Thank you for purchasing the Navtec System VI or VII hydraulic panel. It is made of the highest quality materials available. Used with Navtec Backstay Cylinders, Boom Vangs, Cunningham Cylinders, etc. it will add to your sailing pleasure for years to come. System VI and System VII panels are similar except for their valves. System VI uses standard valves which are closed clockwise to hold pressure, cracked to allow pumping, and opened several turns to release.

System VII uses FAC (fast acting control) valves. These valves are lighter and higher flow than the System VI valves. Both System VI & VII use a two speed autoshift pump, a Navtec exclusive. This pump features an adjustable shift point where two of the pump's four cylinders are taken off line, thus reducing the force required on the pump handle by two thirds, as well as reducing output volume by two thirds. Pump output in high speed is.6 cubic inches per cycle (one stroke each way), and .2 cubic inches per cycle in low speed (the same output as the System V pump).

Principles of Operation:
The pressure output of the pump goes into a valve manifold which supplies any number of valves. A single valve is required for each function. The valve includes a pump/release valve, an adjustable relief valve, a flow regulator and a gauge. Each function is under constant relief valve protection and the pressure in the cylinder is indicated at all times by the gauge.

Panel and Reservoir:
System VI hydraulics come in various configurations depending on the number of functions and customer specifications. They are also available as "in-deck" panels to facilitate flush deck mounting, or on other out-of-the cockpit locations. To mount panels, locate position of the panels keeping in mind normal crew positions while pumping as well as rear access for plumbing. Cut the appropriate hole (see table 1) and mount panels using 1/4" stainless steel fasteners. Using high quality marine sealant between panel and bulkhead will prevent annoying leaks. In locating the reservoir, keep in mind that the higher the reservoir is relative to the pump, the more positive the intake pressure will be. High intake pressure will make it easier to prime the pump and will insure full flow to the cylinders at all pump speeds. The reservoir should also be as close the pump as possible, and the reservoir cap should be accessible for easy filling. Note that the reservoir must be vented. The reservoir cap supplied is vented. If replacing the cap or making your own reservoir, be sure that a vent is included. See the PDF file for reservoir capacities and dimensions.

Plumbing:
The connections between pump and valve manifold have already been completed on 1,2, and 3 function systems. Omit step 1 below with these systems. On function and higher systems, the pump panel and valve panel are separated to facilitate mounting the larger panels conveniently within tight cockpit spaces. With these systems, step 1 is necessary. All high pressure plumbing should be 1/4"OD stainless tubing or 3/16" ID hose rated at 5000 psi working pressure or higher. If long runs or high flow rates are anticipated, 1/4"ID hose is preferable. Low pressure hose connecting the reservoir with the pump and manifold should be 3/8"ID with 250 psi working pressure or better. Such plumbing is available from Navtec or a hydraulic plumbing distributor.
1. For separate pump/valve panels, connect pump output (labeled "out") to valve manifold input (stainless steel fitting on end of manifold) again, this connection is already completed for pump/ valve panels. Valve manifold input and return connections may be made of either end of manifold block.
2. Connect either hose barb at the bottom of the reservoir with pump intake hose barb (#I) using low pressure hose supplied. Be sure there is a plastic oil filter in this line. The two hose clamps provided must be used to secure the hoses to the filter hose barbs. Use the 3/8" low pressure hose and plastic "T" provided. Connect the two remaining hose barbs together with low pressure hose and plastic "T" supplied. Connect "T" to remaining barb 'in bottom of reservoir.

Relief Valve Adjustment:
The relief valve is set at the factory to approximately 4000 psi. Adjustment is provided by the l"(25mm) round threaded cap in the aluminum valve block at the back of the panel. Maximum relief setting is 5000 psi. Turning the cap counter-clockwise will lower the sefting. Clockwise will raise it. The adjustment is about l000 psi per complete turn. To determine the setting without tensioning the rig, disconnect any cylinder from the rigging and pump that cylinder until it bottoms and the relief valve lifts which will be evident when continuous pumping fails to raise the gauge pressure. The maximum pressure observed is the relief valve setting.

Flow Regulators:
The maximum rate of oil flow through the release valve is quite fast when compared to older systems. In some cases, such as the backstay, it may be desirable to prevent maximum return flow to allow the cylinder to return slowly. For this reason, flow regulators may be added in each valve block when as lower rate of release is desired. To change the rate of release, simply unscrew plug at top of block (#4). If there is no spring under plug, there is no regulator in the block. Insert regulator spring into block and replace plug (#4). Regulators are available at no charge. They come in various flow speeds with the standard being a 0.015regulator. If higher or slower flow rates are desired, please consult your Navtec dealer.

The Gauge:
The Navtec gauge has a double ended needle so that two scales can be used. The top scale, which reads in thousands of pounds per square inch, is always included and indicates the pressure within the cylinder and the connecting plumbing. A lower scale, which reads in thousands of pounds of force, can be overlaid on the gauge face if the cylinder size is known. These gauge face overlays are available from Navtec at no charge. Please specify cylinder size when ordering. The pressure within the system can be converted to actual force exerted by the cylinder using the formula below: Pressure (lbs/inch2) x Cylinder area (inch2) = Force (lbs) or viewing the table within the PDF file. Gauges have a special backing card that is specially treated to provide night illumination. If "charge" does not provide enough light, recharge by passing flashlight beam slowly over gauge. Navtec also offers backlit gauges as a retrofit option. Contact Navtec for details.

Operating Instructions:
For the pump: Insert pump handle. To operate, pump back and forth until pumping becomes difficult. Pump will shift into low gear automatically at factory preset pressure (around 1900 PSI). The shift pressure may be increased by turning the socket head cap screw in the black cylinder on the rear of the pump (#3) clockwise, and reduced by turning it counter clockwise. A 5/16" allen wrench will be needed.
For the valves: System VII panels use the Fast Acting Control Valve (FAC Valve) which has a triangular shaped handle and is significantly wider than the System VI valve. Both are non-interconnected valves, meaning that one function can be released while a second is being pumped. FAC valves have a higher flow rate than System VI valves.
System VI panels: To pressurize a cylinder, open the valve controlling that cylinder approximately 1/4 turn and pump. To release pressure, open the same valve approximately 1 112 turns to the release position. If continually operating a function (such as a mainsheet), the valve can be positioned in the pump position, close to the release position, and left there without loss of pressure. As the valve goes from pump to release position, a change in handle resistance will be felt. If the cylinder is to be left at the same pressure (as would be the case in most functions), close the valve to avoid changing pressure when pumping other cylinders. At times, it may be desirable to release several cylinders at the same time. So as not to overload the low pressure return hose, it is best not to release more than two at a time.
System VII panels: To pressurize a cylinder rotate handle one-quarter turn clockwise from vertical and pump. Pressure will be maintained when valve is in pump position. To hold pressure, set valve handle vertical. To release pressure, rotate handle one-quarter turn counter-clockwise from vertical.
Four-way Valves: For double-acting cylinders or two cylinders pushing and pulling.
1. To maintain pressure, close both valves fully.
2. To extend or retract cylinder, open one valve fully or set to dump, and set other to pump. Pump. Close both or set to hold to maintain pressure. To move in opposite direction, reverse valve positions and pump.
It is important to recognize that there is no intermediate position as with System VI and FAC valves. 4-way valves must be fully open or fully closed for proper operation.

Oil and Filter:
Use #10 hydraulic oil or #10 non-detergent motor oil. (Detergents cause foaming). Never use brake fluid as it will attack the seals. Oil should be checked periodically for cleanliness. Any particulate matter in the oil will decrease the life of the moving parts and may also cause immediate malfunctions. The oil filter should be changed if there is any indication of pump skipping due to oil starvation.

Oil Level:
Your system has been supplied with a reservoir appropriate for the original installation (assuming number and size cylinders were known at time of original order). When increasing either the number or size of cylinders installed, reservoir capacity may also increase. To determine, add the volume of each installed cylinder or vang as shown in Table 11 on the PDF file. The proper reservoir is the next larger volume. For special stroke length cylinders calculate volume by multiplying cylinder area by stroke length. The reservoir should be 3/4 full when all cylinders are fully extended. If the system does not pump, check oil level in reservoir to insure adequate supply. Check to be sure cap is a special breather cap.

Bleeding the System:
After installing the panel, cylinders and plumbing, oil should be added to the reservoir and the system bled of all air. Each cylinder and line must be bled separately.
Step 1 - Open valve fully on the SYSTEM VI or set to dump on the System VII.
Step 2 - With hose attached to cylinder, extend cylinder fully. If there is air pressure in lower chamber, the cylinder will extend automatically.
Step 3 - Disconnect hose at cylinder. Note: always disconnect slowly to allow any remaining pressure to decrease slowly. Be prepared for possible oil drips.
Step 4 - Set valve to pump and pump, holding the hose end in a can to collect oil. When oil is bubble-free, reconnect hose to cylinder.
Step 5 - Pump cylinder all the way down (with cylinder detached from rigging). Then open release valve and allow cylinder to return fully.
Step 6 - Repeat above procedure for each cylinder and line.

Cylinders:
Standard Navtec cylinders are equipped with an air-pressure return. This return is pressurized through the tire valve at the clevis end of the cylinder. A bicycle pump or service station air hose can be used to charge the return up to 1 00 psi. The air pressure should be adjusted to give the desired rate of return. WARNING: Once charged, do not attempt to disassemble the cylinder. This should be done only by an authorized Navtec hydraulic service center or Navtec Inc.