch rollers are identical.
Drive ring and bearing cage
5. 6. 7. 8. Place the drive ring (11) onto the back cover, with its lipped edge uppermost. Place the 21 ball bearings (12) back into the ball groove. Roughly distribute the ball bearings around the ball groove this should secure the drive ring. Fit the 3 parts of the bearing cage (10): clip the first part of the bearing cage into the ball groove, capturing 7 ball bearings in the cage repeat for the other 2 parts of the bearing cage when you have fitted the 3 parts of the bearing cage, check that the drive ring is free to rotate

Motor and gearbox

Drive belt and support plate
9. Fit the drive belt (4): fit the belt around the drive ring rotate the clutch eccentrics to make the maximum amount of space between the machined pulley and the clutch eccentrics then fit the belt around the machined pulley
10. Fit the support plate (3): fit the support plate over the clutch eccentrics and gearbox shaft, making sure the plate is pressed down fully insert and tighten the 2 screws (2): torque to 12 lb.in (1.4 Nm)
Clutch lever and ratchet knob
11. Fit the clutch lever (7): place the clutch lever onto the eccentric spindle (it should be positioned between the two pips on the rear of the back cover) insert and tighten the clutch lever screw (6): torque to 12 lb.in (1.4 Nm) check that the lever engages and disengages the clutch 12. Fit the clutch ratchet knob (9): place the clutch ratchet knob over the eccentric spindle insert and tighten the clutch ratchet knob screw (6): torque to 12 lb.in (1.4 Nm) you will need to adjust the clutch after reassembling the wheel drive (Section 3.4)

Motor assembly

13. Fit the motor assembly: carefully insert the gear at the end of the motor (18) into the hole on the gearbox (23), making sure the teeth engage properly also make sure that the pin on the motor engages into one of the 2 holes on the top of the gearbox check that the O-ring seal (20) is still sitting on the motor clamp 14. Fit the motor tube (16): place it over the motor and hand-tighten it onto the back cover 15. Fit the rubber cap (15) and secure it with the plastic collar nut (14), making sure the lip on the collar nut is uppermost.

Front cover

16. Fit the font cover (1): line up the arrow on the front cover with the arrow on the drive ring, then press the cover into place
3.4. Adjusting the clutch
Clutch knob screw Clutch knob
Adjusting the clutch Loosen the screw (2 turns)

D5349-2

To loosen the clutch (4 clicks)
To tighten the clutch (4 clicks)
Tighten the screw (2 turns)
You need to adjust the clutch if you have removed the clutch eccentrics, replaced the ratchet knob, or replaced the drive belt. When the clutch is correctly adjusted: 1. 2. 3. 4. the drive ring can rotate freely when the clutch is disengaged the drive belt does not slip when the clutch is engaged and the motor is driving
To adjust the clutch, make sure the clutch is disengaged. Then: Use a 3 mm allen key to loosen the clutch knob screw about 2 turns anti-clockwise. Turn the clutch knob either 4 clicks clockwise to tighten the clutch, or 4 clicks anticlockwise to loosen the clutch. Use the allen key to re-tighten the clutch knob screw. Check that the wheel still moves freely with the clutch off.
Note: If the wheel does not move freely, reduce the clutch tension by turning the clutch knob 2 clicks anti-clockwise and check again 5. Check the drives operation with the clutch engaged.
This procedure is usually sufficient to correct a slipping or dragging drive belt. In some cases, however, you may need to repeat the steps to adjust the clutch further.
3.5. Cleaning the wheel drive
CAUTION: Do NOT use mineral-based solvents (e.g. WD40) to lubricate or clean the wheel drive as they will damage the material. The wheel drive is designed to run without lubrication. To clean the wheel drive front/rear cover: use a mild detergent if necessary, then flush thoroughly with fresh water. To clean inside the wheel drive: if there is a build-up of salt on the wheel drive bearings and drive belt, thoroughly flush the wheel drive interior with fresh water.
3.6. Fitting spares and accessories
Clutch lever AMk2 Wheel Drive

Clutch lever

M5 x 30 mm screw
4000 Mk2 Wheel Drive - Clutch Lever (A18077)

D5734-2

To replace the clutch lever: follow step 5 of Disassembly to remove the lever follow step 11 of Reassembly to fit the new lever
Clutch ratchet knob A18078

Clutch ratchet knob

4000 Mk2 Wheel Drive - Clutch Ratchet Knob (A18078)

D5735-2

To replace the clutch ratchet knob: follow step 7 of Disassembly to remove the knob follow step 12 of Reassembly to fit the new knob adjust the clutch (as described above)

Support plate A18079

Support plate

M5 x 8 mm screw (x2)

4000 Mk2 Wheel Drive - Support Plate (A18079)

D5736-2

To replace the support plate: follow steps 1-2 of Disassembly to remove the support plate follow step 10 of Reassembly to fit the new support plate fit the front cover

Clutch kit A18084

4000 Mk2 Wheel Drive - Clutch Kit (A18084)

D5740-2

To replace either of the clutch eccentrics: follow steps 1-8 of Disassembly to remove the eccentric: note: you do not need to remove the drive belt follow steps 3-4 of Reassembly to fit the new eccentric and then follow steps 9-12 of Reassembly to reassemble the drive unit adjust the clutch (as described above)

Drive belt kit A18083

4000 Mk2 Wheel Drive - Drive Belt (A18083)

D5739-2

To replace the drive belt: follow steps 1-3 of Disassembly to remove the old drive belt follow steps 9-10 of Reassembly to fit the replacement drive belt and then the support plate fit the front cover adjust the clutch (as described above)

Clutch roller

Clutch eccentric
Drive ring A18076 and Bearing kit A18085
4000 Mk2 Wheel Drive - Drive Ring (A18075)

D5733-2

Ball bearing (x21)

Bearing cage (3 parts)

4000 Mk2 Wheel Drive - Bearing Kit (A18081)

D5741-2

To replace the drive ring and/or ball bearings and/or bearing cage: follow steps 1-12 of Disassembly to remove the ball bearings, bearing cage and drive ring follow steps 5-16 of Reassembly to fit the new drive ring and/or bearing cage and/or ball bearings, and reassemble the wheel drive adjust the clutch (as described above)

Machined pulley A18087

4000 Mk2 Wheel Drive - Machined Pulley (A18087)

D5743-2

To replace the machined pulley: follow steps 1-13 of Disassembly to remove the machined pulley follow steps 2-16 of Reassembly to fit the new machined pulley and reassemble the wheel drive adjust the clutch (as described above)

Gearbox A18088

4000 Mk2 Wheel Drive - Gearbox (A18088)

D5744-2

To replace the gearbox: follow all of the Disassembly steps to remove the gearbox follow all of the Reassembly steps to fit the new gearbox and reassemble the wheel drive adjust the clutch (as described above)

Motor A18086

4000 Mk2 Wheel Drive - Motor (A18086)

D5742-2

To replace the motor: follow steps 14-16 of Disassembly to remove the motor assembly lift up the motor clamp so you can de-solder the motor loom wires from the contacts on the motor solder the motor loom wires to the new motor follow steps 13-15 of Reassembly to fit the new motor assembly
Motor loom and seal kit A18092

Motor clamp

O-ring
Motor loom (with wires attached)

Collar nut

Rubber cap
4000 Mk2 Wheel Drive - Motor Loom and Seal Kit (A18092)

D5746-2

To replace the motor loom: follow steps 14-16 of Disassembly to remove the motor assembly lift up the motor clamp so you can de-solder the motor loom wires from the contacts on the motor
4000 Mk2 Wheel Drive solder the new loom wires to the motor terminals follow steps 13-15 of Reassembly to fit the motor assembly
Front cover AMk2 Wheel Drive
4000 Mk2 Wheel Drive Front Cover (A18074)

D5731-2

To replace front cover: pull off the old front cover drill the relevant spoke clamp holes in the new front cover fit the front cover back onto the drive unit
For more details, refer to the instructions supplied with the cover.

Rear cover A18075

4000 Mk2 Wheel Drive - Back Cover (A18075)

D5732-2

To replace the rear cover: follow all of the disassembly steps follow all of the reassembly steps

Wheel drive unit A18081

4000 Mk2 Wheel Drive Unit (A18081)

D5738-2

Torque restraint A18080

4 mm drill bit

Torque restraint

No10 x 3/4 in screw (x4)

4000 Mk2 Wheel Drive - Torque Restraint (A18080)

D5737-2

Fit according to instructions supplied with the torque restraint.
Single spoke clamp A18089

Spoke clamp insert 12 mm

M5 x 16 mm screw (x2)

Spoke clamp

Spoke clamp insert 16 mm

3 mm allen key

4000Mk2 Wheel Drive - Single Spoke Clamp (A18089)

D5745-2

Fit according to instructions in ST4000+ Wheel and Tiller Autopilots Owners Handbook.
October 2001 Raymarine Ltd Anchorage Park, Portsmouth, England, PO3 5TD Telephone: +44 (0)3611 Fax: +44 (0)4642
Raymarine Inc 22 Cotton Road, Unit D Nashua, NH 03063-4219, USA Telephone: +Fax: +864 4756
www.raymarine.com email: techsupport@raymarine.com

S1 Tiller and Wheel Pilot Service Manual
Document Number: 83187_1 Date: January 2007

Contents

ST6002 control head.... 1 Disassembly/Assembly.... 1 ST6002 spare parts list.... 2 Fluxgate Compass Transducer.... 1 Functional test.... 1 Magnetic deviation.... MK2 wheel drive... MK2 wheel drive test... 3 Spares for 4000 Mk2 wheel drive... MK2 wheel drive exploded view... 5 Tools required.... 6 Disassembly... 6 Reassembly.... 7 Adjusting the clutch.... 9 Cleaning the wheel drive.... 9 Fitting spares and accessories... 10 Tiller Drive Actuator... 17 Tiller Drive Actuator test... 17 Disassembly/assembly... 18 Tiller Drive Actuator GP.... 21 Tiller Drive Actuator GP test.... 21 Disassembly/assembly... 22
Fascia with curved window

Pips Horizontal rib

12 (Note C)

:eto N

3 (Note D)

1.2 Disassembly/Assembly

E12025 and E12100 Light Grey Flush Mount Control Unit
Chapter 1: ST6002 control head
17 (Note A) 4 (Note D) 5 (Note D)

Fascia with flat window

11 (x3) Torque to 0.33 Nm (3 lb in)
11 (x8) Torque to 0.33 Nm (3 lb in)

7 (x2)

8 (Note B)
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 ofthe PCB (10). C. It is recommended that a new case seal (12) is fitted on reassembly. D. Only fitted on units with CURVED window to fascia.
1. 1A. 1B. 2. 3. 3A. 4. 5. 5A. 6. 7.
Fascia (dark grey) Fascia (light grey) Flush mount fascia (light grey) Keypad Label (old profile) Label (latest profile) Window insert LCD surround LCD surround LCD Elastomer strip (x2)
8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Diffuser Reflector PCB Retaining screw (x11) Case seal Rear cover Buzzer connector Back cover label (ST6000+/ST6001+) Bulkhead gasket Keypad shim (earlier units only)
This drawing above is not an exact representation of the present plastics. Following this process will show you how to separate the plastics and seals to replace the PCB as there are no serviceable parts with this item. It is just a case of replacing the PCB if any problems are present

D4586-2

1.2 ST6002 spare parts list
Below is a table populated with Spare parts for the ST6002 as there are no serviceable parts with this product it is just a case of dismantling the unit and replacing the internal PCB.

Spare Part Number

A18012-P A18018-P A18090-P A25004-P Q219 W118 W119-P

Description

Universal Pilot Display Kit ST6002 Surface Mount Fascia Kit ST6002 Spare PCB Assembly ST60+ Surface Mount Sun Cover ST4/5/6001 & 6002 Autopilot Keypad ST4/5/6001 & 6002 Case Seal ST6002 Back Cover Assembly
Chapter 2: Fluxgate Compass Transducer

2.2 Functional test

Disconnect the Fluxgate from the Autopilot and check continuity as follows: Cable color connector pin number Resistance
Cable Color Screen to blue
Red to green Red to yellow Red to screen
Connector Pin Number (2/4)

(3/5) (3/6) (3/2)

Resistance < 10 ohms
< 5 ohms < 5 ohms Open circuit

2.2 Magnetic deviation

The Fluxgate Compass requires careful siting if optimum Autopilot performance is to be achieved. The SeaTalk electronics is able to correct the compass for most deviating magnetic fields present when the linearization procedure is carried out. Any further deviation, introduced after linearization, will introduce an error between the Fluxgate and the ships compass. This can be removed by carrying out the linearization again. If the displayed deviation is greater than +/ 15 degrees the Fluxgate should be re-sited.
The linearization procedure should always be carried out if the Fluxgate has been exchanged, removed or moved from its original mounting position.

Disassembly/assembly

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

D3726-2

Figure 4. Fluxgate Compass exploded view
Fluxgate Compass spare parts list
The item numbers refer to Figure 4: Fluxgate Compass exploded view Item Spare Description Compass base kit, including Pivot retaining screw (x2) Bracket Fluxgate sub-assembly, including Pivot sub-assembly (x2) Fluxgate sub-assembly M022 Part No. M096 Comments
Chapter 3: 4000 MK2 wheel drive

Introduction

This manual explains the service and maintenance procedures for the Raymarine 4000 Mk2 wheel drive unit.

3.MK2 wheel drive test

Note: For information about servicing the ST4000+ control unit and fluxgate compass, refer to the ST4000 Plus Autopilots Service Manual (83115-3)
Switch on. With clutch engaged, check drive ring moves and current is less than 2 A
Remove front cover and visually inspect unit No

OK OK Yes

Rotate drive ring by hand with clutch disengaged Check drive ring rotates freely and belt does not drag
Check gears, belt tension, eccentrics, drive lever, motor Change/adjust as necessary
Change damaged components

OK Yes

Restrain drive ring rotation until 6.5 A is obtained. Check that belt does not slip.
Change/adjust as necessary
Reverse polarity of supply Check resistance across motor connector pins is approximately 1 to 2 ohms Switch on. Check drive ring moves in opposite direction to that of first test and current is less than 2 A Check wiring and connector Check gears, belt tension, eccentrics, drive lever, motor Change/adjust as necessary

Change as necessary

Check motor Restrain drive ring rotation until 6.5 A is obtained. Check that belt does not slip.
Connect power supply (see below)
Drive unit OK. End of test.

D5728-1

12 A Fuse/CB Switch

PSU 12 V 15 A

D5727-1

2 23 21 22

Drive belt Clutch kit Clutch eccentric Clutch roller M5 x 30 mm screw Bearing kit Ball bearings (x21) Bearing cage (x3) Motor Machined pulley Gearbox Single spoke clamp Spoke clamp 16 mm spoke clamp insert 12 mm spoke clamp insert M5 x 16 mm screw 3 mm allen key Motor loom and seal kit Collar nut Rubber cap Motor clamp O-ring Loom plug assembly Gasket Power cable 4.5 m (15 ft) cable with plug at one end and connector spades at the other
Not illustrated Not illustrated Not illustrated Not illustrated Not illustrated

A18061

Not illustrated with exploded unit
ylbm essa evird l e ehw erit n E

48081 A 38081 A 18081 A

Torque restraint No 10 x inch screw (x4) 4 mm drill bit Wheel drive unit

08081 A

Support plate M5 x 8 mm screw (x2) Torque restraint (pedestal bracket)

97081 A

Ratchet knob M5 x 30 mm screw Support plate

87081 A

Clutch lever M5 x 30 mm screw Clutch ratchet knob

77081 A

Drive ring Clutch lever

57081 A

Front cover 6 mm drill bit Back cover

47081 A

58081 A
98081 A 88081 A 78081 A 68081 A

29081 A

3.2 Spares for 4000 Mk2 wheel drive
Item Spare/Accessory Front cover Part No. Comments
Not illustrated on exploded view A18076
Not illustrated on exploded view Not illustrated on exploded view Not illustrated on exploded view

with with with with with

exploded unit exploded unit exploded unit exploded unit exploded unit
3.MK2 wheel drive exploded view

4000 Mk2 Wheel Drive

1 Front cover 2 Support plate screw M5 x 8 mm (x2) 3 Support plate 4 Drive belt 5 Clutch roller (x2) 6 Screw M5 x 30 mm (x2) 7 Clutch lever 8 Clutch eccentric (x2) 9 Clutch ratchet knob 10 Bearing cage (x3) 11 Drive ring 12 Ball bearing (x21) 13 Machined pulley 14 Collar nut 15 Rubber cap 16 Motor tube 17 Motor sleeve 18 Motor 19 Motor clamp 20 O-ring 21 Motor loom 22 Seal 23 Gearbox 24 Back cover
2 (x2) Torque: 12 lb.in (1.4 Nm) (x2)

8 (x2)

10 (x3) 12 (x21) 17
6 (x2) Torque: 12 lb.in (1.4 Nm)

D5721-2

Disassembly and Reassembly
Note: The numbered parts in the following instructions refer to the annotations on the exploded views.

3.4 Tools required

To assemble/disassemble the 4000 Mk2 wheel drive unit you will need a 3 mm allen key.

3.5 Disassembly

Remove the wheel drive from the wheel and release the clutch, then complete these steps:
Support plate and drive belt
1. 2. 3. Remove the front cover (1) by pulling it away from the back cover. Remove the support plate: unscrew and remove the 2 support plate screws (2) lever the support plate (3) away from the back cover Remove the drive belt: lever the drive belt (4) up and over the machined pulley (13) remove the drive belt from the drive ring (11)
Clutch eccentrics, knob and lever
4. Remove the 2 clutch rollers (5) from the clutch eccentrics.
Note: the clutch rollers are identical.
5. 6. 7. 8. Remove the clutch lever: unscrew and remove the clutch lever screw (6) pull the clutch lever (7) off the back cover Remove the clutch lever eccentric (8). Remove the clutch ratchet knob: unscrew and remove the ratchet knob screw (6) pull the ratchet knob (9) off the back cover Remove the clutch knob eccentric (8).
Note: the clutch lever eccentric and clutch knob eccentric are identical.
Bearing cage and drive ring

9. Remove the 3 parts of the bearing cage (10): insert one end of the allen key into the joint between 2 parts of bearing cage (10), then lever one part of the cage up so you can pull it out
10. Push all of the ball bearings together. The drive ring (11) will then be free to move. 11. Hold the drive unit horizontal, then lift off the drive ring (11). 12. Remove the 21 ball bearings (12), taking care to retain them for reassembly (e.g. in the inside of upturned front cover). 13. Lift off the machined pulley (13).

Motor and gearbox

14. Unscrew the plastic collar nut (14) by turning it anti-clockwise, then remove the rubber cap (15). 15. Unscrew the motor tube (16) by hand (turning it anti-clockwise) and then remove it. 16. Lift off the motor assembly, consisting of: motor sleeve (17), motor (18), motor clamp (19), O-ring (20), motor loom (21) and gasket (22). 17. Remove the gearbox (23) by pushing it out from the rear of the back cover (24).

3.6 Reassembly

CAUTION: Do NOT use mineral-based solvents (e.g. WD40) to lubricate or clean the wheel drive as they will damage the material. The wheel drive is designed to run without lubrication.

Gearbox

1. Fit the gearbox (23) by inserting it from the inside of the back cover (24). Ensure that the locating slots on the gearbox are aligned with the lugs in the back cover. Place the machined pulley (13) onto the gearbox shaft, with the recessed face on top.

Clutch eccentrics

3. Fit the 2 clutch eccentrics (8) with their flanges downwards, so that they are clear of the foul pins on the back cover. Note: the 2 clutch eccentrics are identical. Fit the 2 clutch rollers (5) over the clutch eccentrics. Note: the 2 clutch rollers are identical.
Drive ring and bearing cage
5. 6. 7. 8. Place the drive ring (11) onto the back cover, with its lipped edge uppermost. Place the 21 ball bearings (12) back into the ball groove. Roughly distribute the ball bearings around the ball groove this should secure the drive ring. Fit the 3 parts of the bearing cage (10): clip the first part of the bearing cage into the ball groove, capturing 7 ball bearings in the cage repeat for the other 2 parts of the bearing cage when you have fitted the 3 parts of the bearing cage, check that the drive ring is free to rotate
Drive belt and support plate
9. Fit the drive belt (4): Fit the belt around the drive ring rotate the clutch eccentrics to make the maximum amount of space between the machined pulley and the clutch eccentrics then fit the belt around the machined pulley
10. Fit the support plate (3): fit the support plate over the clutch eccentrics and gearbox shaft, making sure the plate is pressed down fully insert and tighten the 2 screws (2): torque to 12 lb.in (1.4 Nm)

Clutch lever and ratchet knob
11. Fit the clutch lever (7): place the clutch lever onto the eccentric spindle (it should be positioned between the two pips on the rear of the back cover) insert and tighten the clutch lever screw (6): torque to 12 lb.in (1.4 Nm) check that the lever engages and disengages the clutch
12. Fit the clutch ratchet knob (9): place the clutch ratchet knob over the eccentric spindle insert and tighten the clutch ratchet knob screw (6): torque to 12 lb.in (1.4 Nm) you will need to adjust the clutch after reassembling the wheel drive (Section 3.4)

Motor assembly

13. Fit the motor assembly: carefully insert the gear at the end of the motor (18) into the hole on the gearbox (23), making sure the teeth engage properly also make sure that the pin on the motor engages into one of the 2 holes on the top of the gearbox check that the O-ring seal (20) is still sitting on the motor clamp
14. Fit the motor tube (16): place it over the motor and hand-tighten it onto the back cover
15. Fit the rubber cap (15) and secure it with the plastic collar nut (14), making sure the lip on the collar nut is uppermost.

Front cover

16. Fit the font cover (1): line up the arrow on the front cover with the arrow on the drive ring, then press the cover into place

3.7 Adjusting the clutch

Clutch knob screw Clutch knob
Adjusting the clutch Loosen the screw (2 turns)

D5349-2

To loosen the clutch (4 clicks)
To tighten the clutch (4 clicks)
Tighten the screw (2 turns)
You need to adjust the clutch if you have removed the clutch eccentrics, replaced the ratchet knob, or replaced the drive belt. When the clutch is correctly adjusted: the drive ring can rotate freely when the clutch is disengaged the drive belt does not slip when the clutch is engaged and the motor is driving
To adjust the clutch, make sure the clutch is disengaged. Then: 1. 2. Use a 3 mm allen key to loosen the clutch knob screw about 2 turns anti-clockwise. Turn the clutch knob either 4 clicks clockwise to tighten the clutch, or 4 clicks anti-clockwise to loosen the clutch. Use the allen key to re-tighten the clutch knob screw. Check that the wheel still moves freely with the clutch off.

Note: If the wheel does not move freely, reduce the clutch tension by turning the clutch knob 2 clicks anti-clockwise and check again 5. Check the drives operation with the clutch engaged.
This procedure is usually sufficient to correct a slipping or dragging drive belt. In some cases, however, you may need to repeat the steps to adjust the clutch further.
3.8 Cleaning the wheel drive
CAUTION: Do NOT use mineral-based solvents (e.g. WD40) to lubricate or clean the wheel drive as they will damage the material. The wheel drive is designed to run without lubrication. To clean the wheel drive front/rear cover: use a mild detergent if necessary, then flush thoroughly with fresh water. To clean inside the wheel drive: if there is a build-up of salt on the wheel drive bearings and drive belt, thoroughly flush the wheel drive interior with fresh water.
3.9 Fitting spares and accessories Clutch lever A18077

Clutch lever

M5 x 30 mm screw
4000 Mk2 Wheel Drive - Clutch Lever (A18077)
To replace the clutch lever: follow step 5 of Disassembly to remove the lever follow step 11 of Reassembly to fit the new lever

D5734-2

Clutch ratchet knob A18078

Clutch ratchet knob

4000 Mk2 Wheel Drive - Clutch Ratchet Knob (A18078)
To replace the clutch ratchet knob: Follow step 7 of Disassembly to remove the knob follow step 12 of Reassembly to fit the new knob adjust the clutch (as described above)

D5735-2

Support plate A18079

Support plate

M5 x 8 mm screw (x2)
4000 Mk2 Wheel Drive - Support Plate (A18079)
To replace the support plate: Follow steps 1-2 of Disassembly to remove the support plate follow step 10 of Reassembly to fit the new support plate fit the front cover

D5736-2

Clutch kit A18084

Clutch roller

Clutch eccentric
4000 Mk2 Wheel Drive - Clutch Kit (A18084)
To replace either of the clutch eccentrics: follow steps 1-8 of Disassembly to remove the eccentric:

D5740-2

Note: you do not need to remove the drive belt
follow steps 3-4 of Reassembly to fit the new eccentric and then follow steps 9-12 of Reassembly to reassemble the drive unit adjust the clutch (as described above)

Drive belt kit A18083

4000 Mk2 Wheel Drive - Drive Belt (A18083)
To replace the drive belt: follow steps 1-3 of Disassembly to remove the old drive belt

D5739-2

follow steps 9-10 of Reassembly to fit the replacement drive belt and then the support plate fit the front cover adjust the clutch (as described above)
Drive ring A18076 and Bearing kit A18085
4000 Mk2 Wheel Drive - Drive Ring (A18075) 4000 Mk2 Wheel Drive - Drive Ring (A18075)

D5733-2 D5733-2

Ball bearing (x21)

Bearing cage (3 parts)

4000 Mk2 Wheel Drive - Bearing Kit (A18081)
To replace the drive ring and/or ball bearings and/or bearing cage:

D5741-2

follow steps 1-12 of Disassembly to remove the ball bearings, bearing cage and drive ring follow steps 5-16 of Reassembly to fit the new drive ring and/or bearing cage and/or ball bearings, and reassemble the wheel drive adjust the clutch (as described above)

Machined pulley A18087

4000 Mk2 Wheel Drive - Machined Pulley (A18087)
To replace the machined pulley: follow steps 1-13 of Disassembly to remove the machined pulley

D5743-2

follow steps 2-16 of Reassembly to fit the new machined pulley and reassemble the wheel drive adjust the clutch (as described above)

Gearbox A18088

4000 Mk2 Wheel Drive - Gearbox (A18088)
To replace the gearbox: follow all of the Disassembly steps to remove the gearbox

D5744-2

follow all of the Reassembly steps to fit the new gearbox and reassemble the wheel drive adjust the clutch (as described above)

Motor A18086

4000 Mk2 Wheel Drive - Motor (A18086)
To replace the motor: follow steps 14-16 of Disassembly to remove the motor assembly

D5742-2

lift up the motor clamp so you can de-solder the motor loom wires from the contacts on the motor solder the motor loom wires to the new motor follow steps 13-15 of Reassembly to fit the new motor assembly
Motor loom and seal kit A18092

Motor clamp

O-ring
Motor loom (with wires attached)

Collar nut

Rubber cap
4000 Mk2 Wheel Drive - Motor Loom and Seal Kit (A18092)
To replace the motor loom: follow steps 14-16 of Disassembly to remove the motor assembly

D5746-2

lift up the motor clamp so you can de-solder the motor loom wires from the contacts on the motor solder the new loom wires to the motor terminals follow steps 13-15 of Reassembly to fit the motor assembly

Front cover A18074

4000 Mk2 Wheel Drive Front Cover (A18074)
To replace front cover: pull off the old front cover drill the relevant spoke clamp holes in the new front cover fit the front cover back onto the drive unit

D5731-2

For more details, refer to the instructions supplied with the cover.

Rear cover A18075

4000 Mk2 Wheel Drive - Back Cover (A18075)
To replace the rear cover: follow all of the disassembly steps follow all of the reassembly steps

D5732-2

Wheel drive unit A18081
4000 Mk2 Wheel Drive Unit (A18081)

D5738-2

Torque restraint A18080

4 mm drill bit

Torque restraint

No10 x 3/4 in screw (x4)

4000 Mk2 Wheel Drive - Torque Restraint (A18080)
Fit according to instructions supplied with the torque restraint.

D5737-2

Single spoke clamp A18089

Spoke clamp insert 12 mm

M5 x 16 mm screw (x2)

Spoke clamp

Spoke clamp insert 16 mm

3 mm allen key

4000Mk2 Wheel Drive - Single Spoke Clamp (A18089)
Fit according to instructions in ST4000+ Wheel and Tiller Autopilots Owners Handbook.

D5745-2

Chapter 4: Tiller Drive Actuator
4.1 Tiller Drive Actuator test
Carry out the passive and active tests detailed in Figure 11. Tiller Drive Actuator test flowchart.

Blue Brown

Fuse/CB 12A Blue

Switch

Actuator deck plug PSU 12V 15A

D2394-2

Figure 10. Tiller Drive Actuator test connections
Start Visually inspect unit OK No Change damaged components Switch on, check thrust rod moves and current less than 2.5A Check gears, thrust rod, actuator body, motor Change as necessary Switch off. Reverse connections to PSU Switch on. Check thrust rod moves in opposite direction to that of first test and current less than 2.5A Connect power supply as in Figure 10.
Extend and retract thrust arm by hand OK OK No Check gears, thrust rod, actuator body, motor Change as necessary Check resistance across motor connector pins 2 and 3 is approximately 1 to 2 ohms OK No Check wiring and connector OK No Yes Check motor OK

No Yes

Check gears, thrust rod, actuator body, motor
Change as necessary Actuator OK. End of test

D3728-2

Figure 11. Tiller Drive Actuator test flowchart
1. Ram cap 2. Thrust tube 3. Lead screw assembly 4. Planet gear (x4) 5. Shim 6. 'O' ring (x3) 7. Gear annulus 8. Motor (Q114) 7 Notes B & C 6
9. Flux ring 10. Motor sleeve 11. End cap assembly 12. Cable clamp 13. Clamp seal 14. Cable clamp nut 15. SeaTalk deck plug

4.2 Disassembly/assembly

Notes: A. Ensure cable clamp nut (14) is unscrewed before undoing the motor sleeve. B. The hole in the gear annulus (7) that accepts the drive gear of the motor (8) is of a different diameter to that of the ST4000+ GP gear annulus. C. Care should be taken not to cross-thread the annulus (7) when screwing into the thrust tube (2). 6
Figure 12. Tiller Drive Actuator exploded view
14 Note A End view of Annulus (7) 9 ST4000+ 13mm diameter ST4000+ GP 16mm diameter 8

D2395-2

Tiller Drive Actuator spare parts list
The item numbers refer to Figure 12: Tiller Drive Actuator exploded view Item Spare Description Drive module Motor End cap assembly Part No. Q047 Q114 W014 Comments Complete drive unit
Tiller Drive Actuator GP conversion kit (W003)
This GP conversion kit (W003) gives the option of converting the ST4000+ which has the power to helm boats of up to 6,500 kg (14,300 lbs) displacement, to the ST4000+ GP which would push the limit up to 9,000 kg (20,000 lbs) displacement.
1. Planet gear (x4) 2. Shim 3. 'O' ring (x3) 4. Gear annulus 5. Motor 6. Motor spacer 7. Cable tie 8. Motor sleeve 9. End cap assembly

D2397-2

Figure 13. Tiller Drive Actuator GP conversion kit (W003)
Chapter 5: Tiller Drive Actuator GP
5.1 Tiller Drive Actuator GP test
Carry out the passive and active tests detailed in Figure 15. Tiller Drive Actuator GP test flowchart.

D2398-2

Figure 14. Tiller Drive Actuator GP test connections
Start Visually inspect unit OK No Change damaged components Switch on, check thrust rod moves and current less than 2A Check gears, thrust rod, actuator body, motor Change as necessary Switch off. Reverse connections to PSU Switch on. Check thrust rod moves in opposite direction to that of first test and current less than 2A Connect power supply as in Figure 10.

D3731-2

Figure 15. Tiller Drive Actuator GP test flowchart
1. Ram cap 2. Thrust tube 3. Lead screw assembly 4. Planet gear (x4) 5. Shim 6. 'O' ring (x3) 7. Gear annulus 8. Motor 7 Notes B & C
9. Cable tie 10. Motor spacer 11. Motor sleeve 12. End cap assembly 13. Cable clamp 14. Clamp seal 15. Cable clamp nut 16. SeaTalk deck plug

5.2 Disassembly/assembly

Notes: A. Ensure cable clamp nut (15) is unscrewed before undoing the motor sleeve. B. The hole in the gear annulus (7) that accepts the drive gear of the motor (8) is of a different diameter to that of the ST4000+ gear annulus. C. Care should be taken not to cross-thread the annulus (7) when screwing into the thrust tube (2).
Figure 16. Tiller Drive Actuator GP exploded view
15 Note A End view of Annulus (7) 8 ST4000+ 13mm diameter ST4000+ GP 16mm diameter

D2396-2

Tiller Drive Actuator GP spare parts list
The item numbers refer to Figure 16: Tiller drive actuator GP exploded view

Spare Description

Drive module ST4000+ GP kit, including

Part No.

Q086 W003

Comments

Complete drive unit Serves as an upgrade conversion kit for the ST4000+ tiller drive actuator.
Planet gear (x4) Shim O ring (x3) Annulus Motor Cable tie Motor spacer Motor sleeve End cap assembly