Raymarine E12207, E12208, M81202, M81203 Installation Instructions Manual

H

ydraulic Linear Drive

Installation instructions

E

12207 Type 2 (12 V)

12208 Type 2 (24 V)
M81202 Type 3 (12 V)
M81203 Type 3 (24 V)

Trademarksandregisteredtrademarks

Autohelm,hsb

2

,RayT echNavigator,RayTalk,SailPilot,SeaT alk,SeaT alk

NG

,SeaT alk

HS

andSportpilotareregisteredtrademarksof

RaymarineUKLimited.Seahawk,Smartpilot,PathnderandRaymarineareregisteredtrademarksofRaymarineHoldingsLimited.

Allotherproductnamesaretrademarksorregisteredtrademarksoftheirrespectiveowners.

FairUseStatement

Youmayprintnomorethanthreecopiesofthismanualforyourownuse.Y oumaynotmakeanyfurthercopiesordistributeorusethe
manualinanyotherwayincludingwithoutlimitationexploitingthemanualcommerciallyorgivingorsellingcopiestothirdparties.

Copyright©2010RaymarineUKLtd.Allrightsreserved.

ENGLISH

Documentnumber:81177-5
Date:05-2010

Contents

Chapter1Importantinformation.............................7

Handbookinformation.....................................................7

CertiedInstallation........................................................7

EMCconformance..........................................................8

Technicalaccuracy.........................................................9

Productdisposal.............................................................9

EMCinstallationguidelines.............................................9

Connectionstootherequipment......................................9

Warrantyregistration.......................................................10

Installationprerequisites..................................................10

Chapter2Planning...................................................11

2.1Installationchecklist..................................................12

2.2Drivetypes...............................................................12

2.3Reservoir..................................................................13

2.4Productoverview......................................................13

2.5Typicalsystem..........................................................14

2.6Partssupplied...........................................................15

2.7Partsrequired...........................................................16

2.8Locationandmountingrequirements..........................16

2.9Productdifferences...................................................18

2.10Dimensions.............................................................18

2.11Dimensions.............................................................19

Chapter3Mounting..................................................21

3.1Mountingchecklist.....................................................22

3.2Hydraulicramalignment............................................22

3.3Hydraulicrammounting.............................................24

3.4Steeringsystemconnection.......................................24

3.5Hydraulicpumpmounting..........................................26

3.6Reservoirmounting...................................................27

3.7Fillingthereservoir....................................................27

Chapter4Cablesandconnections.........................29

4.1Generalcablingguidance..........................................30

4.2Clutchconnection.....................................................31

4.3Coursecomputerconnection.....................................32

4.4Post-installationcheck...............................................34

Chapter5Maintenanceandtroubleshoot-

ing..............................................................................35

5.1Maintenancechecks..................................................36

5.2Bleedingthesystem..................................................36

5.3Troubleshooting........................................................37

5.4Raymarinetechnicalsupport......................................38

AppendixATechnicalspecication.......................39

5

6

HydraulicLinearDriveInstallationinstructions

Chapter1:Importantinformation

Handbookinformation

Thishandbookcontainsimportantinformationregardingthe
HydraulicLinearDrives.

Thehandbookisforusewiththefollowingmodels:

PartnumberTypeVoltage

E12207(replaces
M81200)

E12208(replaces
M81201)

M81202Type312V

M81203Type324V

Additionalhandbooks

Thefollowinghandbooksprovideadditionalinformationrelatingto
theoperationoftheHydraulicLinearDrive,andcompatiblecourse
computers.

DescriptionPartnumber

SPXSystemInstallationguide

SPXSystemCommissioning
Instructions

ng

SeaTalk

ReferenceManual

Type212V

Type224V

87072

81287

81300

CertiedInstallation

RaymarinerecommendscertiedinstallationbyaRaymarine
approvedinstaller.Acertiedinstallationqualiesforenhanced
productwarrantybenets.ContactyourRaymarinedealerfor
furtherdetails,andrefertotheseparatewarrantydocumentpacked
withyourproduct.

Warning:Productinstallationand
operation

Thisproductmustbeinstalledandoperatedin
accordancewiththeinstructionsprovided.Failureto
dosocouldresultinpersonalinjury,damagetoyour
boatand/orpoorproductperformance.

Warning:Switchoffpowersupply

Ensuretheboat’spowersupplyisswitchedOFF
beforestartingtoinstallthisproduct.DoNOTconnect
ordisconnectequipmentwiththepowerswitchedon,
unlessinstructedinthisdocument.

Warning:Entrapmenthazard

Thisproductfeaturesmovingpartsthatprovidea
potentialentrapmenthazard.Keepclearofmoving
partsatalltimes.

Warning:DoNOTashtest

DoNOTperformanelectricalashtestonthisproduct.

Importantinformation

7

Warning:Hydraulicuid

Importantsafetyinformation:

•Eyes—Fluidisunlikelytocauseeyeirritationbut

theuseofeyeprotectionisadvised.Ifuidcomes
intocontactwitheyes,rinsewithcopiousamounts
ofwater.

•Skin—Fluidisunlikelytocauseimmediate

irritation,butprolongedandrepeatedcontactmay
beharmfultotheskin.Theuseofnitrileglovesis
recommended.Ifskinisexposedtouidwashthe
contaminatedskinthoroughlywithsoapandwater.

•Ingestion—Unlikelytocauseadversesystemic

healtheffects.IfingestedDONOTINDUCE
VOMITING,andseekmedicalattention.

•Inhalation—Removetheaffectedpersontofresh

air.Ifrecoveryisnotrapidobtainmedicalattention.

Caution:Ensurecleanliness

Absolutecleanlinessisessentialwhenworkingwith
hydraulicsystems.Eventhesmallestdirtparticle
couldpreventthesteeringsystemcheckvalvesfrom
workingcorrectly.

Caution:Structuralstrength

DuringoperationtheHydraulicLinearDriveproduces
aconsiderableamountofforce.YouMUSTmountthe
Hydraulicramtoaverysolidstructure(forexample,
asubstantialframememberofyourvessel).Boththe
structureandthetillerarmorrudderquadrantMUST
becapableofwithstandingthepeaklevelsofthrust
statedintheTechnicalSpecicationinthisdocument.
Insomecasesitmaybenecessarytobuildaspecially
strengthenedframetomountthedriveunit.Consult
thesteeringgearmanufacturerifyouhaveanydoubt
aboutthestrengthofthetillerarmorrudderquadrant.

Warning:Ensuresafenavigation

Thisproductisintendedonlyasanaidtonavigation
andmustneverbeusedinpreferencetosound
navigationaljudgment.Onlyofcialgovernment
chartsandnoticestomarinerscontainallthecurrent
informationneededforsafenavigation,andthe
captainisresponsiblefortheirprudentuse.Itisthe
user’sresponsibilitytouseofcialgovernmentcharts,
noticestomariners,cautionandpropernavigational
skillwhenoperatingthisoranyotherRaymarine
product.

8

EMCconformance

Raymarineequipmentandaccessoriesconformtotheappropriate
ElectromagneticCompatibility(EMC)regulationsforuseinthe
recreationalmarineenvironment.

Caution:Avoiddamagetohydraulic
ram

Anydamagetothehydraulicramwilldamagethe
sealsandallowairintotheunit,reducingperformance
andpotentiallycausingoilleaks.

HydraulicLinearDriveInstallationinstructions

CorrectinstallationisrequiredtoensurethatEMCperformanceis
notcompromised.

Technicalaccuracy

Tothebestofourknowledge,theinformationinthisdocumentwas
correctatthetimeitwasproduced.However,Raymarinecannot
acceptliabilityforanyinaccuraciesoromissionsitmaycontain.In
addition,ourpolicyofcontinuousproductimprovementmaychange
specicationswithoutnotice.Asaresult,Raymarinecannotaccept
liabilityforanydifferencesbetweentheproductandthisdocument.

Productdisposal

DisposeofthisproductinaccordancewiththeWEEEDirective.

TheWasteElectricalandElectronicEquipment(WEEE)
Directiverequirestherecyclingofwasteelectricalandelectronic
equipment.WhilsttheWEEEDirectivedoesnotapplytosome
Raymarineproducts,wesupportitspolicyandaskyoutobeaware
ofhowtodisposeofthisproduct.

EMCinstallationguidelines

Raymarineequipmentandaccessoriesconformtotheappropriate
ElectromagneticCompatibility(EMC)regulations,tominimize
electromagneticinterferencebetweenequipmentandminimizethe
effectsuchinterferencecouldhaveontheperformanceofyour
system

CorrectinstallationisrequiredtoensurethatEMCperformanceis
notcompromised.

ForoptimumEMCperformancewerecommendthatwherever
possible:

•Raymarineequipmentandcablesconnectedtoitare:

–Atleast1m(3ft)fromanyequipmenttransmittingorcables

carryingradiosignalse.g.VHFradios,cablesandantennas.
InthecaseofSSBradios,thedistanceshouldbeincreased
to7ft(2m).

–Morethan2m(7ft)fromthepathofaradarbeam.Aradar

beamcannormallybeassumedtospread20degreesabove
andbelowtheradiatingelement.

•Theproductissuppliedfromaseparatebatteryfromthatused
forenginestart.Thisisimportanttopreventerraticbehavior
anddatalosswhichcanoccuriftheenginestartdoesnothave
aseparatebattery .

•Raymarinespeciedcablesareused.

•Cablesarenotcutorextended,unlessdoingsoisdetailedin
theinstallationmanual.

Note:Whereconstraintsontheinstallationpreventanyof
theaboverecommendations,alwaysensurethemaximum

possibleseparationbetweendifferentitemsofelectrical
equipment,toprovidethebestconditionsforEMCperformance
throughouttheinstallation

Connectionstootherequipment

Requirementforferritesonnon-Raymarinecables

IfyourRaymarineequipmentistobeconnectedtootherequipment
usingacablenotsuppliedbyRaymarine,asuppressionferrite
MUSTalwaysbeattachedtothecableneartheRaymarineunit.

Importantinformation

9

Warrantyregistration

ToregisteryourHydraulicLinearDriveownership,pleasetakeafew
minutestolloutthewarrantyregistrationcardfoundinthebox,or
visitwww.raymarine.comandregisteron-line.

Itisimportantthatyouregisteryourproducttoreceivefullwarranty
benets.Yourunitpackageincludesabarcodelabelindicatingthe
serialnumberoftheunit.Y oushouldstickthislabeltothewarranty
registrationcard.

Installationprerequisites

Beforeinstallingthisproductyoumustadheretotheinstallation
prerequisites.

Thehydraulicramdrivestherudderdirectlyfromthetillerarmor
rudderquadrant.Beforeinstallingthisdriveunit,checkthatthe
vessel’ssteeringsystemcanbebackdrivenfromtherudder.

10

HydraulicLinearDriveInstallationinstructions

Chapter2:Planning

Chaptercontents

•2.1Installationchecklistonpage12

•2.2Drivetypesonpage12

•2.3Reservoironpage13

•2.4Productoverviewonpage13

•2.5Typicalsystemonpage14

•2.6Partssuppliedonpage15

•2.7Partsrequiredonpage16

•2.8Locationandmountingrequirementsonpage16

•2.9Productdifferencesonpage18

•2.10Dimensionsonpage18

•2.11Dimensionsonpage19

Planning

11

2.1Installationchecklist

D11864-1

D11865-1

2.2Drivetypes

Installationincludesthefollowingactivities:

InstallationTask

1Planyourinstallation.

2

Obtainallrequiredequipmentandtools.

3Mountthesystemcomponents.

4Routeallcables.

5

Drillcableandmountingholes.

6Makeallconnectionstoequipment.

7

8

Secureallequipmentinplace.

Completethepost-installationcheck.

Thereare2drivetypes.Eachdrivetypehas2variants(onefor
12Vsystems,onefor24Vsystems).

Althoughthecorefunctionalityofeachdrivetypeisessentiallythe
same,theformfactorofsomeofthecomponentsdiffersasfollows:

Hydraulicram

Type2drive:

Type3drive:

Note:Thedrawingsincludedinthishandbookareforillustration
purposesonly .Theexactshapeofyoursystemcomponentsmay
differfromthoseshown.

12

HydraulicLinearDriveInstallationinstructions

2.3Reservoir

D11866-1

1

2

3

4

5

D11851-1

1

10

2

3

4

5

6

7

8

9

11

2.4Productoverview

TheHydraulicLinearDriveisintendedtooperateavessel’ssteering
mechanismaspartofaRaymarineautopilotsystem.

TheHydraulicLinearDriveisdesignedforvesselswithexisting
mechanicalsteeringsystems,NOThydraulicsteeringsystems.It
ismountedbelowdecksandmovestherudderdirectlybypushing
thetillerarmorrudderquadrant.

TheHydraulicLinearDriveprovidesatotallyisolatedautopilot
steeringsystemconsistingof:

1.Transitscrew—mustberemovedfromthecapbeforeuse.

2.Screwcap—sealmustberemovedfromcapbeforeuse.

3.Filllevel—reservoirmustbelledbetweentheminimumand

maximumlevels.

4.Mountinghole—forsecuringthereservoirtoasuitablepart

ofyourvessel.

5.Tap—controlstheowofhydraulicuidtothepump.

Planning

1.Hydraulicuidreservoir—supplieshydraulicuidtothe

system.

2.Reservoirpipe—transportsthehydraulicuidfromthe

reservoirtothepump.

3.Rampipe—low-pressurelinebetweenthepumpandthe

hydraulicram.

4.Reversinghydraulicpump—powersthehydraulicarm.

5.Motorcables—forconnectingthepumptoacoursecomputer.

6.Rodend—connectsthehydraulicramtoyourvessel’stilleror

rudderquadrant.

13