Raymarine E12207, E12208, M81202, M81203 Installation Instructions Manual

Download

Page 1

ydraulic Linear Drive

Installation instructions

12207 Type 2 (12 V)

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

Page 2

Page 3

Trademarksandregisteredtrademarks

Autohelm,hsb

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

,SeaT alk

andSportpilotareregisteredtrademarksof

RaymarineUKLimited.Seahawk,Smartpilot,PathnderandRaymarineareregisteredtrademarksofRaymarineHoldingsLimited.

Allotherproductnamesaretrademarksorregisteredtrademarksoftheirrespectiveowners.

FairUseStatement

Youmayprintnomorethanthreecopiesofthismanualforyourownuse.Y oumaynotmakeanyfurthercopiesordistributeorusethe manualinanyotherwayincludingwithoutlimitationexploitingthemanualcommerciallyorgivingorsellingcopiestothirdparties.

ENGLISH

Documentnumber:81177-5 Date:05-2010

Page 4

Page 5

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

Page 6

HydraulicLinearDriveInstallationinstructions

Page 7

Chapter1:Importantinformation

Handbookinformation

Thishandbookcontainsimportantinformationregardingthe HydraulicLinearDrives.

Thehandbookisforusewiththefollowingmodels:

PartnumberTypeVoltage

E12207(replaces M81200)

E12208(replaces M81201)

M81202Type312V

M81203Type324V

Additionalhandbooks

Thefollowinghandbooksprovideadditionalinformationrelatingto theoperationoftheHydraulicLinearDrive,andcompatiblecourse computers.

DescriptionPartnumber

SPXSystemInstallationguide

SPXSystemCommissioning Instructions

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

Page 8

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.

EMCconformance

Raymarineequipmentandaccessoriesconformtotheappropriate ElectromagneticCompatibility(EMC)regulationsforuseinthe recreationalmarineenvironment.

Caution:Avoiddamagetohydraulic ram

Anydamagetothehydraulicramwilldamagethe sealsandallowairintotheunit,reducingperformance andpotentiallycausingoilleaks.

HydraulicLinearDriveInstallationinstructions

Page 9

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

Page 10

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.

HydraulicLinearDriveInstallationinstructions

Page 11

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

Page 12

2.1Installationchecklist

D11864-1

D11865-1

2.2Drivetypes

Installationincludesthefollowingactivities:

InstallationTask

1Planyourinstallation.

Obtainallrequiredequipmentandtools.

3Mountthesystemcomponents.

4Routeallcables.

Drillcableandmountingholes.

6Makeallconnectionstoequipment.

Secureallequipmentinplace.

Completethepost-installationcheck.

Thereare2drivetypes.Eachdrivetypehas2variants(onefor 12Vsystems,onefor24Vsystems).

Althoughthecorefunctionalityofeachdrivetypeisessentiallythe same,theformfactorofsomeofthecomponentsdiffersasfollows:

Hydraulicram

Type2drive:

Type3drive:

Note:Thedrawingsincludedinthishandbookareforillustration purposesonly .Theexactshapeofyoursystemcomponentsmay differfromthoseshown.

HydraulicLinearDriveInstallationinstructions

Page 13

2.3Reservoir

D11866-1

D11851-1

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.

Page 14

7.Pushrod—extendsoutofthehydraulicramcasingtocontrol

D11894-1

D11853 -1

SMARTPILOT

thetillerarmorrudderquadrant.

8.Hydraulicram—aself-containedautopilotsteeringcylinder

withaload-limitingsystemandbuilt-inclutch.

9.Pumppipes—high-pressurelinesbetweenthepumpandthe

hydraulicram.

10.Clutchcable—forconnectingthehydraulicram’sclutchto

thecoursecomputerclutchconnections.Theclutchallows friction-freesteeringwhentheautopilotisnotinuse.

11.Mountingfoot—formountingthehydraulicramtoasuitable

partofyourvessel.

Rudderreferenceoption

Thecoursecomputerissuppliedwitharudderreferencesensor, whichprovidesenhancedperformanceforautopilotsystems.

2.5Typicalsystem

Thedrivecomponentsconnecttoacoursecomputeraspartofan autopilotsystem.

ThefollowingdiagramillustratesatypicalSPX-30autopilotsystem:

Forinformationoninstallingandconnectingtherudderreference optionrefertotheinstructionsthataccompanythecoursecomputer.

1.Autopilotcontroller.

2.SPXcoursecomputer .

3.Driveunit.

4.Fluxgatecompass.

HydraulicLinearDriveInstallationinstructions

Page 15

2.6Partssupplied

D11854 -1

2 3 4 5 6

1.HydraulicLinearDrivecomponents,consistingof:

•Hydraulicuidreservoir.

•Pump.

•Hydraulicram.

2.Tillerpinassembly,consistingof:

•Tillerpin.

•R-clip.

•Locknut.

•Washer(quantity:2).

3.Hydraulicrammountingscrewpack,consistingof:

•Bolts(quantity:4)

•Washers(quantity:4).

•Locknuts(quantity:4).

4.Pumpmountingscrewpack,consistingof:

•Bolts(quantity:2)

•Washers(quantity:2).

•Locknuts(quantity:2).

5.Installationinstructions.

6.Hydraulicuidtransitcontainer.

Planning

Page 16

2.7Partsrequired

2.8Locationandmountingrequirements

Additionalpartsrequired,NOTsuppliedwiththeproduct.

Thefollowingadditionalpartsarerequiredfortheinstallationofthe HydraulicLinearDrive:

•Suitableboltsandassociatednutsandwashersforsecuringthe reservoirtoasuitablepartofyourvessel.Quantityrequired:2.

•Suitableboltsandassociatednutsandwashersforsecuringthe pumptoasuitablepartofyourvessel.Quantityrequired:2.

•Suitablecableandelectricalconnectorsforconnectingand extendingthemotorandclutchcables.

Hydraulicram

Locationandmountingrequirements:

•MUSTbemountedonaverysolidstructure(forexample,a substantialframememberofyourvessel).Thedriveproducesa considerableamountofforce,soyouMUSTensurethatboththe structureandyourtillerarmorrudderquadrantcancopewiththe peaklevelsofthruststatedintheTechnicalSpecicationinthis document.Insomecasesitmaybenecessarytobuildaspecially strengthenedframetomountthedriveunit.Consultthesteering gearmanufacturerifyouhaveanydoubtaboutthestrengthofthe tillerarmorrudderquadrant.

•TheType2drivemaybemountedhorizontallyorvertically.

•TheType3driveMUSTbemountedhorizontallywithitsmounting footonahorizontalsurface.TheswiveljointdoesNOThave sufcientmovementtopositionthefootvertically .

•ThehydraulicrammustNOTfoulanypartofthevessel’sstructure orquadrantthroughoutitsentirerangeofmovement.

•MUSTbemountedinalocationallowingsufcientclearancefor themountingpintoberemovedifrequired.

•MUSTbemountedwithsufcientclearanceattherearoftheram unitforthehydraulicpipes.Youmustallowatleast17cm(6.7in) clearanceattherearoftheunitfortheextrudingpipes.

•MUSTbettedinadryarea,freeofbilgewater(theramisNOT waterproof).

•MUSTbeaccessibleforfutureservicing.

•ThesuppliedM8boltsandwashersaresuitableformounting thehydraulicramtoasurfacebetween1.2cm(0.47in)and2.4 cm(0.94in)thick.Largerboltsandwashersarerequiredfor athickersurface.

Thefollowingdiagramsillustratethecorrectdriveorientation, showingaviewfromabovewiththearrowindicatingtheaftdirection:

HydraulicLinearDriveInstallationinstructions

Page 17

Type2:

D11899-1

D11855-1

Type3:

Hydraulicpump

Locationandmountingrequirements:

•MUSTbemountedonasolidstructuretoavoidvibrationthat coulddamagethehydraulicpipes.

•MUSTbemountedonadryhorizontalsurface,clearofspray waterandpossibleimmersion.

•Excessivetemperature,vibrationandfumesintheatmosphere candrasticallyreducemotorbrushlife.

•MUSTbemountedleveltoorabovethehydraulicram,toprevent airfromcollectingintheram.

•MUSTbeaccessibleforfutureservicing.

Reservoir

Locationandmountingrequirements:

•MUSTbemountedvertically,ideallytoabulkhead.

•MUSTbemountedatleast150mm(6in)ABOVEthehydraulic pumpandhydraulicram,toensureagoodsupplyofuidtothe system.

•MUSTbeaccessibleforhydraulicuidtop-upsandrells.

•RaymarinerecommendstheuseofM8boltsandsuitablenuts andwasherstosecurethereservoirtothevessel.

Pipes

ThepipestransportuidandpressurearoundtheHydraulicLinear Drivesystem.Thesystemissuppliedpre-plumbed,pre-lled,and pre-bled,withjustthereservoirempty.Howeveryoumustobserve thefollowingwhenhandlingandpositioningthepipes:

•DoNOTallowacutebendsinthepipes.Theminimumbend radiusforthepipesis7.6cm(3in).

•PipesmustNOTtouchanypartofthevessel.

•Ensuretherearenokinksinthepipes.

•Ensurepipesarenotcutorchaffed.

Planning

Page 18

2.9Productdifferences

D11868-1

147.75 mm (5.82 in)

101.5 mm (4 in)

386.5 mm (15.22 in)

573.5 mm (22.58 in)

108.8 mm

(4.28 in)

116.0 mm (4.57 in)

2.10Dimensions

FactorstoconsiderwhenreplacinganexistingType2drive (M81200,M81201)withanewType2drive(E12207,E12208).

Thereareanumberofimportantdifferencesbetweenthe2drives:

•TheexistingType2hydraulicram(M81200,M81201)hasa5 degreetoleranceofmovementintheverticalplane.ThenewT ype 2hydraulicram(E12207,E12208)hasa10degreetolerance.

•FortheexistingType2drive(M81200,M81201)thepipesthat transportedthehydraulicuidtotheramunitwereconnectedto thetopoftheunit.FortheNEWType2drive(E12207,E12208), thepipesconnecttotherearoftheunit.Y oumustallowatleast 17cm(6.7in)clearanceattherearoftheunitfortheextruding pipes.Theminimumbendradiusforthepipesis7.6cm(3in).

•Thenewdrive(E12207,E12208)canbemountedhorizontally orvertically.

•Thehydraulicuidreservoirsuppliedwiththenewdrive(E12207, E12208)isadifferentsizeandshape.

Type2drive

1.Hydraulicramatmidstrokeposition.

HydraulicLinearDriveInstallationinstructions

Page 19

Type3drive

D11856-1

101.6 mm (4 in)

152 mm (6 in)

80 mm

(3.15 in)

457 mm (18 in)

690 mm (27.15 in)

D11901-1

14 8.7 mm (5.85 in)

55 .3 m m

(2.17 in)

9.5 mm (0.37 in)

2.11Dimensions

Reservoirdimensions.

1.Hydraulicramatmidstrokeposition.

Planning

Page 20

HydraulicLinearDriveInstallationinstructions

Page 21

Chapter3:Mounting

Chaptercontents

•3.1Mountingchecklistonpage22

•3.2Hydraulicramalignmentonpage22

•3.3Hydraulicrammountingonpage24

•3.4Steeringsystemconnectiononpage24

•3.5Hydraulicpumpmountingonpage26

•3.6Reservoirmountingonpage27

•3.7Fillingthereservoironpage27

Mounting

Page 22

3.1Mountingchecklist

D11857-1

90º

3.2Hydraulicramalignment

MountingtheHydraulicLinearDrivesysteminvolvesthefollowing tasks:

MountingTask

1Ensureyouhavereadandunderstoodthe2.8Locationandmounting

requirements.

2Alignthehydraulicram.

Securethehydraulicramtoyourvessel.

Connectthehydraulicramtothevessel’ssteeringsystem.

Performasteeringchecktoensurethehydraulicramismounted correctly.

6Mountthehydraulicpump.

Mountthereservoir .

Fillthereservoirwithhydraulicuid.

Whenmountingthehydraulicramensureitiscorrectlyaligned.

Hydraulicram

•Thehydraulicrammustbeatrightanglestothemountingsurface.

•Thehydraulicrammustbeinthemidstrokepositionandatright anglestothetillerarmwhentherudderisatmidships.

Thefollowingdiagramillustratescorrectalignmentofthehydraulic ram.Thehydraulicraminthetophalfofthediagramshowsthe viewfromastern.Thebottomhalfofthediagramshowstheview fromabove.Thegreyarrowindicatestheaftdirection.

1.Hydraulicramatthemidstrokeposition.

2.Tillerarmradius,asfollows:

•Type2:180mm(7.1in).

•Type3:267mm(10.5in).

HydraulicLinearDriveInstallationinstructions

Page 23

Pushrodandtillerarm

D11900-1

10º

D11858-1

5º

Thepushrodmustbeaccuratelyalignedwiththetillerarmplane ofrotation.Theballendttingonlyallowsthefollowingdegreesof misalignmentbetweenthepushrodandtillerarmplaneofrotation:

•Type2drive:10degrees.

•Type3drive:5degrees.

Thefollowingdiagramsillustratethedegreelimitforeachtypeof drive.Thediagramsshowaviewfromastern.

Type2:

Type3:

Note:Accurateangularalignmentofthehydraulicramis

extremelyimportant.Y oumustNOTexceedthespecieddegree alignmentlimitsunderanycircumstances.

Mounting

Page 24

3.3Hydraulicrammounting

D11895 -1

56 mm

26 mm

3.4Steeringsystemconnection

Mountthehydraulicramassecurelyaspossibletoensureit performsreliablyandremainscorrectlyaligned.

•Beforemountingthehydraulicram,refertotheguidanceprovided inthe2.8Locationandmountingrequirementssection.

•Drill4holesforthemountingfoot(eachholemustbe8.8mm (0.34in)diameter).

•Attachthemountingfoottotheappropriatepartofyourvessel usingthesuppliedbolts,washers,andnuts.

•Tightentheboltsto17Nm(12.5lbft)torque.

Therodendofthehydraulicrammustbeconnectedtothevessel’s tillerarmorrudderquadrant.

Beforeconnectingthehydraulicramtothesteeringsystem,ensure thatyourvessel’stillerarmorrudderquadrantcancopewiththe peakthruststatedintheTechnicalSpecication.

Useoneofthefollowingmethodstoattachthepushrodtothe rudderstock:

•Independenttillerarm—thisistherecommendedmethod.

•Steeringlinkagetillerarmorrudderquadrant—insome

cases,youmaybeabletoattachthepushrodtothesame tillerarmorrudderquadrantusedbythemainsteeringlinkage. Consultthesteeringmanufacturerbeforeyoumodifytherudder quadrant.

Thefollowingdiagramillustratestheconnection:

1.Tillerpin.

2.Tillerarmorrudderquadrant.

Attachingtherodend

Note:Thesuppliedtillerpinissuitableforaquadrantthickness

of12mm(0.47in)to16mm(0.63in).

1.Attachthetillerpintothetillerarm,asshowninthediagram below:

HydraulicLinearDriveInstallationinstructions

Page 25

i.Insertthetillerpinthroughthetillerarmholesothatthe

D11859-1

angeremainsabovethearm.

ii.Ensurethetillerpinisatighttinthetillerarm.Raymarine

recommendstheuseofasuitableadhesivearoundthetiller pin.

iii.Usethesuppliedlockwasherandfullytightenthelocknutto

27Nm(20lbft).

2.Attachtherodendtothetillerpin,asshowninthediagram below:

i.Placetherodendontothetillerpin. ii.SecurewiththesuppliedwasherandR-clip.

1.R-clip.

2.Washer.

3.Rodend.

4.Flange.

5.Tillerarm.

6.Lockwasher.

7.Locknut.

8.Tillerpin.

9.Holediameter,asfollows:

•Type2:12.2mm(0.48in).

•Type3:20mm(0.78in).

Note:Itmaybenecessarytodrillaholeinthetillerarm.Thehole mustbeofthediameterspeciedabove.

Steeringcheck

Oncethehydraulicramismountedyoumustperformasteering checktoensuretheramhasbeenmountedcorrectly.

Turnyourvessel’ssteeringwheelfromhardovertohardoverand checkthefollowing:

•Angularmovementoftheballendttingislessthan10degrees fortheType2drive,or5degreesfortheType3drive.Ifthis limitisexceededthedrivewillcatchonthetillerarmorrudder quadrantandtheballjointwillbind.

•Ensurenopartofthedriveunitfoulsyourvessel’sstructurewhen thepushrodmovesinandout.

•Ensurethatthetotalruddermovementislimitedto+/-35degrees bythesteeringsystemendstops,ratherthanthelineardrive’s endlimits.

Mounting

Page 26

35º35º

D11860-1

1.Steeringsystemendstop:–35degrees.

2.Steeringsystemendstop:+35degrees.

Caution:T otalruddermovement

Ensurethattheruddermovementislimitedbythe steeringendstopsbeforethepushrodreachesits endstop.Failuretodothiscoulddamagethedrive andwillinvalidatethewarranty.

3.5Hydraulicpumpmounting

Thehydraulicpumpmustbemountedinasuitablelocationto ensurereliableperformance.

•Beforemountingthehydraulicpump,refertotheguidance providedinthe2.8Locationandmountingrequirementssection.

•Drill2mountingholes.

•Securethepumptotheappropriatepartofyourvesselusing suitablestainlesssteelbolts,washersandlocknuts.

•Fullytightenthenutstominimizevibration.

HydraulicLinearDriveInstallationinstructions

Page 27

3.6Reservoirmounting

3.7Fillingthereservoir

Thereservoirmustbemountedonabulkheadasfarabovethe pumpandhydraulicramaspossible.

•Beforemountingthereservoir,refertotheguidanceprovidedin the2.8Locationandmountingrequirementssection.

•Securethereservoirtotheappropriatepartofyourvessel,using themountingholesprovided.Usesuitablestainlesssteelbolts, washersandlocknuts.

Thehydraulicuidreservoirissuppliedemptyandmustbelledto thecorrectlevelwiththesuppliedhydraulicuid.

DoNOTattempttomoveoroperatethehydraulicpushrodbefore completingthefollowingsteps:

1.Thereservoiristtedwithaspecialcapfeaturingabreather hole,whichissealedfortransitpurposes.Removethetransit screwandsealfromthecaptoopenthebreather.Retainthe screwandsealforfutureuse.

2.Fillthereservoirwiththesuppliedhydraulicuidtoalevel betweentheminimumandmaximumindicatorlines.

3.Turnthetaptothe“ON”position(tapshouldbepointingupward).

Mounting

Page 28

HydraulicLinearDriveInstallationinstructions

Page 29

Chapter4:Cablesandconnections

Chaptercontents

•4.1Generalcablingguidanceonpage30

•4.2Clutchconnectiononpage31

•4.3Coursecomputerconnectiononpage32

•4.4Post-installationcheckonpage34

Cablesandconnections29

Page 30

4.1Generalcablingguidance

Minimum bend of cable 100 mm (4 in) radius

Minimum bend 200 mm (8 in) diameter

Cabletypesandlength

Itisimportanttousecablesoftheappropriatetypeandlength

•Unlessotherwisestateduseonlystandardcablesofthecorrect type,suppliedbyRaymarine.

•Ensurethatanynon-Raymarinecablesareofthecorrectquality andgauge.Forexample,longerpowercablerunsmayrequire largerwiregaugestominimizevoltagedropalongtherun.

Alwaysroutedatacablesasfarawayaspossiblefrom:

•otherequipmentandcables,

•highcurrentcarryingacanddcpowerlines,

•antennae.

Strainrelief

Ensureadequatestrainreliefisprovided.Protectconnectorsfrom strainandensuretheywillnotpulloutunderextremeseaconditions.

Routingcables

Cablesmustberoutedcorrectly ,tomaximizeperformanceand prolongcablelife.

•DoNOTbendcablesexcessively .Whereverpossible,ensurea minimumbendradiusof100mm.

•Protectallcablesfromphysicaldamageandexposuretoheat. Usetrunkingorconduitwherepossible.DoNOTruncables throughbilgesordoorways,orclosetomovingorhotobjects.

•Securecablesinplaceusingtie-wrapsorlacingtwine.Coilany extracableandtieitoutoftheway .

•Whereacablepassesthroughanexposedbulkheadordeckhead, useasuitablewatertightfeed-through.

•DoNOTruncablesneartoenginesoruorescentlights.

Cableshielding

Ensurethatalldatacablesareproperlyshieldedthatthecable shieldingisintact(e.g.hasn’tbeenscrapedoffbybeingsqueezed throughatightarea).

Warning:Ensurecorrectvoltage

DoNOTconnecta24Vpumptoacoursecomputer thatonlysupports12V .Forcoursecomputersthat supportboth12Vand24Vensurethatthecorrect voltageisselectedfortheclutchterminal.

HydraulicLinearDriveInstallationinstructions

Page 31

4.2Clutchconnection

D11897-1

D11898-1

2 3

Theclutch(bypassvalve)onthehydraulicramunitmustbe connectedtotheclutchterminalsonthecoursecomputer,and asuitableground.

Theclutchisusedtobypassthehydraulicramandoperatethe steeringsystemmanuallywhenthereisaproblemwiththeautopilot system.Theclutchislocatedattherearofthehydraulicramunit:

1.Theitemlabelled“1”inthediagramaboveistheclutch.

Toconnecttheclutchandgroundcablesyoumustremovethe clutchhousing,usingasuitablescrewdriver.Theclutchhousing containsthe3terminalsfortheclutchandgroundconnections:

ItemDescriptionSuitablecable

GroundconnectionMinimum4mm

AWG)coppercable.

Pin1:POSITIVEMinimum1.5mm

AWG)coppercable.

Pin2:NEGATIVEMinimum1.5mm

AWG)coppercable.

(12

(16

Cablesandconnections31

housingandsecurethescrewusing0.5Nm(0.37lbft)torque.

Oncethecableshavebeenconnectedre-assembletheclutch

Page 32

4.3Coursecomputerconnection

D11896-1

GRO UND

PO WER, 15 AMP

12V

24V

RUDDE R

CLUTCH

PO WERBMOTOR

2 3 4 5 6 7 8

TheHydraulicLinearDrivemustbeconnectedtoanSPX-30course computer.

Hydraulic Linear

Item

Drive

2Hydraulic

ramclutch (+)

3Hydraulic

ramclutch (-)

4Power

6Pump

motor(+)

Pump motor(-)

9Hydraulic

ramground connection

Course computerDescription

Clutch voltage selector

Adjustthevoltagesettingtomatchthe voltageratingspeciedontheHydraulic ramclutch.

switch

Clutch(+)ConnectthePOSITIVEterminalofthe

hydraulicram’sclutchtothecourse computer’sPOSITIVEclutchterminal.

Clutch(-)ConnecttheNEGATIVEterminalofthe

hydraulicram’sclutchtothecourse computer’sNEGATIVEclutchterminal.

ConnecttoPOSITIVEterminalofpower

input(+)

supply(forexample,viadistribution panel).

Power input(-)

ConnecttoNEGATIVEterminalofpower supply(forexample,viadistribution panel).

Motor(+)ConnectthePOSITIVEterminalofthe

pumptothecoursecomputer’sMOTOR Aterminal.

Motor(-)ConnecttheNEGATIVEterminalofthe

pumptothecoursecomputer’sMOTOR Bterminal.

Ground connection

Connecttoadedicatedearthingplatein contactwiththewater,ortothenegative poleofthebattery.

Connecttothesameearthasthecourse computer.

HydraulicLinearDriveInstallationinstructions

Page 33

Note:Forcompleteconnectionandinstallationinstructionsfor thecoursecomputerrefertothedocumentationthataccompanies theunit.

Cableextensions

YoumayneedtoextendtheHydraulicLinearDrivecables.

•Clutchcable(fromhydraulicramtocoursecomputerclutch connection)—useminimum1.5mm

(16AWG)coppercable.

•Motorcable(fromHydraulicpumptocoursecomputermotor connection)—usethefollowingtabletodeterminethecorrect cablegaugerequired:

DrivetypeCablelength

Type2(12V)Upto5m(16ft)

Upto7m(23ft)

Upto16m(52ft)

Type2(24V)Upto3m(10ft)

Upto5m(16ft)

Upto10m(32ft)

Upto16m(52ft)

Type3(12V)Upto5m(16ft)

Upto7m(23ft)

Upto16m(52ft)

Type3(24V)Upto5m(16ft)

Upto7m(23ft)

Upto16m(52ft)

Cablegauge (AWG)

106

810

616

124

106

810

616

810

616

425

106

810

616

Cablegauge (mm

Usesuitableelectricalconnectorsorjunctionboxestoconnectthe HydraulicLinearDrivecablestothecableextensions.

Note:DoNOTuntwistthepumpcablesorremovethe suppressionferrite.

)

Cablesandconnections33

Page 34

4.4Post-installationcheck

Checkthefollowingpointsafterinstallingthedriveandconnecting thecoursecomputer:

Check

2Ensurethatthehydraulicramiscorrectlyaligned:

3Ensurethatthehydraulicramrodendis:

4Ensurethatthemotorandclutchcablesarecorrectlyroutedand

Ensurethatthehydraulicram’smountingfootiswell-securedtoa substantialpartofthevessel.

•Mountingfootcorrectlyorientated.

•Drivemountedatrightanglestotillerarminamid-strokeposition whenrudderisinamidshipposition.

•Pushrodaccuratelyalignedwithtillerarmplaneofrotation (deviationlessthan10degreesforType2drives,or5degrees forType3drives).

•Securelyattachedtothetillerarmorrudderquadrant.

•Attachedattherecommendedtillerarmradiusforthevessel.

securelyconnectedtothecoursecomputer.

Ensurethatallhydraulicpipesaresecurelyconnectedwithnoleaks.

Ensurethatthereservoirislledwithhydraulicuidtothecorrectlevel.

Ensurethatthetransitscrewandsealhavebeenremovedfromthe reservoircap.Ensurethatthecapisttedsecurelytothereservoir.

Ensurethatthereservoirtapisinthe“ON”position.

Check

10Ensurethecoursecomputer’sclutchswitchisinthecorrectposition

Onceyou’vecompletedthecheckslistedaboveyoushouldperform anautopilotsteeringcheck,toensurethattheautopilotcontrolhead, coursecomputeranddriveunitareconnectedandcommunicating correctly.Refertothehandbookthataccompaniesyourcourse computer.

Ensurethatyou’vecompletedthehand-steeringcheck(seeSteering

check).

(referto4.3Coursecomputerconnection).

HydraulicLinearDriveInstallationinstructions

Page 35

Chapter5:Maintenanceandtroubleshooting

Chaptercontents

•5.1Maintenancechecksonpage36

•5.2Bleedingthesystemonpage36

•5.3Troubleshootingonpage37

•5.4Raymarinetechnicalsupportonpage38

Maintenanceandtroubleshooting

Page 36

5.1Maintenancechecks

5.2Bleedingthesystem

Regularmaintenanceisrequiredtoensureoptimumoperation.

Regularchecks

•Checkallmountingsaresecure,especiallythehydraulicram mountingfoot.

•Checkthetillerpinissecurelyconnectedtorodendandtiller armorrudderquadrant.

•Checkhydraulicramalignment,asdescribedinthishandbook.

•Checkallpipesforanysignsofwearordamage.

•Checkallcablesandelectricalconnectionsforanysignsofwear ordamage.

•Lubricatetherodend.Useonlyagoodqualitymarinegreasethat iscompatiblewithnitrileseals.

Annualchecks

•Checkthehydraulicuidlevel.Theuidinthereservoirshould bebetweenthe“minimum”and“maximum”levelsindicatedon thereservoir .T op-uptheuidifnecessary,usingasuitableoilas detailedinAppendixAT echnicalspecication.

•ChecktheHydraulicLinearDrivesystemforexternaloilloss, whichmayindicatethatthesystemneedsbleeding.

Note:Raymarinerecommendsthatbleedingthesystemis undertakenbyanauthorizedRaymarinedealer.

Beforecommencingensuretheoilandanystoragecontainersare cleanandfreeofcontamination.

1.Ensurethereservoirtapisinthe“ON”position.

2.Pushthehydraulicrodinsothatitisfullyretracted.

3.Fillthereservoirandslackenthepipesconnectedtothe hydraulicramunit.DoNOTdisconnectthepipes.

4.Re-tightenthepipesoncetheoilemergesfromthettings.

5.Runthepumpinordertodirectowtothehydrauliccylinder ports.

6.Energisethecylindersolenoidandslowlypullthehydraulicrod outuntilitisfullyextended.Observetheoillevelinthereservoir andtopupifnecessary,usingtheoilrecommendedinAppendix

AT echnicalspecication.

Theoillevelwillrisewhentherodisretractedandmayoverow .

7.Fullyretracttherod,againobservingtheoillevelinthereservoir andtoppingupasneeded.Repeatuntilnomoreaircanbe seentoberisingintothereservoirandthepumptakesover. De-energisethesolenoid.

8.T ocompletethebleeding,energisethecylindersolenoidagain andrunthepumpinbothdirectionstoextendandretract thehydraulicrod.Notethatthecylindermayneedmanually assistingatrsttopurgeanyremainingairinthesystem.

9.T opupthereservoirifnecessarytothelevelindicated.

HydraulicLinearDriveInstallationinstructions

Page 37

5.3Troubleshooting

PotentialproblemswiththeHydraulicLinearDrivesystemandpossiblecausesandsolutionsaredescribedhere.

ProblemPossiblecausesPossiblesolutions

Motordoesnotrun.

Motorruns,buterraticornohydraulicrod movement.

Excessivepumpnoise.

Themotorhasnopowersupply.

Themotorisnotreceivinginstructions fromthecoursecomputer.

Themotorbrushesareworn.

Theclutchinthehydraulicramunitisnot workingcorrectly.

Excessiveairinthehydraulicramunit.

Drivecoupling.

Motormaybedamagedorfaulty.Checkthemotorfordamage.

Excessiveairinthehydraulicramunit.

Drivecoupling.

Checkallelectricalconnections.

Checktheconnectionbetweentheautopilotcontrolheadandthecourse computer,andbetweenthecoursecomputerandthepump.

Checkmotorbrushes.Ifnecessarycontactyourdealerforreplacement brushes.

Checkforclutchoperation.

Checkforairinthehydraulicramunit.Externaloillossmayindicatethis. Thesystemmayneedbleeding.

Contactyourdealerandaskthemtocheckthemotordrivecoupling.The dealershouldensurethatthecouplingisinplaceandalignedwiththe motordrivetang.

Checkforairinthehydraulicramunit.Externaloillossmayindicatethis. Thesystemmayneedbleeding.

Contactyourdealerandaskthemtocheckthemotordrivecoupling.The dealershouldensurethatthecouplingisinplaceandalignedwiththe motordrivetang.

Note:Undernocircumstancesdismantletheunitunlessitis certainthatthefaultisinternal.Doingsowillallowairintothe cylinder,requiringtheunittobebled.

Maintenanceandtroubleshooting

Page 38

5.4Raymarinetechnicalsupport

Raymarineprovidesacomprehensivecustomersupportservice,on theworldwideweb,throughourworldwidedealernetworkandby telephonehelpline.Ifyouareunabletoresolveaproblem,please useanyofthesefacilitiestoobtainadditionalhelp.

Websupport

Pleasevisitthecustomersupportareaofourwebsiteat:

www.raymarine.com

ThiscontainsFrequentlyAskedQuestions,servicinginformation, e-mailaccesstotheRaymarineT echnicalSupportDepartmentand detailsofworldwideRaymarineagents.

Telephonesupport

IntheUSAcall: +16038815200extension2444

IntheUK,Europe,theMiddleEast,orFarEastcall: +44(0)2392714713

Productinformation

Ifyouneedtorequestservice,pleasehavethefollowinginformation tohand:

•Productname.

•Productidentity.

•Serialnumber.

•Softwareapplicationversion.

Youcanobtainthisproductinformationusingthemenuswithinyour product.

HydraulicLinearDriveInstallationinstructions

Page 39

AppendixATechnicalspecication

Specication(at nominalvoltage)Type2Type3

Maximumvessel displacement

Peakthrust

Maximumstroke

Hardovertohardover time(+/-35degrees,no load)

Maximumruddertorque

Conformance(appliesto Type2andType3)

Hydraulicuid

22000kg(48500lb)35000kg(77000lb)

675kg(1488lb)1000kg(2200lb)

254mm(10in)300mm(12in)

10seconds12seconds

1270Nm(11300lbin)2565Nm(23100lbin)

•EN60945:2002(EMC)

–2004/108/EC(EMCDirective)

•EN28846:1993(IgnitionProtection)

–94/25/EC(RCD)

Mineralbasedhydraulicoil:

•minimumISOVG10

•maximumISOVG40

Technicalspecication

Page 40

HydraulicLinearDriveInstallationinstructions

Page 41

Page 42

www.raymarine.com