Garmin 1.2-Liter Pump Kit, 2-Liter Pump Kit Installation manual

1.2 AND 2.0 L HYDRAULIC PUMP

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.

The hydraulic pump steers your boat by interacting with the hydraulic steering system, based on commands from the autopilot system. The pump is not included in the autopilot corepack box because the type of pump you use with your autopilot is determined by the size and type of steering system on your boat.

Registering Your Device

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Tools Needed

• Safety glasses

• Drill and drill bits

• Wrenches

• Torque wrench (if installing unbalanced kit)

• Wire cutter/stripper

• Screwdrivers: Phillips and flat

• Cable ties

• Marine corrosion inhibitor spray

• Hydraulic hose with machine-crimped or field-replaceable fittings that have a minimum rating of 1000 psi

• Hydraulic T-connectors

• Thread sealant

• Hydraulic bleeding equipment

• Hydraulic fluid

• Unbalanced kit (if installing in a boat with an unbalanced steering cylinder, part number 010-11201-00)

• 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

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 1).

• The pump must be located within 19 in. (0.5 m) of the ECU.

• The cables that connect the pump to the ECU cannot be extended.

• 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.

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 (Calibrating the

Unbalanced Valve, page 3).

Before you can mount the pump, you must select a location (Mounting Considerations, page 1) and determine the correct mounting hardware (Tools Needed, page 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.

Using a drill bit appropriate for the mounting surface and

selected mounting hardware, drill the four holes through the mounting surface.

Secure the pump to the mounting surface using the selected

mounting hardware.

Hydraulic Considerations

NOTICE

Do not attempt to use the autopilot to steer the boat until you bleed all air from each part of the hydraulic system.

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).

Do not use plumber’s tape on any hydraulic fitting. Use an appropriate thread sealant rated for marine use on all pipe threads in the hydraulic system.

Before you connect the pump to the hydraulic lines, you should consult the diagram for the hydraulic system of your boat to find the correct place to add the fittings and hose for the pump.

The pump has two sets of hose-connector fittings to allow for different hose configurations. You can use either set of fittings or a combination of the two. Where necessary, add hydraulic hose.

If your boat has an unbalanced cylinder steering system, you must install the optional unbalanced valve kit (Installing the

Unbalanced Valve Kit, page 1).

Installing the Unbalanced Valve Kit

If your boat has an unbalanced cylinder steering system, you must install the optional unbalanced valve kit. The unbalanced valve kit is available from your Garmin dealer.

Remove the four screws that hold the manifold À to the

pump body Á, and remove the manifold from the pump body.

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Replace the O-rings on the pump body with the O-rings

included in the unbalanced kit Â. Place the unbalanced valve Ã between the pump body and

the manifold, with the O-rings on the unbalanced valve

facing the manifold. Apply a thread-locking compound to the longer screws

included in the unbalanced kit Å, and use the screws to connect the manifold and unbalanced valve to the pump body.

Tighten the screws to 35 lbf-in. (3.95 N-m).

After the hydraulic lines are connected, you must calibrate the unbalanced valve (Calibrating the Unbalanced Valve, page 3).

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.

Single Helm without Power Assist Layout

Dual-Helm without Power Assist Layout

Return line

Starboard line

Shadow Drive

valve

Port line

Pump You should mount the pump horizontally, if

Lower helm

Upper helm

Steering cylinder If your boat has an unbalanced cylinder steering

See the installation instructions provided in the autopilot corepack when installing the Shadow Drive valve.

NOTE: You can install the Shadow Drive valve in either the starboard or port line.

possible. If you cannot mount the pump horizontally, you

must mount it vertically with the pump head connectors facing up.

system, you must install the optional unbalanced valve kit (Installing the Unbalanced Valve Kit,

page 1).

Shadow Drive

valve

Starboard line

Return line

Port line

Pump You should mount the pump horizontally, if

Helm

Steering cylinder If your boat has an unbalanced cylinder steering

™

See the installation instructions provided in the autopilot corepack when installing the Shadow Drive valve.

NOTE: You can install the Shadow Drive valve in either the starboard or port line.

possible. If you cannot mount the pump horizontally, you

must mount it vertically with the pump head connectors facing up.

system, you must install the optional unbalanced valve kit (Installing the Unbalanced Valve Kit,

page 1).

Single Helm with Power Assist Layout

NOTICE

You must install the pump between the cylinder and the powerassist module to function correctly.

You must install the Shadow Drive valve between the helm and the power-assist module to function correctly.

NOTE: You may need to remove the power assist-module to gain access to the fittings, hoses, and bleed-tee fitting.

Starboard line

Power-assist

module

Return line

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